Capri MkII Turbo (11-second 1/4-mile) X-pack fitting

Discussion in 'Members Capris' started by therealpinto, 13 August 2009.

  1. therealpinto

    therealpinto Registered Capri Power Member

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    Might be some repeats from the old thread, but...

    From this...

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    ...through this...

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    and that:

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    Add those:

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    Ooops!

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    Development:

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    In 2005 this was the look:

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    Underneath you would find taxi parts...

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    The look of 2006, Escort forest arches at the rear:

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    Another "oops":
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    and double ooops:

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    So lets add this:

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    To a couple (or two couples) of Cosworth pistons and rods.

    Some plumbing:

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    In 2007 it ran with the "big" turbo:
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    A little bit too good perhaps. Ooops time!

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    and in the same run!

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    So lets add some parts for 2008:

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    [​IMG]

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    Quaife diff, T5 gearbox with Steeda Tri-Ax shifter and Dione driveshafts (yes, I broke two drive shafts at the same time in 2007 too!).

    That added up to a good seasong 2008:

    [​IMG]

    But not only straight forward!


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    Best ET 12.2 and 112 mph. Not satisfied with the starts.

    So for 2009 the coilovers were repositioned:

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    A smaller turbo to test with:

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    (HX32 instead of HX35)

    New intake manifold/plenum...

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    First race, the clutch said "no thanks".

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    So we brought in brute force!

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    And now it looks like this:

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    ...and just made a 11.991s /112 mph pass :)

    Gustaf
     
  2. JimmyG

    JimmyG Registered Capri Power Member

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    Always fun to follow your project Gustaf, also really nice being the lone sweden inhere anymore. :D
     
  3. Malky

    Malky Registered Capri Power Member

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    Looks fantastic, I'm guessing you've ditched the EECIV? That exhaust manifold is brilliant!
     
  4. therealpinto

    therealpinto Registered Capri Power Member

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    Yes, the EEC-IV was replaced by Megasquirt in 2003 or so. The best thing I ever did to the car, actually, programmable management opens up a whole new horizon.

    At the moment I'm working slowly with another clutch swap. The iron sinter disc pictured above is just too harsh for me. So I'm going Cossie sized clutch now, on a rather nice flywheel:

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    I also found some action pictures from the 11-second runs...

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    [​IMG]

    Gustaf
     
  5. andyonthejob

    andyonthejob Registered Capri Power Member

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    That looks really impressive Gustaf. You must have the patience of a saint with all the extra power failures. Is that a sierra rear axle in the capri and if so how did you go on with the body mounts? I'm guessing thats why you've added the arches as the sierra runs a wider track than the capri?
    Andy
     
  6. therealpinto

    therealpinto Registered Capri Power Member

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    Actually there has not been a lot of failures. I have been running with a turbo for 10 years and it was really only one year that gave a lot of failures. So basically a 90/10 rate of success vs failure :)

    Yes, a Sierra rear axle. There are some pictures of the progress with that in my album at www.whynotracing.com. The arches are to cover the Sierra track, or more correctly, the Sierra track was chosen to fill X-pack arches one day ;-)

    Regards

    Gustaf
     
  7. escort

    escort Registered Capri Power Member

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    Got some new plans for the winter? Fit the X-pack?
     
  8. Day_Dreamer

    Day_Dreamer Registered Capri Power Member

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    gustaf,

    did you mount an aftermarked fuel pump? I did on mine but placed it inside the boot so the pump is higher than the fuel tank. This leads to that the pump seems to be running dry. where did you place yours?
     
  9. therealpinto

    therealpinto Registered Capri Power Member

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    Winter plans might include the X-pack, if I feel the urge to put the tiger saw to use again. But first the garage needs new doors.

    Yes, a high pressure fuel pump is necessary to run EFI. There are a number of ways to fit them, and I have tried some of them, always using a low pressure feed pump to get the fuel from the tank to the high pressure pump;

    1. Carburator electric pump fitted in front of the tank, feeding a small "swirl pot" that in turn fed the hp pump. The return from the engine went to the swirl pot, and that had another return to the tank. HP pump also fitted in front of the tank. Worked pretty good but very hard to work on the fuel system.

    2. Low pressure in-tank feed pump fitted inside the tank (from a Volvo 940), feeding the HP pump directly through a big fuel filter. HP pump and filter fitted behind the left-side rear wheel, with a spray shield (exhaust moved to right-hand side). This is what I have now and it seems to work fine, that's how the fuel system in the Volvo 940 is done. But I am a bit concerned about the fact that there is little reserve if the feed pump should draw air. But it has worked since 2005 with increasing amounts of power...

    I'm contemplating fitting a hp Walbro pump inside the tank, using an internal swirl pot from a Saab 900, we'll see if that works out.

    Regards

    Gustaf
     
  10. therealpinto

    therealpinto Registered Capri Power Member

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    http://www.youtube.com/watch?v=hTs0CtmRN8c

    Goodbye season of 2009, what better way to say that than go for a short spin?

    Gustaf
     
  11. Finn

    Finn Registered Capri Power Member

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    Amazing, excellent work. Finn.
     
  12. therealpinto

    therealpinto Registered Capri Power Member

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    In the beginning of the week i got time to start this winters projects. Part one was to check that my different wheels would clear the new wings (X-pack!)

    I started by drilling away the old arch (Escort MkII forest arch) on one side, and taped an X-pack wing to the side.

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    It looks pretty hopeful with the R-tires...

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    The ET Streets foul the rear of the fender, just as it turns in. We had the same problems on a MkI with arches, it's usually possible to just cut away a small section and it will clear.

    [​IMG]

    The width is not a problem.

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    The Escos wheels also look pretty good, but they need real tyres (225/45-16 is what I'm planning).

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    Lowered a bit and it looks decent huh?

    I have some fitting questions though. Beneath the "C" window, how do you usually fit the X-pack? I'm specifically thinking about the clips for the window trim. Do I remove them from the steel panel and refit to the plastic, or make cutouts in the X-pack wing? :unsure:

    But i'm starting in the other end...

    ...tonight I put 3 hours into hacking off the right side front wing.

    First, door off. A crane is handy, Capri doors are heavy and I'm built like a F1 driver.

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    Tadah!

    [​IMG]


    [​IMG]

    Spot welds and two seams, and looooaaaads of goo! I used a drill and a chisel. Worked pretty good despite lack of room. I tried to get the wing off reasonably intact.

    The front end is worse...

    [​IMG]


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    Some rust of course and some nice PO had also added random spot welds (of some sort).


    Victory at last!

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    The rear piece had like 2 kg of seam sealer sticking the wing to the car...

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    Freedom at last!

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    It seems the front part here has to be taken off to fit the complete X-pack wings from Fibresports. And here is where I ended tonight.

    [​IMG]


    /Gustaf
     
  13. therealpinto

    therealpinto Registered Capri Power Member

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    Someone has asked about the current state of the engine room. A mess, perhaps?

    [​IMG]

    [​IMG]

    Anyway, I continued to work on what the wing hid...everyone who ever has removed a Capri wing knows what to expect. Rust!


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    The previous owners spotwelded wing rails covered a quite sore edge.

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    Urg.

    The footwells are also a bit holed, the corner as always. I will have to replace some steel there. But at least I started to weld the inner sill.

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    More fun, trial fit of the Fibresports complete wing!

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    The fit of the front end is a bit strange (ideas, where do I cut?) but all in all it looks doable. With some lowering, wheels in the correct position it will be nice.


    /Gustaf
     
  14. Day_Dreamer

    Day_Dreamer Registered Capri Power Member

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    the car is going to be great, keep up the good work. I see you created an oil seperator, where is the clear hose going to? Back to the inlet pipe?
     
  15. therealpinto

    therealpinto Registered Capri Power Member

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    Yes, the clear hose goes back to the turbo inlet. The regulations in Sweden demand a closed loop crankcase ventilation system and this sort of fills that requirement...

    Gustaf
     
  16. capri_turbo

    capri_turbo Registered Capri Power Member

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    The front panel needs cutting to allow the Fibresprts X pack full wings to fit. I literally cut 2 slots and folded it back to form a flange to mount the wing to...

    [​IMG]

    [​IMG]
     
  17. therealpinto

    therealpinto Registered Capri Power Member

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    Thanks!

    I was thinking about modifying the wing but it's probably better to to like you did.

    Gustaf
     
  18. therealpinto

    therealpinto Registered Capri Power Member

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    Some more work done:


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    Now the wing fit is decent, the bonnet is a bit high but it has always been like that. I think that the catch/hold-down for the botten should be adjustable, right? The springy thing and the front...mine wont move!

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    The front valence is cut quite a bit.

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    I tried to duplicate the V6 strenghtening panel for the strut top. I have also made a square tubing section (25x25x2 mm) to run along the top edge but I'm not sure it will actually do much good. Still thinking about that one.

    [​IMG]

    The wing rail (from Veng I think) didn't really fit that good, quite "wavy" and the profile of the bend was not spot on. But it will work.

    [​IMG]

    I added some consoles to really secure the wing to the rail, so at least on four points it will be solid.


    /Gustaf
     
  19. therealpinto

    therealpinto Registered Capri Power Member

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    The week before christmas I caught a flu (no, not the bacon fever) and then christmas meant holidays. But now I'm sort of back on track. But minus 30 degrees centigrade also means it's pretty cold in the garage, despite the heated floor.

    I put the door back to check the fit of the wing.

    [​IMG]

    It fits OK, but I had to modify the lower edge a bit.

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    Finally the top edge also looked OK.

    [​IMG]

    Next mission is to build something to fix the wing to the A-post. It needs to be accessible from the front so I don't have to take the doors off to remove the wings.

    [​IMG]


    /Gustaf
     
  20. therealpinto

    therealpinto Registered Capri Power Member

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    OK, progress has maybe not been rapid the last weeks but it is moving forward. Inspired by the drift Capri here and a good (for me) pound sterling exchange rate, I let the VISA card work at Rally Design:


    [​IMG]

    [​IMG]

    I really don't like rose joints on a road car but it will do for now. There are also some plans regarding the struts themselves but I'm still waiting for parts there.

    The right front wing is done, and the left side is also practially finished. So I started working on the front spoiler.

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    The fit is OK, not perfect but nothing that some heat and a skim of polyester won't fix.

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    [​IMG]

    The wings are not 100% adjusted but the fit looks decent to me.

    Putting a wheel in roughly the right spot is usually good for motivation too:

    [​IMG]


    It's just on the wheel dolly, front suspension still needs to be sorted.

    Then the tiger saw moved on to the rear end of the car. The wheel arches need moving around 6 centimeters.

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    This weekend I started fitting the new tub section too.

    Primer, another giant step!. Yellow CA-primer (epoxy primer) is supposed to be good!

    [​IMG]

    [​IMG]


    /Gustaf
     
  21. Malky

    Malky Registered Capri Power Member

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    I'm loving this car, going to follow you're lead in the future and strap a turbo and megasquirt to my pinto. What injectors and fuel pump are you using?

    Xpack looks great too.

    Jamie
     
  22. therealpinto

    therealpinto Registered Capri Power Member

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    I have Racetronix injectors, 630cc/min or so. Ebay :)

    The fuel pump is a Bosch "984", basically a Capri 2.8i pump.

    MS+turbo+Pinto = :headbang::

    /Gustaf
     
  23. Malky

    Malky Registered Capri Power Member

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    I didnt realise the standard pump could flow so much, if its fine in you're set up it'l certainly fine for what I've got in mind. I have a small T3 which I hope to get 1bar out of, I think injectors around 450cc/min would suit? Once again, great work :thumbup1: .

    Jamie
     
  24. therealpinto

    therealpinto Registered Capri Power Member

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    450 cc should support something like 260-280 bhp with some margin, so that is a wise choice.

    The Capri 2.8i runs a 5 bar fuel pressure so when running the pump at an EFI pressure of 3 bar there is plenty of flow.

    Regards

    Gustaf
     
  25. therealpinto

    therealpinto Registered Capri Power Member

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    So, 2010 turned out to be a lost year. I redid the kitchen instead of the Capri. Well, you've gotta eat, right?

    To be honest, 2010 was not all lost. I managed to order some christmas presents for my self. A strange packet arrived:


    [​IMG]

    A real seat from Sparco. I really don't like these seats on a road car but for safety reasons I want a 6-point harness and then you need the right seat for it to work.

    [​IMG]

    Nice brackets, will be combined with sliders.

    [​IMG]

    One way to improve the seat is to use some cushions, may need more though.

    Just bying parts won't finish a car, so early 2011 I started work on the right rear wing.

    [​IMG]

    The more metal I cut in this car, the more I realize that it is the right car to cut. The panel behind the right hand door has been replaced sometime, the join is right over the rear wheel. The panel still has the Ford stickers on the inside, so it was probably done by a decent shop, probably early 80's. It has held together for many years, but it's just another proof that this car has lead a tough life even before I took over :)

    [​IMG]

    The new tub is welded, just needs paint and sealant.

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    Of course some rust spots appeared, they were fixed during a couple of nights.

    More parts arrived as I fastened the righ rear wing with screws, awaiting the bonding ceremony


    I was given "an offer I couldn't refuse"...

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    A Cosworth YB oil sump in itself is not very exotic. But this one is baffled and winged, has a fitting for serious crank case ventilation and the fitting for a crank sensor. Why? I plan to generate some G's both on track and strip, it would be sad to risk oil surge. The price from a racer in UK was less than a standard YB sump in Sweden :)

    More YB parts:

    [​IMG]

    A water pump pulley in alloy is more luxury than I need, but...

    [​IMG]

    [​IMG]

    ...and so is a crank pulley. But I have my reasons - to fit the alternator with my nice exhaust manifold it had to be lowered a lot. So much that the single V-belt wants to slip. With the pulleys above I can choose to run a poly V belt instead. Plus, I get a nicer trigger wheel than the one I use today.


    I also got a nice tool from Moss.

    [​IMG]

    [​IMG]

    The car will get a dragracing spec roll bar (rear cage) and this will aid in building that, I hope.

    With those parts on the shelf I turned my attention to fitting the seat. Amazingly, the Sparco seat on OMP rails fit the Capri standard mounting points! At least almost. I managed to find a good position that will be even better with a steering wheel spacer.

    With the seat in place I can start working on the roll bar/cage. The dragracing rule book says that the main hoop needs to be no further than 6 inches from the head, I'm pretty short so that means the hoop needs to be approximately right where the B pillar is.

    Anyone who has fitted a cage to a Capri knows that the floor is not flat.

    [​IMG]

    The profiled floor is what gives it the strength, so I don't want to replace it with flat metal.

    I see two alternatives for the fitting.

    On the floor:
    [​IMG]

    I have roughly 50 mm height differences to adapt to. Not too bak inside the car but more work under. A 3 mm plate that is needed will not form easily.

    On the rear seat "beams":
    [​IMG]

    The corner is relatively flat and it's right where the strongest sections are. A "box" will be quite solid, that's my view. The hoop will also be less of an intrusion and leave more room.

    [​IMG]

    It's a little bit more than 120 mm to the floor but I think I can manage to drill straight and put tubes in that let me bolt through the floor and beams.

    Gustaf
     
  26. robt100

    robt100 Registered Capri Power Member

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    Lots of ongoing projects
    Nice to see some progress.........and a sump from Dave White's "linford" being put to good use ;)
     
  27. therealpinto

    therealpinto Registered Capri Power Member

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    More work on the roll bar.

    I choose to use boxes with tubes to bolt it to the floor.

    Trial fitting the hoop...

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    It fits pretty good, especially considering that I made the measurements pretty quickly, and it's bent 700 kilometres south :)

    Drilling straight trough 160 mm of beams and double skins is not easy. But never give up!


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    Lid on:

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    Hoop, and then weld!

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    Time to decide on the rear braces. I can attach them to the wheel tubs, or the coilover mounts. Tubs mean more space, coilovers mean that the roll bar will stiffen the shell more.

    While thinking...

    ...a large milestone has been passed!

    [​IMG]

    The rear arches are fitted. Tomas from RP Glasfiber (north of the polar circle basically!) came to help me. We had a garage marathon and suddenly the car feels a lot closer to "driveable".

    [​IMG]

    Tomas works with glass fibre all day, valuable help indeed. He knows his stuff!

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    Both wings are attached, the joins are roughly finished. Just some filler and paint...

    My Fibresports X-pack parts were of really good quality. Most of the work was on fixing the body. As usual with this car, there were surprises under the paintwork. The rear left corner had a large dent, skillfully fixed with filler. Someone did a pretty good job, it was invisible and has lasted for over 15 years. But now the filler had to go.

    /Gustaf
     
  28. danny69

    danny69 Registered Capri Power Member

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    Great work Gustaf. It is always inspiring to these projects progress and all the minor problems overcome.
    Got to love an X pack.
     
  29. Day_Dreamer

    Day_Dreamer Registered Capri Power Member

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    great progress mate, the cos wheels are nicely filling the arches. I suggest some clearcote and hit the road!
     
  30. chris_gray1980

    chris_gray1980 Registered Capri Power Member

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    looking REALLY GOOD :thumbup1: :thumbup1: :thumbup1:
     
  31. therealpinto

    therealpinto Registered Capri Power Member

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    Thanks! The wheels actually may need 5 mm spacers in the rear to really match the arches. But that's running a Sierra rear axle too, that is quite a deal wider than the Capri axle.

    Up front there is more work to fill the arches but I have a cunning plan :)

    I think we still have 1 meter of snow here so I will hopefully have time to put more than clearcoat on it :)

    Gustaf
     
  32. Day_Dreamer

    Day_Dreamer Registered Capri Power Member

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    Any update's gustaf or did your partner desided you did such a great job in the kitchen this year the bathroom could do with a makeover?
     
  33. Ruaraidh

    Ruaraidh Registered Capri Power Member

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    fantastic work mate, enjoying following this one, please keep the updates coming! :)
     
  34. therealpinto

    therealpinto Registered Capri Power Member

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    Well, the bathroom does need a makeover but this time I think that she who must be obeyed will have to fork out for it, ie hire someone :)

    I have been working on the car, but not very fast. I have spent the last months fitting/making a half cage, and it has taken time. But just the other day I think I finished the welding. I still need to fabricate the seat back support needed for dragracing, and fit the seat belts. Oh, and the mounting plates that go under the floor too.

    Primer and filler is on order for the body, that will be the next thing to tackle. My initial high goals of having the car somewhat painted this summer have sort of changed to being able to test drive it, with or without paint...

    I'm still quite satisfied though, the cage feels pretty good and it has been worth the time to fit it close to the body.

    Gustaf
     

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