MG ZS Turbo *Project Part 2* Results*
 

LAST PAGE UPDATE :)


Well guys and girls, i thought it about time to sort out a bit of an update. I've thrown it into another "project" thread for various reasons, the main one being the first part of the project is mostly now done, so now i can start on various other bits and pieces!

I left the last project thread with the cars FIRST start on Omex management! Quite a bit has changed since then.

Intercooler and hardpipes:
After i decided my intercooler would not be suitable for what i needed i had a change around, i purchased a larger RMD intercooler from Rally Design, its a fair size and was a massive struggle to get it mounted without fouling the fans and bumpers. But seems to be holding IAT right down low!

Oil cooler:
My old oil cooler was obviously front mounted and the pipes were in a hideous location, so i opted for a newer slightly smaller unit, i also threw on an oil thermostat to make sure my oil reaches temperature correctly and is not over cooled.

Fans:
I opted for 2 new kenlowe fans to help maintain water temps, i am incredibly impressed with the units, they run for less than 30 secs and drag temps down lovely. Can highly recommend these units!

Turbo cooling system:
For various reasons i was forced to run a stand alone turbo cooling system, it involved an electric water pump, expansion tank and moto-X radiator. It worked great but took up ALOT of under bonnet space. So i hooked into the current water pipes and have managed to supply the charger with water after it circulates through the heater matrix.

Interior Mods:
I now have a PLX multi gauge mounted in place of the water temp gauge, it registers water temp, oil temp, AFR and oil pressure, in my opinion it looks pretty snazzy and looks nearly OEM :) I've built a car computer also into the centre console to monitor the Omex 600 once up and running ;) while i was there i also thought it rude to NOT throw in some corbeau Sportlines ;)

Fuel pump:
The current ZS fuel pump was on its way to being in over its head, so a swirl pot arrangement was obviously required. The standard ZS fuel pump is used as a lift pump to fill the swirl pot, a bosch 044 then feeds -6AN teflon fuel lines all the way to the fuel rail and back again after passing through a Sytec fuel regulator.

The spec as she stands:

-86mm Arias Forged pistons
-Re-bored and decked block to suit pistons
-Pauter Forged rods
-Gas flowed/ported head
-Omex Series 600 ECU, 3 bar MAP sensor
-Custom one off wiring loom for aftermarket ECU, plug and play baby
-Heavy duty clutch, organic 350ft/lb capabable
-7500cc Siemens Deka Injectors
-Piper 270 cams
-Piper Vernier pulleys
-Standard engine rebuild parts! (shells, big ends, seals and gaskets)
-SPAX coilover suspension
-Alloy Rover 220 radiator custom fit
-Custom water pipes
-Klinger Up-rated head gasket and ARP head bolts
-Larger turbo, Garrett 3071r, 490bhp capable
-Custom built one off Tubular Manifolds with external wastegate
-Custom Turbo back exhaust system 2.5"
-Large front mount RMD intercooler.
-Lightened and balanced flywheel (6.9kg ish!)
-Magnecore leads
-NGK 8 plugs
-External 32 tooth trigger wheel setup
-Green cotton open cone air filter
-New oil pump with oil cooler and thermostat
-Steel caged gearbox
-Quaife ATB Limited slip differential
-Bailey dump valve
-Full hard pipes by ProAlloy
-Gizzmo Boost controller
-Tial External wastegate
-Complete hard boost pipe kit
-Low coolant level setup
-Davies Craig electronic water pump and controller
-External fuel pump and swirl pot setup, bosch 044 pump and filter, -6AN lines throughout, sytec fuel pressure regulator
-Custom intake manifold and large bore throttle body
-Custom breather setup with crank breather mod
-330mm AP Racing 4 pot brake kit and ABS removal

So.. After a week of mapping at ATSpeed Racing in Essex, she's back with results! At 1 bar of boost (14psi) she pulled....

322BHP & 292ft/lb
:mbounce::mbounce::mbounce:

I personally think that is a cracking result at 1 bar!

Here's the pictures for you all to enjoy ;) (apologies for the incredibly bad quality, iphone for you!)

I had a little go on a private road (:joker:) and wow....she is fast... insanely fast! :thumbsup:

http://i4.photobucket.com/albums/y14...pskz3sqiiu.jpg

http://i4.photobucket.com/albums/y14...psbt1pyyjt.jpg

http://i4.photobucket.com/albums/y14...pszq0hb2zc.jpg

http://i4.photobucket.com/albums/y14...psjhafgisf.jpg

http://i4.photobucket.com/albums/y14...ps1p43vc9g.jpg

http://i4.photobucket.com/albums/y14...psmtpfqzgw.jpg

http://i4.photobucket.com/albums/y14...psugstkrkq.jpg

http://i4.photobucket.com/albums/y14...psojw3lu9g.jpg

http://i4.photobucket.com/albums/y14...psdgzvwmg8.jpg

http://i4.photobucket.com/albums/y14...psgnzurzxd.jpg

http://i4.photobucket.com/albums/y14...ps1vjtbvuz.jpg

http://i4.photobucket.com/albums/y14...ps6oc7deiq.jpg

http://i4.photobucket.com/albums/y14...pspbfe0xb7.jpg

http://i4.photobucket.com/albums/y14...ps4ke1n8kl.jpg

http://i4.photobucket.com/albums/y14...psewom8wds.jpg

http://i4.photobucket.com/albums/y14...pszybvywal.jpg

Next jobs:
-Fix the multitude of T-series bloody oil leaks!!! :whip:
-Find a couple of water leaks and fix them
-Few other little odds and sods
-Overhaul brakes again
-Get her ready for the road
-Get her ready for MOT
-Tax, MOT and insure!
-Enjoy it!!!! :lovers:

As and when I decide on other bits to do i'll update this thread :)

Just wow, what a car and what a build!! Well done mate this is simply epic:)

This is spectacular. It's been a long project but worth it I would say!

How much (dare I ask!) do you think it has cost to get you here?

(Front badge needs replaced, better get that on your to do list :P)

Cracking result!

That is an outstanding result from 1 bar of boost, a great project, and a great result.

Mental .....

Well done.

Thanks for posting, great build thread, so much done and sorted.

Pleased for you, to get those results.

Worth all the effort thats gone into it.

:thumbsup::thumbsup::thumbsup: :hooray::hooray::hooray:

Holee crap that's a lot of power.

Love it, what a great build.

Well done.

Words fail me, superb.

Stunning attention to detail.

Power wise it has more than the infamous mental maestro which at its peak was 287.

looking good! :D

Christ. Outstanding.

Immense.
Nothing else needs to be said other than, needs more boost! ;)

Great work again!

That's a phenomenal amount of power, even the supercharged V6s can't get over the 300. Is this the most powerful ZS around at the moment? The only other one I can think of that was over 300 was the VAG powered one. Well done, really well done.

Hat firmly tipped sir!:punk:

i adore the attention to detail and the bling!

P.

Only thing i would say is watch the stock suspension bushes / front wheel bearings.

both were well buggered on the vag zs when i got them apart. were never meant to run that level of torque :-)

P.

Awesome mate, very tidy install!

Love the engine bursting out the front, reminds me of when the HULK gets angry
http://youchew.net/wiki/images/1/10/...K_SMASH!!!.gif

congratulations, that is a very impressive result there and a lot of effort gone in!

that turbo is insanely large - our little derv's are running GT15 family... and 'big' upgrades are GTv 17/18/20 family tops!

Wow.! Always loved this ZS and it's just gotten better.!
I am only 5 mins away from Atspeed, shame didn't happen pain it whilst there as would've loved to have seen it in the flesh.

Awesome beast :)

Cheers for the nice comments guys, im a very happy boy i must admit! Im hoping to get to some meets this year for people to nose about but sorry you missed it bud haha.
Front bushes are a big concern of mine, im hopefully addressing that issue next :) as for wheel bearings we are pretty stuffed i guess?
I stand reserved on the carved up bumper, i think i prefer her old good looks but had little choice :( does look like its ready to burst out though like you said lol
Once she's road worthy i'll try get some vids up :)

Dribbles.......

I'd love to have one

When I'm watching this pic I see the nostrils of a angry bull ! Like the logo of the NBA team Chicago Bulls ! :D

http://a.espncdn.com/i/teamlogos/nba/500/4.png

I love it!! Haha brilliant :thumbsup:

What a truly cool motor,just love it..very well done mate...epic

Hey guys :)
Well i've been fairly productive since getting her back.

-Ditched electric water pump and controller, gone back to mechanical! Diesel pump inlet
-Re-wired the loom
-Corrected fuel pump relay wiring after a huge battery drain was found
-Custom lower coolant pipe from Pro-Alloy
-Electric booster pump for turbo (stays on after shutdown to assist with heat soak)
-New stereo
-Bigger inlet pipe for bosch 044 fuel pump
-Fixed various air leaks on inlet manifold
-Fixed the bootlid to actually hold up (hit my head WAY to many times!!)
-Fitted new (correct) power steering pipe
-Cleaned and fixed coolant tank with level sensor
-Various oil leaks fixed, still more to go (eurgh!)
-Handed fan control over to the omex and moved the relay module
-Fixed fuel leak on lift pump fitting

Brakes:
Well... a while ago i was forced to remove the ABS, i could never get it to work with the Omex, to be fair it wasn't working with the Rover ecu either so you know! Out it came, i bodged the brake lines as a temp fix to be able to move it around until i decided what i wanted to do.
After requesting god knows how many quotes to redo my brake hard lines I got one company who where interested, up until they stopped comms. Enough was enough!!
I started researching how to make my own lines, i ripped the fuel tank out again aswell as half the engine again, after plenty of failed attempts... i gave up!

I then spotted references to stainless braided teflon pipe.
www.torques.co.uk These guys can supply every fitting, every inch of pipe and adapter i could ever want, so a large order later...
I had in my possession 6 meters of -3an stainless braided teflon pipe, handful of various -3an stainless fittings, p clips and a couple of adapters to get from rover fittings to -3an.
I also got my hands on an AP knob style bias valve from burton power, which is neatly mounted in the old bonnet release position. While i was in the ordering mood... i decided that if the brakes are getting overhauled i may as well do them all! So stuck these on order...
clicky (in red of course!)
and the associated handbrake cable too. (330-10966)
She will eventually be running 330mm Wilwood rears, 330mm AP Racing Fronts, braided teflon throughout... some serious stopping power!
So i spent my day today sizing, making up hoses and fixing in place for the front calipers and down to the bias valve, hope you guys agree that it looks pretty neat :)

http://i4.photobucket.com/albums/y14...psp1z7svvj.jpg

http://i4.photobucket.com/albums/y14...psz1w738bv.jpg

Im really chuffed with the outcome, and had LOADS of fun doing it, just got the rears to buy for (when the calipers arrive) and attempt to bleed them through, fingers crossed with no leaks!
Enjoy :)

Epic

Those hoses look good but I bet they weren't cheap.

D'ya know they weren't that bad atall! i've done the entire front end and half way through the car for around £170.. being that i would of paid that in labour alone (plus alot more) i thought it was okay!

That's not a bad price at all, are the end fittings swaged on to the pipes.

It looks a proper job.

Nice work Dan, it certainly paid off.

Proper Job, looks neat.

Well done Dan.

:yes::yes::yes:

Cheers guys :)
Im glad people agree! Im very chuffed indeed!

Not swaged no, usual teflon type fitting with the olive and clamp. Basically a flare in effect. Max pressure of 2000psi apparently... They'll get put through their paces before it hits the road for sure! The hoses that came with the AP kit were the same :)

looks lovely - I've got similar look line on the upgrade hydraulics, though not sure it is that high pressure rated - but it might be.

those rears look interesting - i presume you spent a long time researching what to do with the rears, and why did you pick the wilwoods rather than something else? if i may ask.

Where did you get the brakes from bud?

thx
P.

Nathan with the blue supercharged ZS has them on his motor, the kits for an Integra so i'm presuming they will bolt straight on, which is exactly what i want :) but will certainly let you guys know if they do/dont lol Only Wilwoods for the sheer ease of (hopefully) just bolting them on, no brackets or fine measurements. Plus the price is reasonable when compared to Brembo or AP etc etc..


I got mine ordered direct from Wilwood through a company in Kent called Rally Design :)

cool thanks -Hope they do bolt straight on then!

I am not sure that I would need quite such a large disk on the rear myself - but you are right price is not too bad all inclusive!

Do you mind telling me where you got this made (and if it's not too rude) how much.

James

No worries atall mate, a company called zero exhausts in Ashord.
The whole system was £1500 i think, the guy down there is a top bloke.