Clio K4T Project

[alexandre.]

Hey guys, im from Brazil (where doesnt exist Clio Sport) and 4 years ago i bought the more close to a Clio Sport we have here, its a Clio 2 Dynamique 1.6 16v (k4m) 2 doors.

I have done some trackday with aftermarket suspension only and last year i decided go a little more fast, so i talked with some friends, some guys have swap to a f4r from scenic I but have many problems on track, so i decided install a turbocharger with the k4m, same price for a swap to f4r but more easy to get a target of 200whp.
The is running reaaally good, dont have any intention to add more boost, today is running with a MegaSquirt 2 and 0.8bar pressure with 1 bar in 6700 rpm
Here a video on my local track (hope you guys recognize the track hahaha):



Now with a help of some friends i started get information about the clio sport suspension, so started get the clio cup suspension parts to put in the little wannabe renault sport car hahahaha
already got wishbones, dampers, top mount, subframe (will adapt mine), front hub (54mm), and many other thing are coming, if you guys are interested i could share all my upgrades

 

[alexandre.]

Some photos when i bought the car

First Trackday 4 years ago with custom coilover and used old slick tires haha

 

[alexandre.]

Engine rebuild and turbo install

 

[alexandre.]

New tires

After 3 months building the engine, turbo parts, megasquirt 1 and tuned its time to test on track:
Autodromo Internacional de Curitiba (250 miles away from home hahaha) (new local dampers with eibach pro springs)

 

[alexandre.]

A little about the specs of the car today:


Engine

• K4M 740 Block (10.1:1)
  New Pistons, pins and rings seals (0.50)
  New Can Rods from Cleon 1.6 (no forged but better than original)
  Vibra-Technics Road Engine Mount
• Cylinder Head Rebuild
  New Inox Valve ADM and EXH (Original size)
• Cooling system
  Mocool and Inungel
  Removed all Heater System
• Fuel
  4x Short Deka 60lbs Injectors
  Fuel Pump 8 Bar
  Ethanol
• Ignition
  Spark Plug NGK Iridium (BKR9IX)
• Turbo
  Custom tubular exhaust manifold T2
  KKK K16 Diesel
  Intake 70mm (Alloy)
  Intercooler pipes 60mm (Alloy)
  New Intercooler 550x140x64

Transmission

• JC5 062 Gearbox
  Final ratio 3.866
  Vibra-Technics Road Gearbox Mount
  Lower Gearbox Mount with Polyurethane shore 90A

Suspension

• Front Suspension
  Local custom 1.6 Dampers
  Eibach Pro
  Polyurethane Anti Roll Bar Bushes
  
  
• Rear Suspension
  Local custom Dampers
  Eibach Pro
  Whiteline ARB

Brake

• Overall
  22.20mm Master Cylinder
  Motul RBF 660 Brake Fluid
  
  
• Front Brakes
  Peugeot 307 caliper
  Custom pads
  Braided line
  Sandero RS Oem 280x24 Brake Disc
  
  
• Rear Brakes
  Renault 19 16s Calipers
  Custom pads
  Renault 19 16s Caliper Bracket
  Braided Line

And the Next Upgrades will be:

Fuel Regulator 4.5bar
Gearbox rebuild with new bearings, seals, primary shaft, pms reinforcement plate and quaife
Cup 172 Drive shafts
Yanoo Stiff 3.0
Clio 172 cup dampers
Top Mount
Clio 172 (54mm) Hub
Clio 172 Cup wishbones with pms stiffer plates and powerflex black bushes
New subframe modified to match Clio 172 cup wishbone position mount (8mm outer per side)
Clio 172 Cup front ARB
H&R Super Sport Springs (Blue)
Rear beam whiteline bushes
Top and lower bushes form rear in polyurethane shore 95A (same as powerflex black)
23.6mm master cylinder
Brembo 4 pot with 280mm disc with new braided lines
Upgrade my megasquirt 1 to megasquirt 2

Thinking how can i modify the rear beam, mine have 19mm inner arb but clio sport have 22~24mm
And my dream is a sachs damper kit (front and rear)

This forum help me with many infos, thx a lot haha

 

[Adamxx]

Nice to see something a little different ?

 

[bloke]

get yourself some iapel oversized pistons and f4r supertech valves (1mm oversize)

 

[alexandre.]

Nice to see something a little different ?

Thx mate, its very interesting to see how many thing renault sport have changed to make the clio sport, many suspension details

get yourself some iapel oversized pistons and f4r supertech valves (1mm oversize)

iapel pistons oversized for k4m to get close to f4r?

 

[bloke]

Just as an oversized, think it's only about 1mm over but that will also work better with oversized valves. Forged rods are peanuts as well.

 

[alexandre.]

I dont think is a good ideia continue putting more money on the engine, already made 3 trackdays and close to 14k miles and dont have any issues, the cleon rods are far better then the originals, i ll try find i pic showing the difference. Going to forged pistons and rods will be good if i decide build a N/A F4R, the price of pistons and rods for the f4r cost less than half if they went to k4m.

 

[alexandre.]

Cleon 1.6 (CHT in brazil) Left x K4m 740 Right

 

[bloke]

but for £165 for forged rods it would be daft not to throw a set in, pistons are around £300 from france but could be cheaper for you as iapel are in argentina.

 

[alexandre.]

but for £165 for forged rods it would be daft not to throw a set in, pistons are around £300 from france but could be cheaper for you as iapel are in argentina.

£165 for a set? where?
Here they are around £700 a set of forged can rods

And pistons iapel/iasa are around £500 without rings (8.0:1 compression ratio)

That why i build "stock" internal

 

[william...]

Nice!

 

[Djw John]

Nice project there! Funny seeing the differences in them, the ph1 dash and the undertray looks like its metal. But having experienced the roads around Belo Horizonte I can understand why it would be tougher!

 

[bloke]

Rods are on aliexpress.com majority of forged rods are from China now and when you compare them they are pretty much identical different branded rods.

Pistons were from place in france, will see if I can find a link for you but they came with rings.

 

[Simon998]

Have you weighted those rods Bloke? a few guys run them in 106's that I know of, and apart from some minor flaws they've had no issues with the MaxSpeeding rods. They used to come with 'ARP' bolts though and I doubt they were genuine lol.

 

[alexandre.]

Nice project there! Funny seeing the differences in them, the ph1 dash and the undertray looks like its metal. But having experienced the roads around Belo Horizonte I can understand why it would be tougher!

Thx mate, its amazing see all changes renault sport has made to produce the Clio sport

Yeah, its a ph2 with ph1 interior, i´ve changed the door cards and put the clio sport to make a dark gray interior, now i have to see what todo with the dash, but im focused on engine/transmission/suspension
All cars here use metal undertray, you understand why, the road are not so good, many pot holes too, i changed mine to a plastic one

Rods are on aliexpress.com majority of forged rods are from China now and when you compare them they are pretty much identical different branded rods.

Pistons were from place in france, will see if I can find a link for you but they came with rings.

i saw that, a friend bought one of those rod to make some resistance test, but until now he dont make the test, in other hand, another friend bought a set but has problem with the rods, i,ll try get some photos with him, maybe a lot problem

Nice!

Thx mate

Thats why i will rebuild my gearbox with a new primary shaft and new clutch haha


Here a video about the car, dont know if the subtitle works correctly but try hahaha


You can see i little more lag in this video, the turbo spool around 4k rpm, but we changed the cam position and now the car spool aroun 3k rpm


About the interior of the car

Sparco Corsa VTR Bucket Seat
OMP 6 point Harness
Custom 6 point Rollcage
Ebay Short Shifter (Rubish hahaha)
Clio Sport Door Cards
Sparco L999 330mm Steering Wheel
Remove the rear seats and seat belts
Custom interior roof (Dark gray)
And i thinking remove the spare wheel boot and make a flat floor



After a crash on the road, i remade the intercooler pipes (with alloy), and now look like this:

 

[bloke]

sorry but can't tell anything from the video, generic crap you see on youtube all the time!!! no idea of when it's spooling from it either.

have you got a graph?

 

[alexandre.]

sorry but can't tell anything from the video, generic crap you see on youtube all the time!!! no idea of when it's spooling from it either.

have you got a graph?

LOL thx

original cam position

Custom cam position

 

[bloke]

got to say first graph is nice and smooth. what did you time cams at?

have you got a boost graph?

 

[alexandre.]

Dont how to say correctly in english, we removed overlap.

oem adm - - exh
custom adm \ / exh

but obviously not that much

i dont have the boost graphy, but with the oem position the car was rly terrible when exiting a turn on track 1 gear lower then after

 

[Mazz]

I like this, good work !!

 

[alexandre.]

Hey guys
Santa passed earlier bringing gifts to Clio
Rly thx for the help of @Kev@KAM from Kam Racing


> Powerflex Black Series Wishbone + ARB + Rear beam + Rear upper
> Quaife LSD
> Whiteline Camber Bolts
> PureMotorsport Gearbox Reinforcement Plate
> Grams Brembo Rebuild kit


> New renault oem front 280x24 brake disc


A friend printed for me these two pieces i drew to test the adaptation in the subframe like the Cup subframe are


Testing the bracket


Cleaning the hubs to install the new bearing and stud

Now have to wait the front ARB and right Driveshaft to start change the front suspension, install the new gearbox and the brembo calipers

 

[Kev@KAM]

you have a busy Christmas holiday ahead

 

[alexandre.]

you have a busy Christmas holiday ahead

For sure hahaha

 

[alexandre.]

Removed some bits at the night with a little free time

will convert to EPAS so started remove the Aircon, Alternator and Pas





Already bought the Pas Column, controller, will use the oriinal rack (2.75) and loop, but have to change the inner tie rods
So i found a new acessories support to use with the alternator and aircon

actually:

new:


new support:


Hope i can use my own aircon but will need a new Alternator

 

[k_Leo]

Great project !

Parabéns pelo projecto, está de mais !

 

[alexandre.]

Well, no many progress

Decided to clean the hubs better


Then painted with high temperature primer and matte black (900°C)


30min 121°c > 30min 205°c > 315°c


After gloss black (600°c)


With new bearings


Time to test the new brembo bracket



Well, need remove 1mm from the calipers, 1.5mm from the bracket and wait the studs for the caliper bracket
Brake parts is almost finished

 

[alexandre.]

Well guys, not too much updates but i like to share some ideias

1- Engine

--Turbo
I decided change my turbo configuration, i was running a KKK K16 from a diesel truck (Turbine 49/55mm with .48 turbine house and Compressor 44.1/62mm), wheel like i said before, with the cams in the original position the turbo spool around 3800~4000 rpm and changing the position it start spool around 2800~3000 rpm, but the bad side is with that i lost vacuum on idle.
So a friend give me a new turbo to try a MHI TD04HL-16T (Turbine 45.6/52mm with .47 house and Compressor 43.4/56mm), this urbo come from a Volvo S60, to get some reference i saw some guys running this turbo on 1.6L miata, they said it spool around 2800rpm and sustain until the end, the diff is miata run with 9.5:1 compression and i running 10:1 but i dont know the cylinder head cfm diff
I saw @bloke are running a TD04L-14T (Turbine 41.3/47 with .60 house and Compressor 39.6/51mm) from meggie but dont get to much infos about spool and power delivery

So i decided test it and will make a new exhaust manifold, a new downpipe and ajust the intercooler pipes in March




--Renault Sport upper inlet
I tried test a clio sport manifold on k4m to remove the plastic one and that the visual try:



and here is the problem:



i know they are different but i was thinking adapt the lower inlet with a new flange that match the upper 172 ph1 inlet, but now im thinking of use only the "Renault Sport" and make new runners with k4m flange to connect with the lower inlet.

--Fuel rail
I bought a Laguna I k4m fuel rail with fuel regulator, now just need make the return lines and will help the injectors and a better idle map with aircon


2 - Suspension


--Subframe
Made a new "wishbone bushes house"



They are in production, so will need remove the original one and weld the new one with the same cup wishbone fixing position

3 - Other things

> EPAS installed
> Trying to find someone with knowledge to rebuild my gearbox correctly
> New wheels a set of Konig Dial - in 15x7J ET35 4.9kg each one



I dont know if i use Toyo R888R 205/50 front and 195/50 rear or 205/50 all around


Well, thx guys

 

[bloke]

The 14t would probably be a better choice over the 16t.

Don't mix and match the upper and lower inlets, needs to be as smooth and even as possible. What's wrong with the plastic one?

 

[Martin_172]

What about the twingo rs manifold rather than the f4r?

Good work, love what you have done and looks like it goes well

 

[Mavez]

Awesome build! Good work.

 

[alexandre.]

The 14t would probably be a better choice over the 16t.

Don't mix and match the upper and lower inlets, needs to be as smooth and even as possible. What's wrong with the plastic one?

Renault said it can handle 1.5bar (static) but they dont know how much can handle with turbo and the pressure changing all the time

What about the twingo rs manifold rather than the f4r?

Good work, love what you have done and looks like it goes well

Thanks Martin, lets see the whole difference from renault to renault sport suspension

Didnt find it for a good price on ebay for test and i saw some things are diffence like oil breath, fuel rail without fuel regulator

Awesome build! Good work.

Thanks Mavez

 

[Optimista]

Love it!

 

[bloke]

just run the plastic upper inlet.

 

[alexandre.]

Just to share
Modifying the ph1 subframe to cup spec

 

[scullyg40]

Modifying the ph1 subframe to cup spec

What's the difference? And where did you get the replacement parts?

 

[alexandre.]

What's the difference? And where did you get the replacement parts?

I dont know exactly what models come with that subframe with 8mm more outer, but i know they started with the clio 172 cup models


The blue line is the ph1 172/ph2 172 non cup wishbone position, the red line (8mm out) is the position for cup model

The replecement part was made from a 3D model, so we cut ad folded in CNC

 

[alexandre.]

Hey guys,

A long time without any update, i finished another chapter of the car and i like to share.
The main update was the suspension, i tried to get really close to the cup suspension and im very impressive, not only me but many friends who ride in the passenger seat. I know its only a "normal" suspension but here in dont have many sport compact cars.
I really like how the car turn in so easily and stay in the turn.
But even a "soft" suspension for UK streets, they are uncomfortable for Brazilian streets, if you dont use the car for daily drive they are ok for a spirit drive.

My suspension and tire setup:
Cup Dampers
Grams Springs
Powerflex Black
Cup wishbone with pms stiffening kit
Cup ARB
Whiteline rear ARB
PMS Strut bar and Top Mounts
Modified Subframe
20mm front wheel spacer
25mm rear wheel spacer
A048 195/50r15 front (only for track)
A08R 185/55r15 rear (square set for road use)
1.6 rear axle with internal 19mm arb
Quaife LSD

Well, a very simple setup but made a huge difference on track, at Interlagos i have a new personal record with 189whp 1:59.3, my old record was 2:06.9 with 200whp
Here a onboard lap before running out of battery



At the end of the video you can see a black clio, it has a F4R woth 12.5:1 compression ratio, OEM 172 ph2 cylinder head and aftermarket ECU

Everything looks good, but i have problem with the modified subframe and i have to redo it one day hahaha, i only achieve 2.3° of caster on the left and 2.5° on the right.


Now about the engine, i made a some modifications but internals still the same:
Twingo 2 RS Inlet
New turbo setup using TD04L-13T-6 and stainless exhausty manifold
2.5" Stainless exhausty
Alloy crank Pulley
EPAS
Oil Cooler

I really happy with the engine results too, the older setup i have to run with modified cams position to get a faster spool, now i have exactly the same spool but with a much better power delivery with controlled boost

Dark lines is the new settingafter interlagos trackday and original camshaft position (236whp with 1.1bar / 14.5 psi)