MWP's wannabe Tarmac Rally 5S-GTE ST185 (racing!)

[aus jd 2703]

Will a 215 intake fit a 205 head? Wouldn't mind a side feed option is all

[phattyduck]

Will a 215 intake fit a 205 head? Wouldn't mind a side feed option is all

It takes very minor mods to fit. The throttle body is the only major issue. You either have to mod the throttle body and manifold (205 tb on 215 im) or wiring (215 tb on 215 im).

I'm going to try to figure out a way to do it with the 215 throttle body and intake manifold. Others have done it differently.

-Charlie

[MWP]

Ill be modifying the 205 TB to fit.
I will be running a MegaSquirt though, so may also look for a larger aftermarket TB.

[bozo-merlin]

I'm going to try to figure out a way to do it with the 215 throttle body and intake manifold. Others have done it differently.

That was done in 2009, using the 215 throttle on the 215 nitake manifold is the easiest way !!

[MWP]

Started disassembly to get the engine out:

[MWP]

Started working on the ST215 Caldina head.
Still a lot more to do.

[sleeper]

What did you use to polish the chambers?

[MWP]

A Dremel.
Takes a while, but its much more precise than using a larger air die grinder.
Ill use a die grinder for the ports though.

[MWP]

So i just did compression ratio calculations using: http://www.zealautowerks.com/
Comp ratio is too high with the ST215 head

Code: Select all

Number of cylinders = 4
Cylinder block bore diameter = 87.5mm
Cylinder block deck height = 215mm (i think this is correct)
Stroke of the crankshaft = 91mm
Cylinder head combustion chamber volume = 47cc
Piston dish or dome volume = -8cc
Piston compression height = 1.275in
Connecting rod length = 138mm
Compressed headgasket thickness = 0.045in
Total amount the cylinder head has been milled and the block decked = 0.5mm
Maximum operating RPM to determine mean piston speed and max piston acceleration = 7000rpm
Operating elevation of engine to determine effective compression ratio = 0
Boost pressure to determine effective compression ratio = 8psi


Results are:

Code: Select all

Static Comp Ratio = 11.03:1
Effective Comp Ratio = 17.03:1
Displacement = 2188.8cc
Rod / Stroke Ratio = 1.52:1
Piston-to-Deck Height = -1.384mm
Mean Piston Speed = 1813 fps (552 metres per second)
Max Piston Acceleration = 112755 fps2


[CSAlltrac]

Could go all motor alltrac kidding kidding boost is good.

[Hic]

you can use cometic up to 3mm thick. just buy it and it will lower your comp ratio.

[MWP]

Did more on the head this arvo.
Chambers are now finished. They did have a mirror finish before the cleaning stuffs + water tarnished it a bit.







Then started on an inlet port...

Before i started:


Port matched & knife edged (lots more to do though).


One valve seat & short side smoothed out.

[MWP]

Some updates...

Head porting done


Inlet:


Exhaust, not as polished as i would like, but good enough:


Shiny


Getting there... just rear drive shaft, gearbox cables, PS, and some lil stuff left to disconnect before dropping it out.

[MWP]

Cracked JDM engine out:

[MWP]

More done over the weekend...

One very dirty 205 gearbox:


Now clean... what a PITA & messy job. Looks like its been rebuilt before too, so i wont be opening it up.


Cracks in the engine block: