Z20LET into a Haynes Roadster

[Ben_Copeland]

Its time i posted up my build diary for fitting my Astra turbo engine into my Haynes Roadster, seems to be one of the next upgrades people might start doing.

Firstly it started out with a NA 2.0 16V Vauxhall Engine C20XE so the conversion is a little easier for me. The Z20LET is a 2.0 16V Turbo engine, very similar to the C20LET which is the Turbo verson of the C20XE. This all means that the existing bellhousing and engine mounts all fit straight on, although the passenger side mount needs modifying for the boost pipe to go through.

Picked up a running engine and started stripping it all of bits i wont need anymore....

http://locostbuilders.co.uk/upload/5 Z20LET.JPG
http://locostbuilders.co.uk/upload/IMG_3565.jpeg
http://locostbuilders.co.uk/upload/IMG_3572.jpeg
Its very busy this end and i dont like it !

http://locostbuilders.co.uk/upload/15 Z20LET.JPG
Thats better.

[Ben_Copeland]

Next i need to replace the throttle body, the TB on the Z20LET is fly-by-wire and i cant run that on MS2 (or cant be bothered to work out how)
http://locostbuilders.co.uk/upload/IMG_3567.jpeg

I've bought a throttle body of a X20XEV which is effectively a NA version of my engine (2.0L 16v from a vectra/astra etc)
Its fits straight on and converts to cable throttle, its slightly larger which cant be a bad thing.
http://locostbuilders.co.uk/upload/IMG_3605.jpeg
I actually ended up turning this round 180 degrees so it fits better.
http://locostbuilders.co.uk/upload/16 Z20LET.JPG

[Ben_Copeland]

Next is to remove the sump which is massive and isnt going to fit, also i removed the balance shafts that are mounted over the crank. These sap power and also add a massive weight to the bottom of the engine. Unfortunately they are oil feed from the crank bearing caps, so they need tapping and filling so the oil doesnt come out !
http://locostbuilders.co.uk/upload/20 Z20LET.JPG
http://locostbuilders.co.uk/upload/23 Z20LET.JPG
Tapped and grub screwed.
http://locostbuilders.co.uk/upload/IMG_3592.jpeg

http://locostbuilders.co.uk/upload/IMG_3595.jpeg
Caps back in.
The downside of removing the balance shafts is they also act as crank girdle so you either need to find a X20XEV crank girdle that doesnt have balance shafts (early one maybe) or make your own.

[Ben_Copeland]

Friend of mine sent me this to play with as it didnt fit with his sump....
http://locostbuilders.co.uk/upload/56 Z20LET.JPG

Unfortunately i ended up having to cut it up as it didnt fit with my sump either, but strips are better than nothing.
http://locostbuilders.co.uk/upload/59 Z20LET.JPG
I used the XE windage tray just cutting holes where the girdle stuck through.

I'm fitting a Caterham Alloy Sump from my XE engine, which just fits but ive had to modify the pickup pipe, using the head of the XE one with the oil pump end from the ZLET engine. Its a bit of a faff to sort and unfortunately i didnt take a picture, but just make sure its got no leaks! I also had to drill out the sump bolt holes because they are m8 instead of m6 like the XE, but easy enough to do.

I then started checking over the turbo. It had been fitted with a VXR turbo and wastegate which is a popular power upgrade, pretty much a direct swap and good for about 300bhp.

I had noticed the oil feed pipe was oily and one of the connections was at an angle..
http://locostbuilders.co.uk/upload/17 Z20LET.JPG
Dumb Arse!!!

Took it apart and luckily i rescued it with a small file and a bit of patience....
http://locostbuilders.co.uk/upload/19 Z20LET.JPG
Better.

[Ben_Copeland]

I took the exhaust manifold off to replace the gasket and found 2 stripped threads in the head and rusted studs/nuts
They'll all need replacing before the turbo manifold can go back on... BALLS.
http://locostbuilders.co.uk/upload/34 Z20LET.JPG

I helicoiled the 2 threads in the head and replaced all the studs. While the exhaust manifold was off i painted the block black to get rid of the Red as it didnt match which my cars colours.
http://locostbuilders.co.uk/upload/36 Z20LET.JPG

Also the turbo return pipe was held in with a bolt and self tapping screw and glue. WTF, how difficult would it of been to find another bolt for it. Again, luckily! i managed to remove the glue and cleaned up the bolt hole. Replaced the gaskets and bolted it all back up.
http://locostbuilders.co.uk/upload/18 Z20LET.JPG

I also binned the dump valve bits and fitted a nice alloy recirculation valve, back to standard...ish.
http://locostbuilders.co.uk/upload/26 Z20LET.JPG

[Ben_Copeland]

Moved back over to the inlet side and decided to check the injectors. As i thought standard, and not suitable for VXR turbo power.

I had some Rover 800 Turbo injectors lurking in the garage which are a direct swap, a lot more cc's. So i sent them off to Mr Injector to get them cleaned and check etc.
380cc i believe @ 3 bar
http://locostbuilders.co.uk/upload/27 Z20LET.JPG


Refitted the rail. Done

Got a bit of a painting bug from doing the engine block so decided to do the camcover.

Rubbed down
http://locostbuilders.co.uk/upload/37 Z20LET.JPG

Primed with a etch primer
http://locostbuilders.co.uk/upload/IMG_3615.jpeg

Undercoated white
http://locostbuilders.co.uk/upload/40 Z20LET.JPG

[Ben_Copeland]

Top coated with DynaRod orange and then lacquered to make it oil/petrol/heat resistant.
http://locostbuilders.co.uk/upload/47 Z20LET.JPG

Didnt like the standard yellow oil cap, so rubbed that down and painted it black.
http://locostbuilders.co.uk/upload/46 Z20LET.JPG

Also painted the bolts black too ;-)
http://locostbuilders.co.uk/upload/50 Z20LET.JPG

Fitted and finished with a Black VXR spark plug cover.

[Ben_Copeland]

Time to strip the old engine out of my car. Ive done this a couple of times so should be easy enough.

Fully assembled car including nosecone etc.
http://locostbuilders.co.uk/upload/1 Z20LET.JPG
Ok no nosecone in this picture...

To engine out on the bench in 1hr 15mins... not bad for an evening after work.
http://locostbuilders.co.uk/upload/2 Z20LET.JPG

New engine hanging ready to go in.
http://locostbuilders.co.uk/upload/60 Z20LET.JPG

Engine in and bolted up to the gearbox. Driver side engine mount in and bolted up. Just need to modify the passenger mount to allow the bottom boost pipe to pass through it.
http://locostbuilders.co.uk/upload/62 Z20LET.JPG

Forgot to say: the clutch is ford galaxy 2.8 friction and Vauxhall pressure plate. Using alloy bellhousing and type 9 box

[Ben_Copeland]

Jumped forwards a bit to fitting the radiator and intercooler.
http://locostbuilders.co.uk/upload/63 Z20LET.JPG

Next i made up some mountings for the fans, i couldnt get one big fan into the space behind the radiator so went for 2 smaller ones instead.
http://locostbuilders.co.uk/upload/65 Z20LET.JPG

Radiator is a Honda Civic alloy racing one i bought off ebay and intercooler is a universal alloy one from ebay. Both cost about £75 each

Needed to change the Inlet Temperature Sensor, but couldn't find one that bolted straight into the manifold, so i had to buy an adapter and tap that so the sensor could fit inside.
http://locostbuilders.co.uk/upload/51 Z20LET.JPG

Went to refit the steering column extension, but it fouls slightly on the inlet manifold so i've had to put an extra joint in and rosejoint to support it.
http://locostbuilders.co.uk/upload/76 Z20LET.JPG
Still waiting on some nuts to fit it in place.

[Ben_Copeland]

Next up is the alternator bracket, its one i made for the XE engine so ive reused it and it bolts up in the same place just needed spacing off the engine slightly as it fouled on the cambelt cover.
The adjuster is made from 2 rosejoints, one right hand and one left hand thread with matching threaded bosses welded together with a nut between them. Picture speaks a thousand words...
http://locostbuilders.co.uk/upload/74 Z20LET.JPG

Next i managed to source a belt and new pulley for the alternator that matched the crank pulley.
http://locostbuilders.co.uk/upload/77 Z20LET.JPG

Bought some silicone hose and joiners just before xmas and so i started fitting it all. Got a big list of pipework and connectors that i still need to get, but its nearly there.
\http://locostbuilders.co.uk/upload/78 Z20LET.JPG

I've also started to tidy up the wiring and using all the OEM connectors i can find.
http://locostbuilders.co.uk/upload/73 Z20LET.JPG

[Ben_Copeland]

Bought a T piece pipe for the coolant system off ebay, but i was less than impressed considering it was quite expensive.

http://locostbuilders.co.uk/upload/57 Z20LET.JPG
http://locostbuilders.co.uk/upload/58 Z20LET.JPG

The pipe was all bent and the smaller pipe wasnt drilled out properly.

Connected the laptop up last night and started updating the basic map info to match my engine and i want to test the fans work etc.

[jason 82]

Well done Ben ! That is one of my favourite engines, only 2nd to the honda vtec. That rocker cover looks kick ass ! Has anybody tested the boundaries of the haynes roadster chassis ? For example, how much power you can put through it before you get flexing or stress of the chassis ? How are you planning on keeping the front end down at speed Ben ? I have seen some Caterhams with tiny little fins on the nose cone, but they seem to be a little inadequate for the job. You continue to be one of the bench setters on this forum, I am watching your thread with great interest ! Well done. :cool:

[Ben_Copeland]

Thanks Jason,

I think I'll be testing the limits of the gearbox before the chassis starts flexing.

The cars going to be a bit of a handful so I'll keep the power between 250-300bhp just to stop the gearbox spitting it's innards out. I've got a place that can supply t5 gearbox's but I don't want to go down that route till I have no choice.

I'm going to have the suspension setup at procomp once all the bits are fitted. The caterham canards will do very little for us as they are designed for the caterham and even then they were for aero around the wishbones.
There's a few aero drawings on the equinox Facebook page that's quite interesting and they look at lift etc.

[TheArf]

Is it just me or is it starting to get silly, it's all well and good people putting these rather powerful engines in but do we have the ability to keep these highly powered, yet very light cars sunny side up.
don't get me wrong i admire people who take on the engineering challenges and over come them, good on you but these cars do have a limit as to what they can safely absorb in punishment without bitting back.
Each time I see this improvements in power, bigger engines moreB.H.P. but I never see anyone uprating their brakes, it's easy to make them go its an art to stopping them in a straight line

ah well rant over, good luck with the mods

Arfon

[Ben_Copeland]

I know many cars with more power than I've got. I thought I was being conversative with my choice of engine lol

I didn't find my last engine had enough go in it, it was only 160bhp ;)

Brakes, Tyres etc are already suitable for the power upgrade. :)

[Shorty]

Good luck with that, you're doing well.
Great engine, I had an astra coupe with that engine and was great.
That problem with the exhaust manifold studs must be common as I also had that. Other than that I don't think I had any problems with it.

[Ben_Copeland]

Hopefully it'll be a fairly bullet proof engine !

Modified the Rally Design pedal box to take a Vauxhall accelerator cable, had to add a small box to space up the cable sleeve and bend the back of the pedal up so the cable pulls further.
http://locostbuilders.co.uk/upload/79 Z20LET.JPG

Decided while i was waiting for funds for more parts i'd flared the side panels to get some of the heat out!
http://locostbuilders.co.uk/upload/81 Z20LET.JPG
http://locostbuilders.co.uk/upload/82 Z20LET.JPG
http://locostbuilders.co.uk/upload/83 Z20LET.JPG

Not much left i can do currently

[jason 82]

If cooling becomes an issue, would there be space to lye the inter cooler flat across the top of the engine bay somewhere, & put a kia sedona style scoop & use their inter cooler set up, this freeing up the rad to get some fresh air. Just an idea, as this is the set up in my kia sedona 2.9 crdi. Might be an option ? If there is space of course. :D

[Ben_Copeland]

I did try the intercooler above the radiator in front of the engine but I just couldn't get it fitted in that space :(

[flyerncle]

Widetrack Roadster time:eek:

[Ben_Copeland]

It's already pretty wide :D

http://i775.photobucket.com/albums/yy31/ben_copeland7/AdvertSm1_zpsffa86cc3.jpg

[flyerncle]

I got the feeling Caterham were attempting to spread more of the car to hold the road .:eek:

[Ben_Copeland]

Caterhams are pretty narrow so maybe

[Ben_Copeland]

Sorry about no activity recently, my parts came in dibs and drabs so I didn't bother taking a picture. Still missing some bits which is annoying.

Anyway, I had a go at making an exhaust for the car. Tacked it all together and hopefully I can get it tig up later this week.

http://locostbuilders.co.uk/upload/15Exhaust.jpg

I also had to rejig the coolant lines off the back of the water pump because I found another pipe off the head, which is annoying as it means I cant fill it up with water till I get another t-piece.

http://locostbuilders.co.uk/upload/Found pipe.jpg

That's it for now, i'll hopefully have all the bits by the weekend (except the extra t piece) and I can finish most of the pipework :D

[loony]

Anyway, I had a go at making an exhaust for the car. Tacked it all together and hopefully I can get it tig up later this week.

http://locostbuilders.co.uk/upload/15Exhaust.jpg



Did you tack it with MIG and stainless or just regular MAG ?

I asking because I'm still wondering how to make my exhaust. Last time (turbocharging BMW) I tacked exhaust with SS electrode and stick welder and than had it TIG welded by professionals...

[Ben_Copeland]

Just normal mig mate but I had to turn it down to stop it blowing holes

Taking it to a mate with a tig later in the week.

[deezee]

Really impressed with this engine swap. Obviously know your way around this engine and it makes for a good read, seeing all the tweaks and changes (cosmetic and mechanical) to make it suitable for a kit car. AshG has a Saab turbo engine in his, so I expect the car goes just fine with a turbo in them. I'll be looking forward to seeing this run on the road.

[Ben_Copeland]

Got my mate to tig up the exhaust last week, so fitted it this weekend. Fitted perfect first time, right slap bang centre of the cut out in the side panel too. Really pleased how its turned out!

http://locostbuilders.co.uk/upload/1620261_10152565758329992_2094507055_n.jpg
http://locostbuilders.co.uk/upload/1743302_10152565768089992_1189653514_n.jpg

I'm also struggling to find a place for my airfilter, where am I going to get fresh air from ?

http://locostbuilders.co.uk/upload/1616415_10152564658834992_402771367_n.jpg

[K4KEV]

Hi Ben ....I know this seems obvious, but I will mention it anyway, you are going to need to fit some kind of "rolled" tip on the exhaust outlet for iva
good progress by the way, it's that time of year when you feel like getting stuck in again.

[Ben_Copeland]

No mate, its already road registered :D

[jason 82]

Somebody will be needing an account with Michelin !:rolleyes: fair play Ben, cracking car. ;)

[Ben_Copeland]

That'll be Toyo ;)

[K4KEV]

Dohhhhhh....feels like a right numpty

[beardydave]

Hi, which pattern bell housing does that engine use? Is it the same as the r28 in the omega?

And could you post a pic and a measuerement of the ground clearance under the box please.

I'm trying to fit a saab engine in my build, but with the height of the engine and size of the bell housing around the flywheel I'm going to struggle to keep iva visibility without the bell housing sticking out 4" from the bottom of the chassis.

[Ben_Copeland]

Hi, which pattern bell housing does that engine use? Is it the same as the r28 in the omega?

And could you post a pic and a measuerement of the ground clearance under the box please.

I'm trying to fit a saab engine in my build, but with the height of the engine and size of the bell housing around the flywheel I'm going to struggle to keep iva visibility without the bell housing sticking out 4" from the bottom of the chassis.

Hi Dave

http://i775.photobucket.com/albums/yy31/ben_copeland7/7af0f0239ef9fc950cdc7732c93d9127_zps5d018019.jpg

Yes it's standard GM bell housing pattern. R28 will fit, I have one in the garage :)

[Ben_Copeland]

Well, Huge update time !!

I filled the oil up, cranked it over for a bit till the light went out (with the coilpack and fuel pump unplugged).

Next came the startup. The first actual start was witnessed by yellowcab via facetime... soz

But this is the 2nd start up, not bad considering its still running the same map as the xe, I just upped the req_fuel.

SO here it is :


http://youtu.be/1Qoy9cHD1wQ

Think a belt is too tight, but apart from that. No nasty sounds heard :D:D

[TheArf]

Well done that man

Arfon

[beardydave]

Thanks, even with 2" poking out the bottom like that and spoiling my nice smooth undertray the saab lump is too tall for a sensible seat height.

Guess I'll just have to add 100mm spacers under the seat for the iva and not build the full cage until afterwards. ;-)

[Ben_Copeland]

Wow, have you spoken the AshG?

He's got a Saab lump in his, which fits under the bodywork fine

[Ben_Copeland]

Few more bits done over the past couple of nights.

Boost Gauge, I was going to replace the oil pressure gauge to save drilling another hole but I might swap that for a oil temp gauge instead so I put the boost gauge where I could see it :D

http://locostbuilders.co.uk/upload/1743480_10152580555014992_1827975776_n.jpg

http://locostbuilders.co.uk/upload/1616793_10152581250294992_1432257961_n.jpg

http://locostbuilders.co.uk/upload/1620785_10152580555024992_1834841947_n.jpg

[Ben_Copeland]

Next was some prop catchers, I originally planned to fit 2 sets of catchers inside the tunnel. One set at each end, but my prop is quite short and I had nowhere to mount them other than in the middle.

I got these from FastDan on LCB, they don't seem wide enough for the Haynes Tunnel I'm guessing the locost tunnel is a little narrower so I had to make some crude brackets up, while trying to work in a tunnel with the prop still attached. :o

http://locostbuilders.co.uk/upload/1655953_10152579921264992_1850216235_n.jpg

http://locostbuilders.co.uk/upload/1508138_10152579921309992_1218762997_n.jpg

[Ben_Copeland]

I then decided to tackle the air filter location problem... Somehow I just got it to sit infront of the engine, the 73mm flexy cold feed JUST squeezes down between the radiator/intercooler and nosecone. That should hopefully be ok, just need to work out a way of mounting the air filter.

http://locostbuilders.co.uk/upload/1797174_10152581250199992_327921374_n.jpg

http://locostbuilders.co.uk/upload/1797200_10152581240759992_1165056423_n.jpg

http://locostbuilders.co.uk/upload/1615249_10152581225869992_1891466078_n.jpg

[jason 82]

Hi Ben, I would run the air filter from the driver side of the car, run a duct from the side panel straight up to the filter. Exactly opposite to your exhaust exit on the passenger side. I would put a very small subtle scoop on, a bit like the mk3 Astra gsi ones. Should work a treat. ;)

[Ben_Copeland]

Think the current location is fine. I'll look at finding a fixing for the bracket later once my hang over has cleared :D

[Ben_Copeland]

http://locostbuilders.co.uk/upload/1801067_10152584048209992_1863386355_n.jpg

Enclosed Airfilter mounted using the bracket that came with it, slightly modified. I used the cambelt cover bolt to hold it all in place.

http://locostbuilders.co.uk/upload/1616404_10152584491634992_364813312_n.jpg

I'll have to turn the hose clamp around to stop it getting in the way.

http://locostbuilders.co.uk/upload/1797092_10152584503964992_1333705627_n.jpg

Mounting bracket

[Ben_Copeland]

http://locostbuilders.co.uk/upload/IMG_4412sm.JPG

Small update, couldn't find a t - piece the right size (32mmx18mm) to join that surprise pipe up to the bottom/water pump hose so I had one made :)

I already had the individual pipes so I cut and shaped the smaller one and drilled the larger pipe, then my friend tig'd them together for me.

Hoping tonight I can get all the water system finished :D

[Ben_Copeland]

All plumbed in and filled up with water and antifreeze. No leaks so far:) ran the engine for a bit but it was too late and too noisy.

[Ben_Copeland]

http://youtu.be/n3vVJiQOv-g



I had to turn the oil filter mounting so the pipe connections didn't rub on the alternator belt, I also found the wastegate was rattling, so tightened up the actuator arm.

Hey presto much quieter running engine.

[Ben_Copeland]

Bit of an update, I missed my original tuning booking due to a leaking clutch cylinder and a noisy clutch.

The leak been fixed but the noise is still there, I replaced the clutch bearing but its not that. So don't know what's wrong. I've given up trying to fix it, so it'll either get worse or whatever's touching when the pedal is pushed down will wear away enough to stop :D

Tuning is now booked for Friday 14th March, so i'll update then.

But it does drive fine and the water and oil system all works. I've also fitted an oil temperature sender but i'll update at the weekend once its all working ok.

http://locostbuilders.co.uk/upload/IMG_44541.jpg

[Ben_Copeland]

Forgot I missed a step, Faired side panels... I also meshed them to hide the chassis behind.

http://locostbuilders.co.uk/upload/IMG_4453.JPG

[jason 82]

It would be a real pitty not to get this thing into a magazine ! Has your car got a dual mass fly wheel ? Could be the source of the problem if you do. My mate had a tdi golf, & his car made a racket. I know that traditionally vauxhall used pressure plates, but I am not sure about the VXR unit.

[Ben_Copeland]

No dual mass mate. It's a lightweight flywheel, 2.9 galaxy friction plate and a c20let turbo pressure plate.

What could possibly go wrong :D

Wouldn't mind a magazine feature but no ones ever approached me!

[Ben_Copeland]

Saturday morning I finished wiring in an oil temperature sender. Drilled and tapped the oil cooler line banjo bolt and inserted a smiths water temperature sensor. This was then wired to a switch along with the original water temperature cable.

Basically this all means that I can flip a switch and see what the oil temperature is, then flip it back for water temperature on the same gauge. Otherwise I've got to buy another smiths gauge which are over £50, plus £15 for the sender. That's fine but I'm running out of space on my dash!!

I'll stick a couple of pictures up tomorrow when I get to work as my laptops charger has had it at home.

[Ben_Copeland]

So, the big day was on Friday! Tuning day at Bailey Performance!

Wow what a guy, Dale knows his stuff. I'm going to do a separate thread with a bit of a report with plenty more details.

But, the gory figures are:

272bhp and 308ftlb torque, it's was savage on the rollers and it kept spinning the rear wheels as peak torque come on. We ended up removing the splitter so it could be strapped down tighter.

I've not driven it anywhere yet, but Dale promises me it'll do 30mpg on cruise!

Happy bunny and no Major issues thankfully.

http://youtu.be/S0lndNHN5eY
http://i775.photobucket.com/albums/yy31/ben_copeland7/c6f882ee6bc57cb142de20c886a24e91_zps59ff6eb7.jpg
http://i775.photobucket.com/albums/yy31/ben_copeland7/33b0e9b938ee92334f7c8fa86d8dadfb_zps7c4f03ac.jpg
http://i775.photobucket.com/albums/yy31/ben_copeland7/00551841e5c5eaccddf4807e848a3dcf_zpsb83120d7.jpg

[alga]

So, how does it drive now? What's your 0-60 acceleration?

[Ben_Copeland]

Not had a chance to drive it yet.

Dale recommended I fit colder plugs, also that I convert to a Ford Coil Pack because the GM one was causing a minor miss at high rpm.

Need to also flush the oil out as its a bit dirty.

Tax has run out from last year so i'll retax in beginning of april :D

Which means there will be a Go-Pro video of the first run out.:eek:

[Ben_Copeland]

So, how does it drive now? What's your 0-60 acceleration?

Drove it last night... Holy shit its rather quick. I haven't done any 0-60's as I'm nursing the gearbox slightly. The torque is massive and just throws you up the road.

[Ben_Copeland]

Right, bit of an update.

Had an issue with too hot oil and the rad fan coming on while driving... so I did a bit of research.

Oil temperature is now fine. The thermostat wasn't opening properly and I had the oil temp sensor in the wrong place. Its now located in the sump plug and appears normal.

I also installed a massive oil cooler, but its obvious its not necessary so will probably swap it back to a smaller one.

Water cooling, I had a bit of an issue where the fan was coming on during normal driving. Appears that I wasn't getting enough air in the front.

I'll made some crude cowling to try and force more air through the rads. I've also removed the meshing from the nosecone... The mesh I had was very restrictive. Just need to find something to replace it with.

I've also replace the thermostat with a 82c one and put the heat bypass pipe back in.

I'm yet to give it a blast on a hot day, so I'm hoping for some nice evenings or spot of sun this weekend where I can give it a bit of a hoon and see what's what.

I'm also going to Stoneleigh so come and say hi if you see me / the car.