Green Hornet

[chief1eye]

Hi Everyone

Looking for some recommendations on forged pistons and rods as I'm rebuilding an engine after I threw a big end bearing at the Hampton killer sweeper a few weeks ago. Picked up a second hand engine ex Ngaruawahia last weekend. So I'm building a new engine out my existing and the one I just picked up.

I looking for some specific details on forged piston and rods, as in what type and where to get them e.g. supplier.

Let the build commence!

Thanks

[*84vvt]

MRP LTD - Manon Racing Products
is doing some long rods for the 3gse
might work with the turbo but you may need a after market ECU to make the most of them .

https://www.facebook.com/mrpltd/photos/ ... =3&theater

[Swampy]

Contact Reuban he might have what you're looking for.

[chief1eye]

MRP LTD - Manon Racing Products
is doing some long rods for the 3gse
might work with the turbo but you may need a after market ECU to make the most of them .

https://www.facebook.com/mrpltd/photos/ ... =3&theater

Thanks for the info. I'm running an upgraded ECU already (Megasquirt) Cheers

[*84vvt]

MRP LTD - Manon Racing Products
is doing some long rods for the 3gse
might work with the turbo but you may need a after market ECU to make the most of them .

https://www.facebook.com/mrpltd/photos/ ... =3&theater

Thanks for the info. I'm running an upgraded ECU already (Megasquirt) Cheers

Rods are 6mm longer than stock would be introsting to see any gains from them.

[mickeyduck]

Well you've done it now Ross, you've started a Rides thread.

That means you're just gonna have to document all the stuff you do to the Green Hornet right here on this thread...

Which is of course a great way to get advice, as well as a brilliant way to build a technical reference for others (that's two of the main objectives of the Rides thread as I see it).

I might rename this thread simply "The Green Hornet" as its scope is going to end up encompassing a lot more than just pistons I'd imagine.

If on the other hand this was meant to be just a tech question, let me know and I'll move it into the SW tech section.

Keep it coming mate! And here's to a LOT more fun both on the track and on the road!

[chief1eye]

Just thought Id let people know about my rebuild - resulting from Hampton Downs Killer Sweeper. We wont go into all the details suffice to say I putting a new OBX racing sump ( cheaper copy of the Moroso) on to the rebuilt engine.

I was able to get a good second hand engine and my plan is to use the best parts from each engine. Which is really only using the bottom end of the second hand engine.

Exisitng Modifications on the exisiting engine are as follows;
T3/T4 turbo
Head rebuild and Athena Multilayer Racegasket
Heavy Duty pressureplate, 4 puk clutch - throwout bearing
Upgraded fuel system Walbro 255 and twin entry etc
Megasquirt ECU
JASMA freeflow exhaust
Upgraded Intercooler 2x stock but still not enough
Water/methanol injection

Dynoed at 298WBHP Running 18 PSI all the time.

Anyhow I thought since Ive pretty got the engine all apart why dont I go forged pistons and rods etc to be able to safely increase boost to 22PSI. Bingo Problem!

What Ive learnt is that I would have to go 0.5mm oversize on the pistons so would have to hone block. And what Ive been told is that the 3SGTE block running at high boost is prone to cracking between cylinders 2&3. Now I understand why Shane (Tubby) reasoning to go with the 5SFE block. More robust and can take the boost of 22PSI.

So I am going to use the existing engines to make a reliable safe engine and be happy running 18PSI and 298WBHP. ( By the way I'm on the look at for a cheap 5SFE block if anyone has one for my next project!).

Since the engines are out I'm gonna take the opportunity to tend to all those maintenance type items, replacing hoses, seals etc).

I purchased the stoney racing auxillary coolant and radiator hose sets, they came to other day and I'm really happy with the pricing and the quality is excellent. Thanks to Jim (Benckj) for putting me onto to them. I can highly recommend this supply source.

$184 Stoney Racing - Ancillary Hose set including all S/S clamps
1. Heater Hose No.1
2. Heater Hose No.2
3. Heater Hose No.3
4. Heater Hose No.4
5. Coolant Elbow to Pressure Cap Hose
6. Pressure Cap to Expansion Bottle Hose
7. Expansion Bottle Overflow Hose
8. Throttle Body Coolant Hose No.1
9. Throttle Body Coolant Hose No.2
10. Inlet Manifold Brake Booster Hose
11. Firewall Brake Booster Hose (Not present on all models)
12. Turbo Coolant Hose No.1
13. Turbo Coolant Hose No.2

I've also been waiting for a chance to change to turbo as the T3/T4 has too much lag so Ive got a TD05- Big16G ready for installation. Compressor curves confirm this is a great fit.

[chief1eye]

evo 4 compressor map.pdf

(129.17 KiB) Downloaded 145 times

Here is the compressor map.

[chief1eye]

Hoping to have the Green Hornet ready for the Chrome Event at Hampton Downs on the 6&7th of August.

[Benckj]

Although I'd like to take the credit for the hose kit it was GDII who pointed out the option.

I'm very interested in your TD05-16g results and any issues you have fitting the turbo to your manifolds. Everyone I've looked at would take some serious modifications to adapt compressor and turbo outlets. Like you I have a generic t3/t4 leggy turbo with adapter onto stock exhaust manifold and V-band outlet. Do you have any pics of the turbo you are installing?

[85AW20v]

Just wondering, a couple of posts up in that last picture "Engines side by side", is that the new dump pipe and turbo for the ride-on in the top right corner?

[chief1eye]

Just wondering, a couple of posts up in that last picture "Engines side by side", is that the new dump pipe and turbo for the ride-on in the top right corner?

No that's the old turbo and set up. Which eventually I will sell off.

Here's the specs and picture of the new turbo (off an EVO4) which I will need to adapt. It will be worth it as the compressor maps show that it will be an awesome fit, very fast spooling at around 2500rpm and will go hard well into redline!

Evolution 4
Turbo = TD05HR-16G6-9T
Nozzle Area (cm2) = 9
Turbine = Inconel (steel alloy)
Compressor = Aluminium, 68mm wide

[JasonFriday13]

Interesting, the ct20b compressor wheel is about 68mm wide as well. I'm also interested in the results of the TD05-16G.

[chief1eye]

Finally on the rebuild.

Second hand engine looks good internally. So its the second hand engine bottom end with existing head. And the best best of both bolted on.
ARP head studs and new Cometic Head gasket

[chief1eye]

Going to change the turbo to the following as current turbo is too large and has too much lag. (T3/T4) not sure of wheel sizes that are actually in it.

New (second hand)Turbo = TD05HR-16G6-9T
Twin Scroll


Should be very fast spooling being twin scroll and compressor map confirms that it has excellent flow capacity (580CFM) .
Boost to be set at 18PSI with over protection 20 PSI
Megasquirt ECU + Meth Water Injection should be 300 rwhp +

A twin scroll turbo offers the following benefits over normal turbocharging;
More pressure is sent to spin the turbo which adds more boost.
Reduction in turbo lag as the turbo can function as small turbos and a large turbo simultaneously.
A larger quantity and better quality of fresh air or air/fuel mixture can be forced into the cylinders on each stroke.Reverse rotation turbos and twin sroll turbine housing from EVO4.
p/n = 49178-01510
Turbo = TD05HR-16G6-9T
Nozzle Area (cm2) = 9
TD05HR turbine = Inconel (steel alloy)
Compressor 16G6 = Aluminium
Inducer = 48.3mm
Exducer = 68mm
Turbine housing = twin flapper