パフォーマンスアップグレードを伴うミニ修復の日記 - 第4部

By Chris - of Merlin Motorsport 

PART 4/ THE ENGINE BAY

Read Part 1 - BODY SHELL, SUSPENSION & BRAKES

Read Part 2 - THE FUEL SYSTEM

Read Part 3 - INTERNAL FIT-OUT, ELECTRICS, DASHBOARD & CONTROLS

Following on from Part 3, about internal fit-out, electrics, dash & controls

My mini engine is pretty special, even if I do say so myself! It’s a 1293cc turbocharged fast road engine and I was keen to build it to a very high spec.

I decided to use an Omex 200 series ECU and a Garrett T3 turbocharger, following lots of research it looked to be exactly what I needed so I sourced these from a local company in Cheltenham. I then went for a custom made intercooler using a Pace Products core as I had limited space and could not find an off the shelf solution. I had all of this assembled and welded by Lite Welding and fabrications in Stroud ready to fit to the car.

Above - Intercooler showing Samco Xtreme 'hump' hoses and stainless hose clips

I then set about the rest of the engine ancillaries -

Brakes/Hoses

I fitted OBP brake fluid reservoirs , OBP brake master cylinders and Goodridge brake and clutch hoses.

Above - master cylinders, goodridge feed hoses with OBP small fluid reservoirs

I used Samco Extreme for coolant, induction, vacuum and intercooler pipes. I decided to use Samco Extreme over standard Samco as this can withstand higher temperatures and pressure - it also has thinner walls and is easier to install. These were all universal parts with Merlin universal bends.  I fitted a Forge Motorsport FMDV001 diaphragm type dump valve again due to space restrictions (the joy of a mini engine bay!).  These were all assembled using Merlin supplied hose clips for a professional and secure installation

Above - Samco coolant hose fitted to radiator using stainless hose clips

Above - Samco Xtreme straight reducer hose fitted between intercooler pipe and turbocharger

Above - Forge motorsport FMDV001 dump valve fitted to plenum chamber using a small piece of samco hose with stainless clips and pressure sensing with samco vacuum tubing

 Above - Samco Xtreme straight coupling hose fitted bewteen intercooler pipe and plenum chamber

Air Filter

After a discussion with ITG technical team explaining my issues with limited space / performance requirements - ITG suggested and manufactured a modified solution including a high performance filter with increased surface area and protection to ensure the filter is not draw into the turbo. 

 Above - intake

Above - ITG air filter front

 Above - ITG air filter rear

Coolant

For me Evans Power Cool 180 coolant was the obvious choice because of the benefits of reducing risk of overheating and its "fit and forget” quality (once the system is filled – there’s no need to maintain/replace). The system was sealed with a Stant lever type radiator cap. 

Above - Evans Power Cool 180 fill up

Above - Stant lever type radiator cap fitted

Carbs & Exhaust

The carburettor and manifolds are secured to the engine using Merlin 6 point k-nuts as they have a small hex head to allow better access in awkward locations and are naturally self locking.

 Above - 6 point k-nuts used to secure the carburettor to the inlet manifold

 Above - Shows Merlin 6 point k-nuts clamping down the exhaust and inlet manifolds

I had previously used Merlin Exhaust wrap on the exhaust manifold which was perfectly adequate, but as I had the engine out and was doing a lot of work I decided that to reduce engine compartment temperatures I’d get the unit Zircotec ceramic coated. I removed the manifold and shipped it off to Zircotec and a week later - it arrived back looking great. Now its refitted it is surprising how effective it is - 10 minutes after the engine is turned off the exhaust manifold is cooler than the inlet manifold. 

Above - turbo and manifold

More to follow...