Project Sport 500

[Stefan Ertler]

Well, after almost 9 months waiting for parts and time at Ramspott & Brandt I am entering the last stage of my Sport 500 project, which I want to share with you.

End of last year Garry Kemp had delivered the modified 910 block with 2.6l displacement and the following specs :

- 97 mm bore

- 87.5 mm stroke

- closed deck design

- steel liners, hot honed

- steel crank shaft

- 650 grms conrods

- +2.5 cmm inlet valves

- + 3.5 mm exhaust valves, watercooled to lower the temp by ca 160

Edited August 21, 2008 by Fandango

[Bibs]

If it's one of Garry's creations I'm confident you'll achieve your target. I'm looking forward to hearing more as the install progresses

[Stefan Ertler]

Bibs,

It is one of Garry's creations and in fact he just emailed me to correct a few things in the specs of the engine which I just modified

Thanks for your confident note, I will make sure the forum gets a detailed report as the project proceeds.

[t70]

I'm very interested to see that it appears there is a "block guard" on top of your cylinders. The only concern I have is the steel liners. I've heard both good and bad (and I concede that Garry is a phenomenal engine builder that I look up to) about the steel liners. The issue is the heat being produced at that kind of horsepower and the expansion and contraction of the steel liners vs. the block. This has been noted to cause the headgasket to blow in other builds... though I've also been told never to stroke the engine on the stock liners because they tend to wobble and blow the headgasket from that. I'm really excited to see how this turns out for you..

[SE Owner :-D]

Now that's what we're talking about...!!!

Keep up the good work, can't wait to hear your progress.

[DanR]

Great. Those rods look the goods.

When you get around to changing the turbo, using a separate wastegate might be worth considering for the improved flow benefits.

[Stefan Ertler]

I'm very interested to see that it appears there is a "block guard" on top of your cylinders. The only concern I have is the steel liners. I've heard both good and bad (and I concede that Garry is a phenomenal engine builder that I look up to) about the steel liners. The issue is the heat being produced at that kind of horsepower and the expansion and contraction of the steel liners vs. the block. This has been noted to cause the headgasket to blow in other builds... though I've also been told never to stroke the engine on the stock liners because they tend to wobble and blow the headgasket from that. I'm really excited to see how this turns out for you..

Mark,

Just to clear something up

Edited August 22, 2008 by Fandango

[t70]

Thanks A million for the info! I'm glad to understand what's been going on in this engine with so many rumours about. Anyhow, as for you're wastegate question.. the G-Car is externally wastegated... and the US Spec 1988 Stevens Esprit is too..

[lotus4s]

Awesome job Stefan, can't wait to see it running!

Be sure to take plenty of video...

[Stefan Ertler]

Danny, Mark

I shared som emails with Garry on the external vs internal wastgate. This was his answer : ( which, by the way makes very good sense to me :yes )

Hi Stefan,

The displacement doesn

[Stefan Ertler]

Update 26.08.2008

Hi all

As you can see from the new pictures, progress is taking place step by step

Steffen Brandt is dismantling the old engine, keeping what I will need for the new one, such as header, Turbo, etc.

At the moment he is preparing the head by fitting the valves and the valve springs.

Once all is shifted, my old block will go back to Garry as this is part of the deal.

Cheers

Stefan

[t70]

That's a beautiful head! Thanks to garry for pointing this all out so well. Glad to see the progress coming along!

[rydning]

This is gona be a serios engine..no question about that.

What gearbox mod are you gona use?

And a purpose build engine like that is gona be usable with 600bhp+ for track use.May be not for 24hour,,but who knows?When Lotus raced 24h LeMans the engine lased 9h and 16hour before headgasked failure do to heatsoak when in the pit.And your engineis tested to withstand 900bhp+.

I have maxed out my engine with a 3076 turbo with racefuel (1,65bar of boost and hige timing) on a stock crank,pistons,rods and crank.May be 450-500bhp, so you will be more than fine with 500bhp on your engine.

It looks like the biggest problem is the headgasked problem do the the stock liners.Witch is more than solved in your engine now.

Edited September 8, 2008 by rydning

[rydning]

Any News??

[DanR]

Just read this again. That 2.65L 800hp Indy engine has to be more than 2.5psi I think??? Is it supposed to be 2.5 bar?

[t70]

not likely... the rpm the engine turns is somewhere in the 15000 rpm range... which effectively doubles its displacement to 5.3 litres.. and then 2.5psi makes sense.. it just overcomes the issue with cam duration and breathing ability at that rpm... makes the engine drivable at 3000rpm and still able to generate horsepower at 15000rpm without starving for air.

[Tony94S4]

Well, after almost 9 months waiting for parts and time at Ramspott & Brandt I am entering the last stage of my Sport 500 project, which I want to share with you.

End of last year Garry Kemp had delivered the modified 910 block with 2.6l displacement and the following specs :

- 97 mm bore

- 87.5 mm stroke

- closed deck design

- steel liners, hot honed

- steel crank shaft

- 650 grms conrods

- +2.5 cmm inlet valves

- + 3.5 mm exhaust valves, watercooled to lower the temp by ca 160

[mchlrodrigues]

Just read this again. That 2.65L 800hp Indy engine has to be more than 2.5psi I think??? Is it supposed to be 2.5 bar?

While I'd rarely question Garry on an engine point but 2.5 psi is not correct. Back when turbo Cosworths were used in CART the maximum boost pressure, regulated by the popoff valves on top of the plenum was 45 in. HG absolute, which translates to a little over 7 psi of boost.

With relatively low boost they were essentially "enhanced" N/A motors with relatively high compression and race cams.

[yeti]

Hi!

Awesome build. What sort of budget do you have for this and where do you get all the parts? Might want to do something like this myself one day

Do you plan to reuse the old Renault gearbox too?

Bjorn

[Tony94S4]

any update?

[Stefan Ertler]

Sorry for being silent for so long, but there has been nothing to report.

As soon as the new rods come in from Garry Kemp we will be able to complete the engine.

From that point onwards I will be able to feed you lots of info.

Cheers

Stefan

Hi!

Awesome build. What sort of budget do you have for this and where do you get all the parts? Might want to do something like this myself one day

Do you plan to reuse the old Renault gearbox too?

Bjorn

HI Bj

Edited October 16, 2008 by Fandango

[yeti]

Hi Stefan,

Thanks for the update. I'm going to start saving now

I don't think I've heard about the R & B 6 speed dog box. Do you have any more information or I URL I could try?

Bjorn

[Stefan Ertler]

Finally, we are back on deck.

Rods came in today and as you can see they look the works. They are 1 kg lighter than the factory ones !!

In another thread, I think it was Artie's engine rebuild, there was some talk about iron liners.

Well, here you can see some.

I shall keep you posted hopefully every second day with new piccies as R & B assemble the rest of the engine.

Bear with us

Stefan

Bj

Edited October 22, 2008 by Fandango

[Artie]

Very nice, the rods and pistons look just like mine. Are the rods Saenz rods from JAE in the US? Also, are the pistons JE's?

Artie

[Stefan Ertler]

Artie

The rods I don't know, as Garry Kemp had them made, but the pistons are originally from Mahle and got customised to fit the 2.6l block.