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Thread: An Example of Truly Impressive Turbo Engineering

  1. #1
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    An Example of Truly Impressive Turbo Engineering

    Every now and then I come across something truly impressive. This represents some of the work of Extreme Tuners in Athens, Greece, and the name is no joke. Pushing limits requires funds and skill, and these guys have both. All they do is build and tune engines. The entire lengthy discussion can be found here (http://forums.evolutionm.net/evo-dyn...ne-2007-a.html), but unless you feel like reading quite a few pages of posts, I'll post the highlights here.

    FWIW, this is some of what they've done:

    2006 - N/A ford cosworth 4cylinder 16v engine 119cui: 416hp -11,900rpms
    2007 - Ford cosworth 4cylinder 16v Turbo engine 120cui: 1280hp 47psi (custom triple ball bearing 80mm turbo 119lbs/min)
    2007 Mitsubishi Evo 8 4g63 4cylinder 16v Turbo engine: 1416hp 57psi (custom quad ball bearing 82mm turbo 132lbs/min)

    So, getting 700whp/L from 2.0L @ 8500rpm is no small feat, but what do you need if you get bored and want to shoot for 2000whp?


    Cast Garrett compressor wheels (right) tend to come apart above 50 psi. CNC billet aluminum wheels (middle) are stronger, but why not be different and use your own CNC billet titanium (left) compressor?




    You'll need a turbo big enough for the job, which in this case is a 108mm twinscroll T4 turbo, with custom quad ball bearing CHRA and 100psi capability.








    To get enough airflow at 12,000rpm(!) to get the job done, you'll need a skillfully ported head, complete with titanium valves and copper-beryllium valve seats:








    And you're going to need a set of camshafts to handle the rpm and withstand tremendous ramp pressures, so why not a set of hollow titanium billets with DLC at only 234 grams each?









    And since there is no aftermarket rod up to the task, just ask for a set of billet mmcs-titanium connecting rods at 286g each. Rod/Stroke ratio is 2.07:






    For pistons, a set of custom beryllium pistons with DLC fits the bill, and since methanol is the fuel, 13:1 SCR is fine:







    A strong piston pin is needed as well:






    Toss in a custom titanium billet crank:





    A set of 9000cc/min injectors:




    And since a factory 4G63 block probably wouldn't hold up, just CNC machine your own from billet aluminum:






    No head gasket is used:




    And to put all that power to the gearbox, one needs a suitable multiplate clutch:




    Yes, it is smaller than a cam gear:






    An example of very efficient turbo manifold design from one of their recent projects:






    And last but not least, a dynosheet from this car, running 'only' 48psi and hydraulic cams:

    2003 Mitsu EVO VIII - 2.0L / 600+whp
    1988 BMW M3 turbo - Work in progress. . .
    1986 SVO Mustang - Work in progress. . .

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    Serious engineering!
    .-=[ Kenny ]=-. See the BFc Drag Racing Standings List for BMW street cars. Watch my drag racing movies on YouTube. Some info on
    BMW turbo street car Drag Racing 101

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    Quote Originally Posted by MrBlonde View Post
    Serious engineering!
    Plus 1. Now lets see what that s14 can do.

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    Holy....
    That is incredible

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    Damn! Im amazed!
    This is my signature....

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    I think the story should continue...... as in what was done to the drive line to handle 1500 whp. I'd like to go for a ride to see what it feels like when it finally starts to spool up between 5000 rpm and 6000 rpm!
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    That is sick.

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    My mind = Blown! Thats very impressive work.

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    Quote Originally Posted by GG///M3 View Post
    Plus 1. Now lets see what that s14 can do.
    Yes, and show me how you get a 2.0 litre to idle with 9 litre injectors!
    .-=[ Kenny ]=-. See the BFc Drag Racing Standings List for BMW street cars. Watch my drag racing movies on YouTube. Some info on
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    Drool.

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    Thanks for sharing.

    Truly beautiful what can happen when money is no object and great designers/fabricators/engineers are unleashed.
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    I can only dream of stuff like this, these guys are truly the tip of the sword.

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    Quote Originally Posted by MrBlonde View Post
    Serious engineering!
    +1


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    I am hoping that all that engineering will pay off;
    hence, WIN RACES FOR MONEY
    as the tooling, extravagant expeditures and TIME invested is a bit much for a hobby car.

    Beyond impressive, nonetheless.

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    Quote Originally Posted by MrBlonde View Post
    Yes, and show me how you get a 2.0 litre to idle with 9 litre injectors!
    Maybe it idles at 2k rpm.

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    holy fawk....thats nuts

  23. #23
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    If you look at the dyno chart, it crosses the 200whp mark around 4650rpm, which is actually pretty quick spooling for what it is. It makes so much power that the lines look vertical, but they wanted to make it 'quick spooling', so they did a good job.

    Straight methanol stoichiometry is 6.4:1 as opposed to 14.7:1 for gasoline, so a very high volume, high pressure fuel system is needed. And since 130 octane methanol doesn't 'knock', tuning in those netherworld regions is tricky.

    Since some of you are wondering what this costs, I know the Ti rods are around $3250 each, and the Ti crank is around $31,000. They are now working on a CNC billet cylinder head and carbon fiber turbine housings. These guys have good connections with F1 parts fabricators.

    If you want a turbo, they'll build whatever you want, and their quad BB center sections are damn strong. GM's 1400whp Ecotec project used one of their 80mm turbos:


    If you can dream up a turbo, they can build it:





    They also use straight metal matrix composite (mmc) rods, which are lighter than Ti. The problem is cost and life (120 hours). These use no rod bearing.



    Not often that one sees 13:1 compression ratio beryllium pistons, much less in a turbo engine:





    Ti valves and CuBe seats sure are pretty:



    Some other cars laying around the shop:

    1360whp 2.0L Escort Cosworth







    1070whp Subaru on its way to 1500+whp:



    Anyway, it just takes desire, skill, money, and maybe a kidney.
    2003 Mitsu EVO VIII - 2.0L / 600+whp
    1988 BMW M3 turbo - Work in progress. . .
    1986 SVO Mustang - Work in progress. . .

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  25. #25
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    This is strait bonkers. Seriously, You dont see ANYONE doing these things to motors. THis is damn ground breaking. Imagine if a supra shop with some cash and this knowhow/equipment did this to a 2j. We would likely see 3000rwhp... maybe more.

    Just excellent post, thanks so much for this Ted!
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