Lancer Register Forum banner

Evo 10, (track car) Engine Refresh

28K views 217 replies 30 participants last post by  evogeof 
#1 ·
It's been a few years since I spent much time on here. My Evo 10 is having a bit of an engine refresh, so I thought I would put a thread up about the progress.



The X had a major engine rebuild three years ago by Indigo GT and Race Developments. It had new Capricorn nickel/ceramic liners and pistons, plus some head work with larger exhaust valves and a few other bits and bobs. I have loved the build and it has been driven pretty hard on track at regular intervals since.

Just recently I noticed a slight loss of performance and a misfire. Plus it had been using oil for the first time since the build. I thought we ought to get it checked out.

So the car is now with Simon Norris at Norris Designs. The engine is out and it has been stripped down for inspection. Hopefully the pics come out.







Actually, after a lot of thrashing on track, it looks in amazing condition inside. The obvious problem on examining the parts is that there is very significant wear on all 8 exhaust valves.

It's early days, the parts need measuring to see how much wear there is throughout the engine and the cause of the wear to the exhaust valves is being investigated.

I don't have permission to post much as I am no longer a member, but I hope to post up some updates as it goes along. I'd just like to thank Simon and his team for looking after my car and doing it's rebuild. :smthumbup
 
See less See more
4
#33 ·
Unfortunately, there has been a delay in this build, we are waiting for two things before it can continue.

Waiting for the Tomei Cams to be made in Japan and to be shipped to the UK via the USA. Also waiting for the Samsonas sequential dogbox to be rebuilt. Waiting on parts arrival from Samsonas.

I will be back when we get some news.
 
#36 · (Edited)
I have heard today that the Tomei Camshafts have been Manufactured in Japan and should be with ND in the next 7 working days. So things will soon be moving on with the engine build.

In view of the last post about transmissions and guru's etc. The Samsonas sequential gearbox is with CliveW at the moment. It needs a pretty big rebuild as it decided to lunch itself last year. The last I heard from Clive, he was still waiting on parts from Samsonas, hopefully they will be here soon as I hope to get the car out on track at the end of April (all being well)

Have a few pics, courtesy of Clive from the Sequential box. Oh dear........



 
#37 ·
In view of the last post about transmissions and guru's etc. The Samsonas sequential gearbox is with CliveW at the moment. It needs a pretty big rebuild as it decided to lunch itself last year. The last I heard from Clive, he was still waiting on parts from Samsonas, hopefully they will be here soon as I hope to get the car out on track at the end of April (all being well)

Have a few pics, courtesy of Clive from the Sequential box. Oh dear........
Oh dear indeed. Sad to see this happen to good folk like yourself but at least now you are in the hands of people that know what they are doing and not monkeys. You must be looking forward to a trouble free path ahead and getting back to enjoying the car.
 
#38 ·
Good News

The Tomei Camshafts that were being manufactured in Japan for this build have arrived at Norris Designs this week. The build starts on my car next week and the week after. Hopefully soon to have some pictures and a few updates.

I have a track day booked at Castle Combe on the 28th April. It's going to be a bit tight. But hopefully, with a little luck, we will make it for a shakedown.:smthumbup
 
#39 ·
Looking forward to this :)

The Tomei Camshafts that were being manufactured in Japan for this build have arrived at Norris Designs this week. The build starts on my car next week and the week after. Hopefully soon to have some pictures and a few updates.

I have a track day booked at Castle Combe on the 28th April. It's going to be a bit tight. But hopefully, with a little luck, we will make it for a shakedown.:smthumbup
 
#40 ·
The only disappointing thing is that the Samsonas Sequential Dog Box probably wont be ready in time. Samsonas have been very difficult to get parts from. I have a 5 speed OEM manual box that will get installed again if the dog box isn't ready. Then we can install the dog box next winter. I don't want to hold up the build any longer for that. I just want to drive it again :lol:
 
#42 ·
Clive has the Samsonas box, the manufacturers have been pretty dismal at getting parts to the UK it seems. The manual box is simply a OEM 5 speed with one of Clive's diff pin kits fitted by IGT. If I decide to stick with the manual in the future, I will ask Clive to work his magic on it later :smthumbup
 
#44 · (Edited)
The parts have been the least of my worries, the reliability has been shocking, I'm not saying it's the fault of Samsonas, It's not. But with problems experienced with fitting, maintaining and mapping (from day one), most people would have given up. The manufacturers have been slower than I would have liked in supplying parts. The box is with CliveW now and I know that when it comes back it will be a cracker of a gearbox. So, I am full of the 'power of positive thought'.
 
#56 ·
In the big picture, we have a family issue arising with an imminent death in the family. If the car is delayed, it's not a problem, I have other things on my mind just at the moment. So, there is no pressure on ND to work to a date at the moment, they have been updated.
 
#55 ·
Cheers Gum, that's the bit that I am keen on too, the ND turbo kit. We learn things that don't work don't we. Using the MHI stock frame turbo was a goal of mine. But Having increased the size of the exhaust valves to improve flow of gasses. It looks like it had a knock on effect and the internal wastegate wasn't clearing the exhaust gasses well enough. A backing up of hot exhaust gasses burned all the exhaust valves. Goodness knows how much power was affected by that too. Using a turbo kit with an external wastegate should make it work so much better. The MHI is a fine product, it was abused and never failed, but it has it's limits. Time to move on.
 
#58 ·
This is a shame as those turbos are really good. The problem you have is excessive exhaust manifold back pressure which is a result of pushing the turbo out of its efficiency range by chasing power the turbo cannot safely achieve. Exhaust gas temperatures go through the roof too which is most likely the cause of the valve problem. You had a fancy ecu yes? Were these parameters not monitored?
 
#62 ·
Its a 520-530 hp max turbo with a max boost on an engine like this of approximately 1.6 bar. After that back pressure goes through the roof and turbo shaft speed passes the recommended limits. So if you were over these figures then there is a good chance this has contributed to some of the issues you are seeing.
 
#66 ·
Well, the only update so far is that all the parts have arrived from Samsonas for the dog box. Clive informs me that 3 of the 4 casing bearings have been upgraded to a larger size and will require the casings to be machined to fit them. The output shaft has been modified too. So, it appears that Samsonas are still evolving this gearbox, which is very good to know.

No updates from Norris Designs yet, I think they have a very busy workshop at the moment. More when I get it...... :smthumbup
 
#74 ·
The gearbox is finished and ready to make its way to Norris Designs. Sorry, I have loads of pictures of the gearbox rebuild, but I am not at home at the moment and cannot upload them. I will do that in a few days.

I have heard nothing from Simon at Norris Designs, I am not sure how the engine rebuild is going. I will contact him in a few days and get the latest.
 
#77 · (Edited)
Pictures from CliveW of the Samsonas gearbox being rebuilt with a lot of new parts after it's demise. Thanks to Clive for the photos. Finally, I have all the photo's working on the page. Hope you like them.


Grinding shaft circlip for a high tolerance fit


Circlip fitted

Ready for both cases to be reunited.












Case together, selector barrel and output shaft gears visible

 
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top