Opel Kadett E 1.6i ,now C20LET inside

[Akula]

After my cav almoust broke in half on dyno (mega-rusty bucket ) it had btw 361whp and 525Nm I went to find rust free opel (imposible you say...well,NO )
bougt myself stock kadett E 91.y. ,1.6i,94K km on the clock, lets go edition (it's one with Bayern Munchen stickers on it...there's no that model in UK of course,it would be set on fire by manU or reds fans :P :P

now I mad a swap everything from that rusty vectra A into kadett
its C20LET
forged pistons CR 8:1
steel conrods
ARP bolts all around
XE block,cranckshaft
XE inlet cam
KKK 29/26 hybrid
downpipe with separation of wastegate and turbine gases
80mm exhaust (and backbox has 80mm perfored pipe)
70mm intake pipes with 70mm tophat
intercooler 760x300x100
630cc siemens injectors
F28 box
sachs sport clutch set
Bailey BOV
EDS phase 4
etc
brakes ate power 288mm front,back- stock GSI
koni sport set (springs,shocks-adjustable)
borbet typ T 16"
etc etc


what was at the begining (vectra)

http://www.youtube.com/watch?v=Dqnz_Jp6qHo


later with rebuilt engine

http://www.youtube.com/watch?v=rYzUvFNIVX8


now LET is in the kadett (dont have pics when I was doing the swap,but,let's say that it took me one month to dismantle kadett , stich weld it along with 4x4mm tubes in front,paint it in black(not by me ),than put LET,brakes,GSI optics,seats,instruments etc...

[seanr28]

Where did you get the 70mm top hat? can you get more of them?

[SteveM]

quality work mate! loving that rebuild video as well

[Colonel K]

cool stuff

[16vastraturbo]

if you watch the video mate you will see its a custom job.

[Akula]

Originally Posted by seanr28

Where did you get the 70mm top hat? can you get more of them?

it's a custom job...
just get 70mm 90deg alu pipe,than cut the stock tophat,than make 70mm opening with biax tool than weld it together...it can cost you max 20 euros
just neet to cut and weld that conector for the pipe wich goes into idle valve

[kadettfreak]

Originally Posted by Akula

it's a custom job...
just get 70mm 90deg alu pipe,than cut the stock tophat,than make 70mm opening with biax tool than weld it together...it can cost you max 20 euros
just neet to cut and weld that conector for the pipe wich goes into idle valve

Did you recevied any answer for vectra digital tacho how to reset it ?

dennis18

[Akula]

here is small update for the spring time

few pics of kadett...366whp @ 523Nm...but that was not enough







so,there comes overhaul...a bit more HP and Nm

pistons wiseco 86.5mm





Toga rods 4340 chrome moly 8K rpm 600KS + ARP 2000 and 430g









a slight bigger turbo than old k26

Garrett T3 - T04S 60-1 - Turbine T3 stage 3 A/R .63, Compressor T04S 60-1 A/R .70

before polishing



after polishing (does the trick on a borring day)









exh. manifold mandrel bent,41mm,3.2mm thick, ANSI 304
from nissan s13 sr20det







ARP for the head studs and bolts




ARP for the flywheel




HKS SSQV bov



Bosch 044 fuel pump


injectors Delphi 1000cc



external wastegate (Audi RS)




cometic head gasket x2



bling bling



this is just a small pile of parts...




oil jets

[Akula]

engine head... port & polish,2x valve springs,bronze valve guides...
























next is a downpipe,screamer pipe,Megasquirt etc

[Akula]

T3 flange on manifold




making of downpipe...







50mm crown for the wastegate













screamer pipe

[Akula]

trying to decide how to construct front of the car to mount radiator/IC/fan etc...








btw...dont cut metal tubes without protection for the eyes...its hard with speaker magnet to pull out metal debris

[Akula]

it started with just touch of the key

btw...if someone needs MS config files for 60-2 trigger wheel and setup like mine just pm me
my DIY MS ECU in car amp case













need to mount MS ECU somewhere













my DIY boost controler (from some big compressor) it has 1-4 bar regulation




now to map it and to mount OMP rolbar is next...

[dearing5]

ha nice mate!

keeping an eye on this thread wish i had the money to buy lots of new bits

good luck to you fella

[stevebarker]

why did you use this ?

[vxlgsi]

awsome car, but you shouldnt heat wrap a turbo manifold

[Akula]

2stevebarker: its a flange for strengthening the block ... its done on wrc engines and have use when crank is producing 700+ Nm of torque (than lower side of the block is trying to "strech" ) ...
U need longer bolts (12.9 index strenght) and modify that oil tube wich goes into oil pump

2vxlgsi: after some thinking,I wraped that manifold,screamer pipe and downpipe with TermoTec heat insulator to lower the temp inside engine bay and to keep as much as possible heat energy from the engine wich is spining the turbine wheel

[GTE 16V]

Awesome project, I will be keeping an eye on this!

Keep up the good work and post more pictures!

[Ginge]

Another top thread with some home brew machining coming into to play!

Loving the thread so far, keep up the good work!

Ginge

[Aditi]

correct me if i'm wrong.
you broaden your cylinder space ??>

and now you inserting a much biger pistons ?
A 86.5mm !

if i understand it properly, then what was your original pistons size ?

and one more thing,
until how much hp the Garrett T3 holding on ?
and the Bosch 044 fuel pump ? how much psi he runs ?

[Akula]

yes...block is bored 86.5mm than honed...pistons are 86.5mm
stock block is 86mm

turbo is Garrett T3/T4 wich is
T3 turbine A/R 0.63 stage 3 and
T4S 60-1 compressor is A/R 0.7
it produces enough CFM for 550-600 HP

bosch 044 pump is aprox 300 liter/hour and holds 7-8 bar pressure...and its louder than engine on idle

[rudd86]

good work, got to love a high spec let in the makeing.

[Davey]

Originally Posted by stevebarker

why did you use this ?

Have a look inside a late X20XEV block, they are girdled as standard