T5 Powered Vortex Kit Car

[EddyP]

Thought you guys might be interested to see what i've been up to with a T5 lump.

I originally built the car with a Honda V6 in it, but decided I wanted more power, improved reliability and something a bit different, which is why I decided on T5 lump.
First off, out with the Honda:











Next job was to prove the fit on a spare chassis and fab up a couple of mounts, bit easier on a chassis without a body on:



Its a bit tight:



It fits:

[M-R-P]

Err, that things gonna be a blast! Watching this one with interest

[Wobbly Dave]

How have you mapped it?

[EddyP]

Dave - you're jumping ahead there

These pics are about 2 years old, the car is actually done, although in bits at the moment as I broke the landing on a Mahle piston.
It's running on an Emerald ECU, which was mapped by Dave Walker at Emerald. In fact i've got the original ECU for sale at the moment as i've upgraded to the next version to gain a few features that I want, mainly so that I can get rid of the dizzy.

Made a new mount for the M66 gearbox:







Plasma cutters are great:



Add a bit of triangulation in to suit the new nose mount:



850 engine, with 19T and other mods ready to be detailed:



Cleaned and painted:



Before:



After:

[stribo]

Wow, that's some top notch work, can't wait to see more.

[partsforvolvos.com]

that's awsome!! i bet it is a totally different experience having the t5 engine but without it dragging 2 tonnes of volvo behind it !!

[Wobbly Dave]

Sorry about the gun jumpin'. Just looking at the 19T & how small it looks in comparison to my GTX!

[EddyP]

Bits shot blasted ready for paint:



Painted



Some bits polished, before:



After



Idle Valve





Detailed



Original 4 stud hub



Welded up the original holes, faced the hubs off, and redrilled them for Audi 5 stud PCD so that I could fit better brakes and nicer wheels

[Volvostorm]

I remember reading about the project in PPC, glad to see it still improving

[EddyP]

A standard flywheel, a TTV flywheel to suit an M66 and an S60r clutch:



I needed to fit the Focus ST selector , i've modified the brackets on the gearbox so that the cables work from the opposite direction, this meant the selector itself needed to go backwards too, then custom cable were made up



An airsaw is an essential tool





Catch can and charge cooler header tank



Charge cooler radiator, mounted in the side air intake



Oil cooler, mounted in the air intake on the other side



Walbro pump fitted



At the same time I changed the rear De dion suspension from a panhard rod to a Watts linkage, this helps with the travel of the De dion, so that there's less risk of popping a driveshaft out, which could be a risk as my driveshafts are going to be pretty short


Weld a pivot on, in the centre of the De dion



Turn a boss, and weld it into the chassis tube





Paint the chassis now that all the mods are complete:

[EddyP]

Engine going in





Suspension back on



Now for the driveshafts, Volvo inner needed, and an Audi outer as i'm using Audi hubs, so I started off with a Focus ST shaft, and chopped it up



Then did the same with an Audi shaft



Luckily, the Focus shaft is sold, and the Audi shaft is tubular, so with a bit of turning of the Focus shaft







Now for welding them up, I V notched the ends of the tubes to add in some surface area for welding, then a kind mate Tig welded them up





Done



Bit of wiring next, wanted it to look smart, but didn't want to spend a fortune on Raychem boots, so found these in a breakers yard, Audi/VW use them a lot:

[EddyP]

Then with a pen and some bright heatshrink some nice labels can be made too

[EddyP]

Anyone want more pics then?

[lance]

Yes please

[stribo]

Anyone want more pics then?

Always, it's looking great so far. How did you balance the driveshaft?

[volvokid]

This is looking awsome

[The White Knight]

Anyone want more pics then?

[EddyP]

Got, few more pics for you.

With my ECU I can send it an EGT signal for it to alter the timing/fuelling if things start getting a bit too hot, with the existing manifold and turbo housing being cast I didn't want to get into welding a boss onto it as the expansion rates would be different and then ultimately it would crack, so I got a little adapter made:









Now time to make the exhaust, 3" all the way, start off with a load of bits from Jetex

[EddyP]

All TIG'd up:

[stribo]

Progress looks to be going well, I'd have been tempted to have twin outlets for the exhaust, purely for aesthetics.