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1978 Clubman Fwd Hayabusa Turbo


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#1 proutyc

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Posted 02 May 2016 - 02:59 AM

Just started a winter project down in NZ.

 

The mini is a 1978 Mini Clubman with Metro turbo discs and 4 pots.

 

We're installing a hayabusa turbo using a Promotive diff kit, We mocked it up a few weeks ago and its appears we're going to fit it in the clubbie.

 

Wheels are 13x7 and had the standard upgrades like adjustable arms and camber/toe plates.

 

Hope to have the front subframe out this week and then will start to fabricate the engine mounts.

 

We are using the Hayabusa as I have a turbo Hayabusa kitcar and am using the Gen2 Electric to reflash the ECU for all turbo functions. The Hayabusa ECU will also control all the electrics. We will see 225hp on low boost but maybe a little more on track days

 

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The Engine has had APE head studs, overdriven oil pump gear, billet shift shafts. Undercut transmission and Forged Turbo pistons

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Promotive Diff. Thanks to Phil and his team for sending all the way here. Ratio is 3.1.

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This is a planetary gearbox made by Roadster cycle. We had new custom shafts made as we are tight for space (One of the UK ones would have been better in hindsight but had this one in my garage collecting dust.

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Thanks

Chris


Edited by proutyc, 02 May 2016 - 03:05 AM.


#2 proutyc

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Posted 03 May 2016 - 10:20 AM

Was a little bored tonight and really want to make sure we could fit the hayabusa into the front subframe.

 

The good news is yes it does, just.......

 

We appear to have about 10mm clearance at most places. The turbo plumbing is going to be a challenge.

 

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#3 proutyc

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Posted 19 May 2016 - 07:54 PM

I've managed to get in the garage a bit the last few nights so progress is coming along. 

 

Man everything is tight

 

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#4 jackuig

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Posted 19 May 2016 - 08:11 PM

Awesome little project you've got there, Chris!

Car looks really smart as well! What arches is it you have on your clubman?

#5 dundahead

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Posted 23 May 2016 - 11:45 AM

what wouls the 0-60mph on this project be? and 0-200km/h



#6 proutyc

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Posted 23 May 2016 - 11:08 PM

Thanks for the question. Not to sure at the moment as traction will take some work from 0.

 

I will be experimenting with traction control as used by ecu editor.

 

That said it should be very rapid as I'd expect it to weight 50-70kg less than a A series and have over 200hp at the wheels at 5psi



#7 proutyc

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Posted 30 May 2016 - 08:36 PM

Its starting to get a bit cold in the garage but managing to keep a few things ticking along. Just fabricating the exhaust header now then the subframe will come out for paint. That part is almost finished now, then its the tough part of wiring and certification 

 

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#8 proutyc

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Posted 02 June 2016 - 07:41 PM

Making a little more progress. We really had no option other than turbo as you can see from the exhaust. This only clears the firewall by about 15mm.

 

Exhaust is going off to HPC for coating anf then its onto the turbo water cooled plenum.

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#9 Squares

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Posted 05 June 2016 - 11:14 PM

That is looking great. Good luck and keep going.

#10 proutyc

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Posted 07 June 2016 - 10:10 AM

Many thanks for the comments.

Got the exhaust welded fully and turbo mounted.

The engine back in the car as pictured, it fits but it's all right. Exhaust clears by 25mm, engine clears the bonnet by 10mm and the diff misses engine by 5mm

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#11 proutyc

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Posted 08 June 2016 - 05:29 AM

And the engines in

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#12 proutyc

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Posted 16 June 2016 - 11:16 PM

Still ticking along.

 

Almost at the end of the main fabrication parts. 

 

the exhaust is currently away getting ceramic coated as I'm concerned with under bonnet temps.

 

I'm starting the plan the electrics swap over. The car will have all but the electric water pump, wipers, heater and demister running through the Suzuki ecu. This means a large amount of the existing mini wiring has got to come out.

 

New fuel lines are currently being run. 5/16 from tank to engine bay and a 3/8 return line.

 

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You can see the full length custom radiator, This is 600mm long and 190mm deep (Approx). It is also dual core so should provide twice the volume of the standard hayabusa rad

 

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Edited by proutyc, 16 June 2016 - 11:18 PM.


#13 proutyc

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Posted 24 June 2016 - 01:40 AM

Been waiting for the exhaust to come back but have managed to do some house keeping while we wait. Everything fits Ok

 

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#14 Squares

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Posted 24 June 2016 - 08:31 AM

This is looking excellent. What a great build, that subframe fabrication work is superb.

 

Keep going.



#15 steveo

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Posted 08 August 2016 - 11:15 AM

200bhp @ wheels will be more then fun to get off the lights! With addition to the extra torque the turbo bike engine offers over NA






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