C20XE Turbo Conversion

[jasonb89]

My old build diary was getting abit confussing so i thought i'd redo it :D ! well im basicly in the middle of doing a FWD C20xe conversion and im adapting the original mini subframe to suit. at the moment the engine is running on a F20 box and will be fitted with throttle bodies, fast road cams, decent exhaust and a few head mods to hopefully see around 200 BHP. I will be using the car to do a few hillclimbs/sprints to start with then if im happy with it i will be putting it on road. at the moment i have most of the parts to get the car up and running but i still have alot of fabricating/bodywork to do :( . In the next week or so the shell is going to be sandblasted and then have some new panels welded in and a few body mods to the rear (tubbing,turreting etc). Over the next few days i'll try and upload a few pics of the work i've done so far.

[jasonb89]

here are a few early pics of the build 8)

Engine & box
http://i239.photobucket.com/albums/ff281/jasonb89/DSC00017.jpg

Start of subframe
http://i239.photobucket.com/albums/ff281/jasonb89/DSC00016.jpg

Rear arches ready to be tubbed and turreted
http://i239.photobucket.com/albums/ff281/jasonb89/DSC00018.jpg

2 piece fibreglass front end
http://i239.photobucket.com/albums/ff281/jasonb89/DSC00021.jpg

[jasonb89]

here are some more recent pics of parts that i've picked up.

Throttle bodies and mainifold, these are converted webber carbs. im not sure exactly what has been done to them but it looks like the float chambers have been machined off and then the gaps filled in. not sure what engine management im going to be running these on yet though.

http://i239.photobucket.com/albums/ff281/jasonb89/DSC00066.jpg
http://i239.photobucket.com/albums/ff281/jasonb89/DSC00067.jpg
http://i239.photobucket.com/albums/ff281/jasonb89/DSC00068.jpg

These are a set of 13x7 Aluminium Oz alloys off a formula ford :twisted:. they weight hardly anything but the PCD is 100mm, so whilst im rebuilding the hubs i'll be adapting them to suit

http://i239.photobucket.com/albums/ff281/jasonb89/DSC00065.jpg

Apart from that im just in the process of doing all the boring stuff like re-building the hubs and sorting out bodywork etc but will be looking to get the shell in some form of paint by the end of march

[jasonb89]

progress has been slow lately as i've been busy with other things (mainly watching the rugby :twisted: )
just sandblasted a few parts before most of my stuff goes off for powder coating. having abit of trouble with my local engineering/machine shop as they wont re-drill my flanges or cut/ bend any metal to size for me because the job is too small :evil: so if anyone can recommend a company in the north cornwall/south devon area that i should try that would be cool.

[jasonb89]

small update: i have re-drilled my drive flanges to 100mm PCD so accept the new wheels and added new forged studs, made a start on the subframe. just making it all outa scrap bits to start with then will remake it all again next week when i know how much clearence i will have. i have also brought some recon hubs and a new quick rack (thanks to boots) sohuld finish the frame tomorow night ready to be re made properly and have the engine mounts done by next week. im slowly working my way thorugh the bodywork but its not really my thing. pics..... hope you like

New re-drilled flanges:

http://i239.photobucket.com/albums/ff281/jasonb89/DSC00085.jpg

http://i239.photobucket.com/albums/ff281/jasonb89/DSC00086.jpg

Start of subframe:

http://i239.photobucket.com/albums/ff281/jasonb89/DSC00087.jpg

http://i239.photobucket.com/albums/ff281/jasonb89/DSC00088.jpg

[jasonb89]

ok well i think i've overcome my problems now so the projects back on track :D
i now have my subframe made up and it's just a case of cutting out the old unwanted bits of frame which i hope to do later today with the help of my mates plasma cutter as i tried with a grinder and it was a pain in the sweede.
Also ihad to do something to motivate me abit more with the project so i decided to go turbo! i currently have a brand new turbo and waste gate, BOV, exhaust manifold, 750cc injectors and air intake. hopefully next month i will get a new fuel pump, intercooler, pipe work and exhaust sorted. but my biggest problem at the moment is going to be the inlet manifold.
i will post some pics up later on if any1's interested.

[jasonb89]

a present arrived in the post this weekend :D

http://i239.photobucket.com/albums/ff281/jasonb89/DSC000852.jpg

[XEValver]

wah-woo-wee-woo!! 8) 8) 8)

Where is this turbo going? standard, or remote? and what induction are you using? I guess you just really need to get the full gubbins from a C20LET

[jasonb89]

all being well it will be in the standard position but all depends on if i can fit it all under a cluby front. i can see problem with rad position but i will have a front mount intercooler in front of the front end if that makes sence to give me more room.
i've already got some mahle forged pistons so i think it will just be a case of either getting the rest of a LET bottom end or a turbo crank with aftermarket forged rods.
induction wise im hoping to use my twin webber style TBs on a half vaux half webber manifold with 750 cc injectors and will just be a case of making an inlet chamber out of some ally (i hope) just im not overly sure where to mount the BOV at the moment. i do also have a LET exhaust manifold that i will be using to start with but may make a stainless tubeular one so i can get the turbo to fit better.
my frame is all complete and welded up now so just waiting on my mate with the plasma cutter before i can get a coat of paint on it, oh and still got the engine mounts to make but shouldn't be to much of a problem

[oli]

Have the new studs in your drive flanges got enough metal round them?

[jasonb89]

yes there should be plenty as the holes are only a couple mm bigger than the originals so it should be ok and will hold out better than if i just ran my wheels i have without moding the flanges due to the stress that would have been put on the studs.

[jasonb89]

bit more progress on the frame. most of the old frame removed as i got hold of a plasma cutter which made things alot easier. just got to tidy up the edges and check my clearences now. pics:

http://i239.photobucket.com/albums/ff281/jasonb89/DSC000854.jpg

http://i239.photobucket.com/albums/ff281/jasonb89/DSC000863.jpg

[jasonb89]

small update. i've got myself a cage which should be arriving in a week or so. so thats another thing off the check list. also i've started to make up the engine mounts for the frame so i am going to try and get the engine in the frame sometime next week. also im going to give the enigne a full re-build :D seeing as im now going turbo i thought i'd better make sure it was pritty bombproof before i started. im going to change oil & water pump, all gaskets, core plugs, piston rings, camblet kit, big and main end bearing, change to steel rods with arp bolts,pocketed mahle pistons, de comp plate, get the block tested and possibly dipped and re-bore if needed. the head i have is was freshly reconed when i got it but performance wise i will be porting and polishing the head, high lift cams, solid lifters, bronze valve guides, double valve springs and venier pullies. hopefully with the turbo install, 40mm Tb's, 750cc injectors and a decent fuel pump i should see around 250 BHP on lowish boost with the look to turning it up after im happy with the setup.

[mininut]

750cc injectors and a decent fuel pump i should see around 250 BHP on lowish boost with the look to turning it up after im happy with the setup.

Save your money, 750cc will give you uncontrollable bore wash. 550cc is good or over 400 horse, IIRC the stock 20let ones will be fine for anything up to 250, if you want a little more go for reds.

Bigger is not always better :wink:

M.

[jasonb89]

oh really? didnt realise 550cc would be able to supply that much fuel for 400hp. thanks for that, means i can spend abit more on something else :D injector wise what would you recomend because am i right in saying that some injectors have a 2way spray pattern and some have 4 way? i presume 4way would be better as it gives a more even distribution?

[mininut]

IIRC the stock ones are good for near 250. Then saab reds do the trick for a further 50 or so hp.

M.

[jasonb89]

ok cheers for that, i got a little way to go before i'll need them yet but i'll def keep all that in mind. project may have to go on hold again as im losing my garage :cry:

[The Mighty Mallott]

You said rebore if needed! i thought you already had the pistons?

I have to say this would be better going in the back, at least then you will have a good chance of keeping the power down.

Mat

[jasonb89]

yea i do have the some pistons but there just the standard early XE ones, they are forged but i don't know how much they can take. so if the bores are ok i'll use them if not i'll get a rebore and some aftermarket forged pistons as i was going to do this anyway at some point.
i would really like to put it in the back! i just havn't got the skills to do it unfortunatly :(

[MarkLD]

Get yourself a set of LET pistons, they come up quite often on MIG

[jasonb89]

are they dished to give a lower comp ratio?

[jasonb89]

ok, so after mallot's comment it's sort of given me the kick up the backside i needed to turn it rwd. i wanted to do it anyway but just thought it would be too hard for my 1st conversion. but to hell with it :twisted: i been looking at a few of the conversions on here and it seems that i can use the front subframe that i have built already and mount it from an extension of my rear cage. with that in mind and a mate of mine who's doing the all the welding on my mini in exchange for my compressor who's a top notch fabricator i tihnk i might be able to pull it off :D

[monsterer]

ok, so after mallot's comment it's sort of given me the kick up the backside i needed to turn it rwd.

Good man! A tubro RWD XE is going to be very very fast :shock: :)

edit: however, i would urgue you to reconsider a LET in the back - if it would fit better than the in front, that is... :)

[jasonb89]

i think getting it to go in a straight line and around corners in my biggest worry :shock: but yea should give some of the local hillclimb boys a good go!

[monsterer]

i think getting it to go in a straight line and around corners in my biggest worry :shock: but yea should give some of the local hillclimb boys a good go!

Just don't boot it mid corner, only when you're in a straight line, then open the gas :)

[XEValver]

good man! about half way through my build i wished i'd gone for rwd! :(

[jasonb89]

shame. least it gives you an idea for our next project though :D as isaid i always wanted to do it and now going turbo it's pobally a good idea too. good thing is i havn't done much to the shell yet so going RWD is just going to be down to my skill :shock: or lack of them

[XEValver]

haha. my next project wont be a mini, but will be another british classic. it'll be RWD but front engined.

crack on with yours and i'll pop down and check it out 8)

[jasonb89]

sweet, i was cosidering scraping whole mini idea the other day and just getting a caterham! hopefully in a few weeks i'll be able to move into a new garage, then the fun can begin :twisted:

[jasonb89]

well i've finally sorted out another garage until november which is all good so once i get the shell back i can finally start on getting on with RWD setup. im going to mock everytihng up with some old scaffolding poles then remake everything out of CDS and attach it to my rear cage that should be coming next week. i think im going to do a design similar to Ed's and Terry's conversions as they both seem to have worked really well.
i'll keep you updated!

[cooper_mark]

so u going to finish it now.........?????? or is it still a nogo area

[XEValver]

so u going to finish it now.........?????? or is it still a nogo area

pretty sure he's still selling up. he's minus a pair of doors now anyway :oops: :o

[jasonb89]

yea its all going im affraid :(

[cooper_mark]

have u got anything left to put on the mini...

i've had the bulkhead box and lifting bracket

[jasonb89]

i've got a front end, bucket seat, front converted subframe for the c20xe, couple of sets of alloys, turbo kit, throttle bodies, few body panels and a few other bits and pieces