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NorthloopCup likes a challenge, right?



NorthloopCup

ClioSport Moderator
Well it’s update o’clock!

Cylinder head is now fully assembled and ready for the shimming. Just to reiterate, I f**king HATE BUILDING CYLINDER HEADS. PIECE OF s**t COLLETS BOIL MY URINE.
Now that’s out of the way I’ll bang some pictures up. Lol!
Nicely lapped valves - you’re looking at the grey area on the valve head if you’re not sure which bit to look at 👍🏻
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And here we have a mirror image of the grey area on the valve seat.
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Fully assembled cylinder head.
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And now for something a little different............

So remember I said we needed to sort a cam sensor pickup and mount? Well here’s the 3D printed mount for the sensor pick up. 😎
I think it’s safe to say, it’s a first. 👍🏻
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As are the R8 coils on an f4r I think?

More to come. 🍆
 

youngarthur

ClioSport Club Member
  Clio 197,with megan'
I spent many hours in my youth, lapping in valves, and If I has £1 for every collet that pinged past me, never to be seen again, plus several permanent scars around my eyes?. AH the good old days.
 

frayz

ClioSport Club Member
Lol, I’m sure you guys all know, but to those who don’t.
Grease on the valve collet grooves should stick the collets in and hold them firmly in place when releasing tension on the springs compressor.
(prototype engine build engineer for 15 years) 🙂

Nice lap job fella 🙂👌🏼
 

NorthloopCup

ClioSport Moderator
Lol, I’m sure you guys all know, but to those who don’t.
Grease on the valve collet grooves should stick the collets in and hold them firmly in place when releasing tension on the springs compressor.
(prototype engine build engineer for 15 years) 🙂

Nice lap job fella 🙂👌🏼
That’s exactly how I go about doing them mate! Lol! It’s still a f**king spiteful job!

Cheers!
 

NorthloopCup

ClioSport Moderator
Lockdown update!

Cylinder head shimmed up. 😎

Bring on the trumpets!
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Got the lower part of the inlet manifold to match up with the spacers.

And..............f**k off the trumpets!!
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What we have here are some 3D printed one-off custom designed inlet trumpets. EVERYTHING in the simulations points towards improvements to air flow. But, as with everything - the proof is in the pudding.

And to finish off, here’s the beginnings of the airbox design. Just the secondary injector mounts to add in.
4D650F40-2115-4857-B985-31119D0DC45E.jpeg


Enjoy!
 

Attachments

Louis

ClioSport Club Member
Lockdown update!

Cylinder head shimmed up. 😎

Bring on the trumpets! View attachment 1466962View attachment 1466964

Got the lower part of the inlet manifold to match up with the spacers.

And..............f**k off the trumpets!!View attachment 1466965View attachment 1466966View attachment 1466968View attachment 1466969

What we have here are some 3D printed one-off custom designed inlet trumpets. EVERYTHING in the simulations points towards improvements to air flow. But, as with everything - the proof is in the pudding.

And to finish off, here’s the beginnings of the airbox design. Just the secondary injector mounts to add in. View attachment 1466976

Enjoy!
Would the plan be to have these 3D Printed in steel eventually?
 

NorthloopCup

ClioSport Moderator
Forgot about these little bits 🤦🏻‍♂️

So we have had a re-design of the cam sensor. I was concerned that the pick up trigger wasn’t going to be large enough. This led to what we now have for the sensor - same position on the end of the cam, just in a different orientation.
D7FEF34A-8A59-487B-8536-FA486F4B3293.jpeg
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Don’t worry! That’s not the finished item. It’s been part 3D printed to check fitment/clearances.

As you can see, it’s improved the surface area which will definitely help the ecu read the signal.

And to finish off we have these little 3D printed spacers for the Audi RS coils that this engine will be running.
CDDFAFB6-92A2-439A-BD5F-0142E17DCC2E.jpeg
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Engine building will commence in the coming weeks. 👍🏻
 

NorthloopCup

ClioSport Moderator
Lockdown update #2

I needed to calculate the compression ratio just in case any adjustments were needed, and it will also be needed come mapping time.

So here’s a few pictures taken during the calculations for the cylinder cc. Working it out is a bit of a pain with the dome of the piston protruding out the top of the block, but a bit of maths and she’s reet! Couldn’t find my plexi glass, so I had to improvise lol! It did the job though!

Here’s some pictures:
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Armed with the necessary measurements I made the calculations for the comp ratio. End result is a nice and lively 12.9:1 👍🏻

After that it was time to start pulling it apart to as it will be rebuilt with liberal amounts of graphogen. As you’d expect, here’s some pictures!
DA3FA627-DFFE-4473-B6D9-A78220908041.jpeg
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N
No oil squirt jets in there! 😎

And the 2 ring pistons with Saenz long rods. How long the pistons will last I don’t know, but I can get them custom made to have 3 rings as and when the time comes.
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Wallop!
 
If you wanna know this stuff then watch the vid ETCG did with Kalvinator engines. They explain everything to do with measuring bore/compression/cc

Same with the TSF and John, they did a vid too. The vid might be an hour-long but it feels like 10 mins when you're engrossed haha
 

NorthloopCup

ClioSport Moderator
Lockdown update #3

Had a spare hour this afternoon after the wife took over from daddy daycare, so went in the garage to get the block pulled apart.

EC144D8E-447E-45FD-8683-92141FFFEDD9.jpeg

Here you can see the oil squirt delete better, and we also have some improvements to the block in terms of reducing crankcase pressure.
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And a couple of randoms.
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Angle grinder fun coming up soon as the block needs modifying for the dry sump setup.

More to come.
 

Hazza462

ClioSport Club Member
Awesome work so far, very jealous of the engine spec was speaking to Tom the other day about it.

Is that external machining of the block the only 'modification' required to fit the dry sump setup then, or is there more internal work needed like blocking off galleries etc? Reading this has made me want to get mine fitted!!
 

NorthloopCup

ClioSport Moderator
Awesome work so far, very jealous of the engine spec was speaking to Tom the other day about it.

Is that external machining of the block the only 'modification' required to fit the dry sump setup then, or is there more internal work needed like blocking off galleries etc? Reading this has made me want to get mine fitted!!
Cheers mate. Lol I don’t think there’s a day that goes by that I don’t speak to Tom tbf! 😂

Yeah there’s a hole or 2 that needs blocking off mate, but I’ll be covering that through the build process. At least people will be able to see what the craic is when fitting one. 👍🏻
 

Hazza462

ClioSport Club Member
Cheers mate. Lol I don’t think there’s a day that goes by that I don’t speak to Tom tbf! 😂

Yeah there’s a hole or 2 that needs blocking off mate, but I’ll be covering that through the build process. At least people will be able to see what the craic is when fitting one. 👍🏻
Perfect that was gonna be my next question haha, look forward to seeing those thankyou very much!
 

Eddie555

ClioSport Club Member
  Q7 2018 & 172 Cup.
Cheers mate. Lol I don’t think there’s a day that goes by that I don’t speak to Tom tbf!

Yeah there’s a hole or 2 that needs blocking off mate, but I’ll be covering that through the build process. At least people will be able to see what the craic is when fitting one.
I know for sure that the pipe coming out of the water pump will need modification as it will be obstructed by the oil pump shaft. But you may already know that clever clogs.

Sent from my SM-G977B using Tapatalk
 

numbers_

ClioSport Club Member
I have to ask after seeing it a few times now, why do you want to block off the oil squirters? I would have thought the cooling would have been beneficial
 

NorthloopCup

ClioSport Moderator
Long time since any updates on this! There’s been a lot of stuff going on that’s needed custom parts, but I’ll go into that in a bit more detail later on. For now it’s a few pics - everyone likes pics.
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King race main bearings
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Graphogen loveliness
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King big end bearings
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original oil feed in the block blanked off
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New cam sensor mount finalised and 3d carbon printed
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Head stud kit fitted
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Will be updating through the day with pics and waffle. 👍🏻
 

NorthloopCup

ClioSport Moderator
New ECU Master components and the Maxx Race ECU. (Tom is a dealer for ECU Master - if you need owt speak to him 👍🏻)
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Time to get the party started and do a bit of dialling in the cams
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And in the next exciting instalment there will be a lot of disappointment, swearing and very large dose of me getting very annoyed. Lol
 


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