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Extra turbo

Done a couple of small jobs.

Removed fuel pressure gauge from the reg, and blanked the hole now the fuel pressure is set, as they are not supposed to be permanent. The original gauge that was fitted started leaking, not taking any risks. Cant see it from the drivers seat either so pretty pointless apart from a static test.
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Custom lux suede gear gaitor fitted.
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Big updates coming soon too watch this space;)
 
So the day came and it was time to get the Extra mapped.

Filled the tank with tesco's finest 99 momentum and set off on the journey to Efiparts. Had a steady drive on the way down as the base map was ok but not great, sat at around 50-60mph. The weather was exceptionally hot around 25 degrees, but did not cause no cooling issues and the engine quite happily cruised along at 75deg.

Stopped off at Warrington as needed to go and brim the tank with tesco 99. Hit mid day traffic and ended up crawling along for a while, rad fan singing away keeping the temp around 80degrees and paddle clutch was awful in traffic.

Filled up and set off on the short journey, got there early and a megane was just finishing off on the dyno so took a seat outside in the sun.

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Time comes and its strapped onto the dyno. Fan looking rather large compared to the van!

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Chris done some initial checks, first was to check the base ignition timing was set correctly with a strobe light. It needed adjusting as i had set it slightly out and was 4deg retarded.

He then started doing some low speed mapping on part throttle. I was keeping my fingers crossed that the fuel system and ignition would be ok as largely untested under load. I had only seen around 4k rpm on the road and no real load on the engine.

I explained the mac valve was on a switch so with the switch off it would run gate pressure, and high boost with switch on.

After a few runs we were up to a respectable 171hp/167ftlb @13psi gate pressure. Listening to the engine sing round to 7500rpm for the first time was awesome. The setup was working well and responding well to boost.

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So the next question off Chris was "How far do you want to push it" and my answer as usual was "all the boost";) push the engine a bit and see what its capable of, within reason as its pretty much stock bottom end and 200mm ap paddle clutch.

Started ramping some boost in and the power came up fast, seen 200hp, 220hp, 230hp without flogging it too much. I was happy at this point as it had met what i had wanted hp wise.

Started really leaning on it and boost up to 29psi to see what it was capable of on some runs, with the power still coming up. Great buzz hearing the engine picking up power and sounding stronger each run.

Dyno cell temps of 27 degrees at this point which was not helping things!

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So after exploring the limits and pushing the engine, the power came up a bit more than i was expecting.

The end result is 249hp/227ftlb.

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The boost had to held back a little under 6krpm as close to knock, then ramped up to 27psi over 6k. Torque is limited to keep the stock rods and drivetrain happy.

First test drive, took it down the road on wastegate pressure of 13psi and was quite suprised when it was scrabbling for traction in 2nd gear, felt quite fit. I then tried high boost, its pretty lairy as expected, feels quick and makes all the right noises. Its a drag strip tune, so good for short blasts on high boost but will need knocking back a few pegs for hard track use, which is what i expected and ill be happy with 200-220hp for track use at lower boost.

To put it into perspective, its as quick as my mrs meg 250 cup on wastegate pressure, and long gone on high boost.

Worked out its around 270hp per ton on high boost, so no slouch.

Overall it drives great, starts up hot and cold like an oem car, cruises along at 14afr nicely at 70mph. Very happy with the whole setup, engine is a lot more responsive low down with raised compression, turbo spools up faster and on boost around 1k rpm faster than the previous setup. Done 30+ runs up to 7500rpm on the dyno no issues, no misfiring, did not need to lay a spanner on it. Mapped and drove home:)

Chris done a great job mapping it so big thanks for showing the full potential of the setup, went above and beyond to get the best out of it. He is the best in the business in my opinion, cant recommend him enough.

The plan is to drive it a bit this summer, then invest in some stronger bottom end components and get this Gtx 2860r bolted on and see what happens;)

Thanks for reading!!
 
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Brings it all back Brigsy - loved my time at Scoffs, you know it's in the best hands.

As for the work you've put in and the attention to detail you can see it has really paid off. Well done fella, now go see how that feels on track.
 
Blinding stuff, that thing will be a right weapon! Well done mate, all the hard work worthwhile :)

Great result @Brigsy

You got a switchable map now on this EFI conversion?? Had that on my VAG Clio and loved the fact I could turn things up when needed..
You set the MAC valve up for high boost, then basically put a switch in the signal line to the ECU to create a break, that keeps the valve off and it just runs gate pressure.
 
Cheers all, its awesome to be able to give it some decent boost again. Hooks up great with the quaife lsd too.

@DaveL485 you are bang on the money it is switched mac valve at the moment. Boost by gear and possibly a 3 way switch for different boost levels would be nice, Ideally i would like gate pressure, 21psi then high boost.

Im sniffing about for another good used Adaptronic 420/440d, as my usb port is knackered and i can only write the ecu on 2.5mm jack, so using the old version of wari to suit the 420c. Bought a 440d last week on ebay and got refunded typically!

Have considered just upgrading to the m1200 too, will see.
 
Did you have the diff in pre rebuild / mapping @Brigsy ?

Ive just fitted the diff with the new engine, Old setup was stock gearbox.

Only really tested it coming off a few roundabouts but it certainly turns in better on throttle without the understeer it used to suffer from. Ive yet to sort the suspension, its the same avo shocks on 350lb springs at the moment and hardly any camber. Hoping with some decent negative camber dialled in and Leda shocks/roll correction kit, it should be pretty tidy.
 
Ive just fitted the diff with the new engine, Old setup was stock gearbox.

Only really tested it coming off a few roundabouts but it certainly turns in better on throttle without the understeer it used to suffer from. Ive yet to sort the suspension, its the same avo shocks on 350lb springs at the moment and hardly any camber. Hoping with some decent negative camber dialled in and Leda shocks/roll correction kit, it should be pretty tidy.
Going to be a different car van even if you just changed the box! Will go well now.
 
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