Bockscar 2.0

[Stainless1]

Jerry, those were cranking compression at WoS or WF last year... just haven't put a little thinner on a rag yet to erase.  That hat has spacing for multiple motors I have laying around.  It's a handy chalk board area for notes.

[Stainless1]

Its been a while since the last post and a lot has happened.  Joel Jackson came down to help dyno the 3/4 on E85... We put boost control on and figured that out I think... Then the 3/4 came out and the 1 liter went in and we started looking at the new turbo installation.  Joel was great help... 

I ended up building a new exhaust for the 1 liter Busa motor.  The new turbo, same one I used on the 3/4, did not fit the old exhaust system.  So I put duals on this one too.  The big pipe from the 3/4 is reused... luckily I made that one kind of universal. Tried to make the wastegate pipe work, gave up and just built a new one. It looks like the new airbox/filter box will also adapt to the Busa motor
One issue with this setup is the oil filter was about 1/8 inch from the turbo turbine making exhaust system removal necessary for oil filter replacement.  The bikes have the same issue, so there is a $200 fix... an adaptor that turns the oil filter 90 degrees. 
Removed the exhaust system after the picture and started wrapping all the pipes before it goes on the dyno for a check out... time is getting close and there is still plenty to do.   So with any luck the remaining re-assembly is final assembly.

[floydjer]

Almost there...looks great Bob.

[Little Puke]

Good beer, great food, and having an opportunity to wrench on the car made it difficult to board the flight back home. Bob, both you and Linda are superb hosts; I appreciate all you guys did to make sure I had a fun stay. I look forward to seeing you and car on the salt in a few weeks.

PS: the focaccia was excellent, got to share the last couple pieces with family over the 4th

[Stainless1]

Y'all might remember I mentioned I ran out of injector with the 1 liter on E85... with 650cc injectors so I popped in the 1000cc injectors.  Well idle is about 3500 and wants to climb as it warms.  I lowered fuel pressure and idle went up  yea that made it slightly leaner... So I ordered some 750cc, but they wrote back and said they were out... not expecting more for a couple months.   But they had 850cc in stock... those are on the way.  Have my fingers crossed they will idle under 2500.  The 650's idle under 2000 with a 1 millisecond spray, minimum on the 1000cc was 1.6 milliseconds.  I will have to look at the specs for cycle and dead time on the 850s when they arrive. 
While I wait I've been doing clean up and final assembly on everything else.  Yes I still need to run it on the dyno. 
If you see a loose bolt let me know...

[Stainless1]

Of course all 4 wouldn't fit in one post... so moving on to the top and other side...

[Stainless1]

850cc injectors are in and it starts and idles at an acceptable 2K rpm. Ross came over to help run the motor on the dyno.  Had to do a little clutch adjustment... ended up making a new clutch pusher rod to make adjustment easier.  Managed to get one pull in at 7000 rpm... the entire map was too lean... not just a little lean, so we pulled the plug and I started working on a richer map.   
Ross coming back this evening to run it again... I'll try to be ready

[mc2032]

This EFI stuff is part science, part magic.  When it works it's great, when it doesn't you learn a whole new vocabulary of swear words.  But I have faith Bob will get it sorted out.  I will try to get a few pictures or a video to share.  Two weeks till we load the trailer for the trip west.

[Rex Schimmer]

Electronic FI can do some amazing things. Watch Steve Morris Racing Engines on Youtube. He takes a turbo big block and makes 2500+ hp on methanol then "converts" the engine for street driving on 93 octane gas, and makes 1300+ hp, and it is all done with the electronic fuel injection control! I can guarantee you that you couldn't do that with a constant flow system, and make it streetable.

In my next life we will have EFI on our motor but right now we race what we got, Kinsler sprinkler system.

Rex

 

[Stainless1]

We were tuning E85, 10K rpm... looks great, 32 lbs of boost was what I asked for in boost control... yep...  then the motor burbled... Ross said there was a small fire... and blue smoke puffed out the pipes.  The center section of the turbo took a subaru.... no clue what happened... the oil looks good.... except for the crap what choked up out of the turbo into the scavenge pump... a ball bearing and some other stuff stopped the scavenge pump from pushing the contaminated oil into the motor.... and the oil and sparkles that choked up into the intercooler... luckily no oil at the output of the intercooler or the hat.
Clean up is ongoing...  the only things I have left are the intercooler and pulling the oil pan to see what the .010" of oil in the bottom of it looks like. 
The new turbo center and compressor show up tomorrow by noon according to FedEx... The old parts will be headed to Garrett for analysis... too bad that answer won't be back before we head to the salt.  The new turbo had almost 30 minutes of time on it... about 50% just running and the remainder at full throttle, first with the 3/4 then with the 1 liter.
The turbo supplier asked if I had water cooling hooked up... well Garrett said it would last longer with water cooling... I wasn't thinking they were talking forever vs minutes....
But in an abundance of caution I started figuring out how to water cool the turbo while I wait for the new parts... more pounds of subaru in my 5 pound sack....
Just like every other Bonneville... the thrash is on.... 

[sabat]

That SUX, good luck with swap out. Was it a plain bearing or ball bearing? Dean

[Stainless1]

Dean... Garrett GTX2863R Dual Ball Bearing Turbo... I liked that one because it has a large high efficiency output island.  It worked well with the 3/4 liter and was doing well with the 1 liter... all the way till it died.  Most of the 3/4's boost and running was at 20lbs total manifold pressure... only was above that for tests for the open loop boost control. The 1 liter testing was for closed loop control.... that's what I was hoping to run at Bonneville. 
The new parts just arrived so off to the shop...
I still plan to make the races. 

[sabat]

Thats a nifty turbo, not cheap either! Hope Garrett cuts you a break. Hope to see you in 2 weeks

[Stainless1]

Well the $100 chiturbo was maxed out and operating in the inefficiency zone... The garrett made 20 more HP at the same boost level.... just before it quit.... 
Spending the kid's inheritance having fun... 

[Seldom Seen Slim]