InsaneSwede's Astra MKI

[5tox]

good to see the project back on track, ive missed reading this thread

[alexcrosse]

enjoyed reading through this thread! that astras an absolutely insane machine! well done

[InsaneSwede]

Not much, but i´ve done a bracket for strengthening the gearbox a bit:



Tomorrow i´m about to mount the engine and gearbox back in the car to see what i have to modify with the new inlet manifold.

[InsaneSwede]

Testing new inletmanifold:


This is BMW E36 M3 throttles.

[Rs1]

Love how compact the m3 TB's are, i did look into some from jenvey that were even more compact but only 38mm..... not usre if that would be big enough, what size are the m3 tb's?

[InsaneSwede]

ohh.. i can´t remember exatcly. became unsure.. but i think they are 52mm

[ashtal]

Nice, not looked at this thread in ages!

[Stefan]

Testing new inletmanifold:


This is BMW E36 M3 throttles.

Will you flow test head with new intake on? How did old intake + head compare to piston cfm demand?

[InsaneSwede]

Will you flow test head with new intake on? How did old intake + head compare to piston cfm demand?

Honestly Stefan, I don´t give a f**k about flow.
I recon diggin deep in teories is for those who not have the talent to see how the air behaves.

This is my ONLY flowed head as i was a little bit curios how i stood up against the Swedish pro´s.(and cncheads.co.uk)

This head flows 308CFM at 13mm lift and 28", there were no testing, just straight off my hands.

Other unflowed heads i have produced always deliver good hp.

example:
Vauxhall: 800hp powercurve still heading upward at 7k rpm were the valvesprings started to float, more rpm would have given about 860hp.(the turbo also had a little bit more to give, so about 900hp could have been a reachable goal.)

Audi: 881hp at 2.4bar(later on raised to 2.7bar,and trapspeed at 402m also went better, about 930-940hp at 2.7bar)

so with that in mind, i´m thinking,, no need to flow any heads...

[InsaneSwede]

Update:
been carpenting onthe new plenum a little:

[InsaneSwede]

[TigraTurbo]

looks great Swede

[Kamilc20xe]

Hello. What power to the GT35?

[InsaneSwede]

Kamil, I really don´t understand the question, do you mean how much power the GT35 could deliver?

[InsaneSwede]

Coming together, The idle airsystem is a thing i have given a thought or two.
You can see the canister on the strutbrace, this is the 'plenum' for giving me an 'complete' vaccumsignal for the mapsensor, and you can also see that i got a manifold that looks like an fuelrail, this is where i inject the idle air into the runners.
My thought of this is to atomize the fuel more on idle as the air has an higher speed next to the fuelinjector than if i used the throttles.
Not many of you guys will ever have this problem as i´m running quite big injectors(1680cc) and on a small engine the injectortimes will be so very short that the fuel won´t be atomized correct.

I hope this helps out.

[InsaneSwede]

this thread makes my brain hurt
pistons in the bin, 'only' 2 bar, full boost at 2800, am i reading all this right lol?!!

Yes you´re reading correctly.
If you put some thought into it,, big volume engine,big NA power equals a lot of exhaustgasses, this combined with an correct designed exhaustmanifold, and by that i dont just mean the manifold, i mean the whole system, i got some trick up my sleeve.

take a look at the closest lorry or what they are called, cargotruck?
with an small tiny turbo that delivers about 350 diesel hp, produces slightly the double on an petrol engine.
The air and exhaustsystem is massive on those, with no restrictions at all.
From airfilter you got about 8" pipe
and from turbine you got about 6" system.

Put that in mind and you get the idea that the turbocharger doesn´t want any restrictions at all.

Plus that fact that i´ve tuned the NA engine quite high.
simulations on engine says me that it will produce about 270hp with no boost.
At as low rpm as 7000rpms,,
At 3000rpm it produces almost the half of the top end power(120hp)
An std LET engine produces about that amount at 6000rpm with no boost.

Rgds.

[corsakid]

very impressive patrick

[InsaneSwede]

Today i have plumbed the pipes and hose for the new hydraulic clutch.
No pic, but pedal felt perfect.

With my 1000Nm+ clutch the pedal felt just like an std clutch =)

Maincylinder from Toyota was easy to mount in Opel, almost like the had some work together back at -84 Opel and Toyota

[InsaneSwede]

another post,,

I might have forgotten to tell you about these new mods i´m updating the car with.
Last summer when i drove the car, it was very 'on the edge' and hard to drive, had to be sharp all the time.
Engine was easy to stall when releasing clutch.

Why?
because the clutch was HARD to operate and lumpy camshafts with a light cranksystem in engine.

I´m hoping now with clutchmod and individual runner manifold it should be much smoother to drive.
I have also mounteed back the complete std interior and have built exhaust all to the back on the vehicle.

I might have been infected with my other cars qualities *lol*



(yes it´s mine, I also got an Vectra OPC -06 but no pics)

[Jack]

You're going soft! lmao

[Kamilc20xe]

hehehe . yes .how much power the GT35 could deliver ?

[InsaneSwede]

It depends on a little bit.
wich fuel and wich exhausthousing
And how the engine is tuned.

Say you got an 200Hp NA engine and runs on E85(colder gasses from exhaust)
2bar on that is ~600hp.
This turbo looses effiency fast over 2.2bar(640hp)

But if your engine is producing say 270hp as NA the turbo won´t be able to produce all that boost, it might run into wall at somewhere around 1.7-1.8bar
But in that area the turbo is quite a lung, calculations says ~750hp
and the worldrecord i´ve seen is i think NorrisDesigns and 739hp.
My engine was in that area too.the boost adjuster was in the far end and i got no more than 2.08bar at 6000rpm and lowering down to 1.88bar at 7800rpm.(closed wastegate)

Rgds.
Patrick

[InsaneSwede]

Comptest done: almost evenly at 13.4bar on all cylinders.
Oilpressure built up: 3.5bar with really bad battery,, and i mean REALLY bad...
New oilpump is a little sweetie,, pressure builded up on just ~2 revs...

[kontraman]

Go on Patrick...

You gave me some ideas...4WD...Toyota...

[Rs1]

Looking forward to seeing some monster graphs from this, more cc's is the way to go in LET's now i think.... makes them driveable on a decent size turbo's. Just getting the correct technology into a LET block is rare as rocking horse **** as nobody really is pushing vaux turbo's over here, its all cossies and evo's.