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as i said over on .org that is really good info.
I would be really interested to see the dyno plots of both sets just to look at the way the torque is generated. Having been bitten by the wingy's once, I am a little suspicious of too much fuel being thrown at things with not suitable atomisation/control etc. |
So, another quick update for anyone interested.
I had a problem with the car slowly losing water which was gradually getting worse. I located the issue to either the seal between the water pump housing and block or the water pump itself. Both areas were wet so naturally I went all out and replaced all the seals. Taking the mounting bracket off was a bit of a pig but it has fixed the problem so well worth doing http://i276.photobucket.com/albums/k...ps9a4cbcd8.jpg http://i276.photobucket.com/albums/k...ps050eb149.jpg http://i276.photobucket.com/albums/k...ps7bacbd32.jpg New pump, there are rubber seals below the silicone http://i276.photobucket.com/albums/k...ps41964ed1.jpg http://i276.photobucket.com/albums/k...pscf132c2e.jpg I was then on a roll so decided to replace the crappy after market cam cover gasket for a genuine Land Rover one. At the same time I took the belts and pulleys off allowing me to remove the cam carrier and re seal that with the genuine Rover sealant just to be on the safe side. http://i276.photobucket.com/albums/k...pse949426c.jpg Cam removed http://i276.photobucket.com/albums/k...psd3069aaa.jpg Quick de-grease and going back together http://i276.photobucket.com/albums/k...psd981c6d3.jpg All back together and filled up with new OAT coolant, now completely oil leak and coolant leak free. http://i276.photobucket.com/albums/k...ps051a2f6e.jpg Then we gave them both a quick wash: http://i276.photobucket.com/albums/k...ps9b683414.jpg In other news I have sent a set of ZS injectors to United Diesel to be re-built with new Firad nozzles and both opening pressures increased. They have also been completely balanced and flow tested. These results show the difference in flow between standard nozzles and the DSLA 145P 208 nozzles. If anyone wants the exact specs of what has been done I'd be glad to help. Cant wait to get these fitted on Sunday. Also Ive given my turbo map another tweak on my other 200tdi hybrid injectors and she really is flying at the minute. Just need to get my new turbo core fitted now and oil drain to sump, then maybe a hard cut limiter (just for giggles) and she will be virtually finished (3 years on) http://i276.photobucket.com/albums/k...sb43c0eef.jpeg |
Awesome project and workmanship
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Love the detail, make it sound so easy, when its so hard and time consuming.
:yay::yay::yay::yay: |
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As always, thanks for the comments. Too true about modified cars never being finished but we'll see.
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wow - should see some much better figures with that extra flow!
watching with bated breath as ever :) |
I had the same issue with the coolant, big thanks for the pics.
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I managed to get my new injectors fitted.
Link to the company who did the work: https://www.uniteddiesel.co.uk/ Specs of the injectors: Firad 145P 208 nozzles (aka 200 tdi nozzles) First stage opening pressure set to 220 bar Flow tested and balanced (see print out in previous post- very well balanced) All cleaned up and amazing presentation, they look like new: I posted them to united diesel after helpful emails being exchanged, we agreed on the specs of the injectors and they were posted. He got to work on the injectors straight away and had them finished on Thursday last week. I got a phone call at 4:30 saying they were done and they arrived the next day, amazing service. This is how they were returned: http://i276.photobucket.com/albums/k...ps28679c08.jpg http://i276.photobucket.com/albums/k...ps759366b5.jpg http://i276.photobucket.com/albums/k...pse3d3fb99.jpg http://i276.photobucket.com/albums/k...ps8c83253e.jpg Comparison before and after: http://i276.photobucket.com/albums/k...psfba6f1db.jpg The engine starts just like standard, I cant notice any increased diesel knock and they are just so smooth. Anybody wanting an awesome injector upgrade, you have all the info here you need, so refreshing to got such good service from a company. United Diesel, recommended! Anyway, gave her a clean an got all patriotic: Before: http://i276.photobucket.com/albums/k...ps527e4aef.jpg http://i276.photobucket.com/albums/k...ps375f7e42.jpg After: http://i276.photobucket.com/albums/k...ps8f469032.jpg http://i276.photobucket.com/albums/k...ps32b76171.jpg |
Also,
I've had my up-rated core to fit since November but not really had chance to fit it. So I took advantage of the lovely weather we've been having over the last couple of weeks and cracked on with it. Its completely brand new with staggered oil seals (for running higher boost and low back pressure exhaust) and professionally balanced. Cant say the box wasn't well boxed in the box for the box... :D http://i276.photobucket.com/albums/k...ps04b9fbd9.jpg http://i276.photobucket.com/albums/k...pse05629ca.jpg http://i276.photobucket.com/albums/k...psddfc0e3d.jpg Gave the VNT mechanism a good strip down and clean while I was there. http://i276.photobucket.com/albums/k...psaa7e2518.jpg After: http://i276.photobucket.com/albums/k...psaddac714.jpg All re-assembled and setting the actuator up with a vacuum pump: http://i276.photobucket.com/albums/k...ps65f86fd5.jpg While I was at it I wanted to re-do the oil drain. It worked the way it was but was far from ideal so it was sump off time! http://i276.photobucket.com/albums/k...psf40bfdb6.jpg Modified a standard ZS oil drain to bolt up to the sump and made a custom gasket: http://i276.photobucket.com/albums/k...ps5d4de4e0.jpg Found some pipe perfect for the job: http://i276.photobucket.com/albums/k...ps72fcd7c0.jpg http://i276.photobucket.com/albums/k...psed003aae.jpg http://i276.photobucket.com/albums/k...pse7cc7953.jpg I then needed something to bolt to the turbo and discovered this accidentally on ebay. Its the drain from an earlier 420d which has a much longer corrugated section, perfect for the job! It came like this: http://i276.photobucket.com/albums/k...ps09f0e871.jpg And I modified it to this: http://i276.photobucket.com/albums/k...psca05e036.jpg Completed it looks like this: http://i276.photobucket.com/albums/k...ps11d020bf.jpg New genuine sump gasket and fresh oil and filter at the same time: http://i276.photobucket.com/albums/k...ps20baaa36.jpg http://i276.photobucket.com/albums/k...psce30da6a.jpg To blank the original hole in the block, the local hydraulic shop sorted me out with this: http://i276.photobucket.com/albums/k...ps2aa37f94.jpg http://i276.photobucket.com/albums/k...ps68eafcc3.jpg I also got around to fitting my new splitter, a sneak peak here: http://i276.photobucket.com/albums/k...ps4c6e3985.jpg Ill take some pics of it from the visible side when I've given the car a polish. |
Can they upgrade the o/e injectors???
Or do they want the SDi's??? Love the mods. |
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They can upgrade either stock or SDI injectors. They are really just the same apart from the nozzles and opening pressures and since both of these are modified it doesn't matter which they start with I wouldn't have thought. They set the first stage to 220bar and the second stage was set by looking at flow rates. I sent the stock injectors. That said, for anybody with SDis, a remap and standard turbo these are pointless... However for people requiring more fuel after a turbo upgrade OR if they have a standard car and fit these with the standard map I think it would have a similar effect to fitting SDIs and a remap. These with a remap and standard turbo however is asking for a smoke screen! |
Cheers Phil, that was what I was wondering, have a quick blast of smoke, but its only when first booted and it does go off.
Wont bother with the upgrades as I'm happy with my ones performance!!! :devil: :beer2::beer2::beer2: |
Fair enough :)
I suppose they could also re-build your SDI injectors to standard spec and re-balance them should they ever get tired. Apparently the nozzles wear away and the spray pattern deminishes over time, 100K miles is a figure which floats around but not sure how significant it all is. As long as your happy is all that matters, they certainly do shift with the right mods even with the standard turbo :). In all honesty I do this because mechanistry is a hobby and I get as much enjoyment from tuning the car as I do from taking it for a blast. Performance on yours will be way more than a match for most modern traffic. |
I reckon that the 200 nozzles will be too much for a OE turbo on anything but a 101 map, and still think that smoke would be pretty epic.
I've seen some of the more aggressive remaps with SDI's and the smoke levels is way higher than I would put up with - and why I downgraded from my wingy's (and also cos they were faulty). I am still curious what nozzles were used on them, so maybe i should send that set off when i get round to the last parts of the project! |
Another update...
Was back to see Kris at Darkside a few weeks ago to play around with the map since the new core and injectors had been fitted and I had played around with the map of the turbo. We had the rollers for half the day and did loads of pulls, cutting a long story short, we decided to leave fueling as it was but changed the opening pressure on the wastegate as well as played around with the controller map so she now boosts at 29psi. The amazing thing is EMP peaks at 23 psi, something you will simply not achieve with a non-VNT turbo with any kind of quick spool. Because of the external wastegate on my VNT set up there is no spike so literally have the best of both worlds. I should say that the 197.7 result was with the rollers set with slightly higher resistance which helped the boost spool. The 184 result was consistent with the dyno on shootout mode for FWD forced indiction cars. The reason i am posting both graphs is because on the FWD forced induction mode (184bhp) the boost was dropping off to about 25psi. This does not happen on the road, on the road it sits at 29psi to the redline as it did with the rollers set to higher resistance when it pulled 197 bhp. Im not saying one is right and one is wrong, just trying to give the full picture. Either way, safe to say its got well over 300 ft/lbs torque and considerably more power than a ZS180, needless to say it is quick. It was always my aim to have a 50+ mpg RELIABLE ZS with more power and almost double the torque of a standard 180. I think it has now been met. http://i276.photobucket.com/albums/k...ps3127bd32.jpg http://i276.photobucket.com/albums/k...ps1f9ba5e3.jpg |
Good results.
:wave::wave::wave: |
Very very impressive, a great result there :)
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That's a cracking amount of power right there.
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That is rather impressive. Well done mate!
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Cheers for the replies guys, pretty chuffed!
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Another little update since I've spend the day tidying.
Been meaning to get this wheel on since December! How my steering wheel looked this morning: http://i276.photobucket.com/albums/k...ps9835b37a.jpg New bits: http://i276.photobucket.com/albums/k...psd60d9af6.jpg Close ups of an adapter which is required to self cancel the indicators: http://i276.photobucket.com/albums/k...psb340b65d.jpg http://i276.photobucket.com/albums/k...ps37c2985d.jpg http://i276.photobucket.com/albums/k...psb279d09c.jpg http://i276.photobucket.com/albums/k...ps7a0d0d79.jpg http://i276.photobucket.com/albums/k...ps13ac0898.jpg ZS coupler: http://i276.photobucket.com/albums/k...ps2d1f0f5e.jpg Replaced with a TF one so it plugs straight into the TF airbag: http://i276.photobucket.com/albums/k...psa638de9b.jpg The finished product, such a good mod: http://i276.photobucket.com/albums/k...psab913d25.jpg |
Looks great :thumbsup:
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This car must be priceless to you. A testament to the amount of time and effort put in!
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Looks good - which airbag did you use?
When I got FE54 it had a TF wheel but the badge was black. I swapped the wheel on to the ZR and fitted my R45 wheel into the ZS, the smaller wheel suits the ZR better IMHO and doesn't need the adaptor. |
Congrats Phil - that is a cracking result there.
Even though there is so much more torque later in the rev range, you are still sing more than a standard car's peak at 1800rpm. Really glad that the end result is what you wanted, and I am wondering whether the additional external wastegate is not the way to go as well on a future build of my own. really well done there - am really pleased for you :) |
Sorry for lack of reply, only just checked the thread! As always, thanks for the comments.
Talkingcars, I used a TF airbag which plugs straight into the TF rotary coupler. I think there are different designs used for the badge in the F/TF, I specifically wanted the "coffee and cream" coloured one so waited until one came up. p_b82, yeh, Im pretty pleased with the results, I think I've gone as far as I can with power whilst keeping a degree of reliability. I'm definitely glad I fitted the WG for what it cost. It just gives so many options, you could even just set the vanes on any old VNT to a set position and then use it as a bigger externally gated turbo if you didn't want to bother with vane control. Are you any closer to deciding on a turbo/ spec? |
Yes - but for now it is going to be a surprise until it is all sorted out, few things still need sorting out first.
Hopefully I will have a decent update in the not too distant future though - and that is all relative with this project of mine lmao :) |
Fantastic work! The car is a testament to your mad skills ;)
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oooh I like surprises...
For those who can't be bothered with the VNT route (fair enough, its no walk in the park), it looks like Dark Ice Designs are making some progress with a bolt on kit which they are claiming should be good for 185bhp. Personally however I think those figures are a bit optomistic for a wastegated GT17. |
Yeah - many people do, I would like to get it all sorted then share what details I can afterwards.
working out timings and costs really as the final hurdle - but as ever proving to be a little bit of a challenge due to the not off the shelf situation. but I'll work it all out in time I am sure :) You might get 180+ with 200 nozzles, but I suspect emp will be high again with that. not going to be an option on SDI's only I don't believe. |
Its been a while so thought I'd give a quick update.
Nothing new mechanically, just lots of TLC. Last shot of her with the winter wheels (if anyone wants to buy them, make me an offer): http://i276.photobucket.com/albums/k...pse52b23cc.jpg The TLC started with the summer wheels, gave them all a complete waxing which took hours and dressed the tires with gel. I also re-painted all the calipers in the same xpower green color to brighten them up: http://i276.photobucket.com/albums/k...ps5e10656a.jpg http://i276.photobucket.com/albums/k...ps9469d61b.jpg Next was the roof, see if you can guess whats going to happen :D: http://i276.photobucket.com/albums/k...psb9a63edf.jpg http://i276.photobucket.com/albums/k...ps10d7bc29.jpg http://i276.photobucket.com/albums/k...ps242f3143.jpg So these pics show the roof design half finished (more to come up there), they also show the splitter which I haven't posted before and the shiny new calipers: http://i276.photobucket.com/albums/k...psaaf44621.jpg http://i276.photobucket.com/albums/k...ps249b567b.jpg These caps are now on the car to complement the roof, I'll get more pics of the whole car when the design is finished: http://i276.photobucket.com/albums/k...ps4cb51f80.jpg |
Ooh, St George Cross or Union Flag?
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A clue is some MINIs have it however I've never seen one on the road, should be a bit different I hope :) |
Looking forward to seeing what it'll be!
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Black and White chequered ?
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Confederate flag, general lee style
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Awesome! Motorhead inspired at all?
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haha slightly yeh plus the fact it's the highest card and also found out they tried to use it as psychological warfare in Vietnam. Amazing what Wikipedia can tell you :P
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