Most quality & performance engine builders should chemically clean

As for cost, its nothing compared to the over cost of full engine build, after all its only a chemical bath.

Most engine tuner/ builders provide such service.

If you require further details of companies that offer such service, message me.

clifford cox who machined my block, cleaned up my block while it was there, think it was summit like another £40 on top, not a great deal.

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Pete
ST185
Basingstoke

The surface 'rust' visible in the waterways this is probably due to the fact that the block was brand new and had been in storage for several years. It's never been exposed to any oil or coolant so there was no need to chemically clean it. I personally inspected the inside of the block/crankcase before the bottom end was built up and it was spotless. The head, which is a used TTE spec item, has been chemically cleaned before the subsequent modifications detailed earlier in the thread. All sharp edges have been deburred particularly around the area of the water pump where the standard waterways have some rather nasty and unnecessary lumps.

Regarding the exhaust manifold there are not many options available if you want to stay with a cast item. In fact, since the supply of Corolla WRC manifolds has dried up there are no options at all! I am not keen on fabricated exhaust manifolds as they tend not to last being prone to vibration/stress cracking. The WRC manifold, even although the 'runners' are not exactly equal length, should be good for up to 600bhp based on Fensports experience. I'm not planning on more than 450-500 at this stage. Experience shows that the blocks and transmission become the limiting factors at power levels above this.

Clutch is an RPS twin plate carbon 'basket' design.

ECU will continue to be the MoTeC M4 Pro with wideband lambda, datalogging and AIM MXL Pro 05 digital dash/datalogger.

Cage will be a proper motorsport MSA/FIA type NOT a Cusco 'bolt-in' design.

I've now aquired a spare set of front and rear subframes which I intend to refurbish and fit with the uprated TRD 'metalastik' type mounts.

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Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Can only think of two words, very nice

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'92 GT-Four RC - Project Rufus - something of a mover.
'05 Audi A3 3.2 V6 Quattro S Line - not bad for a daily.

Latest pics of my engine with all the major components bolted together. Just waiting for the side feed intake plenum, top feed fuel rail, 1000cc RC injectors and 70mm throttle body from Engine Logics.

















Some pics of my new GT30BB Hybrid turbo by Owen Developments. See if the eagle eyed among you can spot the mods

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Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

Very very nice indeed don, i am really happy that your build is coming alone well. Be careful when replacing the engine into the car with the alt still attached because it makes things very tight.I would for the sake of a few minutes remove it before fitting.
Is datajon getting commision on the throttle bodies i dont like the look of them at all. To close to the bulkhead for me.
Anyway all the very best for the rest of the build.
Hutch

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Please take your nails out of my dash..........501.1 Whp

Looking quite nice there Don

Apologies everyone but I have already spotted the mods and have a confirmed win
Feel free to guess for second place though

Don - is that a 7 bladed compressor wheel? Thought the GT30 had a 6?

Also, what are those 2? red attachments to the outside of the compressor housing?

That compressor housing looks odd!

_________________
Kris
95 ST205 - slept for 10 years, now waking up...
Avensis
http://www.gtfours.co.uk
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Turbocharging - the replacement for displacement

there's 3 red attachments, they are grubs screws and lock nuts holding the center inlet piece in place.

i'm probs way off but could be a ported shroud and diffuser mod?

all looking very nice though

how come the stock cat bracket are fitted?

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Pete
ST185
Basingstoke

Pretty close Pete

Think about what **might** happen if all 3 grubs were undone

Hope that's some high temp Loctite Don lol

Thanks for the comments everyone.

The standard compressor wheel has been replaced and the ported shroud is designed to improve spool up and combat surge arising out of using a larger compressor. Apparently HKS use a similar system on some of their turbos. There is some internal detailing but photos and tech specs are off-limits I'm afraid. Suffice to say that the mods are designed to not only improve performance but also reliability. The stock Garrett GT3070 is fine for fast road use but with sustained use of high boost on track they have been known to fail.

Don't pay too much attention to the ancilleries at this stage. The installation detail for oil and water has still to be firmed up. Now that the WRC manifold, wastegate and turbo are with JEMS the mating faces need to be decked (they distort during the welding process) and the oil and water feed lines designed and fabricated. The compressor will also need to be clocked so that it is oriented correctly for the FMIC.

I'll keep adding to this thread as we progress the build.

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Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp

It all looks very nice and very expensive..Looking forward to seeing it all in place..

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Had it, written it off..enuff said !

Looks great Don

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GT4DC Events Co-ordinator
1996 ST205 UK

very nice indeed Don. How about a spec sheet woudl like to know what cams you are using and what teh cam pulleys are - they look well engineered unlike some on teh market. Close up piccies of the porting work on teh head too would be nice

Interesting alteration to the compressor housing, the design looks nice - as above I would be concerned about the screw-loose syndrome which could get very expensive - I assume the additional housing will not slide into the compressor wheel. So what size is teh compressor wheel? Must be a Gt3076 or Gt3082?? In which case any assistance on teh surge & spool front wll help in the driveability. Looking forward to teh passenger rides this year

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JP
GT4DC Treasurer

Grey St185 RC
Silver BMW E46 M3
Multicolour yawn Honda VFR400
Silver Honda Civic Type-R

Hutch, I should clarify that the pics Datajon showed on another thread of Engine Logics throttle bodies is not related to my engine build. My setup will use a single 70mm Ford Mustang throttle body.

My intention is to dyno test the Engine Logics side feed short runner plenum (same as used by Smithy) against the OEM centre feed long runner design to differentiate the power and torque characteristics. I don't want to shoot myself in the foot by opting for a design that will compromise my lap times through a lack of mid-range torque.

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Don
GT4DC Chairman
1994 Toyota Celica GT-Four ST205WRC JDM 269bhp @ 0.9bar
1994 Toyota Celica GT-Four Special GT 590bhp @ 1.8bar
1989 Van Diemen RF88/89 Formula Ford 1600
2008 Nissan Patrol GU 3.0L ZD30DDTi 154bhp