Jacks Cossack Grey S2 Turbo

[Jack-Cooley]

Originally Posted by Saxman2014

wow that Manifold is like proper car porn! are there any plans for it to be polished or wrapped? this thread has really caught my eye! keep up the good work.

321 stainless is nearly impossible to polish.

May wrap it one day if it discolours badly but for now it will do

Thanks

Originally Posted by French4ever

I too have to admit that air intake looks bloody good.

Air intake? The rover inlet setup?


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[Tom5190]

Is the flow rate on the rover inlet better than the standard one?

[Jack-Cooley]

Originally Posted by Tom5190

Is the flow rate on the rover inlet better than the standard one?

Depends who you speak to.

The actual diameter of the throttle body is about 4-5mm larger on the rover one. Plus there isnt the odd bottom section like on the 106 one so it should flow better.

Looks better.

And has better fittings and vac line points.

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[Rossp]

More importantly won't split like the plastic ones can. You don't want to go too large with the TB. The standard DP TB (70mm) is far too large and makes tiny throttle openings (1-5% load) difficult to map and drive with in the real world. I've reduced from 70mm down to 65mm now because of that.
Thanks josh for clarifying re bracket. Yes I mean bracket - sites the alternator lower giving more clearance (will also mean you can get that downpipe sorted as it's not ideal (will be "ok" but I'd change it personally).

[Jack-Cooley]

Originally Posted by Ross

More importantly won't split like the plastic ones can. You don't want to go too large with the TB. The standard DP TB (70mm) is far too large and makes tiny throttle openings (1-5% load) difficult to map and drive with in the real world. I've reduced from 70mm down to 65mm now because of that.
Thanks josh for clarifying re bracket. Yes I mean bracket - sites the alternator lower giving more clearance (will also mean you can get that downpipe sorted as it's not ideal (will be "ok" but I'd change it personally).

Ill measure the TB tomorrow, does anyone know the size of the original Peugeot/cit one?

okay so the bracket dosnt make the alternator sit any further left or right just lower down, thus moving it away from the alternator (Fingers crossed)

as for the downpipe you would have it more off the turbo and hooped around rather than how it is now.

Not a massive fix really im sure GR said they could do me one for around £150-200


ive also spoken with a mates mate who owns a machine shop about making me a fuel rail.

id have a go myself but in the end id have to go to them for the welding so ideally i should just have them do the lot.

unless you know a place that does alloy/steel fuel rails for these engines. i cant seem to find one that is a specific upgrade on the original plastic setup.


also anyone know a decent FPR company/brand

[Rossp]

Standard vts is 63mm

John at gmc will do you a fuel rail.

You can see how much extra room it gives you here. For reference, that's a 3" downpipe, not 2.5"

[Jack-Cooley]

Yeah so i bet the rover ones 65/66 at the most.

Looks well there.

I will look into it thanks ross

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[Rossp]

Rover 220 turbo manifold TB is 56mm.

Edit to add: you really don't need bigger. Honestly.

[Jack-Cooley]

56mm? Thats smaller than a vts one? I put mine against the rover one earlier and it was larger

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[Rossp]

Google it. That's all I did.

60mm will support 500hp+.

Going larger than you need is daft - you just reduce resolution. In simple terms, if you have a TB that can supply the 100% engine load air requirement at 70% throttle opening, you've now only got 0-70% resolution to drive with.
In a gale opening a door just a crack gives a huge draft and almost rips the door out your hand. Open a small window by the same crack and it's much easier. 1-2% of a small window is much less volume of air than 1-2% of the door.

[Jack-Cooley]

Very good explanation

Gotcha!

Ill stick with this rover one what ever the size may be

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[Rossp]

It's a good shout - Martin will be making 400+ on one so you'll be fine

[Jack-Cooley]

Yes i should hope so.

Next few buys should be fuel rail, oil temp gauge, and the owens development gt28 clamp kit

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[jpsaxo]

Yes the 8v alternator moves the alternator further down (away) from the turbo / manifold so gives you more space Jack

[tweeqd]

The ax gti uses a single v belt so sits further away from the turbo, with the 16v bottom cambelt pulley bing wider than the 8v the alt is spaced away even further so there is loads of room for a decent downpipe angle

An off the shelf fuel rail wont work as the injector spacing wont be the same as standard

[dannygti]

The GTI throttle body is tiny, the opening is a decent size but because the idle control valve. The butterfly itself is only about 45-50mm IIRC

[Jack-Cooley]

Yah exactly danny a lot of the space is taken by the idle control

I have a few questions about the inket though, what do i do with intake air temp, icv and the other sensor that i dont know what it does?

I know i may need the tps plug changing unless i can bolt on the peugeot tps?

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[tweeqd]

If you keep the rover lower section instead of the bodged pipes you can use the rover IAT sensor, use the rover TPS and calibrate it to the ecu
And dont run IAC, mine doesnt and idles at a steady 800rpm

[Jack-Cooley]

Do the rover bottom halfs fit straight onto the 106 head?

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[welshpug]

50mm still plenty bit enough, WRC cars run 33mm restrictors currently on 1600 turbos, fiesta is making 300, and 450 nm, polo is making 315 but a bit less torque at 425.