I want to share with you something.

[scuzzy]

Today I took my rally car out on the road for one more drive before it gets too cold here in Nashville. It was a beautiful 70F today.

First, this is the car:
http://www.youtube.com/watch?v=MWw5Y5Ndo4Y

This is a quick 1-2 pull I did on my street, I didn't take it any further cause this is still a neighborhood:
http://www.youtube.com/watch?v=DAXtfjN9nUo

Boost then was 15PSI peak with a 10PSI settle, I still hadn't worked out the kinks in the MBC.

So that's the short of the history, here's some specs:

= Bone stock EJ22T from a mechanical standpoint, with a RHB5 VF-11.
= 3" Downpipe mating into a 3" Moroso Steel Spiral Resonator
= Manual boost controller made out of bits and pieces.
= Walbro 255 HIGH-PRESSURE fuel pump
= Dual-feed fuel rails.
= stock EJ22T injectors
= Aeromotive 1000 series regulator set at 60PSI base pressure.
= Link G4 Storm ECU (Standalone, I wired it in)
= Dual Ignitors for when I eventually switch to direct ignition.
= Custom made intake pipe from steel stock - runs under the intake manifold. Plus a 4" Cone filter I picked up locally really cheap.
= AWIC fed by some high-pressure high-flow 12VDC pump I picked up at Harbor Freight. cooled by an inefficient transmission cooler. Looking at getting my own radiator built to do the job.


Here's the recent (last week to today) history...

I've been fiddling with my MBC, trying to get it to deliver me some boosts past 10PSI. No amount of adjustment-screw tweaking really does the job. I finally figure out that regardless of the setting, air is leaking past the check ball due to the uneven shape of the surface it sits on. Instead of trying to fix this (I actually did, somewhat unsuccessfully) I just drilled a 1/16" hole in the thing.

I took the car out for a spin then, and in a 2nd gear pull I wailed against 18PSI. AFR's were good (I was watching closely as they fell into the 10:1 range). So I did another 2nd gear pull after slowing. It was absolutely delicious. I was datalogging this, so I downloaded that map and went over some of the numbers. Everything looked good so I left it be. I like 18PSI and it pulled like nuts.

My timing is still really conservative, at that particular pressure around 5500RPMS I was only running 18 degrees timing and was seeing AFR's sinking into the low 10:1 range - safe to say, I'm not concerned about knock. I'm also using 93 octane, so that helps.

I took the car out again today, after welding up a new exhaust hanger and some other stuff.

Well, somewhere along the way the ball in my MBC stuck against the surface sealing it shut (I had to tap it to get the ball to drop out after removing the spring later on); effectively I was running without a wastegate.

while in the midsts of overspooling my turbocharger, I took a couple datalogs.

http://gallery.thelostdays.com/store/20 ... r-pull.png

This is a 1-4 gear pull I did on an open road. At the RPM I was in for 4th gear I estimated my speed to be around 85MPH, and judging by the datalog it took approximately 7 seconds of power (not counting shift times cause I was granny shifting it) to achieve that speed. I estimate the 0-60 mph would be on the order of 5.5 seconds.

The plug gap on these plugs was also 0.040" which is too wide. I turned them down tonight to 0.025" because It feels like the power is sagging off too far at high rpms.

On the 1st gear pull, I had the rear of the car step out, so I stayed in the throttle to straighten the car up, which ran me over into an RPM limiter at 6000 rpms and caused little weird things to happen on the datalog. Boost in this gear was 90kPa = 13PSI

2nd gear was stronger, boost came on strong and peaked at 17PSI tapering to 13PSI at 6000 RPMS. IDC was almost 90% as I let off the throttle.

3rd gear was stronger still with a peak at 17PSI and tapering to 13.5PSI - IDC peaked at 80% when I shifted at 5500RPM

4th was the strongest of them all. I think this is where the MBC stuck closed and the turbocharger was allowed free range. Boost rose sharply and peaked at 18PSI. The little VF-11 held this from 4000RPM to 4500RPM just fine, tapering to 17PSI before I let off. IDC peaked at 70% and AFR's were 10:1 range.

I was going at a pretty good rate and felt the car had plenty left, but I decided to slow down and see how it did from a 2000 RPM roll in 4th gear.

Well, our little VF11 spins to infinity and beyond, and at low RPMs it builds a shit-ton of boost. I don't know how much exactly because I've got a MAP limiter on which kills ignition and fuel when I cross 130kPa (20PSI), but this was the event:
http://gallery.thelostdays.com/store/20 ... rboost.png

The huge spike in AFR was a charge igniting against the hot turbine vanes in the exhaust. It sounded like a gunshot and scared the hell out of me. I thought I had thrown a rod. I was paying really close attention to the AFR's and boost as I rolled into the throttle (you can see i didn't get past 80% when the turbo hit 140kPa = 20.3PSI)

I had video of this event, but it was poorly taken so i just extracted the audio instead:
http://gallery.thelostdays.com/store/20 ... 110709.mp3



Well, this is my rally car.

The cage goes in around January, about the time I have to haul it down to Birmingham and have it custom fitted. I'm buying seats hopefully in December, and a new steering wheel as well. Next year is going to be a wild ride, this car already is! I'm hoping to get some dyno time coming up soon but I've got to find a 4 wheel dyno nearby. So far I've just been starting very conservative and tuning slowly, reviewing the logs, making adjustments, and going back out there.

I hope you guys enjoy this as much as I do!

[206er]

pretty cool. how much does it weigh in that state? its the most heavily gutted legacy wagon Ive seen.
what is your ultimate goal with the car, pro rally or?

[scuzzy]

no clue what it weighs, but if I had to guess I hear most wagons are around 3100. The bumpers were 85 with covers or so? the interior, fuel tank, door cards and dash, well I imagine most everything else was between 200 and 300 pounds.

I put it in the vicinity of 2700lbs; hopefully lighter.

Hell, the wiring harness was ten pounds. Plus all the steel under the dash was probably another 20. The dash itself was 20. the A/C and blowers, connecting lines and such came in around 75lbs.

Ultimate goal? To have a ton of fun, but in the short term I'm going to participate in SCCA Rally-X. I built the car to those rules... I doubt it's legal in any other sanctioning body.

I would love to get into pro rally as a career choice, maybe one day.

[scuzzy]

The fact that this thread is quiet with so many views bothers me.

[Grayguy]

why don't you have bumpers?

[206er]

weight! if he doesn't have to run them for rallyx it is a good place to shed weight at the ends of the car. it certainly looks mad max. maybe you could reinstall the bumper skins with some small tabs of metal for the looks.
i wouldnt even put in a cage for rallyx. too much weight and expense when its not required and you wouldnt have a bad enough roll in rallyx to need one anyway.
scuzzy i think you need to break out the cutting wheel next. there is a lot of sheetmetal in the rear doors, hood, core support etc. that you could get rid of.

[Mattheww044]

damn, that thing sounds MEAN! nice setup and best of luck!

[scuzzy]

I want to run a cage because a roll at 50mph in this car will still be pretty nasty. If you ever take the covers off the steel around the B pillars, pull the seatbelt tracks out, and take a real good look, it might bother you too!

Plus, I need a way to get a 5 point harness anchored in the car. A cage will also stiffen the car up immensely. I'd rather spend the 2 grand on a cage (about what it costs at a place I know) than 2 grand on hospital bills due to injuries without a cage.

I doubt I'll ever have a problem, or ever roll the car, but the cage is for the unknowns

[206er]

fair enough. you will like the added stiffness too, makes it much funner to drive.

[scuzzy]

I added a new video, this one with a camera mount I built this afternoon. Much better viewpoint!

Also got the MBC working right and dialed the boost down to 15-16PSI

http://www.youtube.com/watch?v=i3bvFzMI_k0

[Grayguy]

it just doesn't make sense to me to have all the vitals in front of the car exposed. One mess up and your motor could be destroyed.

[scuzzy]

it just doesn't make sense to me to have all the vitals in front of the car exposed. One mess up and your motor could be destroyed.

Uhm, any messup at all and it doesn't really matter if there's a bumper there or not, you're going to do damage. Think about it!

Frontal impacts are almost non-existant in rally, usually cars slide into something on their side The bumper isn't going to stop rocks, dirt or mud, water. It's for spreading a frontal impact out over the frame of the car to lessen the damage to the passenger compartment.

Remember, this isn't a car I drive on the street to any destination with; I'm trailering it to the rally cross site. It's far beyond street legal.

[Smithcraft]

It sure sounds nice!

SC

[NuclearBacon]

I also agree!! it sounds awesome! i'm looking forward to seeing what you end up doing with it!

Awesome!

[NICO]

WOW !! that is one stripped down legacy, nice job it looks crazy. it should be fast as hell with everything out of it.

[cartwheels]

Loving the car. Where'd you source that AWIC? That's not a stock EJ20 intercooler from a first gen, is it?

[scuzzy]

It's from over the big pond, I believe. I bought it from someone on this forum - just can't remember who.

Think I paid $75 for the AWIC.

the latest is:
http://www.youtube.com/watch?v=8PJPVlqBZRk