- Post is under moderation912hp from four cylinders? Turbo S14-powered E30 will blow your mind.
912hp turbocharged #S14 E30
We’re not sure what’s scarier: building a 912hp turbocharged S14 E30 or driving it. Neither experience is for the fainthearted… Words: Elizabeth de Latour. Photos: RonV Photography.
Let’s talk about specific output. Whatever horsepower figure you may lay bragging rights to, generally speaking it doesn’t matter how you got there, all that matters is what you’ve actually got. We all love power and having lots of it is great. But, what impresses everybody is making a lot of power from a little engine. Big V8s with big turbos are awesome, we’re big fans, but to get a small engine to produce some big numbers takes an inordinately large amount of effort and it’s something that elicits the universal respectful head nod because you have to be pretty flipping hardcore to go down this route. Surely only some sort of madman would attempt to extract 900hp from a 2.3-litre, four-cylinder S14? Surely?
Well, in this case only a Maatman would attempt to do that. Tim Maatman, that is. Tim Maatman is hardcore. One glance at his purple monster of an E30 should tell you that. The car you see before you started out life as a shell, with no interior and no engine. It did have the Sport body kit already attached but that was it. Tim bought it off a friend and it was crying out for a greater purpose in life. That purpose was to serve as the host for a turbocharged engine, which itself had started out life in Tim’s E30 Touring and had been built up to 430hp. However this wasn’t enough to slake his thirst for power and so the past two years have been dedicated to the evolution of that original turbo engine concept into the beast of a powerplant you see before you here.
Okay, Tim probably had a life around all that engine building but the idea of him locked away like a mad scientist working on his doomsday machine is the one we’d like to stick to.
This mental image is given weight when Tim tells us that he’s done most of the work on the car himself. As you can imagine, a project like this requires a huge amount of work and most of that has been poured into the engine. It really is an incredible thing to look at, that engine, so industrial, mechanical and more than a little bit intimidating. It’s like the rest of the car has been built around it as some sort of containment system trying to rein in all that raw energy.
The road to turbocharged S14 glory begin with Tim swapping his Touring’s original M40 to a slightly more potent M42 and the addition of a turbo running a KMS MP25 management system and, later, H profile con rods and turbo pistons. So far, so good. At least it was for a few weeks until the head cracked. “I spoke to John at KMS and he offered me an alternative: to supplement the parts ordered and my M42 engine for an S14 engine they had ready for a turbo,” Tim relates. “It was such an attractive offer that I couldn’t say no! The S14 was just fitted with CP turbo pistons while the other parts of the S14 were OEM, even the head gasket and head bolts. I picked up that engine and connected the MP25 management and an exhaust system made with a Precision 6262 turbo and it made 430hp at 0.8bar of boost.”
Tim was happy, as any of us would have been, and ran the car in that configuration for a couple of years, taking it to his local drag strip numerous times with his personal best being an extremely impressive 11.7sec quarter-mile. But Tim had developed a taste for power and he wanted more…
“I came into contact with Pure Performance Factory in Sweden and started to collect all the turbo information on the company’s forum. I then began buying all the beautiful parts I needed for a major renovation because I wanted at least 700hp,” Tim explains with a grin.
The first incarnation of the new engine was ready in 2014 and Tim headed over to DP Engineering to see how much power he was making. “Over 680hp the V-belts were flying off and started breaking and we managed to hit 745hp before anything broke,” Tim continues. “I then fitted a larger turbo, a Precision 6466 dual ball bearing Gen 2, and we hit the dyno again; we started out on the old wastegate spring, which had held 0.8bar at 500hp but with the bigger turbo the boost creep caused this to shoot up to 1.3bar and on the first full run it made 700hp. This was not according to plan and less power than before so I changed the wastegate spring and this time we hit 850hp. Pieter at DP Engineering asked me how far I really wanted to go so I told him that 900hp is a nice number, so he started increasing the boost. At 1.9bar the engine made 880hp and at 2.0bar it hit 912hp and 685lb ft of torque so we stopped there; we then did numerous runs for fine tuning and the day ended with a big smile.” We’d be equally happy if we’d just come away with 912hp from a turbocharged S14. And, if you want to talk about specific output, that works out at 397hp/litre, which is eye-watering stuff. Absolutely awesome.
The final spec list for this S14 is nothing short of astonishing but you’d expect nothing less from an engine making this sort of power, especially one this small. The engine runs the stock S14 crankshaft, although it’s been polished and balanced, along with H-profile con rods, CP pistons and an oil pump modified as per DTM specs. Larger intake and exhaust valves have been fitted as well as PPF valve springs and a custom PPF cam, adjustable camshaft pulleys and an S50B32 chain tensioner.
We’ve mentioned the monster Precision turbo above and it sits on a custom manifold, sucking in air via a massive 130mm BMC cone filter and it runs a Precision 46mm wastegate, 50mm PPF blow-off valve and a custom 3.5-inch exhaust with a single Simons silencer while the exhaust itself exits under the offside sill.
A massive 600x300x100mm front-mount intercooler helps to keep the intake air temperature down and it all feeds into the engine via a custom aluminium intake. As you’d expect from a car like this, the boot is filled with the E85-based fuel system, with a 45-litre Jaz fuel cell, twin Bosch 044 fuel pumps, and a number of Nuke Performance components including a Y splitter, fuel filter, fuel rail with four massive 2200cc Bosch motorsport injectors, FPR and vacuum station.
Building your 900hp engine is one thing but keeping control of all that power is another matter altogether. And with so much effort having been expended under the bonnet you’d be shocked if Tim had scrimped elsewhere. Don’t worry, he didn’t…
Step one was to sort the transmission because there’s a hell of a lot of power and torque trying to get to the rear wheels and you need something strong enough to cope with all of that, especially when drag racing, as Tim planned to. The gearbox in this E30 is an E60 530d six-speeder mated to a lightweight PPF 6kg chromoly flywheel, a Sachs motorsport clutch rated to 811lb ft of torque, and a custom propshaft by DriveteQ. An E28 M535i 210mm diff has been fitted, modified by Hardeman Motorsport with 30º/45º ramp angles and 75% locking, along with custom driveshafts and uprated CV joints. On the suspension front, KW V2 coilovers have been fitted up front along with GAZ camber plates from Hardeman Motorsport. At the rear you’ll find AVO drag coilovers with compression and rebound adjustment and rear camber and toe adjustment for maximum grip, Ireland Engineering anti-roll bars all-round, Powerflex rear subframe bushes, and Tim’s also carried out a five-stud conversion allround. The benefits of this are two-fold: it means he can run those extremely sexy AC Schnitzer Type II Racing wheels; more importantly, it also means he can run his 334mm Tarox discs with Porsche Brembo four-pot calipers up front on custom brackets with Ferodo DS2500 pads. The rears haven’t been forgotten about, sporting E30 Touring calipers (as they have a slightly larger piston), Tarox discs and Ferodo DS2500 pads with Goodridge hoses fitted all-round. Now often when a car is built for outright performance, aesthetics take a bit of a backseat. However, when you’re starting with an E30 you’re starting with a car that can’t help but look good, especially when it’s wearing the Sport kit like Tim’s is. Painting it Daytona violet certainly hasn’t done any harm either. The front spoiler has been drilled for lightness, there’s a lightweight Einzel Motorsport bonnet, and a Hartge rear spoiler as well.
The interior is most definitely all business and we like the fact there’s nothing glamorous here: it’s all about making this E30 light, safe, and giving Tim somewhere to sit while he pilots it down the drag strip. There are no carpets or doorcards but neither are there are fancy metal chequer plate floor sections or lightweight door panels; there’s just bare metal and wires. The dash has been flocked and there’s a plethora of Stack gauges mounted where the central air vents would be to enable Tim to keep an eye on boost pressure, fuel pressure, oil pressure, the oil temp and EGT. There’s also an OMP steering wheel, a pair of single-piece Toora buckets with QSP fourpoint harnesses, plus a full, TIG-welded chromoly steel roll-cage.
With 912hp and weighing just 1130kg, thanks to Tim’s extensive weight reduction programme, this E30 has 807hp per ton, more than any road-going Koenigsegg, Porsche, Lamborghini or Ferrari. This means that when Tim gets the chance to take it down the strip it’s going to be absolutely insane. Until he gets there he’s been enjoying it on the street: “It’s nice on the highway, the acceleration is delicious!” Of course, if you think 912hp is enough, you’re wrong because Tim is already thinking of more power, as he tells us: “There is still more to come with this setup. Four digits would be nice, though there are other things that I would like to do first, like install a carbon diffuser, the cage needs a little work, and I may even also go for methanol injection. My goal was always to build a nine-second car and I will achieve that. The question is ‘when’? If the engine survives this season then maybe in winter 2016/2017 I’ll try for 1000hp and then this project will be closed.”
For a minute Tim looks deep in thought. “Given that I know I can build up an S54 to 1500hp I wonder if it would fit in the engine bay with a turbo on it?” he questions. We get the feeling he’d be up for finding out. For now, though, he’s got 900hp of turbocharged E30 to enjoy on the street, in sprint events and on the drag strip. And while building it may have been daunting, we wager that driving it is going to be an awful lot of fun.
TECHNICAL DATA FILE #BMW / Turbo / #BMW-E30 / #BMW-E30-Turbo / #S14B23 / #S14-Turbo / #BMW-S14 / / #BMW-3-Series / #BMW-3-Series-E30 / #Precision / #CP-Carrillo / #Bosch-XR4CS / #VAC-Motorsport / #AC-Schnitzer-Type-II-Racing / #AC-Schnitzer / #BMW-M3 / #BMW-M3-E30 /
ENGINE 2.3-litre four-cylinder S14B23 from E30 M3, polished and balanced S14B23 crankshaft with 84mm stroke, #ARP-2000 main studs, ARP block girdle, H-profile con rods with ARP 2000 bolts, CP Carrillo 94.5mm pistons, 9.0:1 compression ratio, HD piston pins, #Athena cut-ring head gasket, M52B28 piston oil squirters, modified DTM-style oil pump, 39mm Supertech Teflon-coated intake valves, 33mm #Supertech Inconel exhaust valves, S50B32 valve buckets, uprated PPF valve springs, custom PPF 283/283 11mm/11mm camshaft, adjustable camshaft pulleys, BMW S50B32 chain tensioner, engine blueprinted, 7.0-litre sump with VAC Motorsport oil pan baffle, custom T321 steel turbo exhaust manifold, aluminium intake, #Precision-6466-DBB-Gen-2-V-Band .82 AR turbo, Precision 46mm wastegate, PPF 50mm blow-off valve, 130mm BMC Twin Cone filter, 600x300x100mm tube and fin intercooler, three-inch intercooler piping, Samco connectors, 3.5-inch exhaust with single Simons silencer and exhaust tip exiting from sill, #Mocal oil cooler, Griffin aluminium radiator, Goodridge hoses and connectors, Jaz 45-litre fuel cell, 2x Bosch 044 fuel pumps, Nuke Performance Y-splitter, fuel filter, fuel rail, FPR and Vacuum Station, 4x Bosch motorsport 2200cc fuel injectors, #Goodridge PTFE AN08 feed, Goodridge PTFE AN06 return, Flex Fuel sensor (not connected), E85 fuel used, VEMS ECU, 2x EGT, Lambda, fast air temperature sensor, turbo back pressure logged, custom cam sensor, MAC four port boost control valve, Bosch XR4CS spark plugs, VAG coils, Moroso spark plug wires
POWER AND TORQUE 912hp (2bar) @ 7500rpm. 685lb ft of torque (2bar) @ 6600rpm
TRANSMISSION E60 530d six-speed gearbox, PPF 6kg chromoly flywheel, Sachs 811lb ft motorsport clutch, DriveteQ custom propshaft, #Hardeman-Motorsport E28 M535i 201mm diff with 30º/45º ramp angles and 75% locking, custom driveshafts, uprated CV joints
CHASSIS 8.5x17” (front) and 9.5x17” (rear) AC Schnitzer Type II Racing wheels with 215/40 (front) Toyo or Zestino semi-slick tyres and 255/45 (rear) Dunlop SP9000 or Zestino semi-slick tyres or Hoosier D06 9.0/26/15.0” drag racing slicks, #KW-V2 coilovers with adjustable rebound (front), #GAZ camber plates, uniballs and M3 supporting arms, AVO drag coilovers with compression/rebound adjustment (rear), rear camber/toe adjustment Ireland Engineering anti-roll bars, #PowerFlex rear subframe polybushes, five-stud hub conversion, Porsche Brembo four-pot calipers with custom brackets and #Ferodo DS2500 pads and Tarox 335x32mm discs (front), E30 Touring calipers with Tarox discs and Ferodo DS2500 pads (rear), Goodridge brake hoses (f&r)
EXTERIOR Daytona violet, M Tech II body kit, #Hartge boot spoiler, lightened front bumper, Einzel Motorsport fibreglass bonnet
INTERIOR Full chromoly TIG-welded roll-cage, flocked dashboard, Stack boost pressure, fuel pressure, oil pressure, oil temperature, exhaust gas temperature gauges, OMP steering wheel, Toora bucket seats, Samsonas H-pattern shifter, QSP three-inch four-point harnesses, VEMS app on tablet/phone
THANKS Thanks to my friend Robin Kal for helping with building my engine, Pieter Oonincx from DP-Engineering for mapping the car, Gerben Vlogman and Robin Langeslag for all the custom machined parts, my wife Chantal for all her help with money and all the times I was away from home!
“It’s nice on the highway the acceleration is delicious!”
“At 2.0bar the engine hit 912hp and 685lb ft of torque so we stopped there”Stream item published successfully. Item will now be visible on your stream.
- Post is under moderationMITSUBISHI MUSCLE 700BHP VARIS-KITTED EVO X
Eric McWilliams swapped his mustang muscle car for a slice of Japanese speed in the form of this 700bhp Varis-kitted Mitsubishi Evo X, and he’s never looked back…
Words: Dan Sherwood and Eric Mcwilliams. Pics: Viktor Benyi
American muscle fan swaps his Mustang for an Evo X and never looks back!
Looks can be deceptive. When you first clap eyes on Eric McWilliams’ evil-looking Mitsubishi Evo X, resplendent in its aggressive Varis wide arches, high-level carbon GT wing and the malevolent satin black deepdish ISS Forged split rims, you’d be forgiven for thinking that Eric was a dyed in the wool import fan, brought up on a strict diet of Paul Walker and Vin Diesel. But the fact is Eric only got into the Japanese scene in 2009; before that his automotive fantasies were much closer to home.
Now a resident of the glitzy town of Las Vegas, where he works as an engineer at one of the top casinos on the famous strip, Eric originally hails from a small town in the state of Iowa in America’s mid-west. A state known for its agriculture, Eric was more likely to swoon over a John Deere tractor than a tricked out Mitsubishi as he was growing up, and in fact his dream ride for the majority of his life was the good ol’ boys’ favourite: a V8 Mustang. Eric went on to eventually own the Pony car of his dreams and had big plans to give the mighty muscle car a steroid injection to turn it into a full-on drag machine. However, before he could complete his quarter mile queen, he cashed in his chips on his life in sleepy Iowa, to make a new one in America’s City of Sin.
‘Las Vegas opened my eyes to a whole new genre of cars,’ recalls Eric with a smile. ‘Before I moved there I was all about US muscle cars, but seeing tuned Japanese metal screaming around the sunscorched streets really sparked my passion for something a little more exotic from the Far East.’
And it was when things started to ramp up on his Mustang project that Eric got his first real taste of Japanese machinery, when he decided to take the ’Stang off the road and get a new ride for daily driver duties. The car in question was a 2008 Evo X.
‘Coming from the Mustang, the Evo was a revelation!’ Eric enthuses. ‘Even in standard spec it was so fast and cornered like nothing I’d ever felt before. It didn’t have that deep V8 rumble, but it was just on another level in just about every other area, and the more I learnt about them and what was possible, the more I was eager to start the tuning process.’
As the weeks and months passed, Eric’s love for his slice of Far Eastern fun was beginning to take over his life and the Mustang was steadily gathering dust as his passion for it diminished. Eventually, he decided it was time to move on and sold the shunned muscle car, leaving him free and unburdened to focus all his attention, and money, on the Mitsubishi.
‘At the time there was a whole host of companies producing parts for the Evo X and it was exciting planning the Evo’s evolution from mild to wild,’ Eric says with a grin. ‘In the end, rather than simply settling on one route to take the build, I decided to take on everything and make the ultimate, street driven, trackready, show ride capable of completing a 10 second quarter mile!’ Not too much to ask for then! Phew!
First up on Eric’s wish list was to sort the performance. As an avid fan of the legendary AMS brand, it was an easy decision to outfit the four-cylinder turbo motor with a host of the firm’s bolt-on bits.
Matched with bigger injectors and fuel pump, a drop-in turbo upgrade and a high-flow manifold, the car became more juiced for the track while still keeping its smooth daily drivability with a quick turbo spool and low-end torque. The final result was 467bhp at the wheels and a flat torque curve peaking at 350lb ft.
With the engine power suitably increased, Eric attended Motion Auto Show in Long Beach, with high hopes of some recognition from his fellow tuning fans for his hard work, unfortunately, and to his shock, the car didn't even get noticed!
‘After the disappointment of the show I knew I’d have to improve the Evo’s appearance if I was to get the attention that I craved,’ says Eric. ‘Luckily, it was around this time that Varis Japan had released a widebody kit for the Evo X, which was the perfect way to get the visual edge I needed.’
To source the stunning body addenda, Eric got straight on the blower to Ben Schaffer and the boys at Bulletproof Automotive in Los Angeles, California. As fate would have it, Bulletproof said they already had one of the rare kits winging its way from Japan to the US.
Result! As the third ever kit to grace US soil and the first to feature on a car on the West Coast, Eric was sure the new look would go down a storm, and when fitted and drenched in the bright Carolina Blue with blue pearl paint (which was actually a hue based on the colour of Eric’s favourite BMX bike that he had as a kid) he tested the kit’s attention grabbing merits at the 2012 SEMA Show in his adopted hometown of Las Vegas.
‘The kit extends each corner of the car by 35mm and I filled this extra girth with a set of wide satin black Enkei wheels with 265-section tyres,’ Eric recalls. ‘The car looked so much better and people where raving about it at the show. I knew straight away that I’d made the right choice.’
His build now had the looks to turn heads, but he had already got used to the power provided by the AMS bolt-ons, meaning the next stage of engine development was required.
‘After doing some research I decided to go down the route of a rebuilt engine, uprated turbo and drivetrain. In the end I went for a full 2.2-litre stroker build with 90mm CP pistons, Manley I-beam Turbo Tuff rods, ACL race bearings, ARP main studs and Golden Eagle sleeves,’ Eric says. ‘The build itself was carried out by Trevor at TrevTec Motorsports in Las Vegas and also incorporated extensive head work with Ferrea +1mm oversized valves, FIC 2150cc injectors, GSC S2 cams and Supertech dual valve springs and retainers.’
The turbo side of the equation was met by an AMS 900X turbo kit controlled by a Grimspeed three-port electronic boost controller. This was then complemented by an AMS front-mount intercooler and hard-piping, plus an AMS 3in cat-back exhaust system.
‘As anyone that has undergone a similar build could tell you, the process will test your patience and passion for the car and mine was no different,’ laughs Eric. ‘The motor build alone took over a year due to several complications, but it did give me more time to spend on other areas of the car, such as removing any and all unnecessary weight.’
Eric removed everything he could from the Evo’s innards, including scraping off the sticky tar-like sound deadening under the carpets. The car is now definitely a case of function over form when you pull open the driver’s door, with only a single Recaro Pro Hans racer seat with Takata four-point harnesses plus the top half of the dash and door cards left for comfort.
When the potent new motor was finally finished and installed, Eric wisely sought to increase the car’s safety with a custom rollcage.
‘The car was sent to Merrill Performance in Colorado who handled the custom fabrication of a six-point weld-in ’cage built to the class-specific Time Attack regulations,’ Eric explains. ‘It’s a pretty comprehensive piece of kit with X-brace door bars and pillar tubes that plunge through the Alcantara trimmed dash top and mount to the front footwells. Hopefully I’ll never have the need to test it out!’ With the engine work, and then the interior tweaks, taking up so much time where the car was off the road, Eric decided that it would be rude not to give the exterior a refresh to match the new interior and engine.
‘I liked the Carolina blue paint, but felt it needed more of a race look, so tasked Paul at Grafik Impact with designing a custom Time Attack livery for the car,’ Eric recalls.
Sticking with the blue and black theme, graphic guru Paul came up with the cool black strake design that whips up the car and incorporates a huge Varis logo – just in case you were wondering which kit was on the car.
‘I debuted the car’s new look at Import Face Off and took home the award for ‘Best Evo’,’ smiles Eric proudly. ‘It was a fantastic result, but the one thing that stood out to me was my old wheels. I really wanted a three-piece wheel so I could ditch the spacers I was running and get more dish.’
To remedy his lack of girth on the rim front, Eric contacted Brent at ISS Forged to have a set of custom wheels made. Once they were completed and shipped, Eric was only too keen to install them, unfortunately the stress of the spacers on the stock wheel studs had took its toll…
‘I was driving to a local meet on my new rims when a stud snapped off on the front passenger side and destroyed the face of the wheel. I had to send the wheel out to have a new face cut for it,’ he says with a roll of his eyes. However, with a car build such as Eric’s, there’s no such thing as downtime, so while he waited for the damaged rim to be repaired, it seemed like an opportunity to finish up some other areas of the car.
‘I sent the car off to Mad Kustomz to have Ahmad and James install an AMS carbonfibre roof, colour match the door jams, rollcage and a new Stoptech big brake kit that I had acquired for the car,’ he smiles. ‘They finished everything up just in time for the replacement rim.’
Now that the car was finally all back together – a full nine months after having the motor installed – Eric decided to see what his new engine could really do and committed to a full mapping session to take things closer to the limit.
Well known in the US for their tuning skills with Japanese cars, especially Evo Xs – English Racing built the world’s fastest and quickest Evo X – Lucas and Aaron from English Racing came down to Las Vegas to tune several Evos at the Dynojet research facility and Eric’s was one of the lucky rides on the list. The final numbers it put down on a conservative road/race tune was 640bhp and 476lb ft at the wheels @28psi. Impressive numbers, but what’s more impressive is how much more there is left in reserve.
‘Yeah, Lucas and Aaron said that there's plenty more in her, but after such a long time without the car I’m just looking forward to spending time behind the wheel and driving it as much as I can,’ Aaron explains. ‘Chasing numbers is all good, but it’s more than fast enough for me – for now at least – and I don’t want to risk more time with the car off the road to fix things if we push it much further.’
So for now, Eric is happy with his Evo, and even if the urge to push on gets too strong and he gives in to his speed and power cravings, it’s good to know that his desires are only a dyno mapping session away, meaning he may be down a Mustang, but his malevolent Mitsubishi has got more than enough muscle to compensate!
TECHICAL SPECIFIFCATIONS #Mitsubishi-Evo-X / #Mitsubishi-Evo / #Mitsubishi / #Mitsubishi-Lancer-Evo-X / #Mitsubishi-Lancer-X / #Mitsubishi-Lancer /
ENGINE: 2.2-litre, 4-cyl, 16v, #4B11 engine built by #TrevTec , #AMS-900X turbo kit, AMS front-mount intercooler and hardpiping, #AMS 3in cat-back exhaust, AMS fuel rail and fuel pressure regulator, AMS motor mounts, ACL race bearings, #ARP main studs, CP 90mm pistons, #Cosworth 90mm head gasket, Ferrea oversized valves, FIC 2150cc injectors, Golden Eagle sleeves, Grimspeed 3-port electronic boost controller, GSC S2 cams, Manley I-beam rods, Mishimoto radiator cap, gauge and hoses, #Mishimoto 10in slim fan, #Password JDM dress-up bolts and carbon-fibre ignition cover, #Supertech dual valve springs/retainers, TiAL QR blow-off valve, Merrill performance catch can, Walbro 450lph fuel pump
TRANSMISSION: 6-speed manual gearbox with Exedy triple-plate clutch, Jacks Transmissions ultimate final drive
SUSPENSION: #KW 2-way adjustable Clubsport coilovers, Agency Power rear lower control arms and anti-roll bar drop links, Cusco front and rear strut braces, Cobb front anti-roll bar, Whiteline rear anti-roll bar
BRAKES: Stoptech big brake kits front and rear
WHEELS & TYRES: 11.5x18in ISS Forged FM-10R Spec B 3-piece wheels with 295/35/18 BF Goodrich Rival tyres
EXTERIOR: Varis carbon-fibre wide-body kit, front splitter and dual hyper canards, AMS carbon-fibre roof, Aeromotion R2 static wing, Ralliart tail lights, Seibon carbonfibre bonnet and boot lid, Carolina blue pearl paint, custom Time Attack livery
INTERIOR: Agency Power short shifter, AMS shift knob, AMS small battery kit, custom black suede dash, arm rest and shift boot with blue stitching, custom carbon-fibre gauge cluster, Glowshift boost gauge, Innovate Motorsports LC-1 DB gauge, NRG black suede steering wheel, Recaro Pro Hans racer seat, Takata 4-point harnesses, Works Bell hub, 6-point weld-in rollcage
THANKS: Team Hybrid, Founder/President James Lin, LV Chapter Director Archie Concon, Scott Dean, Jesse Ramirez, Hybrid Hunnyz, BFGoodrich, Mishimoto, Meguiar’s, K&N, NRG, Sony, Seibon, Exedy, Bulletproof Automotive, Grafik Impact, Trevor from Trevtec, Pete Makowski and also my mom, dad, brother, family and friends for all their support!
‘A CUSTOM WELD-IN ROLLCAGE WAS INSTALLED TO MEET TIME ATTACK REGS’
The Carolina blue paint that covers the EVO is inspired by Eric’s favourite BMX bike that he had as a kid. the searing blue hue accentuates the lines of the awesome varis widebody kit, which is actually made of lightweight carbon-fibre. Combined with a varis vsdc carbon front splitter and varis carbon dual hyper canards the front end looks proper aggro! But that’s not all of the exotic black weave, as Eric’s Evo also has an AMS carbon roof and seibon vented carbon bonnet and boot lid! For a similar hardcore Japanese tuner-look for your Evo, check out www.indigo-gt.com. Based in tredegar, south wales. Indigo GT is a licenced varis dealer and has form for supplying these awesome aero kits to some of the hottest cars in the UK.Stream item published successfully. Item will now be visible on your stream.
- Post is under moderationTHE BIG PICTURE
With a wide-body kit, #4WD and the small matter of 840 turbocharged horsepower, this #BMW E46 is a ferocious machine. It might look outlandish, but this E46 Saloon has more than enough go to back up its show… Words: Daniel Bevis. Photos: Patrik Karlsson.
Here’s an idea that you may have considered before: what’s the future of your car after you get rid of it? Assuming that you’re not planning to keep your jamjar until it crumbles away into dust, there’s a fair chance that you’ll sell it at some point – and then what? It’s actually a very big question, as cars are such personal and emotive things, there are memories, sensory touchpoints and stories tied up in them that your brain cleverly locks away, ready to spring back on you at surprising moments.
When I see the dash vents on a Mk1 Cavalier, the faux-wood trim on the doors of a late-Eighties Rover Vitesse or the barrel speedo of a #Citroen-CX , I’m suddenly a child again. There’s a certain smell in the Magic Tree range that instantly transports me back into my first 205 GTI. And the tactile fragility of an early-Seventies BMW 2002 door handle puts me right there in my old road-rally Touring, all Redex and steamy windows.
My point is this: picture a car that your parents had as a kid – that old load-lugger that drove you to school, took you to see grandma and down to the supermarket for the weekly shop, ferried you about on those joy-strewn family holidays. Imagine if, after all of those miles of family life, someone bought that car, your car, your memories, and turned it into a bonkers race machine. It’s quite a thought, isn’t it? Jarring and strange, but exciting too. Something you know intimately, transformed into something alien.
With this in mind, there must be a family somewhere in Sweden who have no idea that their old BMW has turned into a supercar-slaying turbo nutter. Their intrepid old four-door E46, that saw them through over a quarter of a million faithful kilometres, has changed from a dependable old workhorse into a rejuvenated, frightening whippet with aggression in spades and a healthy disdain for the rules. Sure, it looks similar in profile, but there’s all sorts going on beneath the surface – that insane rear wing, a triumph of functionality, is merely the cherry on a flavoursome cake.
For Erik Wedlund, these sorts of transformations are nothing out of the ordinary; the overtly extraordinary is merely his oxygen, his everyday. You show him an unremarkable family runabout, he’ll have it whipped up into a Porsche-troubling frenzy before you can say ‘beige corduroys’.
“I started modifying cars about 12 years ago, with an Opel Ascona B,” he explains. To the uninitiated, this was a sensible-trousers commuter hack from an era when it was deemed noteworthy to offer a laminated screen as a no-cost option. “That went through a full rebuild to become an Ascona 400 replica, and after that I had an Ascona A from 1975 – first with a 2.4-litre CIH motor, which I then swapped out for a 420hp BMW M50B20 with a turbo, running E85.” Ah, so the story’s starting to loop into our world of Bavarian tuning now. It was bound to eventually – the long Scandinavian winters always lead to outlandish builds of awesome power and improbable stats; if it’s not Volvopowered, it’ll have a BMW engine. Thudding cylinders and big turbos are what help stave off the frostbite, and it’s clear that the lure of the BMW camp is what did it for Erik.
“I later built a 2.8-litre M50 for that car, which made 572hp on pump fuel,” he says casually, just tossing the numbers into the conversation as if it’s no big deal. Scandinavians have a different perspective on horsepower, don’t they? It’s bizarre.
We begin to spot a theme in Erik’s narrative here too – a tendency to find the best engine for the job, then replace it with something better, then take that engine and put it in a different car… it’s not so much a conveyer belt of performance, although there is an element of that, but more that he treats his projects like grown-up Meccano. The car is entity A, the engine is entity B, the chassis C, the way it deploys its power D, and so on.
Every now and then he likes to shake up the letters and bolt the parts together in different ways, creating something new and more impressive with his big boy’s toys. And so the evolution continues…
“I ended up selling the Ascona on as a rolling shell, keeping the 2.8-litre engine to fit into a 1986 635CSi that I’d bought,” he recalls. “I built up new exhausts and manifolds for it. It was making 750hp at the time – it was road-legal too.” Just sit and savour that figure for a moment – an old sharknose Sixer with more power than a Pagani Huyara. It’s staggering.
But Erik wasn’t done yet. Far from it. Having put a good 11,000km under the CSi’s wheels, he was beginning to yearn for the madness and, ultimately, lightness of the old Ascona. The itch became too much not to scratch, and the 635 was sold complete with its manic motor so that Erik could roll his sleeves up and get stuck into an E36 Compact. And while this may seem anathema to some, just keep in mind what the fella’s capable of.
“I began to build it up with the driveline of an E46 330xi, combined with that of an E39 M5,” he explains, again just throwing these mad ideas out there as if they’re totally vanilla. “It was finished within six months, but it got wrecked on the way home from a dyno session; I braked to avoid a deer and flipped the car into a ditch – it was all scrap aside from three wheels and the engine.” We’ve seen photos of this and it really isn’t pretty; it’s a good job that Erik’s a dab hand at fabricating roll-cages…
But let’s not forget his indomitable spirit, his Stig-like obsession with speed above all else, and his Terminator-esque sense of focus. The engine was still good, so that was hoiked out of the mangled wreckage and dropped back into the oversized Meccano box, and within three days Erik had found himself another toy to play with.
“I bought this E46 330xi a few days after the accident,” he says, with an even tone worthy of Räikkönen himself. “It was in a sorry state when I bought it, with rust and 250,000km on the clock, but that didn’t really matter much given what I had planned for it.”
That fiery engine was duly deployed, and it’s worth taking a moment to consider the spec: we’re looking at fundamentally an original 330xi M54B30, although it’s been played with quite a bit. A healthy bore job along with bigger pistons and a raised compression ratio work with a Precision turbo and plenty of internal upgrades to deliver an astounding 840hp at the wheels, all overseen by MaxxECU management. A huge set of numbers. And what’s particularly impressive is that so much of the driveline remains stock, demonstrating just how overengineered these 4WD 3 Series are; the gearbox and driveshafts are all factorystandard, as are the front, rear and centre diffs (albeit with a bit of welding to the centre item to firm things up).
The result of all of this insane, gibbering torque and horsepower? A four-door E46 that’ll accelerate from 0-285km/h (which is the point at which it redlines in fifth gear, equating to around 177mph) in 14.5 seconds. “With the running gear sorted, I fabricated a roll-cage for the car and took it on a few airfield events,” deadpans Erik. “After crushing a RUF 996 GT2 in a straight-line race, the oil pump shaft broke at 280km/h and took a few bearings with it, so I took the car apart and sent the engine off to my friend Åland at AllMek for a rebuild. While this was happening, I painted the body in British Racing green and decided to enter the Time Attack series, which was a pretty new thing in Sweden at the time. With the car back together and working well, I competed in the TANU series through 2015, replaced the three gearboxes that failed under the increased strain of competition, and just pushed the car to the very limits its heavy drivetrain and toonarrow tyres would allow.”
It may not surprise you to learn that the E46 has now, like so many chapters of Erik’s motoring history, found its way to a new owner. “If I’d have kept it, I’d have probably experimented with different diffs and wider tyres, but there’s always a new project on the horizon,” he says, devoid of sentimentality and already dedicated to the next step. A little birdie tells us that he’s actually working on two projects at the moment, the first being an E36 M3 3.2 that’s becoming a streetlegal track car, while the second is an M1 Procar replica with a V10 motor.
So spare a thought for that Swedish family, their cherished family runaround transmuted into an aggressively bewinged leviathan with a proven ability to show Porsche’s widowmaker GT2 a clean pair of heels. But then disregard them out of hand, as Erik does at the end of each personal chapter, because this isn’t about the past – it’s about living in the now, and keeping an eye on the future. Sentimentality will only get you so far, and then you’ll be blown into the weeds by a turbo as big as your face. An 840whp four-door E46 is an incredible thing to us laymen, but to a tuning superhero like Erik? It’s just part of the bigger picture…
9x17” E34 M5 alloys fitted all-round with 255/40 rubber front and rear.
DATA FILE #BMW Turbo E46 330xi / #BMW-330xi-E46 / #BMW-E46 / #BMW-330xi-Turbo / #BMW-330xi-Turbo-E46 /
ENGINE 3.0-litre straight-six #M54B30 / #M54 / #BMW-M54 , bored to 84.5mm using stressplate, CP pistons, #PPF forged rods, 10:1 compression ratio, #Supertech 1mm oversize valves and valve springs, #Precision-6466-turbo / #Precision , GTR intercooler, balanced crank, #ATI Super Damper, #ARP bolts throughout, copper ring head gasket, stock cams, functional #VANOS , #Bosch 1300cc injectors, #MaxxECU management, #KS-Racing (Thailand) intake manifold, S54 oil thermostat housing, #VAC motorsport oil pump upgrade, #Canton Accusump, 3.5” stainless steel exhaust system, #Aeromotive fuel pressure regulator, 2x Bosch 044 fuel pumps, catch tank fed by Deatchwerks 301 in-tank pump. 840whp/782lb.ft @ 2.1bar, 0-285km/h (177mph – fifth gear redline): 14.5s.
TRANSMISSION Stock 330xi gearbox, stock centre, front and rear diffs (centre diff welded), stock driveshafts, M30B35 flywheel, Sachs 765 pressure plate, 6- puck sintered KEP clutch, Samsonas gear shifter.
CHASSIS 9x17” (front and rear) E34 M5 alloys with 255/40 (front and rear) Kumho V70 Medium tyres, K-Sport Supersport two-way adjustable coilovers, bushings replaced with uniballs, -3 degrees camber all around, 7 degrees caster, custom chromoly antiroll bars, M3 CSL 345x28mm front discs, M3 calipers, PFC 01 pads, stock rear discs and calipers with PFC 08 pads, E46 M3 master cylinder.
EXTERIOR Hard Motorsport M3 Saloon arches, E36 M3 British Racing Green paint, custom front splitter and rear wing.
INTERIOR Custom roll-cage with integrated reinforced subframe mounts, Rado Power bucket seats, TRS four-point harnesses, Sparco leather steering wheel, stock dash and doorcards, Lenovo tablet for MaxxECU read-outs.
Hardcore interior features Rado Power buckets and a Lenovo tablet acting as the MaxxECU display.
It was in a sorry state but that didn’t matter given what I had planned for it…Stream item published successfully. Item will now be visible on your stream.
- Post is under moderationRED LETTER DAYS #Audi A4 2.0 TFSI 500bhp, big turbo B7 / Words Dan Goodyer / Photography AJ Walker /
Audi never sold a Misano red DTM A4, so Craig Collingworth built his own – with a top-mounted GT3076r and 500bhp under the bonnet for good measure!
At first glance you might think this is a factory-built B7 A4 DTM Edition with a set of aftermarket wheels. However, look a little closer behind those 19in BBS alloys... Large Brembo brake calipers from a Porsche Cayenne S hint there’s a bit more going on here than you might expect. If you know your quattro from your Quattro, you might also be aware that Audi never sold the DTM Edition A4 in this stunning shade of Misano Red Pearl. Or you might just have read that fact in the intro. Either way, colour is very important to the owner, 31 year old Craig Collingworth, a man who has sprayed cars for a living.
Craig bought the car around four years ago. It began life as a 2006 B7 A4 2.0 TFSI quattro Special Edition. Already a very nice car to have as a daily-driver, it had leather trim, lots of toys and a BUL engine with a K03 turbo pushing out around 220bhp. For three years Craig restrained himself from tuning it. He didn’t feel the need, only fitting the BBS wheels after finding them for sale on eBay at a ridiculously low price. Then in early 2014, Craig bolted a hybrid K04 to it, some S3 fuel injectors and a Unicorn Motor Developments remap – and recorded the second-fastest known quarter mile time in the world for a 2.0T A4!
He explains: “We started going to York Raceway for a bit of a laugh. Rick at Unicorn Motor Developments had re-flashed the ECU to make the engine produce 360bhp and 360lb/ft torque, and added launch-control and flat-shift. The surface at York isn’t great to be honest but we still managed a 13.4s at 101mph, which according to all the info we could find on the AudiSport and Audizine forums, was the second-fastest quarter ever recorded for a non-S 2.0-litre A4. Thing is, that just made me want to go faster.”
At the time Craig had bought a genuine DTM Edition A4 in need of a new engine. The plan was to source a new engine for it and then sell it. Then he had an idea: “I realised the BUL engine in my A4 was exactly the same as the engine fitted to the DTM, so I swapped it over and sold the DTM complete. They only ever made 250, so I really wanted to keep it on the road. Plus the money from the sale helped me set up my own company and part-funded the next step of the project.”
Craig had been working for Elite Customs in Leeds. Specifically, he was working for Elite Wheel Repair, using his painting skills to good effect. He then set up his own business on the same premises, CR Motorsport. Specialising in painting and drag racing to begin with, the company quickly grew to carry out engine work, servicing and more. His A4 would become the unofficial company demo car, so it needed a proper engine build.
To cut a very long story short, a lot of money was invested in a fully-forged S3 CDL engine that went bang. It featured trick parts including a set of pocketed pistons to allow the use of high-lift cams. However, Craig had out sourced the head-work, which included a set of oversized valves. He speculates some of the valves came into contact with each other, sparking a chain of events that wrecked the whole engine and turbo. Not wishing to be burned twice, Craig looked around for an alternative and found a proven engine for sale. It had been built by Rob at TSR Performance and was already making good power.
Using that engine as the base, the CR Motorsport guys went about doing something a bit different. Craig created the first top-mounted TFSI A4 in the UK by importing an AR Design exhaust manifold from the States. Onto this he placed a Garrett GTX3076r turbo built by Turbo Clinic, Craig adds: “The turbo recommendation came from Paul at Turbo Clinic. He’s been extremely helpful during the build and I highly recommend him. I ordered a 3in AR Design downpipe and had Tony Banks Exhausts in Leeds mate that to a Milltek Sport 3in system, featuring just one silencer box on either side of the rear bumper. On a dark night with the flat-shift switched on, you can see 4-foot flames shooting out the back of it and from the screamer pipe at the rear of the bay!”
While the car was off the road, Craig had also taken the opportunity to upgrade the suspension and brakes, along with fitting an OEM DTM bodykit that he resprayed himself. He explains: “The ride was very wallowy but I didn’t want to turn it into a stiff racecar, so I went for Eibach Pro Street coilovers and fixed anti-roll bars. The result is perfect in my opinion. The whole car feels like it’s factory-spec when driven normally, then transforms into a much more capable car as soon as you start pushing.”
He continues: “A lot of thought has gone into the car. I’m always on the Audi forums under the username “CraigCull”. Hours of research have gone into every aspect but with a very specific plan. The whole tuning thing is something I’ve been into for a long time, but I’ve only felt the need to act on it again in the past year or so. These days I’m into cars that look relatively standard – subtle, but with insane performance available, which I’d like to think I’ve created here.”
He’s not wrong. The mapping is still a work in progress but the car is already very quick, especially for a regular A4. Read the spec for some of the highlights; custom air intake that solves the heat-sink problem, custom breather system, a second set of injectors, water-methanol injection, the list goes on. At the moment it’s running two maps, both written by Rick at Unicorn Motor Developments. One for 25psi boost and around 450bhp, the other a 30psi map for around 500bhp.
With a bit more boost the engine should make 550-580bhp, that’s Craig’s aim anyway. Then it’s back to the drag strip to see if he can break some more records, and confuse more people with the only red DTM Edition in existence.
SPECIFICATION #Audi-A4-2.0TFSI-Quattro-Special-Edition-B7 / #Audi-A4 / #Audi / #Audi-A4-B7
ENGINE: CDL 2.0 TFSI S3 engine rebuilt and forged by #TSR-Performance including 83mm #Wössner pistons, Wossner connecting rods, 1.8T oil pump conversion, #Supertech valves and valve springs, #F-Tech-Motorsport inlet manifold with second set of fuel injectors, RS4 fuel injectors, fuel pressure regulator, in-tank fuel pump and controller. Autotech high pressure fuel pump, #Garrett-GTX3076r turbo with .63 a/r turbine housing and v-band clamp, #AR-Design top-mount manifold and 3in downpipe, #Milltek-Sport 3in exhaust with two rear silencer boxes and 2.5in tailpipes, TiAL Sport MVS external wastegate with screamer pipe, TiAL Sport 50mm recirculating diverter valve, custom front-mounted intercooler with 2.5in hard pipes, AEM Water/ Methanol injection, IE valve cover with vent-to-atmosphere catch can replacing pcv, N205 camshaft adjustment valve delete, N249 pressure control valve delete, inlet manifold runner flap delete, 3in MAF sensor, custom air intake, OEM ECU re-flashed by Rick at Unicorn Motor Developments with 4 switchable maps.
TRANSMISSION: 6-speed manual gearbox, #APR / Southbend Stage III clutch and single mass flywheel conversion, USP short shifter, launch control and flat-shift.
BRAKES: 6-pot Porsche Cayenne S 18z #Brembo calipers up front with machined ML55 345x14mm grooved and drilled discs, S4 rear brake conversion including single piston floating calipers and 300mm drilled and grooved discs. Pagid Fast Road pads all round, braided lines.
SUSPENSION: #Eibach Pro Street coilovers, Eibach front and rear anti-roll Bars.
WHEELS & TYRES: 8.5x19in BBS CH009 alloy wheels wrapped in 235/35x19 Michelin Pilot Super Sport tyres.
EXTERIOR: DTM Edition OEM bodykit including carbon fibre rear spoiler, Misano Red Pearl paint.
INTERIOR: #Audi-A4-Quattro-B7 Special Edition leather trim.
TUNING CONTACTS/THANKS: Rick at Unicorn Motor Developments, Paul at Turbo Clinic, Dave and Martin at Elite Wheel Repair, Rob TSR.
Above: quattro helps get the power down.
Above: Calipers are from a Porsche Cayenne S Bottom: A4 is around 250kg lighter than a B7 RS4 and more powerful!
Left and below: Craig has equipped his A4 with a genuine DTM Edition bodykit, including the carbon fibre rear spoiler.
Below: GTX3076r turbo provides ample boost to create a claimed 500bhp.Stream item published successfully. Item will now be visible on your stream.
- Post is under moderationMKS MONSTER AUDI S3 8L
Methanol injected monster. With a double injection of methanol, this #MKS-Performance-S3 is the most powerful K04 hybrid 8L we know of – who says you need a big turbo…? Words Davy Lewis. Photography Adrian Brannan.
Everyone has their own way of doing things. From cooking your steak, to cleaning your car – you find a way that suits and you stick with it. And to a certain extent this extends to the world of performance tuning. There are many different ways to create more power and everyone has strong views on which is the best method.
For a forced induction car, there’s no doubt that increasing turbo efficiency is the most effective way to increase power. However, there’s more to it than simply bolting on the largest turbo you can find on eBay. Turbocharged engines present a particular set of challenges for tuners. The bottom end needs to be strong enough to handle the extra boost; the cooling system must be uprated to deal with the high temperatures created by harnessing the spent exhaust gasses; and supporting upgrades all need consideration including fuelling, airflow and engine management.
When Matt Shannon began tinkering with his S3, he had a very fixed idea of what he wanted to achieve. “I’d already owned a tuned Octavia VRS 4x4, which is basically the same car underneath,” he comments. Having a lot of experience with the ubiquitous 1.8 20v turbo unit, Matt decided to purchase an S3 to work on, although he admits, “I bought it behind my wife’s back.” Brave man.
The original plan was to rebuild the engine so that it would make 500bhp with a big turbo. But, at the last minute, he changed his mind. “It’s harder to achieve good power with a K04 hybrid, than with a big turbo,” he says. Which is why this particular BAM unit runs dual methanol injection. “The largest port injects it immediately after the intercooler to keep the charge temps down, while the second injects it immediately before the throttle body. This helps to cool the cylinders and also increase the octane rating, as well as keeping the exhaust gas temps at a safe level. “It effectively ‘steam cleans’ the engine,” smiles Matt. Should the meth run out, the map reverts to its lower state of tune at 280bhp to prevent damage.
An oil and gas engineer by trade, Matt has been building up MKS Tuning for a few years now. It was a part time job until redundancy gave him the push to go full time and the S3 has become his demo vehicle to showcase what can be achieved.
The engine itself has been fully blue printed – a highly skilled method of measuring oil clearances to indicate how much life is left in vital components. The stock pistons were deemed good enough to use, but were fully refurbed with new shells etc. You can see the detailed engine spec in the spec box later on, but it’s a comprehensive build that ensures the S3 can take 500bhp if Matt wishes to fit a big turbo at some stage.
Having done the entire build himself, the only outside help came in the form of the balancing (which requires highly expensive machinery) and the custom map. Badger5 took care of the map and have created a set up with five settings, from a low stressed 280bhp, right the way up to the full-fat 370bhp with methanol.
To get the power down, Matt has done away with the dual mass flywheel and fitted a meaty Loba single mass kit. There’s also a rare Haldex Blue controller, which allows power to be adjusted front to rear as required. With sticky Yokohama Parada Spec 2s, this fierce S3 lays down its ample power very effectively. Key to this is the nature of the K04 hybrid, which spools up quickly, delivering a linear response, rather than the big bang associated with a big turbo. The great thing about this precision build is that it is very drivable; the turbo kicks in at 3000rpm, so there’s always power there when you want it.
With the ability to hit 60mph from rest in around four seconds and some pretty lively in-gear acceleration, it’s easy to find yourself moving at a rapid rate of knots in this S3. Matt has wisely fitted some hefty stoppers in the form of D2 six-pots which clamp down on 356mm discs. Tucked up behind the timeless Rota Grids in a beefy 9.5x18, they do an admirable job of standing this S3 on its nose.
Now, it would have been easy to strip the interior and save weight, further improving the performance of this hard-charging S3, but Matt wanted to retain its usability. Inside it’s all very nice with stock electric, leather Recaros and Bose audio – so stripping it was never an option. There are some additions though. A Liquigauge unit has been mounted in the driver’s side air vent. This offers a multitude of functions, from checking essential EGT, boost and other data, to reading fault codes – there’s even a performance timer incorporated.
Pop the tailgate and you’ll find the plumbing and tank for the methanol injection kit, plus a battery. Both had to be relocated with an already tight engine bay, but sit neatly in the spare wheel well.
Outside, apart from the MKS company logos and the cut outs to the front bumper to maximise airflow, you’d think this was just another lightly tuned S3, possibly making 260bhp with a remap and performance exhaust. But once that needle hits 3000rpm, you’d realise it has serious potential – enough to keep up with a B7 RS4 and leave stock Evos wondering what just happened. As Matt says, it would have been straightforward to bolt on a large turbo, strip it out and create a big boosting monster. But that’s not the point. For him, this build was about doing things differently. Creating a powerful, but usable road car that retains its original character. The fact it still has the original 122k-mile block and uses a K04 hybrid makes it all the sweeter. It goes to show what a proper engineer’s approach to engine building can achieve.
SPECIFICATION #Audi-S3-8L / #Audi-S3 / #Audi-S3-MKS-Performance / #Audi-A3-8L / #Audi-A3
ENGINE: 1.8 20v turbo BAM with full #MKS-Performance rebuild and motorsport blue print, #Badger5 custom map, 5 map selectable programme, 370bhp & 364lb/ft max with power ranging down to 280bhp min, #Supertech Nitrate inlet and Inconel exhaust valves with HD springs and single grove collets, #BADGER5 V2.2 80mm turbo intake pipe with BMC induction filter and heat shield, BADGER5 V2 high-flow cast manifold with large port mod, BEACHBUGGY TURBO Stage 4 Hybrid K04 turbo also with B5 large port mod in hotside, AEB large port cylinder head, Supertech Nitrate inlet and Inconel exhaust valves with HD springs and single grove collets, 600x300x76mm Toyo sport type B front mount intercooler, Pipewerx 3in down pipe and custom 5in sports cat, #Milltek cat back exhaust, Devilsown dual port 100% methanol injection with solenoid upgrade and inline pressure gauge, DO3 injector post front mount intercooler and DO1 injector pre throttle body, 550cc Bosch injectors, IE Tuscan rods (rifle drilled), #ACL big end shells and #Mahle main shells, #ARP main and head stud kit, OEM pistons but new rings still at 81.5mm bore, full Forge coolant hose kit, Forge 008 DV, Draft45designs oil catch can with custom catch can system, N249 valve delete.
TRANSMISSION: Loba stage 2 single-mass flywheel kit, ECS metal clutch bleeder (must have for smf kit), #Haldex blue controller.
BRAKES: D2 356mm 6-pot brakes with drilled rotors
SUSPENSION: AP coilovers, adjustable rear control arms for camber control.
WHEELS AND TYRES: Rota Grid Drift, 9.5x18in, Yokohama Parada Spec 2 rubber.
EXTERIOR: 2x genuine #Audi front wings inc. bumper respray, cut out front bumper, black Audi badges, MKS graphics.
INTERIOR: Liquigauge (obd data screen) in D/S air vent, batt relocation to the boot, Devilsown 2.25gal race baffled meth tank in boot, boost, oil and meth pressure gauge’s with meth injection kill switch.
TUNING CONTACTS: MKS Performance www.mksperformance.co.uk Badger5 www.badger5.biz
Top: This S3 can shift Above: Would make a cool necklace for petrolheads!
Left: Liquigauge is neatly mounted Below Left: Go Go Juice aka methanol injection!
“The ability to hit 60mph from rest in around 4 seconds”
Above: D2 6-pots right: Battery and methanol tank in the spare wheel well.
Right Heat management is taken seriously Below: 1.8T look immaculate.
Above: 9.5in wide Rotas look great.
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- Post is under moderationBITS OF AN ANIMAL COSWORTHS AT COSWORTH A MEET LIKE NO OTHER - COVER STORY
Is it an #Audi , is it a #Ford , is it a Cossy? Read on. / #Ford-Escort-Cosworth-MkV / #Ford-Escort-MkV / #Ford-Escort
This is a 900bhp #Ford-Escort-Cosworth . Except it’s not, because it’s powered by a five cylinder Audi engine connected to a Skyline gearbox with a rear subframe from a Nissan S14. Oh yeah, it also has electronically adjustable four-wheel drive…
CHRIS POLLITT /// PATRIK CARLSSON
This Escort Cosworth, if you can call it that, is what marketing people would call ‘a game changer’. Now, this is a phrase that tends to get casually tossed about when someone does something just a teeny weeny bit different and people, who want you to think that that something is actually a lot more exciting than it really is, will call it ‘a game changer’ in the hope that it will grab your attention and make you all giddy. Well, this is more than just a bit different; this is a car that completely and utterly redefines what is possible with the Escort Cosworth and even if it has done so by removing almost all of the #Cosworth DNA, which we know is going to upset quite a few purists reading this, the finished article is so spectacular, so face-meltingly well engineered that anyone who dismisses it for being ‘not a proper Cossie’ needs to go and sit in the corner and have a quite word with themselves. This is proper alright, and it’s all down to the skill, determination and downright bloody-mindedness of its genius owner, Joakim Stigenburg.
Part of the reason we’re getting so hot under the collar about this car. of course, is because the Escort Cosworth is such an iconic machine, most people are reluctant to mess around with it too much. And this is perfectly understandable, it is an appreciating classic after all. Yes, there have been plenty of stunning big power projects over the years, all based around the equally as iconic Cosworth YBT and yes, we’ve even featured one or two examples that have been the subject of an engine swap as well – but nothing like this. In a world where your typical modified EscCos has a stage four conversion, some coilovers, a set of AP Racing 6-pots and some Compomotive MOs, you have to admit that a five-cylinder Audi 20v turbo engine conversion that’s putting out 900hp at the hubs combined with a Nissan drivetrain and an electronically adjustable four-wheel drive system is something of an eye-opener to say the least – especially so when you consider that our man Joakim did the vast majority of the work himself, at home, and in an unheated garage. And that’s actually quite a big deal, because for starters Joakim is a carpenter by trade, not an engineer or mechanic, so he’s had to learn all the skills you might imagine are essential for a build like this from scratch. Secondly, he’s from Sweden, so on the nights when he started work on the car at 8 o’clock at night and would finish at two or three in the morning, having to do so in a freezing cold workshop really does highlight the determination and passion he has had for this project. How long did it take him to finish it? Ten long years. And it all started when he took delivery of a completely standard 1994 model year Escort Cossie.
“I started off with a 330bhp stage three kit, but after only a couple of months I wanted more power, so I modified it to stage four and around 450bhp,” remembers Joakim. “At this point, I decided that I should really have a roll cage for safety reasons, so I stripped the interior out and started work on building myself one. I guess this was the point where things started to get out of hand!”
“THIS IS MORE THAN JUST A BIT DIFFERENT; THIS IS A CAR THAT COMPLETELY AND UTTERLY REDEFINES WHAT IS POSSIBLE WITH THE ESCORT COSWORTH”
We suspect that from the very start, Joakim had his sights set on more than just a stage four conversion – he’s Scandinavian after all, and when it comes to building big project cars, events like Gatebil are proof that these guys don’t tend to do things by halves. It was the Norwegians that made the quantum leap in Cosworth tuning at the start of the noughties, and we have to assume that these kind of extreme machines served as an inspiration for Joakim as well. In short, he had to have more power and as such, he set about building a fully forged Cosworth YB in order to achieve it and to extract as much potential as he could from the freshly caged shell.
And when we say ‘more power’ we do mean just that, because rather than the 500-600bhp that most people would deem to be about the limit for anything approaching vaguely useable for a fast road car, Joakim had his heart set on double that – and as such, he decided that the standard Ford transmission just wasn’t going to be up to the task of processing that amount of grunt. So, an alternative was required, and as luck would have it, one was about to present itself in the form of a Skyline GT-R33 gearbox, complete with a Pftizner Performance ‘dog engagement’ gear set.
According to Joakim, a similar set-up had been proven on a Skyline with around 2,000bhp so he was pretty confident it was going to be man enough to deal with the power he had planned for the Escort. All he had to do now, was find some way of getting it to fit. The answer to that was to spend many, many hours fabricating and welding in his garage, and whilst he did in the end manage to successfully get the Skyline ‘box in place, by the time he did so, he’d somehow managed to completely change his mind on what engine was going to be attached to it!
“WE SUSPECT THAT FROM THE VERY START, JOAKIM HAD HIS SIGHTS SET ON MORE THAN JUST A STAGE FOUR CONVERSION HE’S SCANDINAVIAN AFTER ALL”
The forged YB was built and dyno’d, but the consensus was that it was just going to take too much hard work in order to push it close to the 1000bhp mark and that, once there, it would just be too fragile. So, it was put to one side and the hunt for a replacement began. And for those that are thinking it’s a crime to discard a Cossie YB in such a careless manner, don’t fret – Joakim ended up de-tuning it to a mere 590bhp and 457lb/ft and slotted it into his Sapphire Cosworth instead.
As it happens the Saph was to take centre stage for quite some time, because after finding a new engine for the Escort, which turned out to be a turbocharged Volvo five-cylinder unit tuned to around 700bhp, this engine ultimately proved to be more trouble that it was worth, and Joakim became so frustrated with it all that he put the Escort to one side in order to spend some time with the Sierra.
“WITH JUST OVER 900HP ON TAP THE 2.5 LITRE AUDI BASED 5 CYLINDER ENGINE THAT NOW RESIDES IN THE FRONT OF THE ESCORT IS AN ABSOLUTE MONSTER”
That was until about two years ago, when the half finished Escort was dragged to the front of the workshop so that Joakim could finally finish what he’d started. Job number one was to find yet another engine, and whilst the six-cylinder turbocharged unit from a Skyline could have been an obvious contender in so much as it would have matched up to the gearbox and would have easily provided the power required, Joakim had other ideas. Again, we suspect that the final choice of engine was inspired largely by the no-holds barred creations that crop up at events like Gatebil, but whether that’s the case or not, with just over 900hp on tap the 2.5-litre Audi based 5-cylinder engine that now resides in the front of the Escort is an absolute monster.
Built up around a super strong diesel spec 2.5-litre, five-cylinder Audi block, the top half of the engine incorporates an old school Audi 7a five-cylinder 20v head. Again, Joakim has done the vast majority of the engine build himself, which has included not just mating the head and the block, but fitting JE pistons and H-section rods, a VAG coil pack conversion, custom Cat cams, a custom dry sump and CPS inlet and exhaust manifold – not to mention the small matter of bolting on a Precision 6466 billet roller bearing turbo and then getting the whole package up and running with MaxxECU engine management. On top of that, he’s had to chop around the front of the Escort in order to get the engine to fit and match it up to that bulletproof Skyline gearbox as well.
The time and effort that has gone into the engine build is one thing, but the amount of custom fabrication and engineering involved throughout the whole car is another thing altogether. For instance, Joakim had to design and build a custom suspension set-up at the front of the car, using a combination of custom driveshafts and Nissan hubs to get power to the front wheels. If that wasn’t complicated enough, the rear of the Escort has basically been converted to a semi-tubular chassis, with a Nissan S14 sub-frame in place that in turn accommodates a hybrid Ford/Nissan suspension set-up. And then there’s the Rallycross style rear mounted radiator, the dry sump tank and fuel cell boot install, the custom home-built cage, the custom centre console that houses all the switch gear…the list goes on and on.
“THE REAR OF THE ESCORT HAS BASICALLY BEEN CONVERTED TO A SEMI-TUBULAR CHASSIS”
One of the Escort’s biggest party tricks, however, is not the top of the range hardware or bespoke fabrication, but the electronic wizardy that’s been employed to make the whole thing work in the first place. The heart of this is a MaxxECU engine management system, and whilst it does the normal things that ECUs do with regards to engine duties, it also supplies huge amounts of data to the large electronic screen situated behind the steering wheel and even allows Joakim to switch from super grippy four-wheel drive, to ultra skiddy rear-wheel drive at the flick of a switch.
Considering the Escort has been built to contest both drift and regular motorsport events, it’s a brilliantly clever modification and one that we’ve never seen before on a Performance Ford feature car.
But then, we’ve never seen a car like this before in PF full stop. Yes, we’re aware that it’s lacking its original Cosworth components and for some, this will always be a step too far, but we reckon that in this instance it doesn’t really matter. Think of this Escort as a source of inspiration, proof of what can be achieved with just a cold garage, lots of late nights and a sheer bloody-mindedness to see a dream project car through to completion. So grab yourself a second hand welder and get to it…
TECH SPEC Ford-Escort / #Ford-Escort-Cosworth / Fifth generation / #Ford-Escort-MkV
ENGINE: Audi 2.5-litre diesel block, JE pistons and #H-section rods, CrMo flywheel, ported Audi 20v turbo 7a head, #VAG coil pack conversion, Cat cams, bronze guides, #Supertech valves, #CrMo retainers, dual valve springs, Precision 6466 billet roller bearing turbo, Precision 46mm wastegate, Tial dump valve, custom dry sump, CP-S stainless exhaust manifold, CP-S inlet manifold, #Accufab throttle, #MaxxECU engine management, rear mounted radiator, dry sump tank and fuel cell, 904hp at the hubs, 752lb/ft
TRANSMISSION: Electronically adjustable 4WD system allowing for full rear wheel drive or 50/50 four wheel drive, R33 Skyline ‘box with Pftizner Performance ‘dog engagement’ gear set and modified transfer box, Nissan S14 rear cradle with adjustable trailing arms, custom prop and driveshafts, Skyline differentials, custom trailing arms, knife edge anti-roll bar.
BRAKES: #Alcon 6–pots with 356mm discs (front), Skyline GT-R 2-pot #Brembo s with 320mm discs at rear
Suspension: custom front suspension with #GAZ-Gold adjustable dampers, Nissan S14 rear sub-frame with Cosworth spec #GAZ Gold adjustable dampers at rear.
CHASSIS: #1994 Escort Cosworth, semi-tubular chassis at rear with #Nissan-S14 subframe, poly windows Interior: full weld-in custom roll cage, custom centre console, custom pedal box, Sparco Lico seats, Sparco plumbed in fire system, hydraulic handbrake.
EXTERIOR: Audi Ibis white Wheels: Nissan hubs, 8.5x18-inch #Toora alloys, #Maxxis Ma-Z1 tyres.
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