New engine is now fitted and working.
Spec
998cc , my original imp engine which had water loss issues - traced to leaking liners, which were re-glued in position.
Hepolite/powermax pistons (2nd hand) with lightweight 5/8 pins and new rings
Lightened and balanced imp rods with 3/8 cap head bolts.
Block strengthening plate (homemade) with blocks and M12 Studding
Std sump with lots of baffling
Extra large capacity oil pump.
The head gasket is a bit special, its a laser cut alloy plate 1.4mm thick with the 4 bores being the outside diameter of wills rings. Paper gaskets 0.25 mm thick are fitted either side and the wills ring is fitted inside the alloy plate. There are no grooves in the head or block, effectively the alloy plate holds the rings in position and the 1.4+0.25+0.25 = 1.9 mm gives the correct squash on the wills rings. This gives me a bit lower compression to suit the 12% bigger engine.
The rest of the engine, head, turbo, cam , injection etc is the same as the old engine
Fitted last weekend but couldn't start it, the turbo oil scavenge pump didn't work. Found out the old escaping cap had hit it and slightly damaged the outer casing, damaging the magnets in the process. A quick strip down of the motor and clean up and all was working.
Fired it up and it just ran, tweeked the fueling a bit at idle but thats about all i could do.
Took it today to Bradleys for Rolling Road tuning, and got 144hp at the wheels at 13 psi and 8000 rpm, which is about 165 hp (they recon 170) at the flywheel.
with peak torque being 132 lbft at 6200 rpm. very happy.
The engine has potentially more to give (more boost), but at that boost the engine was leaning off to 13.8 AFR at 8000 rpm. We increased the pulse rate but it made no difference, so we came to the conclusion that the Honda CBR600 injectors have run out of flow. Bigger injectors required or fit the 4 extra ones as fitted to Honda CBR600RR. Lowered the boost to 11 psi which stopped it going too lean, for safety, turbo engines tend to run rich at high revs and boost to help cool the pistons.
Anyway - i'm a happy bunny, and will be bringing it along to Anglesey on thursday for a laff (it will only manage about 4 laps on a full tank)
Eric