The Boy Did Good !!

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The Boy Did Good !!

Postby Paul S » Tue Sep 21, 2010 3:35 pm

Tasked with the challenge of making my Daughters Turbo Astra produce over 400bhp, what is a chap to do?....... Get the tools out and have loads of fun, thats what.
Final figures on the dyno this week were; 418bhp with 423lbs of torque.

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Re: The Boy Did Good !!

Postby Mr G » Mon Sep 27, 2010 4:39 pm

Did you document it in the end? Would be interesting to read/view through if you did :)

Cheers

G
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Re: The Boy Did Good !!

Postby Cossydut » Tue Sep 28, 2010 10:40 am

Will be fun off the line,when do you hope to have it all up and running.
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Re: The Boy Did Good !!

Postby Paul S » Mon Oct 04, 2010 3:11 pm

Took a few pics along the way :)
Start with a mad Daughter who loves her cars, and say's give me more horse power Dad!
The Shopping List

Free flowing inlet plenham
Garrett T30 Turbo
Tubular exhaust manifold
Balance shaft deletion kit
Uprated oil pump
Fast road inlet cam
Vernier inlet cam pulley
Large capacity front mount intercooler
Larger induction pipes
Modified air box
80mm air flow metre
Wossener low compression pistons and Rings
Steel con rods (with oil spray)
Bearing shells
Helix clutch
Quaif Limited slip diff

Work to undertake

Porting and polishing cylinder head
Re cutting valve seat angles
Balancing of Crankshaft/Flywheel/Front pulley Assy
Removing crankshaft balance weight assy
Honeing of bores
manufacture alternator bracket
manufacture actuator bracket

SIMPLES !!!??? :shock:
She did help to strip the engine, bless her.
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More to follow...
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Re: The Boy Did Good !!

Postby jonno » Mon Oct 04, 2010 6:40 pm

That much power in front wheel drive will be interesting :D
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Re: The Boy Did Good !!

Postby Paul S » Mon Oct 04, 2010 9:44 pm

The Astra G Turbo engine Z20LET, has a set of contra rotating balance weights, slung in a cradle below the crankshaft and driven by a gear which is cast into the crankshaft. These can be disposed to make the engine rev freely and reduce a lump of weight, so out they come. Vauxhall supply a kit that contains a new cradle, baffle plate and extended oil pick up. This will also help with a few extra horses at top end. The oil feed to the balance shafts are through drillings in one of the main bearing caps, so these are plugged with a pair of grub screws. Due to problems with supply of the extended oil pick up, I had to make a pair of brackets up myself for the supports.
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Re: The Boy Did Good !!

Postby Paul S » Tue Oct 05, 2010 7:34 pm

Work on the cylinder head was to be quite extensive, there was a large difference between the diameter of the ports on the new inlet plenham and the ports on the cylinder head, I had to remove a rather large amount of material from the head to make the two the same size. Smoothing out the ports and reducing the webbing (not sure if that’s the right name) between the two valves in each port to a knife edge. Cut the valve seats to a three angle configuration.
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The crankshaft, flywheel and front pulley was sent to an engineering firm for balancing and to be polished as there was a few marks around one of the main bearings, I was concerned that removal of the balance shaft assembly would leave the crank out of balance, you can see the drive gear mounting for the balance weights cast into the crankshaft. The bores were honed as well. Image
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