Out with the old...in with the new...Britain's Racecar Development, Subaru Engine, Lotus Suspension! Time to go racing! Options

[Britain Smith]

Progress has been a bit slow the last couple of days, but it is starting to pick back up.

Finished up the front truck area. I replaced the foam in the fuel tank and completed all the fuel lines.

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Got the AIM MXL dash mounted and ordered the Subaru interface harness so that I can read everything off the ECU.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1294527193.2.jpg)

I also started plumbing all the brake lines and drew up the wiring diagram.

-Britain

[Hontec]

Read the whole topic ......again...... Simply amazing work Britain..

Love the Tilton pedal box.......I will be installing a similar one......
Keep up the great work, you're certainly doing a lot in a short period of time.... (IMG:style_emoticons/default/piratenanner.gif)

[Britain Smith]

Thanks Hontec...your work is far superior, I am just trying to get my car together before the race season starts.

I got the welder back from my buddy who I am borrow it from so I was able to make good progress tonight. First I finished up clean the firewall. There were several large holes that were used to secure the 914/6 engine mount that have now been welded up.

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View from the backside of the firewall with the holes welded up and the brake line rerouted to avoid hitting the turbo.

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Turbosmart Dual Stage Boost Controller taken off my '69 912 Turbo project. This will work well for those tighter courses or wet weather occasions.

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Pedal assembly plate welded in. These welds are not as pretty as I would have liked, however trying to weld in the cramped footwell was not easy and I had to ensure I didn't burn thru the floorpan.

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Tilton pedal assembly mounted. The positioning is perfect and the mount is very sturdy.

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Intercooler ice box mounted. This will fit just in front of the passenger seat when I take passengers.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1294571217.6.jpg)

Ice box plumbing. There is a ball-valve to drain the water under the car.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1294571218.7.jpg)

Ice box plumbing view down to the water pump. Had to route the lower water hose thru the crossbar so I welded in a tube to keep the strenght.

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Off to bed, more to do tomorrow.

-Britain

[plymouth37]

Beautiful as usual, this is going to be one hell of a ride!

[Britain Smith]

Ha, you are up just as late as I am...best time to get things done.

-Britain

[Hontec]

Lookin' good!!! really love the pedalbox! and the dash is (IMG:style_emoticons/default/first.gif)

[Britain Smith]

Took the son karting yesterday. It was his first time at a dirt flat track and although he started off slow, he really got the hang of it and it was a lot of fun.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1295250444.1.jpg)

Anyway, back to work. Got the business end almost completed. Just had to put the seat back in to feel the new pedal/shifter/dash set-up. I will admit, I did sit there and make car noises for a bit. The last thing that needs to get done here is a panel for the ignition switches.

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Reinstalled the engine to take some measurements for the throttle cable and clutch hose. Got the air intake installed and a bracket made to mount it.

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Fuel lines installed. Startlite line may cost a little bit more, but it is SO much nicer to work with and lighter.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1295250445.4.jpg)

Got the intercooler back from being welded up by Marty Staggs (www.m-specmotorsports.com), turned out perfect.

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Starting to fab up a heavy duty mount off the engine block. The intercooler is fairly heavy as it sits and will be twice as heavy when the water is added.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1295250445.6.jpg)

Hopefully I can wrap up all the fab items over the next week or so and then focus on the wiring. Although I am still waiting on my custom flywheel, I am still on track to have this thing fired up by the beginning of Feb.

-Britain

[Britain Smith]

Was able to take the intercooler mount to the machine shop today and get welded up so that I could finish the routing of the intake piping. I also had some aluminum standoffs machined up to mount the bracket to the top of the engine block where the original alternator and power steering brackets were secured. I will take the rest of this to get welded up later this week.

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Intake piping between the turbo and intercooler mocked up.

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Even though I rotated the compressor side of the turbo I was still able to use a Grimmspeed bracket (with a little modification) to lock the internal wastegate closed.

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Found a nice solution for the oil feed to the turbo from Forced Performance. Consists of a custom made banjo bolt machined with an AN-4 male fitting on the end. The stock hard line that used to feed the turbo has a machined fitting to cap the oddball size threads. I will run a short lenght of AN-4 hose over to the turbo.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1295421420.6.jpg)

While I was having other aluminum stuff welded today, I took the time to add some reinforcements plates to the shifter housing after I found that it was flexing just a little bit where the cable mounts.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1295421420.7.jpg)

-Britain

[URY914]

I like it. (IMG:style_emoticons/default/beerchug.gif)

[sean_v8_914]

bravo zulu!

[sawtooth]

Fantastic! Nearing the end of my suby conversion, I am baffled by the mount of knowledge and confidence it would take make something like this come together, especially how fast you are getting it done. I'm jealous of your knowledge of turbos, what to use and why, and how to make it all come together. Keep up the great work, hope to see your car run ax at WCR!

[Britain Smith]

I learned a lot when I did my 912 Turbo project. I have also done a lot of research and planning...that and I like to do things a little different.

-Britain

[Elliot Cannon]

Will we see this monster at the WCR?

[Britain Smith]

That is the plan...

-Britain

[Walter]

Very nice work indeed!
If you're aiming at ~400 hp, I would have chosen a 3" downpipe however, especially since you've also routed the wastegates in the 2,5" piping.
Well, you can always 'upgrade' later if you would want to ;-)

[Britain Smith]

The wastegate piping goes from 1.5" to 1.75" then into the exhaust which is 2.5"

-Britain

[Walter]

The wastegate piping goes from 1.5" to 1.75" then into the exhaust which is 2.5"

-Britain

I know, I had read that (IMG:style_emoticons/default/biggrin.gif)
Its just a little better then internal wastegate(s) what you did as the whole idea to external besides the control side is to not 'mess up' the exhaust flow giving it extra back pressure, even if its a few psi.
Turbo's are very sensite to back pressure and 2.5"is on the small-ish side for 400 hp. Better is to route ext. gates into their own downpipes and their own silencers.

Another thing to consider if you get dB problems with some tracks is the ext.gates actually need even better silencers as they don't have the turbo to pre-silence them... I also found this out the hard way at soem track when my wastegate opened and I got past the post that measured sound...

Just thinking along with you Britain ;-)

[Britain Smith]

Understood Walter.

Since the engine is only a 2.0L and I am running the stock turbo (for faster spool time) I don't plan on getting 400hp...more like 350hp max. The path towards external wastegates was for better control of boost pressure as the internal gate has issues when running over 20lbs of boost as I plan to run. It also helps that I am partially sponsored by Turbosmart and have their wastegates, BOV, and fuel pressure regulator on my car.

Regarding the exhaust routing, the need to combine them into the exhaust stream was necessary due to not only sounds requirements but also restricted space. By dumping into the exhaust stream, I am able to control the sound levels thru muffler arrangements. Now, you are correct it would have been better to dump into their own silencers, however space is limited and that also weighs more (IMG:style_emoticons/default/smile.gif)

-Britain

[plymouth37]

Wow! Looks amazing!

[Elliot Cannon]

That is the plan...

-Britain

Will we all get to drive it? (IMG:style_emoticons/default/driving.gif) (IMG:style_emoticons/default/driving-girl.gif) (IMG:style_emoticons/default/lol-2.gif)