Austin Cooper K20A2 Swap

[TheMagicalBra]

thats bad as fuck. ridiculous amount of room you get in a cooper lol

[Drewski's]

Originally Posted by cptkirk

for those that may have missed the link to the intercooler thread heres some pictures:


http://i290.photobucket.com/albums/l...ACAD-Model.jpg



http://i290.photobucket.com/albums/l...i/IMG_0475.jpg



http://i290.photobucket.com/albums/l...i/IMG_0479.jpg



http://i290.photobucket.com/albums/l...i/b0b7920a.jpg



http://i290.photobucket.com/albums/l...i/d55f3887.jpg



http://i290.photobucket.com/albums/l...i/384267d2.jpg

Holly hell!!!! Awesome work!

[SA_DC5_NW]

ow man i went through every page this is so sick, post a video plz....

[2001GTTT]

that is so badass, I followed this since day 1, simply amazing.

[Conan O'Brien]

love the build. job well done. curious: i'm 6'2". could i fit comfortably into a late model mini? i fit just fine in the S2000.

[cptkirk]

Originally Posted by SA_DC5_NW

ow man i went through every page this is so sick, post a video plz....

Go to Youtube and search - "cpt. kirks mini jrsc" and all my vids will come up.

Originally Posted by 2001GTTT

that is so badass, I followed this since day 1, simply amazing.

Thanks.

Originally Posted by Conan O'Brien

love the build. job well done. curious: i'm 6'2". could i fit comfortably into a late model mini? i fit just fine in the S2000.

If by later model you still mean the same shape as mine then the shell didnt really change through its development and years of production. I am 5'11" and fit just fine, with a helmet on I still dont hit the roll cage and there is a bar running straight over my head, admittedly my seat is a whole lot closer to the floor than in a standard car and can go lower still if needed.

[cptkirk]

.
I decided to ditch my Acetal thermal gasket as I was concerned about heatsoak when shutting down a hot engine after being on track so I looked deeper into plastics and their respective thermal properties and have decided to use Polytetraflouroethylene (PTFE) as it has amzing heat resistant properties, its good from -260 to +260 Deg C (-436degF to + 500degF) and is readily available in sheet form of many thicknesses.

I am going to stick with the Acetal between the charger/aftercooler and the aftercooler/manifold.

The PTFE is also much easier to work with if you have limited resources, again I produced the part with a pillar drill, a 4mm drill for chain drilling, a 12mm drill for the top of the ports and then also for smoothing the ports and finally a 9mm drill for the bolt holes. Be warned if using a hand drill the material will pull you into it as it is quite soft material.

Unfortunately the only photo I took so far is with the OEM gasket on it being used as a template.





























And I my K24 CP (6.37") in the post on Monday (thanks E.):









.

[cptkirk]

ALSO POSTED IN SUPERCHARGED SECTION



Some more done over the weekend:



1) Crank Pulley replaced.

Before I put the new pulley on I decided to weigh it, more out of curiosity thatn anything else and the results were really quite surprising. Below is a photo of the two next to one another and then them seperately on the scales.




K20 original:








K24 6.37":






Yes thats right, 20g's lighter and considerably bigger.














2) Snout Clamp

I offered up a paper template of the latest and simplest design, pretty close, just a couple of mm adjustment and we are there.



















3) Thermal Gasket

I got a better photo of the new PTFE Thermal Gasket when I pulled the charger off the motor again.

[Drewski's]

Custome fab work at its finest!

[Timtamtt]

Just went through the whole build, this is one sick car!!

[Bflaker]

Looking good. Keep us updated.

[cptkirk]

ALSO POSTED IN SUPERCHARGING SECTION:

Originally Posted by stwatson

Those belts are REALLY close to each other....better hope that measurement is dead on...

Im also really excited to see how that new thermal gasket works. I have a feeling the Hondata gasket I have does little to nothing.

I double checked the dims and fixed the model, always good to have another pairs of eyes look at something for you.

The cover over the grooved odler is to protect my fuel line that comes in that side of the fuel rail.

Latest screen shot:

[Drewski's]

[cptkirk]

PRE RAD IS FIXED IN PLACE

I got my pre rad fully fitted into place on saturday, proper chuffed with it, I even got the grille back on and it only fouls a tiny amount, not that anyone would ever notice, unfortunately I dint get any with the grille on but I will in the near future.

I am going to see what the engine temps are like before I decide if I need anymore cool air ducting past the pre rad into the engine rad.

I ended up with the pre rad upside down to its normal usage position, this might sound odd but it has worked out for the best as its drainage plug is now a bleed screw, perfectly placed to get rid of any air in the system at the top on the drivers side of the rad. By jacking the beast up on the drivers side whilst bleeding out the air will totally get rid of any air in the rad.

I havent got it piped yet as I was waiting til I put the engine back in so I have it on ramps to fit the pipework.

A few photos of it installed:

[Drewski's]

Looks good and if it works, fuck it.

[cptkirk]

Snout Clamp/Support Complete

Posted in SC section also.





I'll let the pictures speak for themselves:













































Kirk Out......



.

[Drewski's]

[cptkirk]

NEW THROTTLE CABLE HOLDER

Also posted in Supercharged section.

Due to the repositioning of the throttle body I have had to redesign the throttle cable holder, the TB is now 3" more outboard and 3.5" higher, the throtle cable did not have enough extra length in it to be able to meet the old throttle cable holder.

So a series of pictures, running from the design in CAD, through the production to the final part:










PRODUCTION

















FINAL PART

[K20A2]

on the SC bracket, do you think that will help with belt issues? I would make them if it works.

[LimaRSX]

This is one amazing project, looks fantastic!

[cptkirk]

Originally Posted by K20A2

on the SC bracket, do you think that will help with belt issues? I would make them if it works.

The key difference between my setup and an RSX is that I now have the aftercooler unit sandwiched between the charger and the manifold so I have loads more room to play with for inserting extra pulleys. To do this on a regular RSX setup you would need to use much smaller pulleys, which in turn means higher spec bearings as they will be spinning up in the 30-40K region.

In answer to your question I beleive it will help with belt slip compared to the setup I had before where the belt went from the CP round the auto tensioner to the BP. I am looking into a restrictor for the auto tensioner, it will allow the tension to go on incase of belt stretch but not allow the tensioner to release tension under load.

[cptkirk]

Originally Posted by LimaRSX

This is one amazing project, looks fantastic!

Thanks

[cptkirk]

Also posted in SC forum

Fitted new cltuch and flywheel and the weekend and also the new belt (fits like a dream), I also got the motor back in the car so its all go to get it running and ready for a track day on 2nd June.


New clutch and flywheel:












new belt:

[Petrol-head]

love it!

[Drewski's]