Toby
Premium Member
Registered: 29th Nov 05
User status: Offline
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Oulton wasn't much fun when it was raining. Damp was ok but not rain! Hoping weather forecast is bollocks and its dry! Seems to be our luck at the mo!
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Kyle T
Premium Member
Registered: 11th Sep 04
Location: Selby, North Yorkshire
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Had a really good year last year with weather, didn't see rain at all on a track day.
Looks like it's pay back in 2015 
Lotus Elise 111R
Impreza WRX STi
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Kyle T
Premium Member
Registered: 11th Sep 04
Location: Selby, North Yorkshire
User status: Offline
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In the absence of actually needing to do jobs on my car, I made myself some work tonight and did what I've wanted to for ages, going way back to when I first bought the car and I had a whistle under boost.
I wanted to make a boost leak tester, basically I bung off the intake and pressurise the system, without the engine running. This allows me to hear evidence of any boost leaks.
I didn't set off tonight to troubleshoot anything, because the car has been performing brilliantly. I just wanted to see what size bungs and stuff I'd need to put together an eBay order.
As I took off the induction cone to measure my intake, I couldn't help noticing something on my shelf... a spare snowfoam bottle looked like the perfect fit 
I got thinking about how I could attach a tyre valve to the snowfoam bottle, and then realised that one of my blanked off intake hose thingies was the perfect fit for the nozzle of my compressor
So with no effort, I had a boost leak tester!
With nothing else to lose, I decided to test it. Immediately I could hear gushing air, and it was coming from the silicone elbow which connects the cone (or snowfoam bottle) to the intake. A slight adjustment and that was fixed, but I could hear another one.
This one was coming from another blanked off intake nipple which I believe used to be part of the recirculated head breathers (made redundant by catch can).
Upon inspection, the bung was far too big for the nipple and a cable tie had been used to "make it fit". I didn't have a smaller bung to hand, but a small jubilee clip did a better job than the cable tie and sealed it off.
Both of these fixed leaks were pre-turbo, so of course not under pressure when the car is bombing a long. The next one however, was a good catch!
The next hiss came from the MAP sensor that was fitted into the FMIC piping. This one of course is in the pressurised side of the system whilst under boost so presumably I'll be suffering a fraction of extra spool time because of it. I'm still hitting target boost, so it won't be a significant change I'd think?
My plan is to have somebody weld a bung on the intercooler pipe, then that should provide more threads for the MAP sensor to seal. It's currently tapped directly into the pipe, so only has like two threads!
I couldn't think of anyway to seal it up myself tonight, so as a test to make sure there were no other leaks, I took the MAP sensor out completely and covered the hole with my thumb. Silence on the next test!
So there we have it, I have a boost leak. Should be easy to fix, two jubilee clips and the section of pipe comes away easily so I can take it wherever I find some welding services.
Lotus Elise 111R
Impreza WRX STi
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--ToM--
Member
Registered: 23rd Nov 07
Location: Wirral
User status: Offline
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Was gonna say the washer on that map sensor isn't gonna seal on the pipe where it's positioned on a bend like that lol I had to do the same on my 200sx and have a threaded bung welded on
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CORSA NUT
Member
Registered: 3rd Aug 01
Location: Wirral
User status: Offline
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Can't believe someone would thread straight into that pipe 
What's under that black blank thing to the right? Just a straight pipe?
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--ToM--
Member
Registered: 23rd Nov 07
Location: Wirral
User status: Offline
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Looks like a DV outlet
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Kyle T
Premium Member
Registered: 11th Sep 04
Location: Selby, North Yorkshire
User status: Offline
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Aye it's the blanked off DV.
Lotus Elise 111R
Impreza WRX STi
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CORSA NUT
Member
Registered: 3rd Aug 01
Location: Wirral
User status: Offline
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Oh yeah of course, leak could POSSIBLY have been the cause of that fuel cut type problem you had??
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Kyle T
Premium Member
Registered: 11th Sep 04
Location: Selby, North Yorkshire
User status: Offline
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quote:
Originally posted by CORSA NUT
Oh yeah of course, leak could POSSIBLY have been the cause of that fuel cut type problem you had??
Perhaps, I dunno.
That issue hasn't shown up since the car spent the best part of a month at the shop, with "no issues found".
Touch wood it remains that way!
Lotus Elise 111R
Impreza WRX STi
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Kyle T
Premium Member
Registered: 11th Sep 04
Location: Selby, North Yorkshire
User status: Offline
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Just to correct myself, I always call it the map sensor but it's not - it's a temp sensor.
Doesn't change anything though!
Lotus Elise 111R
Impreza WRX STi
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Kyle T
Premium Member
Registered: 11th Sep 04
Location: Selby, North Yorkshire
User status: Offline
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I got restless today...
As I have a track day tomorrow, I was detirmined to cobble together a solution for my boost leak before getting it properly welded.
I tried gorilla tape, no good - the air always found a way out. Proximity to the DV port made it hard to apply the tape properly.
I then stumbled across what may be a terrible idea I had a tin of exhaust putty in my box of random bits.
I may pay for this later when trying to clean it all off - but I applied it as so, and left it to go a bit hard whilst sticking my trackday wheels on ready for tomorrow.
After getting the car otherwise sorted, I did the compressor test and voila, no more hissing.
After giving it a bit more time to harden, I went out for a drive.
Now I know people will claim placebo, but I swear the car is now pulling my face off
It sounds different, and pulls significantly harder. I even had to concentrate on keeping it in a straight line on a 3rd gear pull, with R888's in the dry. I've not experienced such behaviour since having a FWD hot hatch.
I'm not sure if peak power has improved as such, but it pulls much cleaner and harder - even though in hindsight I don't remember the car feeling at all "bad".
I did a load of pulls in various gears, and across the board the car feels much quicker.
Incredible
I'm not sure how long my putty solution will last, but every mile I get out of it between now and it failing will be much more enjoyable 
Will hopefully get it welded at the weekend 
Happy days.
Lotus Elise 111R
Impreza WRX STi
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CORSA NUT
Member
Registered: 3rd Aug 01
Location: Wirral
User status: Offline
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Result
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Darryl H
Organiser: South Central
Premium Member
Registered: 19th Nov 09
Location: Camberley Drives: Porsche 944
User status: Offline
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Great work Kyle, I need to do this to mine at some point
|My Corsa|SC|My Instagram|
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Brett
Premium Member
Registered: 16th Dec 02
Location: Manchester
User status: Offline
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Can I come and have a go on the leak detector?
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Kyle T
Premium Member
Registered: 11th Sep 04
Location: Selby, North Yorkshire
User status: Offline
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I'd recommend it to anyone with a turbocharged car tbh, well worth the effort.
Another succesful trackday ticked off, Cadwell went without any major drama.
Drove there in the rain, and the track was soaked. Luckily it stopped raining during the sighting laps and was fully dry by about 11am.
I'd still never really done Cadwell in the proper dry, and I'm amazed at how fast you can go round some of the corners, combination of uphill sections and generous camber I guess - but you can carry so much speed through, and even at the end of the day I felt I had a ton more room for improvement.
Couple of little issues, had massive fuel surge just before lunch - after the left hander of park and during the long sweeping left of chris curve - the car completely stalled out at about 90mph
I didn't immediately notice it had stalled, with the helmet on and the adrenaline etc - didn't realise the engine had gone silent. All I knew was throttle was totally unresponsive - my first thoughts were that throttle cable had come off!
I then started to appreciate dash lights, immediately saw oil pressure light on but gauge still showed around 6 bar.
Stuck hazards on and coasted to a stop on the grass, marshall came running over but restarted the car and drove it off the circuit.
It was on 1/4 tank when this happened. Swirl pot is the only fix for this, or more regular fuel stops.
Filled up at lunch, did a couple of sessions and noticed the car started sounding a bit funny and maybe felt a little tiny bit down on power - so assumed my gungum was coming off
Next session out, 120mph at the top of the hill and then BANG, massive pop and loss of boost. You can imagine my thoughts as I cruised round to the pits.
Luckily just an IC pipe coupling had popped off. Admittently one I'd taken off to "fix" my boost leak, so probably just badly refitted.
No issues after that, just a nice sunny afternoon of quick running. Can't wait to get back to Cadwell, loads of time to make up I feel.
Had GoPro issues almost all day (turns out SD card was knackered), but got one full session. Should be uploaded tomorrow.
Lotus Elise 111R
Impreza WRX STi
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taylorboosh
Member
Registered: 3rd Apr 07
User status: Offline
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3rd gear on a 4wd car in the dry on super sticky tyres and it wont go in a straight line easily? Gtf
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--ToM--
Member
Registered: 23rd Nov 07
Location: Wirral
User status: Offline
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What power is this? My classic was 420bhp at the fly and spun in second in the dry on proxies But only for a second
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Kyle T
Premium Member
Registered: 11th Sep 04
Location: Selby, North Yorkshire
User status: Offline
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quote:
Originally posted by taylorboosh
3rd gear on a 4wd car in the dry on super sticky tyres and it wont go in a straight line easily? Gtf
It's a poor man's evo remember.
Just the shit roads tbh, rutted and knackered which just seem to make going straight a challenge with a bit more power.
Lotus Elise 111R
Impreza WRX STi
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Kyle T
Premium Member
Registered: 11th Sep 04
Location: Selby, North Yorkshire
User status: Offline
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https://www.youtube.com/watch?v=FhhD03-eYOI
Camera mount is finally suffering
Lotus Elise 111R
Impreza WRX STi
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Kyle T
Premium Member
Registered: 11th Sep 04
Location: Selby, North Yorkshire
User status: Offline
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Had a cheeky half day at Blyton today, didn't book - but went down anyway and put myself on the reserve list.
Took somebody about an hour to break down, then I was called up. Took the missus for the first time, I think she quite enjoyed it!
Unfortunately, the day was cut short at lunch. I developed an up pipe leak which resulted in horrible noises and a real big power loss.
Coincidentally, one of the lads that works on my car at Richard Henry Autos was attending, who scrabbled around to confirm - but really nothing we could do at the circuit.
Ah well, much worse reasons out there to finish a track day early I guess.
Lotus Elise 111R
Impreza WRX STi
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AlexW
Member
Registered: 25th Oct 08
Location: Essex
User status: Offline
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I really fancy doing Cadwell, shall have to book it up sometime.
Quiet intersted in your thoughts on Blyton? I have a trackday there this weekend, Never done it before. What layout did you do? Is it anti-clockwise?
Cars awesome as always, up pipe leak easy fix?
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Wrighty
Member
Registered: 28th Feb 04
Location: Howden
User status: Offline
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up-pipe gasket gone?
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taylorboosh
Member
Registered: 3rd Apr 07
User status: Offline
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Not just this, but most track cars - seem to broken lotsssss
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Kyle T
Premium Member
Registered: 11th Sep 04
Location: Selby, North Yorkshire
User status: Offline
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It's the gasket aye, one between the turbo and the pipe. Cheap enough to swap, but might be a bit of a pig to get to as turbo needs to come off.
quote:
Originally posted by AlexW
I really fancy doing Cadwell, shall have to book it up sometime.
Quiet intersted in your thoughts on Blyton? I have a trackday there this weekend, Never done it before. What layout did you do? Is it anti-clockwise?
Cars awesome as always, up pipe leak easy fix?
I think Blyton is excellent, but I know it divides opinion. It doesn't have the character of "proper" circuits like Cadwell, with no undulations or scenery. Facilities are fine though, the surface is good and the runoff is generous. It encourages you to push on, and it's my nearest track - so bonus.
It's anti clockwise, but they do two layouts as far as I'm aware. I've only ever done the "outer circuit", the "eastern circuit" uses some infield bits I've never used before.
Boosh - bit of a given that track cars will break more I suppose but it's not ideal. This gasket going I think is more likely to be either a poor quality gasket or a fitment issue from the work I had done near Christmas. I've not done much mileage on it, and wouldn't expect a genuine gasket to fail so quickly regardless of how it was used.
Lotus Elise 111R
Impreza WRX STi
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Kyle T
Premium Member
Registered: 11th Sep 04
Location: Selby, North Yorkshire
User status: Offline
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Had a pretty eventful saturday, learned lots!
On Saturday morning, the realisation dawned on me that I wouldn't really get time to get my car off to Bradford for the replacement up-pipe gasket before Elvington on Friday.
I started coming round to the idea of doing it myself, the job is only made tedious by the fact the turbo needs to come off to access the stud nuts
I was discussing this with a friend on saturday morning, and he suggested I talk to a lad called "tweaks", or Tim to his missus.
My friend dropped him a text to start introductions, and within minutes Tim had offered to sort my car that very evening provided I could get the gasket, so off I went to the nearest Subaru dealership (80mile round trip ) and a couple of hours later I had a brand new up pipe and downpipe gasket.
Tim cut his teeth working for a Subaru specialist some years ago and quite recently has gone into his own mapping. Teamed up with his friend (and garage owner) Ben he does a fair bit of work on the local japanese performance car community. Tim has built a couple of big power cars in the past, and Ben has done plenty of Evo rebuilds etc.
We decided to do the swap at Bens shop, in case we needed any extra tools or bits and pieces - which turned out to be a good idea. Got to the shop at 16:30 and we had a casual start, letting the car cool off and drinking tea mainly.
Tim had a good look under the car, and spotted a leaky cam seal. Something to keep an eye on and probably get changed at somepoint, bit annoyed this didn't get picked up on when my belt was changed a month or so ago.
Sequence was:
Slacken off hose clamps and remove intercooler hoses that are in the way
Downpie disconnected from centre section
Heatshield off turbo
Undo top downpipe bolts
Undo bottom downpipe bolts and remove from car
Disconnect water/return
Disconnect oil/return
Undo up pipe bolts
Lift turbo out
Due to a few stuck bolts and us not really being in a rush - this took us a couple of hours. In the meantime, Ben had challenged us that he could mate up an Evo gearbox and engine, then fit to a car...
Once onto the penultimate step of undoing the uppipe bolts, we found they were all really loose... like not even hand tight beginning to think the gasket may actually be fine, we lifted the turbo off to find:
I would have expected a leaky gasket to have blown all the way out, rather than just losing a corner of it. Perhaps the loose bolts helped this sort of damage though?
A couple of the studs were looking a bit scruffy, so we cleaned two of them up with a die and replaced one with a spare that was knocking around. Everything brushed up to look like new.
Turbo was looking healthy on the surface.
We paused for some food, then got back to re-assembly. Engine was in the Evo at this point, and wiring had started.
Getting the turbo into position was a bit of a work of art. Lining up the unsighted oil return, intake hose and studs seemed impossible for a one man job. We eventually wiggled it into place.
Steadily got everything back together and it was now somehow about 22:30 Evo was about ready to go
Topped the coolant up, and then started the car up. Sounded beautiful, so much smoother and no immediate leaks or dramas. We let the car get up to temp, then had a look underneath.
Disaster oil return was pissing oil out of it once up to temp. We really couldn't see how this was possible, the hose was visibly clamped on. With some awkward neck craning we finally found what we thought was the cause - the flange connecting the oil return pipe to the turbo was leaking. We'd not even touched this, and no way had we manhandled the turbo enough to crack the pipe or flange so after a bit of head scratching... turbo back off again!
Uber pace this time, turbo was off in about 12minutes - both working independently on different ends of the turbo without Tim needing to talk me through everything.
Turbo came off and upon inspection and a blow test (Oil, yum) it appeared the flange to turbo gasket was leaking.
Unbolted it to find no gasket at all, just a load of silicone sealant?
Upon closer inspection, I found the flange to be bent - so somebody in the past had obviously slapped sealant on it to "fix" it. This could have gone at any time I guess, but the aggro of refitting the turbo tipped the scales. So relieved it didn't happen whilst out or on track, as it would have been a recovery truck home.
Really quite annoyed at this. I'm wondering if the turbo has always been like this whilst in my posession or whether it was leaking on fitment at Bradford and this was the "fix". It took Ben about 5mins to flatten out the flange, and by some miracle he had the right gasket and we had it sorted properly.
Turbo back on and coolant topped again, then finally road tested and sent on my way - at about 00:30 Sunday
I thoroughly enjoyed it, having access to experts but still being able to watch and get involved with the spanners was a brilliant experience. I'll hope to do a lot more work on my car like this with Tim, if he welcomes me as a regular customer.
Car drove brilliantly on the way home, as I expected. Sounds smoother than it has in ages, and pulls as hard as ever.
Little bit disapointed with a few discoveries on the car, but feel better for discovering them!
Tims' attention to detail is fantastic, he treated my car like he was working on his own - and he refused to go home at 10:30 when we found the leak. Properly nice guy, and knows his way around the Subaru.
Lotus Elise 111R
Impreza WRX STi
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