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SuperS Forged Turbo Build

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Not a lot to report at the moment. Car is taking a bit longer than anticipated for the charge piping. Long story short, the main UK distributor for Vibrant Performance components went into administration the same week the car was dropped off, so we've been waiting for the new legal entity to be formed so that we can put in an order for parts we need to finish the job off. Sod's law saw that our timing there was impeccable :LOL:

I started to get bored and, given we've got another nice weather snap, I decided to order in some carbon fibre sheet and a small selection of permagrit tools, so I could get on a make myself up a nice dash mount for the ECU CAL switches.

Given that this is a race car and I have zero plans to run a cabin heater, I decided to re-purpose the ports. My SuperS center console is not available since it's in the car, so I used my later facelift dash as a working model. Fits perfectly and will enable easy changes to the traction control and map tunes as required plus, there's a spare for anything else I decide to use in the future. Labels will go in the bottom section once I've got some vinyl letting in :)

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Not much to report on the charge piping side of things. Vibrant are now shipping hardware to the newly formed Evoke Performance (formerly known as BTN Performance), so my order has left the USA at least. Hopefully it won't be long before some fabrication can get underway and I can finally get on with the build.

While waiting, I decided to get some gear in to treat the SuperS shell to some corrosion protection. It's a solid shell and I want to keep it that way for as long as possible, but there are a few areas that could do with a once over. So, I had some discussion with the guys at Bilthamber and put in an order for a selection of various gloop. Picking up the tin of Electrox is funny being that it's basically a lump of zinc in a tin :LOL:

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Just a quick heads up to say, the car's being collected next Saturday.

The astute members among us will immediately realise that's JAE weekend but, I have far too much on at the moment to be able to attend and it's the last chance in a good few months that I'll get to collect it.

Engine bay pics of the completed work to be expected :)
 
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In preparation of the SuperS coming back to me this weekend, it's time to start stripping the old shell down further.

Brakes off, which thankfully didn't require me to break out the impact wrench 😋

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Finally got the car back yesterday. It took way way longer than anticipated and has set me back a long way for this year's plans. However, it's back and I have a hoard of parts to get stuck into. For now, the car needs a good wash and a vacuum inside before I can get make some much needed progress towards it being mechanically complete.

For all those who were waiting patiently for some engine bay shots, here's one I took as it rolled into the garage :)

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And another showing a bit more detail into the much improved charge pipe routing and construction. Zero chance of blowing a hose off this time around!

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Slam panel / intercooler bracket and charge piping dropped off for powder coating.

It's a good feeling to be making some much needed progress!
 
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Powder coating back and loosely assembled to see what it looks like. Needs some decent bolts on the slam panel and intercooler to make it 100%.

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Turbo oil feed is going back to a banjo affair, otherwise it will clash with the Aspect bonnet vent.

Turbine housing needs to be sent off to Zircotec to be coated. I've got a full loom, dash and some bits to collect from Matt Humphris, so I'll drop that off since they're only a stone's throw away from his workshop.

Can anyone spot the saw thumb? Yup, that blue lower rad hose just HAS to go. Yes, and the nasty top clamp on the top rad hose too :p

To finish, there's some more parts worming their way over from Japan. The March plastic headlights currently on the car are honestly a bit long in the tooth. One of the grille mounts has snapped and they are a bit yellow, so I snagged a much nicer set on Yahoo Auctions as well as a brand new 'old stock' grille from a March G# :)

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Not much of an update. I cleaned out the intercooler and charge pipes post fabrication to flush out any grime. Fitted a fresh set of JDM March plastic headlights, as the other set had sadly yellowed too much and were covered in micro cracks which, if I ever bother to MOT this thing, would be an instant fail.

The original loom has been ripped out, as it's sadly suffered from old age and isn't viable to repair. So, this is as clean as the engine bay will ever look.

It's getting a full coilpack loom transplant as I'll be using the later coilpack dash and speedo binnacle. It won't please the SuperS purists but I like the later dash for switch placements and this build is about pure function.

I landed a new job a few weeks ago, so as a present to myself, I replaced all the OEM carbon steel fasteners for the rocker cover, wings, headlights. slam panel and intercooler for a bunch of Ti fasteners from RSR.

Next, it's over to the inside of the car to finish gutting the loom and removing the dash, center console etc before swapping everything over. The later coilpack car is donating a fair bit of gear that's done less miles. Namely the steering column, so I can use a decent set of non sun faded stalks, wiper mechanism so I don't have to put up with wipers that squeal continually.

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A black bolero dash be lovely in that if ur into the facelift set up
It’s way nicer
I know what you mean. I've got just a bone stock grey dash going in for the moment, as anything fancy in that area is extremely low on the list.

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I know what you mean. I've got just a bone stock grey dash going in for the moment, as anything fancy in that area is extremely low on the list.

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A yea I fully understand you it’s not a major thing on list at the moment, but would look cool,

Personally I don’t like the flocked dash or parts thing
Looks tacky in my opinion

Shiny plastic is always a win
 
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A yea I fully understand you it’s not a major thing on list at the moment, but would look cool,

Personally I don’t like the flocked dash or parts thing
Looks tacky in my opinion

Shiny plastic is always a win
True but my motivation is to avoid any screen reflections, so flock or some Milano faux suede will be where I'll eventually go with it.
 
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Wow. Almost 4 months past since the last update.

Due to a recent job change, winter taking hold and subsequent lack of time, nothing much has been going on physically on the car. I've been spending any spare time doing research on the next steps. This has been in the form of spec'ing out what sensors to run with the new ECU, spec'ing out some new hardware and figuring out what to do with respect to wiring solutions.

I put in an order to KA Sensors last week for a load of sensors which will cover IAT, MAP, eMAP, OTS and OPS. Factory sensors for CAS, CTS and CPS will stay put as they're more than adequate. I'm awaiting a response on knock, wideband and flex fuel but will hopefully have those on order soon.

Hardware wise, I've got a bunch of kit coming from Turbosmart in the form of a dual port IWG-75 and 4-port solenoid, which will give the best boost control range to support boost by gear. There's also a FRP 1200, billet fuel filter and fittings coming in. Finally, there's an eMAP canister and vaccum block on it's way from the states from Full Function Engineering which will allow us to instrument turbine back pressure and route all our pressure sources around the engine bay in a discreet manner (I'm not a fan of vacuum hoses running everywhere like a bowl of spaghetti).

Wiring wise, I sourced a cheap OEM Motronic ECU off eBay which has been canibalised for the header which will form the basis of an adapter harness to allow us to utilise the OEM coilplack loom to hook the Syvecs S6plus into. That will take care of the OEM sensors (CTS, CAS, CPS). Depending on what the wiring diagram shows, we may also be able to utilise some unused wiring for additional sensors for the DBW throttle control (TPS and IACV may be good candidates there). The rest will be wired in directly via an auxiliary loom.
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In terms of connectivity, there's also a 'nice to have' in the form of a portable mini router which will provide wireless access when we get closer to mapping time.

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First parts haul in :cool:

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Sensors and the rest of the coilpack loom should arrive next week, plus a few bits and bobs.

Final bits to remove from the other shell before that goes. Then I can make room in the garage to start on the loom transfer and to populate the engine bay and get closer to a finalised layout.
 
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Installed the DBW transducer in the pedal box. OBP haven't quite got their kit 100% correct, so I've got a slightly longer M3x25 SHC and a 5mm nylon spacer coming to ensure there's no clashing between the main body and throttle pedal on full travel. I'll make a point of providing some engineering feedback to their tech support team when complete to improve the setup for future customers ;)
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Meanwhile, I stripped the rest of the exhaust (still on in the photo), rear BC dampers and the rear wheels off the blue shell. Just the rear springs and spring seats to remove, a few bay fittings, wiper assembly and that's the last of the external parts. Just internals remaining to take and it's ready for the heap.

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DBW transducer successfully installed on the throttle pedal with no clashing.
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Next job is to mark out the positions for the flex fuel sensor and fuel filter on the back bulkhead so I can order up the end fittings and hose to complete the fuel system.
 
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Marked up the rear bulkhead for mounting the flex fuel sensor and fuel filter. Was about to set to getting them mounted so I could tackle the feed and return lines when I found I had no M6 rivnuts left in my stash and my step drill had seen better days.

Ebay to the rescue yet again. I'll get some decent photos for the next update.....honest :giggle:
 
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Loads going on what with covid-19 and all that. Managing to do a bit here and bit there each day while working from home.

Mostly been working on converting the SuperS over to a coilpack setup, which involves quite a few bits from the Sport+.

Got the interior loom loosely in, steering column, stalks and Works Bell quick release in. I also stole the wiper assembly as the bearings on the original one were completely worn out.

Next is to work on more wiring, e.g. heated screen, marking what isn't needed for a potential loom diet etc. Cutting the dash to suit the cage, installing the dash cluster, centre console with CAL switches etc.

For the moment it looks pretty tatty but I'm hoping it'll take shape in the next week and start looking a bit more like a car inside again :)

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Trial fitted the dash. Next is fitting the loom in properly (terminating all the grounds etc), mounting the interior fuses and hooking up the heated front screen.

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Glen

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can you not sell the shell of the blue micra? seems a shame to scrap as it looks like a solid shell? (I might be wrong)
 
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can you not sell the shell of the blue micra? seems a shame to scrap as it looks like a solid shell? (I might be wrong)
No. It's suffered from the usual rot. Front cross member, rear sills, rear arches where they appear to have been rolled a little or where the wheels scraped the arches. Rear spring cup area etc. Rear axle is also not that pretty either

I spent a great deal of time on my SuperS shell putting all that right and it's not something I care to undertake a second time.

Quite a few body parts went to a well known MSV member so I think the Micra karma is good even if it is a shame to scrap a Sport+ in general.
 
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Started stripping down the heater controls from the Sport+ to add the A/C switch to the dash. It'll make a perfect telltale switch for the WiFi to enable ECU calibration. It'll be wired into a permanent 12v supply, so it will do away with having to wait for the router to reboot upon engine shutdown & restarts.

I'll also add the decals for the CAL switches to finish.

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Spent the last few days stripping the rest of anything useful from the blue shell (boost controller, wideband unit, MAP sensor etc), to get it ready to fill with all the leftover bolts, brackets and other trash that can join it on its one way trip to the scrappers.

I rolled the SuperS shell out for a bit of a clean before I start prepping the front bumper to fit with the new intercooler. Given the weather, it was too good an opportunity to pass up for a quick photo.

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What a really smart looking build, i love the way that some experienced members still have the micras and are now implementing modern day tech into them .

looking forward to following it along.

what was the main choice for the syvecs over lets say a link or ecu master ?
 
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What a really smart looking build, i love the way that some experienced members still have the micras and are now implementing modern day tech into them .

looking forward to following it along.

what was the main choice for the syvecs over lets say a link or ecu master ?
There's a few reasons. But the big ones are that my tuner is extremely experienced in calibrating Syvecs ECUs, I live very close to Syvecs HQ / Surrey Rolling Road and know the owner on a semi-personal level so, the level of support isn't something I'll easily duplicate elsewhere.

It's also an extremely capable piece of hardware, with a solid track record that's capable of supporting some very big stuff and, if I ever decide to build something different, it will easily move on to another vehicle together with the fuel system, sensors etc with little effort.
 
There's a few reasons. But the big ones are that my tuner is extremely experienced in calibrating Syvecs ECUs, I live very close to Syvecs HQ / Surrey Rolling Road and know the owner on a semi-personal level so, the level of support isn't something I'll easily duplicate elsewhere.

It's also an extremely capable piece of hardware, with a solid track record that's capable of supporting some very big stuff and, if I ever decide to build something different, it will easily move on to another vehicle together with the fuel system, sensors etc with little effort.
Sounds like a excellent reason to choose syvecs then ! I have never really looked into them much as they are not a well used brand here in ireland and I was curious.
 

Craig

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Yeah. They're a bit ratty but fine for the price and how much weight they save over a standard tailgate.
I couldn't quite get my head around how light those tailgates are, I presume you'll by fitting a poly rear screen too? I've been meaning to ask, what are the front wings you've got, GRP versions also?

Craig
 
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I couldn't quite get my head around how light those tailgates are, I presume you'll by fitting a poly rear screen too? I've been meaning to ask, what are the front wings you've got, GRP versions also?

Craig
The bare tailgate is 3kgs and yes, it'll get a lexan window at some point. I expect the final weight to be about 7kgs, which is a lot less than the 19.6kgs of a fully loaded OEM item.

Same goes for the bonnet. The upper and lower moldings aren't square but it's a non starter when you use aerocatches. Less saving there though at 5kgs vs 12kgs but, given the cost of them both it's decent to knock almost 20kgs off the car.

Front wings are GRP wings from Aspect Japan.
 
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