Chris' (worzel) Black LCR - BT Build

[wild willy]

I fitted mine with the head on and unless you've done it yourself you have no ideas how stressful it is.
Sounds great now though worzel.

 

[ibizacupra]

The love is back but by god what a complete nightmare journey. *Recap, I took the engine & gearbox out to fit forged rods and an LSD, & whilst out I fitted a JBS mani and garret 2871r eliminator (for k04 flange fitment). *The BT didn't like the mani at all so bought the relentless v3 mani.

Fast forward to last week & took Friday off to fit the new mani. *Removing the JBS mani was a job in itself especially with the engine in. *Removed the dogbone mount, the down pipe, detached the turbo & moved to one side, then disconnected the drivers side engine mount to move the engine forward a bit, which gave me more room between bulkhead and engine to get the spanners in to undo the mani nuts (some undid from underneath). This probably took 6 hours! *We then dropped in the v3 with supplied gasket, which slotted in beautifully I have to say. *Did up the nuts easily and went home to carry on on Saturday. *I only had a couple of hours as my boy had a party to go to, so got up extra early to crack on putting everything back together.

This you think would be straight forward...no! *I mated up the turbo to mani & of the 3 studs one is almost inaccessible, sitting right under the tubes of the mani I could not for the life of me get any kind of spanner on it. *So with time running out I did everything else up and just tightened the 2 nuts that I could access. *Knowing that one was not tight I started her up and with no surprise hot gases were leaking through the flange in to the bay, and with the car sounding like a bag of spanners I decided I would risk the short drive home ( with the bonnet on it's catch to try and add some cooling). *Car has been sat beside my house all this week until today...

More on next post...

You can see and follow my recent moans/frustrations/modifications required to fit a V3 successfully in my Facebook page> http://www.facebook.com/Badger5Ltd Pictures of the inaccessible stud + spanner shown, and Required Mods..

 

[worzel]

Nice work. I've been reading Bills comments on fitting the relentless on FB. It looks a pig of a job to do with the head off let alone on!
You can't beat a dirty car with big breaks

Thanks, was a high five moment once fitted.

I fitted mine with the head on and unless you've done it yourself you have no ideas how stressful it is.
Sounds great now though worzel.

Agreed...lots of patience. True modding when you have to fashion your own parts.

Bill, whilst not ideal inserting a spacer as I have (acknowledging I had to due to BT) gave me extra clearance resulting in easier access, not much but every little helped.

 

[worzel]

New DV and piping ready to DIY cold side relocation...not all the bits but you get the idea

Had to take this for comparison

 

[worzel]

Quick update. DIY DV relocation done. Shame that supersize DV is so hidden. Function over form eh!

I bought some flex silicone hose (seen in previous pic) that I didn't actually need to use. I cut the intercooler relocation hose to get a 90 degree angle which you can see connects to hose coming off the TIP.

It's only boosting 15psi but still very rapid...more tweaking & proper logs needed I think.

 

[Bonzy1800]

Looks awesome Chris good job, must be rapid now.
seen my old beast about a month ago at the st brelards bay hotel

 

[worzel]

Pics for Balazs

B5 V1

Lambda

Up to date bay pic

Progress none existent at the moment due to lack of funds...childcare is sooo expensive but not forever. Roll on next year!

 

[James23Parkin]

Looking good Chris. Sorry to hear about the recent woes mate. Back to driving early next year?

Was the car running well after its engine mods? May be some time over the winter to get things buttoned up and ready for the years of future ownership

Oh, and yes, we're just beginning to experience child care costs now that our son is going into Nursery... Ouch... But so worth it.

 

[worzel]

Thanks James, will be later next year unfortunately before I can drive. But as you say time to get things done, and the list is quite extensive. Due to some changes in family circumstances, both our little ones are in full time nursery now...monthly fees are equal to a mortgage...but so worth it, the benefit my 3 1/2 year old gets is immeasurable, so much more on the social development.

Car is running ok and I make the wife take me out in it occasionally (much to her dismay), keeps the fluids circulating and the battery topped up, but as you can imagine she won't put her foot down (and rightly so considering our transport limitations), so the turbo doesn't even engage lol. It's nice when she makes comparisons to the Forrester, that the LCR feels so planted to the road (her words), and she likes the brakes...she hates the noise though. It definitely needs a custom map which I can only get done in the uk, so that is a long way off.

I have the OEM parts that got replaced to sell; Brembo's (once I've refurbished) and the K04 turbo (only 45k miles - bit of a plug there)
I'll do list so I can cross off as I go along.
Chris

 

[czaki]

Pics for Balazs

B5 V1

Lambda

Up to date bay pic

Progress none existent at the moment due to lack of funds...childcare is sooo expensive but not forever. Roll on next year!

Thanks for the pics Chris! The weather was really awful here in the past few days, but when it gets better I'll try to take some pictures of my engine bay.

My engine layout is basically the same, the only difference is that the LHD has its brake master cylinder on the left side of the car. Which makes really hard to install a big bore TIP...

The JBS manifold I bought from you has the same layout as my OEM manifold, except its size: the JBS one is much bigger, the tubes running to the collector are really thick compared to the original one, that's why I couldn't manage to fit the lambda sensor to its original position. I assume the other reason is the bigger, 3" Milltek downpipe, simply not enought space left for the sensor. As a solution my mechanic drilled a hole 2-3 inches further away from the original lambda boss and welded a new one in. Unfortunately I had to put a nut in the first hole to cover it, not the best for looks. By the way it cured all my problems, no rough idle, no CEL, car runs happily.

The other downside is that my MPG went down a bit, but perhaps because of two reasons. Firstly, I've installed a Badger5 V2.2 TIP along with the manifold, so maybe more air with freer flowing exhaust and manifold needs more fuel too? And secondly I have to put my foot down more often because the whole car feels more alive and sounds so much better better now.