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golfduke
golfduke Dork
9/21/21 9:14 a.m.

this thing is bananas in all the right ways... 

 

 

adam525i
adam525i Dork
9/21/21 9:28 a.m.

Your garage door is wide enough, right?

If this thing is going to be on track in October I think I need to sign up for that school so I can witness it, just need to fix the heater in my car so it isn't digital anymore for the cooler weather.

BigD
BigD HalfDork
9/23/21 1:16 a.m.

Thanks guys! 

adam525i said:

Your garage door is wide enough, right?

If it's not, it's about to be.

BigD
BigD HalfDork
9/25/21 2:20 p.m.

Finishing touches. I think I'll paint the airdam kickout bodycolor with some acrylic spraybomb I should have left, and leave the airdam raw/polished.

 

mjlogan
mjlogan New Reader
9/27/21 11:34 a.m.

Love the car but I think my favorite part is the progression of your fabrication skills

Anyone who is scared to pick up a welder and start learning needs to read your thread.  From a few less than stellar MIG welds (no offense) in the beginning to miles of beautiful TIG welds, what an inspiration.  Thanks for sharing the wins and fails too, hard to learn without both.

I hope you look back on the first couple pages from time to time and pat yourself on the back.  Really have nothing constructive to add other than nice work and thanks for taking the time to share.

 

BigD
BigD HalfDork
9/27/21 6:00 p.m.

Thanks! No offense at all, it's not like I meant for any of it to suck, I'm proud of all of it - it's what I could do at the time. Even now, I dream of what I could do if I had a real paint booth and a space where I could fill and sand to my heart's content without worrying about cleaning up dust all the time to not make the garage a complete disaster. Or if I had the time and space to strip the car to a bare shell/bare metal and not work ad-hoc pragmatically. But again, it's what I can do with the limitations I have, and I'm proud of it. It's part of the reason I'm not interested in following unlimited resource builds - they better be flawless. Like this asstastic work I saw on the frame of the Zonda R. They charge millions for this? I have even scarier photos from underneath McLarens.

 

Anyway, back to my junk, splitter almost ready to go, few more touchups. Need to secure the back of it and then start assembling the car. Need to install the 22ch CAN module for the inputs I moved off the ECU to free up inputs for the DBW. Figuring out dyno time...

BigD
BigD HalfDork
10/13/21 10:51 p.m.

 

BigD
BigD HalfDork
10/21/21 10:34 a.m.

Can't win em all. Dyno didn't happen as the car is very grumpy at idle, wouldn't want to idle well below 1700rpm and I thought maybe something's wrong. It turned out that it was my inexperience with aggressive cams and I refused to believe that a garbage idle has to be accepted. Here I thought I had most of EFI figured out but I got a good lesson on injection timing. By drastically delaying the injection timing at low engine speeds, it transformed the way it ran. The way I had it explained to me is that with the epic duration, the amount of overlap means that most of the fuel is getting swirled around and kicked out of the exhaust with overlap, and I'm probably having to drown it in fuel to make it run. It was neat watching the car run richer by doing nothing other than retarding the injection. I got it to idle great at 900-1000 rpm, might even be able to go lower but I'm happy with this. Unfortunately, this meant the dyno day had to be cancelled, and in turn, this weekend's track visit. But I still took it around the block and almost most importantly, I get to make this post, 2 years later. The lead is buried at pic 7. The level of satisfaction is about 11.5. Thanks to all of you for sharing this journey. Hopefully track action comes sooner than later.

 

Ian F (Forum Supporter)
Ian F (Forum Supporter) MegaDork
10/21/21 12:58 p.m.

Maybe I missed the cam discussion some time back, but I thought cams with a lot of overlap were to be avoided in forced induction engines?  Since the overlap essentially blows the intake right out the exhaust?  

BigD
BigD HalfDork
10/21/21 1:21 p.m.
Ian F (Forum Supporter) said:

Maybe I missed the cam discussion some time back, but I thought cams with a lot of overlap were to be avoided in forced induction engines?  Since the overlap essentially blows the intake right out the exhaust?  

Yes and no, like all of this junk, it depends. If you forget the turbo, a boosted engine is just like any other but living in a much denser atmosphere. Even in the ideal world, the pressure it takes to drive the turbo is usually not far from the intake pressure, ie compressor output. So while this remains true, the engine will still benefit from overlap for the same reasons as one without forced induction. Where things get difficult is when the drive pressure starts exceeding the boost pressure, where you start running into and climbing past the wall of efficiency of the turbo and your setup (the limiting factors could be various, from the turbine size, turbine housing size, downpipe and exhaust size, cats, mufflers etc - anything that creates a restriction). When that happens, then the overlap actually ends up hindering the ability to fill the cylinder.

So in my case, the cams are timed to retard the intake 9 degrees and advance the exhaust by 9, which, going by the cam card, results in reduced but not eliminated overlap, and the theory is that with VANOS enabled, which advances the intake 25 degrees, I should be able to have an improved idle from reduced overlap (not enough as I've recently learned) then during high performance mid-range, benefit from overlap, and then VANOS turns off around 5k rpm because based on previous data, my turbo starts to choke around then. Even with a 1.45 hotside housing and a 4" straight through exhaust pipe, around 5k rpm my exhaust pressure starts exceeding boost.

In theory, it should be the best of both worlds. Not as ideal as a more modern motor like the S54 with full control over both cams but should be darn good... we'll see.

Nader
Nader New Reader
10/21/21 4:38 p.m.

Very cool!  I'm surprised how quiet it seems.  Isn't your exhaust just that turbo dump coming off the hood?  Is the gear whine from the transmission?

BigD
BigD HalfDork
10/21/21 6:07 p.m.
Nader said:

Very cool!  I'm surprised how quiet it seems.  Isn't your exhaust just that turbo dump coming off the hood?  Is the gear whine from the transmission?

Yup, but the turbo takes a lot of the edge off, makes straight pipe exhaust a lot less obnoxious.

Yeah that's the sound of glorious straight cut gears (except for when I first pull away from the house, that was an angry power steering pump, as it seems I didn't fill the system enough).

BigD
BigD HalfDork
1/12/22 4:28 p.m.

Quick update, the parts for everything I want to do this winter are here and I'm so excited that I just can't hide it.

First a gratuitous photoshop goof:

 

Ordered a VW TPMS setup off Alibaba for 130 bucks shipped, instead of a box of rocks I surprisingly got what looks like a real setup, and so far it even does what it should. Sending it the appropriate messages for it to enable, it reports the expected message with the expected data, but the sensors won't pair and transmit until they see working tire pressure so that step is TBD until I can get the sensors in the wheels. But, so far so good.

"209" is the tire pressure message

 

Improved Racing has released an adult sized thermostat so I'll add it and an oil cooler back (removed it since my oil was never getting over 80C with the remote drysump tank).

 

Penskes are on their way to their place of birth for a once-over, maybe some valving changes and droop limiters.

 

Annnd this finally happened. Full Bosch Motorsport M5 ABS setup

FUHRAZE ONLY

 

With help from the Bosch dealer and some friends online, I managed to track down the DF11 sensors that the system requires to work that actually came in some flavors of Z3 and E46

 

I may spend a few more nights sleeping with it and then start the install.

To be continued.

Honda_newb
Honda_newb
1/12/22 10:05 p.m.

I just want to say this car is what I dream to attain one day in fabrication skills now I just need a car a welder and ton of metal to burn through. You've done a fantastic job at building this absolute monster!

BigD
BigD HalfDork
1/13/22 8:19 a.m.
Honda_newb said:

I just want to say this car is what I dream to attain one day in fabrication skills now I just need a car a welder and ton of metal to burn through. You've done a fantastic job at building this absolute monster!

Thank you! As you can see from page 1... all it takes is time while trying more and more things out of your comfort zone.

birdmayne
birdmayne Reader
1/14/22 9:04 p.m.

Holy E36 M3 dude. I'm blown away by this build. Super inspiring for some one like myself.

 

BigD
BigD HalfDork
1/15/22 11:25 a.m.
birdmayne said:

Holy E36 M3 dude. I'm blown away by this build. Super inspiring for some one like myself.

 

Thank you!

AngryCorvair (Forum Supporter)
AngryCorvair (Forum Supporter) MegaDork
1/15/22 6:12 p.m.

Damn son, the hits keep coming!

BigD
BigD HalfDork
1/16/22 1:54 p.m.
AngryCorvair (Forum Supporter) said:

Damn son, the hits keep coming!

Haha, thanks for sticking with me for so long, it's been quite the journey! I feel like I owe some of you a shot of my boobs or something.

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