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Old 1st March 2012, 14:33   #1
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Default Turbo charged Street Gypsy - project of the month

Now working on a Turbo Charged Street Gypsy King. The project is under progress and features:

1. KKK Turbocharger
2. Closed Loop Boost Control
3. Top Mount Intercooler
4. Extra Injector
5. Stock engine internals except for reinforced bottom
6. Unichip Q+ engine and turbo management

Will be posting details on a periodic basis with pictures.

Below is a pic of the hood with the work-in-progress scoop for the intercooler.

Also the oil drain arrangement for the turbo.

Please watch this space for updates !
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Old 2nd March 2012, 23:10   #2
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Default Re: Turbo charged Street Gypsy - project of the month

if your engine has done a few miles, you might want to consider putting in new valves and seals and gaskets. These tend to blow when you suddenly feed them steroids in their middle ages
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Old 3rd March 2012, 14:01   #3
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Default Re: Turbo charged Street Gypsy - project of the month

@53BHP - thanks for the advice. The engine is as good as new - run only 10588km! So do not see a problem with the engine's health.

Project Update:

Engine going into the engine bay. Please note upgraded clutch fixed on engine.
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Engine located in engine bay ! In the background is our next project - a monster truck based on a Nissan Patrol. Note the running board height in relation to the Gypsy.
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A view of the exhaust manifold.
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The intercooler will be fixed today and we hope to complete the plumbing tomorrow. The wiring is going on simultaneously.
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Old 4th March 2012, 08:30   #4
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Default Re: Turbo charged Street Gypsy - project of the month

Located the intercooler and the turbocharger in the engine bay. Seems like a snug fit. Being a top mount intercooler, we went in for a slightly oversized intercooler for better performance.

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Work on the plumbing is going on. Hope to finish on Monday.
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Old 5th March 2012, 19:07   #5
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Default Re: Turbo charged Street Gypsy - project of the month

Disappointing day ! The electricity situation (or the lack of it) is causing havoc with schedules.

Managed only to get the turbo to intercooler piping and the exhaust downpipe and mid section ready.

Seen below is the turbo to intercooler pipe
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This is a picture of the elbow/downpipe and the mid section of the exhaust:
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Hope we are able to make some progress tomorrow !
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Old 5th March 2012, 20:11   #6
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Default Re: Turbo charged Street Gypsy - project of the month

That looks like a mighty quick and quite an interesting build sapl. What kind of output are you looking at?
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Old 5th March 2012, 22:22   #7
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Default Re: Turbo charged Street Gypsy - project of the month

Quote:
Originally Posted by balenopower View Post
That looks like a mighty quick and quite an interesting build sapl. What kind of output are you looking at?
We are looking at 120 - 130 bhp.

We thought we should do this whole project in a week from start to finish. But looks like people are conspiring against u
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Old 6th March 2012, 17:59   #8
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Default Re: Turbo charged Street Gypsy - project of the month

Quote:
Originally Posted by sapl View Post
We are looking at 120 - 130 bhp.

We thought we should do this whole project in a week from start to finish. But looks like people are conspiring against u
Woah.. IMHO will that not be way too much on a gypsy?? are you sure the foundation will hold strong? From 80 to 120.. 50% increase?

Secondly are you planning to RIP the 4wheel off!!! I heard this year on the 2011 Himalayan raid, there was a Gypsy with turbo charger..

Way to go on the project!!! Looking up for the final projects, BTW you patrol projects are coming up great.. Killer looks the machines have...
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Old 6th March 2012, 20:42   #9
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Default Re: Turbo charged Street Gypsy - project of the month

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Woah.. IMHO will that not be way too much on a gypsy?? are you sure the foundation will hold strong? From 80 to 120.. 50% increase?

Secondly are you planning to RIP the 4wheel off!!! I heard this year on the 2011 Himalayan raid, there was a Gypsy with turbo charger..

Way to go on the project!!! Looking up for the final projects, BTW you patrol projects are coming up great.. Killer looks the machines have...
Hi

We feel that the 120 bhp is about the limit on the oe internals. We have in any case strengthened the bottom with a girdle.

Incidentally, the turbo Gypsy in the Raid was also prepared by us.

Thanks - we hope to be able to get it all done within the next week or so. btw, only one of the Patrols is our project - the other is being done by GT Tuners at Bangalore.

Managed to make some progress today - completed the inlet plumbing from the intercooler to the throttle body
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and the air filter pipe. We also completed the turbo oil supply and drain.
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Old 7th March 2012, 10:19   #10
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Default Re: Turbo charged Street Gypsy - project of the month

Wow! Killer project Can't wait to see the final outcome. Please do upload videos of the same too, can't wait to see how she goes.

Just one query, how much does turbocharging effect engine life. For example, let's say a stock 1.3 Gypsy King engine is good for approx 1.5 L km (Of course it may vary according to how it has been maintained). How much can you expect out of the engine after it has been turbo charged?

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Old 7th March 2012, 10:50   #11
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Default Re: Turbo charged Street Gypsy - project of the month

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Originally Posted by aadithsince1980 View Post
Wow! Killer project Can't wait to see the final outcome. Please do upload videos of the same too, can't wait to see how she goes.

Just one query, how much does turbocharging effect engine life. For example, let's say a stock 1.3 Gypsy King engine is good for approx 1.5 L km (Of course it may vary according to how it has been maintained). How much can you expect out of the engine after it has been turbo charged?
Thanks, will try to upload some videos - may be the dyno run itself !

As far as your query about engine life goes, it is purely dependent of the way the engine is used (or abused). If the extra power on tap is used judicously, there should hardly be any effect on the engine life.

However if the driver decides to have a leaden foot and keeps flooring and pushing the engine all the time, it is bound to take a toll on the longevity of the engine.
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Old 7th March 2012, 15:08   #12
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Default Re: Turbo charged Street Gypsy - project of the month

any similar projects on a Baleno in the works or done before? im really looking forward to getting force induced!
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Old 7th March 2012, 15:26   #13
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Default Re: Turbo charged Street Gypsy - project of the month

Quote:
Originally Posted by balenopower View Post
any similar projects on a Baleno in the works or done before? im really looking forward to getting force induced!
Somebody did enquire about a blown Baleno project, but we have not done any Baleno forced induction project yet.

However, I really dont see any difficulty in doing something similar on a Baleno.

In fact our race car engine is based on a Baleno block. It is very similar to the G13 block and we are familiar of the Baleno block like the back of my hand ! The only issue with the Baleno is that for extreme applications, the crank becomes a weak spot and you may have to change to a forged shaft, as we have done for our race car. There are also some subtle differences in the block design itself, but nothing that makes such a project infeasible.

As far as we are concerned, we are just about to begin a couple of projects using superchargers - one on a Swift and one on a Gypsy.

@twinn: Here are the responses to your queries:

1. The internals are stock in this build. this is good enough for a sensible driver who will not abuse the engine However, if it was an unknown driver, we would have recommended for forged rods at least.

2. The girdle is a simple device which takes up the additional stresses on individual main bearing mounts. We have developed our own design of a girdle and would like to protect its design for sometime !

3. The performance of the Gypsy in the Raid was satisfactory. We have gathered a lot of data about how a vehicle performs in such varied conditions. We did have a coupe of mishaps - we lost brakes and a shock because of a pothole on a long stage - Rungdum to Padum and back and that pushed us back from 2nd position to the bottom.

4. yes, one of the Patrols (the champagne coloured one is at our garage - but that main thread is about the Patrol being prepared by GT Tuners. I will be posting details of our Patrol after we complete the Gypsy.

Last edited by sapl : 7th March 2012 at 15:52.
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Old 7th March 2012, 15:37   #14
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Default Re: Turbo charged Street Gypsy - project of the month

Quote:
Originally Posted by sapl View Post
We feel that the 120 bhp is about the limit on the oe internals.
So the internals are all stock No need for forged parts??

Quote:
Originally Posted by sapl View Post
We have in any case strengthened the bottom with a girdle.
Please can we have a pic of the girdle. Just curious!!!

Quote:
Originally Posted by sapl View Post
Incidentally, the turbo Gypsy in the Raid was also prepared by us.
How was the performance matched??

Oh I saw a pic of a patrol with a gypsy in one of the treads, I thought its was your garage..
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Old 7th March 2012, 16:01   #15
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Default Re: Turbo charged Street Gypsy - project of the month

Thanks Mate, If i ever get a chance to catch you folks during the raids or INRC events (if at all they come up) I would definitely be interested in looking at the girdle

Now to the main:

1.What would be the RPM increase in this build?
2.What would be the exact RPM at which the turbo would start engaging?
3.Would you also port the cylinder heads for this build? If yes do you reposition the intake and exhaust ports or not?

Mate maybe these are really dumb questions, but please adjust
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