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 Post subject: Re: GTi Build diary: from block guard to f%$#@d!!!
PostPosted: Fri Nov 06, 2009 11:57 pm 
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Capt_Gherkin wrote:
Dudes!
I have also today shared the pics with Abe and he says that the blockguard is actually a good thing, and that without it "the cylinders do walk around a bit" if you have >180hp.
He also says that the cracking is common, but it is due to fatigue and happens over time, particularly on turboed Suzukis because the engine torque is pulling against the back engine mount. In other words the damage was probably already done on my block from it previously being campaigned hard!
He says that a blockguard works well, if fitted correctly, and that Pete is very thorough in this work.

He also said that it is hard to pick up the cracking in that location before it is serious, and because the G13B are roughly cast they cannot be x-rayed, only visually checked with crack-test dye.
And therefore it is important to get a non-turbo, non-distressed block as a replacement.



James I have spoken to Abe about these problems before. It seems we are talking about different questions or different person. His opinion when I spoke to him was very similar to RUNUT's summation so i wont repeat it.
His race engines run at 1 bar mostly (non swift) and do not require block guards. His prefers dovels pins if more then 1bar is required (more then 1 pair per cylinder) as they are more predictable then a blockguards you buy ready made. Ideally custom block guard is the way to go but as RUNUTS suggested at a great expense to have one properly fitted.

I hope you achieve what you set out to do quickly and hit the track soon.

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2006: Mk1- yeah well at some stage to go on track...
2003-2005 Mk3(retired)- EC 1:54.6 , Wakefield 1:13.14 , OP (short) 52.00 , OP GP 1:24.40


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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Sat Nov 07, 2009 12:16 am 
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Sorry to here it happened, :cry: :cry:
as runnuts said the fit was not good and as i was saying earlier it needs to be made out of the exact same metal compound or the expansion rate is different and puts load on the block, this also may have been the problem with the TimGuyPerson block after hammering in the block guard distorted the cylinders.

I run with no block guard and track race a fair bit, never had a problem, after pulling the head off a few times the gasket does not look the best from movement but is not leaking or let go.

With O-ringing just need to make sure the gasket is made to sute the o-ring correctly, the question is with or with out the receiver groove,
All i can say is hang in there, if is was easy we all would have fast cars.
You have my number if you need to chat

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 Post subject: Re: GTi Build diary: from block guard to f%$#@d!!!
PostPosted: Sat Nov 07, 2009 7:21 am 
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Capt_Gherkin wrote:
And therefore it is important to get a non-turbo, non-distressed block as a replacement.

So next question should it be o-ringed or not?! 8-[

Get yourself a g13ba block, much less chance of it having been thrashed compared to a g13b.
Why not go the mls head gasket and do without the o-ring? Might be worth looking into.


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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Sat Nov 07, 2009 2:28 pm 
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viewtopic.php?f=7&t=36355&hilit=pressure&start=40


Thats the link to my SAGA with this well known workshop and their engine building "service"

Yes I was running a blockgaurd with the engine that cracked the block, although I still am running a blockgaurd with the engine that I am currently running and everything is exaxctly the same

there havent been any real "issues" since getting it back after them rebuilding the cino block, Touch wood,lol

although just make sure that YOU Get the timing checked after aswell as THEY Cant set timing on and engine or AM computer, with mine set at 20deg advanced


ive PM'd you my number and replyed to your PM


BRAD

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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Mon Dec 20, 2010 10:45 pm 
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Can I dredge this up from 12 months ago and find out what the outcome was?

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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Wed Dec 22, 2010 8:51 am 
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fair question sk4wd!

It was a long story and becoming too depressing to keep updating..

But now it has been running well for about 9 months and occasionally doing trackdays again now - and updating the thread & posting some track footage has been on my To Do list for a while!! Will do it soon! :wink:

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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Wed Dec 22, 2010 12:05 pm 
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Capt_Gherkin wrote:
fair question sk4wd!

It was a long story and becoming too depressing to keep updating..

But now it has been running well for about 9 months and occasionally doing trackdays again now - and updating the thread & posting some track footage has been on my To Do list for a while!! Will do it soon! :wink:

Pick me up on the way past next time you go down :wink:

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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Wed Dec 22, 2010 8:13 pm 
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waylow wrote:
Pick me up on the way past next time you go down :wink:


what a good way to reignite a need for speed (and tinkering) by watching somone elses swift go around the track.

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2006: Mk1- yeah well at some stage to go on track...
2003-2005 Mk3(retired)- EC 1:54.6 , Wakefield 1:13.14 , OP (short) 52.00 , OP GP 1:24.40


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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Wed Dec 22, 2010 9:49 pm 
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Waylow has had a drive of my beastie a while back too - he immediately started mumbling something about "..getting me a turbo!!!" :lol: :lol:

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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Thu Dec 23, 2010 9:11 pm 
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Capt_Gherkin wrote:
Waylow has had a drive of my beastie a while back too - he immediately started mumbling something about "..getting me a turbo!!!" :lol: :lol:


Turbo aint going to help him too much now, as he has no car, Well none of his own, I gather he will be driving his brothers for a good 6 months before he gives it back.

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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Fri Dec 24, 2010 9:19 am 
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moylee19 wrote:
Capt_Gherkin wrote:
Waylow has had a drive of my beastie a while back too - he immediately started mumbling something about "..getting me a turbo!!!" :lol: :lol:


Turbo aint going to help him too much now, as he has no car, Well none of his own, I gather he will be driving his brothers for a good 6 months before he gives it back.

Give it back? I thought possesion is 9/10th's of the law?

Yes James, is right, I WAS hooked in no time, so I went and got one. Has a better badge on it though :lol:

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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Tue May 03, 2011 9:23 am 
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Just curious. Who did the machining on your rims??
How much metal is left on the hub face of the rim?

I just rang performance wheels to price a set of 13x7's for mine but they only came in -7 offset..
The next best was 13x6 and it was at +23 which will still need some gaurd work..

I don't expect answers straight away but it's got me thinking :idea:

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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Wed Feb 01, 2012 10:22 pm 
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Hi all,

I have said for (cough :wink: ) quite a while that I would update the build thread of my GTi - those who have read previous pages will know that it was an expensive and frustrating saga.. in fact I stopped in the end as it was too depressing.

So I am not going to dwell on what happened in the several engines it went through, but I am very pleased with how it is going now.

More than a year has passed of driving a high-powered GTi as my daily driver (including 4 track days), and actually it has been very reliable - a clutch, a cracked rotor, and a dynotune have been the only significant costs in the last year or so..

So here is a summary of where the car is at now, in terms of specs and mods;

A car with some History..It was well known in the early GTi days as CMYTOY, owned by Michael. It was in Hot4s mag http://www.ssgti.net/main.htm , did low 12sec 1/4 miles (http://www.redlinegti.com/qmt/), even won 'best enginebay' autosalon2000!!
It was even voted in top 3 all time coolest GTis viewtopic.php?f=4&t=48295&hilit=cmytoy&start=0 . :lol:
It is very clean, with Cosworth bonnet vents and a wide stance being the only giveaway that it is not standard.

Engine Specs (145kW atw at 15psi, re-built about a year ago)
new vf45 twin-scroll turbo (spools from about 2200rpm! ) and tuned manifold from DMWDave - this is the jewel of the engine and spools early and steadily. Will spin wheels in 4th just by flooring it! :twisted:
Haltech E6X ECU
Forged CP pistons & rods, ported & polished head &flow tested,oversized exhaust valves, Cultus cams, crank & pistons balanced.
Block from DMWDave, o-ringed, sonic tested, and grout-filled (up to the water pump intake,this helps the rigidity of the block. no freaking blockguard or dowel either!!)
9:1 comp ratio
Cam sensor for sequential injection (has made it significantly smoother,especially at low throttle)
Xtreme racing clutch (Exedy brassbutton HD clutch did not last a year)
DMWDave 4.5kg? lightened billet flywheel
Greddy Profec B Series II Electronic Boost Controller - Now ‘Low’ = 10psi (everyday road use) and ‘High’ = 15psi (trackday use)
New waterpump, oilpump, genuine Sards FPR, oversize fuel rail,
ColdAir box, urethane back engine mount, oil catch can (which drains back into the sump), oil cooler, Oil filter is inside the corner of the quarterpanel, with braided piping
new Bosch 450cc injectors
Modena LSD, one or two straight cut gears I think, Cino 5th ratio, lower ratio crownwheel (not sure exactly what)
2½inch exhaust with offset muffler, hi-flow cat - not super loud but sounds great..

Handling Specs
13x7” Minilites (with max offset machined), and Yoko A048 Semi slicks 205/60 13 (this made a huge improvement, improved 3secs at Marulan over the previous 17" 40 profile wheels!! Tyre press recco for A048 by Waylow which seems to work well; 28 psi front cold, 31-32psi rear cold => 36psi hot. Also 205/60-13 is only 6% larger diameter than standard 15" according to my GPS)
The big advantage here is that a whole set of the A048s can be bought 2nd hand for just a few hundred dollars, after 8 laps on an Aussie Racer!
Front brace with Engine steady, underbody front brace, rear brace, (Viagra to a GTi!)
Koni Yellow Front & Rear shocks, (rear less than a year old)
king springs Front 225lbs(I think?) , 600lb custom wound King spring rear
urethane bushes all over
Suzitech front coilovers ( http://www.suzitech.com/ ).
Not tweaked suspension at all - initially set it up moderately, with "2 - 2½ degrees negative camber, as much caster as possible and 1mm toe out on each tyre (front and rear)".

Honda Odyssey front calipers and DBA rotors with Ferodo 650C track pads and Castrol Super DOT4 brake fluid. braided lines. Also alloy air scoop on the hubs to direct air onto the brakes.
ie, stopping power is bezerk, hardly ever met a car I can't outbrake on a track!!
SUZ137 tierod arms
Lightweight Odyssey PC680MJT battery in boot, external isolator switch
Power steering (purchased from It'sUIt'sme) really helps with torque steer and also slow carpark turns!

Other mods
Progressive Shift light
decent alarm/immobiliser
Autometer oil temp & oil pressure & boost & voltage Gauges
'Tekkie-style secondary bonnet restraint'
Suzitech Shortened shifter, billet knob,
Greddy Remote Switching button so I can flick to high boost without taking my hands off the wheel (it is a wireless switch, $185, http://www.rmsmotorparts.com.au/cgi-bin ... tching.htm seemed like a good idea at the time, but I never use it!)

Further possible Mods?
I have thought long and hard about a rollcage, but it is too hard to use as a daily driver! (often dropping the kids to school or whatever)
Mark Chapman from MRC says that the BOV is currently constraining it from getting more boost than 15psi - so next time I have a bit of cash spare that is top of the list.
Also the TPR sensor was not working - so Mark de-tuned it a bit to compensate (down to 140kW atw). I now have a new one so just need to get it fitted too.

Track Times:
Marulan 46.0secs
Eastern Creek 1:59secs (first time)
Oran Park 1:29secs
Wakefield 1:17.9 secs (wet)

Some video footage at; http://www.youtube.com/user/T0yRac3r

A few pics and other info soon, but there it is.. finally!! :wink:


Attachments:
File comment: SUZ137 strengthened tierod arms
tierod arms.jpg
tierod arms.jpg [ 168.6 KiB | Viewed 168 times ]
Swift-at-Marulan-with-Minilites.jpg
Swift-at-Marulan-with-Minilites.jpg [ 137.94 KiB | Viewed 109 times ]
File comment: Exedy brass button HD clutch was disappointing
crap Exedy.jpg
crap Exedy.jpg [ 102.13 KiB | Viewed 4297 times ]
File comment: new block with forged CP pistons
CIMG4910.JPG
CIMG4910.JPG [ 638.5 KiB | Viewed 110 times ]
File comment: Cam sensor for sequential injection
16052010165.jpg
16052010165.jpg [ 1.78 MiB | Viewed 119 times ]
File comment: A pic of the GTi in action at Marulan
Marulan 26Feb11 A.JPG
Marulan 26Feb11 A.JPG [ 3.07 MiB | Viewed 113 times ]

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Last edited by Capt_Gherkin on Wed Feb 01, 2012 11:56 pm, edited 3 times in total.
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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Wed Feb 01, 2012 10:58 pm 
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The way I look at it, is your never losing money if you never sell it. :lol: its just modifying constantly.

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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Thu Feb 02, 2012 1:11 am 
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What BOV are you currently using? I have a Turbosmart Kompact PB series BOV and it works a treat. No probs with 18psi and after a quick enquiry with the guys at Turbosmart it's supposed to hold whatever you throw at it.
http://www.carmodsaustralia.com.au/turb ... -0203-1221


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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Sat Feb 04, 2012 8:19 pm 
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current BOV is a Turbomaster ICV 32.

Sounds like it is time to replace it with something more serious..

By the way - I have just reluctantly listed it as an EOI..
viewtopic.php?f=13&t=48904

This does not mean I definitely will sell it, but I probably will.. :cry:

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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Sun Feb 05, 2012 1:33 pm 
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Not interested in a liberty GT James? :wink:

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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Mon Feb 06, 2012 8:51 am 
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that is tempting Mark, but I really would like a smaller rocket than yours, like the Golf R32 I mentioned.. :wink:

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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Fri Feb 10, 2012 4:16 am 
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hi Capt_Gherkin,
how does the car drive with those 600lb springs on the back of your car for street use, especially bumpy roads? i am hoping my car can preform the same duties as yours, daily driver with some track/autocross use.


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 Post subject: Re: GTi Build diary: from street tough to track day
PostPosted: Fri Feb 10, 2012 5:59 am 
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600lbs progressive rate springs on road car is fine. Have them on my car.

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