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Old 12th March 2013, 15:57   #31
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SGP Mls head gasket was delivered today. One often few off the shelf options available apart from cometic and felpro.



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1.4mm uncompressed , 1 mm compressed


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Silicone hoses for the itb setup came in too.

With these two having come in, the engine should be put together tomorrow and hopefully will fire her up for the first time day after!

Last edited by binz : 12th March 2013 at 16:01.
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Old 23rd March 2013, 20:06   #32
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After a couple of delays, the block finally got put together today. Sanjay felt the need for good main and rod bearings in this build so Clevite bearings were used along with assembly oil from the UK given to me by a good friend and extremely well known rally driver(You know who you are, thank you!).

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The stock Baleno flywheel was lightened and dynamically balanced keeping in mind that this engine will revved high.

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We're using an Exedy stage 2 clutch(for now) which will be upgraded as and when the need arises.

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With those things in, the bottom end is finally complete. The pistons sit 1mm below deck at tdc. Words cannot describe how sweet this build is turning out to be.

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My 'special' electronics are coming in on Monday. Should be good considering its one of two made in the country!

Stay tuned!

Last edited by binz : 23rd March 2013 at 20:16.
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Old 26th March 2013, 17:00   #33
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Electronics

One of the few reasons we opted to go the ITB/Turbo route was because we knew that at the end of the day we could put whatever we liked in the engine bay and it would be tuned to perfection by Karthik. Having watched him road tune everything from a Ktm Duke to an 800hp Supra to the Desert-storm winning XUV-500s, there is no doubt that he will be able to bring out the best in this build.

Sanjay is going all out on this car mechanically and Karthik is making sure this car has the best electronics the country has to offer.The car will run the latest version of the RACE dynamics RD0901 Standalone ecu with data logging and in addition to the standard features, it will also have the following:

Anti-lag
Launch Control
Traction control
Closed-loop with target afr for fuel economy
Flat-shift
Electronic boost control with boost by gear and rpm
Automatic triggers for the intercooler spray as well as for the water injection system thats planned later on.

In addition to this, the instrument cluster is going to be replaced by a prototype digital display system which will display Rpm, boost pressure, throttle position, speed, injector duty cycle and wideband afr. As of now only one car on the circuit runs this unit and the baleno will be the second. The team is integrating real time fuel consumption onto the display for the sole purpose of getting better economy in the city.

Stock cluster housing modified to accommodate the display.
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Startup sequence
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The sweep has all thee shift lights coming on sequentially, first green then yellow and red. These can also be programmed individually to come on at a specified rpm

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This is an older version of the display. A custom version is being developed for the car with a touch screen interface.

Last edited by binz : 26th March 2013 at 17:02.
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Old 26th March 2013, 19:16   #34
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Default Re: Building a G16b - Turbocharged + ITBs

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Originally Posted by m4ugr8 View Post
Awesome build looks very promising indeed. I have a few questions

1. What Engine Management are you going to use ??
Have answered your question above.
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Old 27th March 2013, 19:45   #35
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Can the rpm leds be added to any car if the rd 0901 is being fitted, more specifically a civic?
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Old 27th March 2013, 20:46   #36
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Multi layered steel gasket going in as opposed to the stock graphite headgasket
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Head mounted and bolted on
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Torquing down the head bolts
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All done! Gearbox will be refitted in the morning.
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As of tonight, the engine is completely assembled. The entire manifold and downpipe till the flex pipe has been wrapped with almost 75 feet of heat wrap. Itbs have been mounted and hopefully we can have everything up and running by tomorrow.


Quote:
Originally Posted by SonnyCK View Post
Can the rpm leds be added to any car if the rd 0901 is being fitted, more specifically a civic?
The rpm LEDs are a part of the display, and yes it plugs into any Rd 0901 system
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Old 27th March 2013, 21:11   #37
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Default Re: Building a G16b - Turbocharged + ITBs

Binz,

Got here late - but still: great build going! Have a lot of queries- but will begin with this(not sure if already answered). Which TC is going to be used - I presume anything smaller than a T25 would not be appropriate for this build?
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Old 27th March 2013, 21:40   #38
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Quote:
Originally Posted by theMAG View Post
Binz,

Got here late - but still: great build going! Have a lot of queries- but will begin with this(not sure if already answered). Which TC is going to be used - I presume anything smaller than a T25 would not be appropriate for this build?
Using a Td05 big16g, commonly found on the Evo 3. You're right, a t25 would have been too small on this build - would've maxed out at around 200hp to begin with and run out of steam at higher revs. The td05 isn't the most efficient compared to the modern stuff available today, the only reason it's going on is because I had it on hand. Going by the compressor map, it's most efficient at around 21psi with power in the range of around 350-385h
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Old 27th March 2013, 22:03   #39
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Default Re: Building a G16b - Turbocharged + ITBs

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Originally Posted by binz View Post
... Going by the compressor map, it's most efficient at around 21psi with power in the range of around 350-385h
If this build is aiming even anywhere at the foot of that power hill, it leads to my next query - what's planned to be able to utilize that output at the wheels - without the wheels spinning away to glory ?!
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Old 27th March 2013, 22:18   #40
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Default Re: Building a G16b - Turbocharged + ITBs

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Originally Posted by theMAG View Post
If this build is aiming even anywhere at the foot of that power hill, it leads to my next query - what's planned to be able to utilize that output at the wheels - without the wheels spinning away to glory ?!
We're aiming big, but not that big It is a baleno after all, not a honda!
Have invested in some really good tyres to put the power down, Hankook Ventus EVO S1s in 215/45-17

With boost set by gear and rpm, wheelspin will me limited to an extent, further more .. a unique traction control system has been incorporated into the Ecu by karthik - The rate of change of rpm has been preset on the standalone with an injection cut or ignition cut kicking in if the rpms increase beyond this rate. Its been tested and it works really well!

Last edited by binz : 27th March 2013 at 22:30.
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Old 27th March 2013, 22:27   #41
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Default Re: Building a G16b - Turbocharged + ITBs

Sounds evil. I definitely need to experience this build when its complete/teething issues sorted out!
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Old 28th March 2013, 06:46   #42
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Default Re: Building a G16b - Turbocharged + ITBs

@Binz: Why have you gone for steel gasket as opposed to graphite? Dont you think graphite is better than steel when it comes to arresting leaks.

Waiting to see the car at action soon - All the best
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Old 28th March 2013, 07:48   #43
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Default Re: Building a G16b - Turbocharged + ITBs

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Originally Posted by headers View Post
Dont you think graphite is better than steel when it comes to arresting leaks.
Graphite gaskets are better at sealing leaks, but not strong enough to handle boost. For high boost applications, steel is the way to go.

Last edited by Rehaan : 28th March 2013 at 17:58. Reason: Fixing unclosed quote.
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Old 28th March 2013, 16:43   #44
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Query no. 3: which engine oil is planned? An off-the-shell synthetic or some witch's brew/snake oil?!
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Old 28th March 2013, 18:20   #45
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Default Re: Building a G16b - Turbocharged + ITBs

Am following this build keenly!

Quote:
Originally Posted by binz View Post
it will also have the following:
Anti-lag
Video please

Quote:
Originally Posted by binz View Post
Flat-shift
Given that this is not a sequential box, how will you be doing this?

Will the gear lever knob have a sensor on it like a regular flat shift system? Or will you just use the clutch sensor and take a guess at the revv-matching based on whether its above or below certain RPM thresholds?

Do you think you'll be able to shift without the clutch, or is this only a way for you to keep the boost high and match revvs better?

Quote:
Originally Posted by binz View Post
Electronic boost control with boost by gear and rpm
Does the Baleno know which gear it is in, or will your guys need to add a sensor for that?

I guess cars today (eg. Vento) have upshift indicators built in - so they would have this info.

Quote:
Originally Posted by binz View Post
iAutomatic triggers for the intercooler spray as well as for the water injection system thats planned later on.
Cool

Quote:
Originally Posted by binz View Post
In addition to this, the instrument cluster is going to be replaced by a prototype digital display system which will display Rpm, boost pressure, throttle position, speed, injector duty cycle and wideband afr.
Thats a lot of info for an instrument cluster! Since i know Karthik probably writes the code himself, it would be cool if you could press a button to switch to a cleaner display screen - where only the key pieces of info for driving are displayed.

cya
R

Last edited by Rehaan : 28th March 2013 at 18:23.
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