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Old 08-11-2009, 09:41 AM   #1
P20SPD
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Smile UK GC8 2.35 twin scroll build

Thought you guys may be interested in seeing what we get up to the other side of the pond. Copies of my posts on uk forums.

Lateral Performance 2009 build

So, this is how the car finished 2008, looking like this after finishing time attack at Snetterton, where it finished 2nd with Andy driving and a fubarred head gasket!


Along came late March this year and I was speaking with Mark at Lateral, when he asked me if I wanted the car back at mine to do so work on it, as he knew I wasn’t doing anything with my own car this year. When I asked what his thoughts for the car were, I was quite surprised.

The conversation kind of went like this:
Mark: Well, I guess the car has done enough as it currently stands, pretty much running full weight, so I regard the shell as a scrapper, do what you want to it
Steven: What I want?
M: Yeah, whatever you want?
S: Hang on, do you mean, ANYTHING?
[long pause]
M:………Yes, anything!
M: may regret saying that though!
S: nice one, angle grinder to the rescue!

The car had been corner weighted just before Snetterton at 1280kg without a driver.

The car arrived at mine in early April, but I didn’t really start doing anything on it until the back end of April where I started by removing the dash.


This enable me to start picking out the wiring loom, to ditch unwanted wires. However, after spending what felt like an eternity with an hour here, and hour there, I quickly rang David Wallis and asked how long it would take to make a fresh loom, and what it would cost us in parts. 5 minutes later, the car looked like this. Apologies for pics, done with my blackberry camera thing, when I could remember.



You will not that I have started to remove the sound deadening. The main focus was remove as much weight as possible, although I ended up missing several things in the end.

Diff cradle was removed to make it easier to remove the fuel tank.


Oem fuel tank removed, not required anymore. Quite light actually.



Next up was the removal of the boot floor, which would also come in hand as a bin for all the sound deadening. By the time this was removed, and full of sound deadening, it was quite awkward to move about.


Now to the other end of the car. Everything removed from the engine bay, so I have a clean drawing board so to speak. Chop out the slam panel, and the lower cross member as they will be in the way.


Front wings at this point had been removed early to aid removal of the loom. Just sat a bumper in place for some mad reason, and got the welding stuff out, as an Omp bolt in cage was going to be installed due to the doors changing over to fibreglass ones with poly carb windows.
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Old 08-11-2009, 09:41 AM   #2
P20SPD
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Cage going in



At this point my shed looked like total devastation, I hate working in a mess, but sometimes it cant be helped.


By now it was mid may, and at this point I broke off working on the car so as to strip down my old engine, which I had promised John Stevenson loan of, if anything went wrong during his Time Attack campaign. After stripping the engine down, John didn’t need it. Whilst my back was turned stripping the engine, Mark picked up the angle grinder and started attacking the rear arch to gain clearance. 30 minutes later this was what I saw!


We will be needing a body kit then to hide that mess

I then had a weekend away at the end of May supporting John Stevenson in his Time Attack campaign, where sadly he had another head gasket failure. At this point John asked me if my offer was still there, which it was, so the following weekend I built up my engine, whilst Mark and David Wallis set about installing the body kit which had arrived.

David cutting the rear quarter out, carefully around the RCMS drag wheel I borrowed.


Mark removing unnecessary panel from the fibreglass door supplied by John Stevenson.


Rear quarter bonded on, and rear door ready for panel.


Front wing, rear door, and rear quarter all bonded on, now the other side. By this time it was 9pm Sunday 14th June. Six weeks and TOTB is over!


During the next week, when I had a moment or two after work, I threw in the dummy engine (my broken Ej22block), david wallis’s emty gearbox, so that I could start and work around clearances for the turbo, radiator and intercooler.

As time was running out, I borrowed Davids front mount twin scroll manifold together with GT4094, both of which were destined for his own car.
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Old 08-11-2009, 09:42 AM   #3
P20SPD
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Its going to be tight for clearances with that lot in there!




Before I knew it, the next weekend was upon us, so Saturday morning of the 20th June I started doing more an more to the car. David came across to help Mark with the rest of the body work. In the mean time, Mark add commissioned Andy of immortal performance to make some fibreglass bonnets and boots, one of each will be destined for the car.

Whilst David and Mark were busy with the nearside panels, I tackled the fabrication of the front end to hold the intercooler and radiator. The intercooler is a core from a Hybrid setup, the rad at this point is unknown, but will be custom made.


At this point I had found a suitable dummy radiator, that happened to be 40mm thick and could be cut to shape easily. A kitchen worktop that was lying around in the shed. So, intercooler support made, bumper initially cut, and sat in situe. The way this has been done, means that the intercooler and rad can come off as one, still attached to the mounting bracket.



Doors on, getting there! A mini skip was filled with the crap that came out of the car!


Almost ready for paint, NOT! Sunday 9pm 21st June 2009


At this point I must apologise, as time seemed to disappear and I forgot to have pictures.

The following weekend was a miss from me, as I was down at Brands Hatch with John Stevenson in Time Attack, however, David Wallis, Andy and Andy came over both days to sort the body work out, ie filling, sanding, filling, sanding, filling, sanding etc etc

I must point out though, that although not a lot appeared to be happening to the car during the week, there was a hell of a lot of work going on in the background, ordering parts, ensure Mark was up to speed, and making sure he was keeping up to his end of the bargain. All this takes a serious amount of time and thought.

I basically operated with a policy of, if I thought about it, it got written down. Very useful walking around with a car build pad! If you don’t do that, you WILL forget something, and it will be something crucial to the progress of the car.

Upon returning from Brands Hatch, I found that the trio of nutters (aka Exceptionally good friends) had done a superb job smoothing off the lines of the car, although they themselves weren’t happy, I was.

The following weekend, 4th July came round very quickly. Yet again, I would be hampered by other arrangements, namely Emma’s grans 85th birthday BBQ. Not a problem though as on the morning of the 5th I dropped the car off at Immortal Performance for Andy and David Wallis to do their thing.

They started on the car Sunday night, and by Monday at 6pm it looked like this
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Old 08-11-2009, 09:43 AM   #4
P20SPD
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David and Andy worked from 6pm to 2/3am most nights as they have day jobs to get the car to this stage by Wednesday 6pm.




I picked the car up from them on the evening of the 9th July, and judging by the looks the car got when it was on the trailer, I knew it was a marmite thing, but one thing was evident, it got looks.




The hours spent deliberating over what colour to paint the car were worth it, especially as my two boys had stayed up to see what the car looked like, and they were over the moon.

If i can just step back a week, and behind the scene of working the car, i had mapped out in my head, and on paper how i wanted the fuel system to look, and how i wanted the brake lines to run through the car, in particular passing through brake bias valve and the hydraulic handbrake.

I ordered, or told Mark to get, a K sport hydraulic handbrake, as this as a latch mechanism so you can lock the rear wheels without constantly holding the lever.

Having selected everything i wanted to order for the brakes and fuel system, i happened to be on the phone to Paul Blamire at Zen Performance and just mulling over my plans, when Paul said he had most of the stuff on the shelf, and wanted it out of stock, but more significantly suggested he would come up to mine for a bit of fun and play with someone elses car for once. Bonus!

So the scene was set, Paul would come up to mine on the 10th July late in the evening with a view to having a blitzing session on the car. Paul arrived late evening, with Liz and his two kids, before we knew it, it was way past midnight and we were reasonably drunk!

I woke up at 6 am, and by 6:15 Paul was also in the shed and we had started on the car. Mark joined us around 9:30, and it was the first time he had seen the car in its new livery! David Wallis and Andy joined us mid morning, with Pat Herborn joining us around lunchtime.

So, its chaos. Paul is doing the fuel lines, i am doing the brake lines, David is doing the wiring for lights, ie car loom, Pat is starting on the ecu to engine loom, together with all the other sensors the Solaris S8 can take, and Andy is fettling bodywork, transferring door locks etc, and getting door gaps as good as possible.

I had also hooked up with Gary Plant, aka Gazzasti, to help out with all the exhaust work. Gaz came up on Sunday, and worked his stuff!

The pictures from here to Sunday evening are a bit of a blur, partially due to alcohol drunk, and the speed at which things were done.

Final mock up starts, as i don’t have an engine at this point.


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Old 08-11-2009, 09:44 AM   #5
P20SPD
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Drivers seat in, steering wheel in, THE handbrake in, pedals in


1500hp Fuel lab fuel pump, filter in, and fuel tank (courtesy of John Stevenson) sat roughly where it will end up

View from rear window. Electric control panel, made from a carbon fibre sheet i had hanging around. This was Davids domain, and its so neatly done, really chuffed how he did it. Super lightweight fuel lines on left hand side.


Rear door trims on and handles, brakes swapped to type r 2 pots on rear and oem 4 pots on front, more pictures on them later


Whilst all the above was going on, Jim Litten was very kindly running in a very expensive OS Giken triple plate clutch, so it was bedded in before it had the crap beaten out of it

So, a few more pictures to show what else had happened over that weekend.

Fuel tank with –10 feed welded on for the fuel pump. Rear bumper starting to take shape.


Closer pic of fuel arrangement. Small tank, feeding 1550hp pump through –10 pipe, -8 pipe to fuel filter and –8 to front of car, -6 return line
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Old 08-11-2009, 09:45 AM   #6
P20SPD
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Another pic of dash area, minus the dash board at this point but showing the AIM digital dash and fuse locations.


Dummy engine still in, with manifold mocked up, and car loom well underway.


Another view of cockpit area, again minus dashboard, but “the” handbrake, brake bias valve, brake lines, and battery wires all situated properly.


To me, this just looks like a jumbled mess, but to Pat it’s the start of his custom ecu loom for the Solaris S8!


Closer pic of the front dummy engine mock up


Side view, not the rust old 4 pot oem brakes (cheers John ) these are so that the 15” drag wheels will clear. They still need cleaning up massively though!


Whilst the above was going one, and by the end of that weekend, 12th July, I had received a EJ22t short block with a billet 79mm crank and Lateral rods attached. All I had to do was get the rest of the engine built up.


During the week, I started to tackle the rest of the engine build each night. Whilst I was doing various bits like the ring gaps and inserting the pistons, I had my youngest at the other side of the shed cleaning the callipers a whire wheel
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Old 08-11-2009, 09:45 AM   #7
P20SPD
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Short block built with Lateral pistons and on the stand ready for the heads.


RCMS 14mm head stud kit installed on one side, ready for the D25 AVCS head.


At this point I was missing the dowel pins for the heads, so tackled the sump area. Cosworth baffle plate designed for EJ257 block, pen marks show what needs to be removed to clear the EJ22 block.


Baffle plate on and sump pick on, and carefully spaced so as not to stress the pipe and cause a fracture. You can also see one head attached.


Thanks to Daz davies who acted as a courier, new dowell pin sourced from Zen and allowed me to attach the other head.


Both heads on, Cosworth cams in, and ready for final shimming of the valve clearances.


Again, I must apologise, as I didn’t get many pictures through the next few days as it was another frantic weekend with Mark, David, Andy, Pat , Gaz, Stewart and I all working on the car.

In summary, AVCS inlet pullies bolted up, CDF adjustable exhaust pullies bolt up, Cosworth cam belt installed, RCMS Cam Belt guide installed, timing checked and adjusted, rocker covers bolted up and engine installed in engine bay.

Turbo, GT4094 installed onto the twinscroll manifold, two 38mm v-band waste gates feeding into their own silenced exhaust point to the passenger side. Turbo dumping through a short 3” exhaust to drivers side.

Pat finishing the loom in situe


Fuel lines expertly done by Paul, feeding the 4 Carl Davey rails via an RCMS distribution block which is fed by the –8 fuel line across the bulkhead. Nitrous solenoids mounted and setup by Mark. Intercooler pipes made by Gaz, nearly done. 63mm leaving turbo expanding to 76mm before intercooler and remaining 76mm thereafter. SFS Black hose joiners where appropriate. Note new screen had been fitted too.


More to follow
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Old 08-11-2009, 10:14 AM   #8
subyboo
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skeet skeet
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Old 08-11-2009, 01:31 PM   #9
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What kind of timing covers are you going to run? Dont you think that the standard cover will just melt off? Great build!!
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Old 08-11-2009, 02:11 PM   #10
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very sick, my pops is from lewisham; love to see the work you guys do!
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Old 08-11-2009, 02:32 PM   #11
Artie@Agile Auto
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Good job!
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Old 08-11-2009, 02:41 PM   #12
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I'm a fan!
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Old 08-11-2009, 04:42 PM   #13
P20SPD
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Quote:
Originally Posted by foolio View Post
What kind of timing covers are you going to run? Dont you think that the standard cover will just melt off? Great build!!
no timing covers at all, not necessary for the type of use it sees. Never had an issue in 4 years of not running them.
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Old 08-11-2009, 09:17 PM   #14
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This thing is amazing bro! Bad ass for sure.

I can't wait to see more please hurry
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Old 08-11-2009, 09:27 PM   #15
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hey i just bought a bare ej22t block and am starting to decide what parts to use for my short block. could i get some details on your short block, what rod, crank, pistons (and size) and bearings are you using. The forged 79mm crank where is that from. which bearings did you use since the thrust is in the middle and not on the end and how much clearance did you run. i will be bolting my block up to cosworth big valve heads.
thanks in advance. good luck !
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Old 08-12-2009, 06:14 AM   #16
P20SPD
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All parts were supplied by my friend Mark at www.lateralperformance.co.uk

Have a word with him, and he will guide you in the right direction.
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Old 08-12-2009, 01:34 PM   #17
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Awesome pictures! I love the build

Keep it going!
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Old 08-12-2009, 10:26 PM   #18
bugeyesubie
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Quote:
Originally Posted by P20SPD View Post
All parts were supplied by my friend Mark at www.lateralperformance.co.uk

Have a word with him, and he will guide you in the right direction.
thanks a bunch good luck
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Old 08-12-2009, 10:46 PM   #19
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Wow, very nice build! Can you get a better camera though?
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Old 08-13-2009, 04:43 AM   #20
P20SPD
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Quote:
Originally Posted by 9vapors View Post
Wow, very nice build! Can you get a better camera though?
I have two, its just everytime i come to use them, my kids have drained the batterries! So i end up using the one on my blackberry which isnt to good, but it's better than no pics at all.

Steven
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Old 08-14-2009, 02:32 AM   #21
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I would suggest a better oil pickup, stock has a bad track record.
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Old 08-14-2009, 05:52 AM   #22
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Cheers for the heads up, we are aware of a few issues in the uk. That particular pickup has been on for 2 years, and everytime the engine comes apart for a checkup and refresh, it is checked religiously.

One of the key things is to ensure that it sits in a free state, ie. the stay isnt pulled down to the block, which puts stress on the base of the tube itself. This is clearly seen when sat on the engine stand. I have used a 6mm shim between the block and the pick up stay.
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Old 08-14-2009, 09:19 AM   #23
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cable tb and cossie mani? Please explain how you did it! I want to replicate that!
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Old 08-14-2009, 12:43 PM   #24
P20SPD
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22mm teflon spacer between cossie manifold and throttle body.
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Old 09-15-2009, 01:49 PM   #25
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What tensioner are you using for the cam belt?
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