Rapid washing machine!

CaneyJ

CaneyJ

CaneyJ

Associate
Joined
15 Dec 2002
Posts
1,087
Location
Birmingham
Well autumn has been a fun time. Ingrained oil, nasty prickly heat wrap, countless burns, scraped knuckles and swearing but I said I would do it and now it’s complete! The cinquecento is now not only Punto engined but now turbocharged, oooohh the fun is definitely there!

Yes it’s barmy but there are still possibly worse ways of blowing your money other than keeping and spending it on your first car. Anyway here is a brief log of which the conclusion is…I’m never getting under a car again!

After my previous engine swap, this was the next stage in the cars long term fun plan. The engine swap I did last summer was covered here.
http://forums.overclockers.co.uk/showthread.php?t=17611642&highlight=startername_caneyj . If anything, this build was even harder! The aim was to create a reliable conversion whilst sticking within a reasonable budget. With the car having covered 200 mixed miles I believe the reliability is holding out though through unforeseen circumstance it wasn’t quite as cost effective as I’d hoped he he but still it wasn’t that bad considering.

I had all the parts including a compact K03 turbocharger scavenged off a turbo diesel golf, a custom exhaust manifold to mount it, a fuel injector computer, a cosworth 2nd injector and throttle body mount as well as a number of smaller components.

Big problems came fitting the turbo and manifold to the car finding they were not only too far forward fouling the radiator but the actuator was also on the back meaning the water rail path from the engine block was blocked meaning a new fabricated radiator mount to bring the rad forward as well as a completely re-worked cooling system to get around the turbo’s awkward location grr.

With the assistance of an engineer friend we got the new parts welded up and a new front exhaust downpipe made at long life. A trip to Mocal (just down the road from me) also saw me with an oil feed for my turbo to which I reached this stage.

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I also had bespoke boost and induction pipes made up at long life so was also able to get the rest of the basics mounted.

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Since I was re-doing the coolant system, I decided to use a more aesthetically pleasing Seicento water bottle and a cheap but functional cone filter resulting in this.
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Finally got round to re-fitting the coolant system and got the piggyback fuel computer and fuel cut defender wired to take it on initial test runs.
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The next couple of weeks were crazy doing test runs and learning from the multiple mistakes that occurred including the car surviving a 4 mile limp along the M25/A3 with no water in it, a dangling turbo from the manifold (giving the interesting sound of a VW bug he). However with more fabrication and components ordered, both of those main gremlins were finally worked out.

The turbo I had was also over boosting at too high a pressure being a minimum of 10psi when I only wanted 5 which was kinda fun except it would eventually result in holed pistons, not so fun. Instead of being logical and buying a new turbo and reforming the manifold I did some stubborn turbo surgery by grafting a turbo fiesta T2 actuator onto the K03 forming somewhat of an interesting hybrid.
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For extra protection I fitted additional heat wrap which really worked wonders on the temperatures pumped out from under the bonnet.
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And after all this the car finally came together last week with the mapping being made, the boost gauge fitted and the car being given the wash down it deserved after being on jacks the last couple of months before driving it to Worcester last weekend.

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Despite the money, stress and pain I believe over time I will grow to think it has been worth it. The end result is unique and interesting to say the least he he. With such a small turbo it spools up the second you touch the throttle and from similar setups, the predicted performance is 100bhp (needs to go on the rollers but on a 740kg car you do the mathS ;) with a sub 8 second 0-60 time! My club officer who also runs a similar low boost car says that on a track, the car will see its way to the end of the gearbox at about 125mph and unlike the standard cinq, from 70+ it is still very quick making overtaking a breeze.

It has so far been fine at holding temperatures even during my commutes in heavy traffic though the plan is to get a new rad, cooler thermo and fan switch fitted come summer. Other mods of more simple nature next summer include a much needed engine bay tidy up, a bigger throttle body, up rated plugs and ignition leads, a supersprint exhaust and a fuel map to match. After that I can probably then finally start saving for my next proper car he he. Was thinking along the lines of a smart roadster coupe or a Lupo GTI which would probably be the Cinq’s spiritual successor.
 
Bet that's fun :)

You've done some good work, impressed you got it all into that!

What managemnet system are you using?
 
Nice to see it done! :D Would love to see your car sometime, sounds fun really and a project I would abolutely love. Shame I can't add a turbo easy to my car. :(

Edit - What gain will the extra bits and bobs do?
 
A company called Van Aaken produced a turbo kit for cinquecento's a few years ago which is what I based mine on and where I sourced some of my second hand parts such as the manifold, piggyback ECU and injector/throttle body mount.

The car as standard runs 54bhp and 63lbft of torque. Predictions are atm it's producing near 100bhp and 120ish lbft but as said, it'll need rolling road to justify. I plan to bore out the throttle body from 30mm diameter to 40mm and change the peashooter exhaust to something freer flowing but small tipped to keep people guessing.

As for fuel management, it's quite crude. It's a modified Aquamist MF2 injector controller usually used for water injection but can also be used for fuel. The one I have is bespoke from Van Aaken and has a 2nd map sensor built in. In conjunction with a fuel cut defender box to fool the ecu, fuel is adjusted in 500rpm increments using pots on the circuit board and a little led bar graph gives rough indications. This was done with a mechanic friend with a wide band lambda sensor off the downpipe to get the fuelling right across a variety of driving conditions.

As for the down pipe, there are no issues. The sump is in fact at the same level if not slightly lower and it takes the same course as the original and is welded onto the end of the existing CAT. Even if it were, the car has only been lowered by a minimum of 30mm so there isn't an issue with speed bumps besides hardness of ride.
 
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