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

MWP

New member
Engine plan now looks like this....

ST215 (Caldina) head + intake manifold (port clean up, match & polish)
ST205 exhaust manifold + CT20b turbo
Camry 5S-FE engine block (strong version) + crank (resized big end journals)
CP Custom 10:1 CR pistons
Eagle 3S rods
ARP main, rod & head studs
High flow 5S oil pump
5S or 3SGTE (gen2) sump
ST205 (if it fits) water pump
Current large A2A IC
Xtreme 5S Chromo (or Ally) flywheel + Xtreme 3S 6 puck cushioned clutch (DSBHD)
Injector Dynamics ID1000 (or ID1600) injectors + custom fuel rail + turbosmart FPR
Custom laser cut crank trigger wheel + Solaris 5S crank position sensor
MegaSquirt 3 (v3.0 PCB), with MS3X

... my head is about to explode :eek:
 

MWP

New member
So i finally got a chance to look at the ST215 head stuffs today.
Gave it all a good clean so i could properly inspect the head and make sure everything needed was there.

Comparing intake manifolds (ST205 left, ST215 right)
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Comparing valve covers (ST205 left, ST215 right)
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And again. Timing belt covers will be an issue :(
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Pile o ST215 valve gear
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Cleaned up ST215 head
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ST215 cams
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All looks ok :)
 

phattyduck

New member
aus jd 2703":2259bvfs said:
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

New member
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

New member
phattyduck":2bl1dxrl said:
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 !!
IMG_5582.JPG


:p :p :p
 

MWP

New member
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

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

Code:
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:
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
 

MWP

New member
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.

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Then started on an inlet port...

Before i started:
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Port matched & knife edged (lots more to do though).
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One valve seat & short side smoothed out.
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MWP

New member
Some updates...

Head porting done :)
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Inlet:
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Exhaust, not as polished as i would like, but good enough:
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Shiny :)
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Getting there... just rear drive shaft, gearbox cables, PS, and some lil stuff left to disconnect before dropping it out.
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MWP

New member
More done over the weekend...

One very dirty 205 gearbox:
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Now clean... what a PITA & messy job. Looks like its been rebuilt before too, so i wont be opening it up.
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Cracks in the engine block:
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