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Author Topic: FarmBoy Fab: Mindy's Merkur, I title "Progression to RWD"  (Read 84166 times)
ricardodemoraes
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« Reply #150 on: March 23, 2015, 11:24:34 AM »

Nt01s?Huh?? Cheater!!!
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catapultkid
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« Reply #151 on: March 23, 2015, 02:15:18 PM »

I know right! Had to do something since im in c prepared now...
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-Paul
1990 k20 swapped Gti (3rd motor)
1985 merkur xr4ti (4th motor)
1989 6.0 lsx swapped k2500 (2nd motor)
2000 honda insight (1st motor... yay)
catapultkid
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« Reply #152 on: March 24, 2015, 09:19:43 AM »

Put a hundred or so miles on the car last night. Everything seems good. I call it "big foot" now. The tires are much less precise than before and the gearing is completely different. I can hit fuel cut at 21psi pretty quick with the new downpipe so I've got to turn it down a bit. It comes on strong but not as strong as I thought it would be due to the extra large tires. I can be mid corner and plant the gas and it hunkers down and grips coming out. Remember I'm still on stock turbo making maybe 170whp at most with a bunch of low end torque. From 2.5k to 4.5k it is pretty torquey. Other than that it is dead, I may have made the car worse this winter but we will see how it does next weekend on its first autox of the season and I'll adjust from there.





-Paul
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-Paul
1990 k20 swapped Gti (3rd motor)
1985 merkur xr4ti (4th motor)
1989 6.0 lsx swapped k2500 (2nd motor)
2000 honda insight (1st motor... yay)
GeneCooley
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« Reply #153 on: April 03, 2015, 02:47:29 PM »

Paul, I was thinking about what you said about your problem stopping the car on Sunday.  Is there any chance that boost is getting into the vacuum side of your brake booster?  This was fairly common on turbo cars of the 80s (my Pontiac Sunbird Turbo for instance).  After a long pull the boost would fill the "vacuum" side of the brake booster.  At that point you didn't have brakes until the pressure was gone.  It usually didn't have much noticeable effect on short pulls.
Gene Cooley
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catapultkid
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« Reply #154 on: April 06, 2015, 06:50:34 PM »

Paul, I was thinking about what you said about your problem stopping the car on Sunday.  Is there any chance that boost is getting into the vacuum side of your brake booster?  This was fairly common on turbo cars of the 80s (my Pontiac Sunbird Turbo for instance).  After a long pull the boost would fill the "vacuum" side of the brake booster.  At that point you didn't have brakes until the pressure was gone.  It usually didn't have much noticeable effect on short pulls.
Gene Cooley

Not a bad thought Gene, and something I should check. I know the biggest issue was the finish was fast and I had the throttle pinned going in a left hand arc and I couldn't lift until I got the car straight and settled. Then I'd hit the brakes and they would lock up quick and we'd slide. It was pretty bad.


First Autocross with the setup two weekends ago. Car did ok, more grip than before. The steering inputs where not as precise however due to the sponginess of the tires. Stopping however was still a big concern as I just had put EBC yellow pads in. Tires pressures are still something we need to play with as they fluctuate a lot being as large as they are.

So here are my rotors after a year of autocrossing (12 events and 3 pratices) with 3 drivers... I can still see the factory cross hatching. It basically polished them. I replaced the pads and in a single event have worn off all the cross hatching with 3 drivers. These old pads are worthless.



Swapping pads.



At the event





More photos and bigger update coming soon when David releases his photos.
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-Paul
1990 k20 swapped Gti (3rd motor)
1985 merkur xr4ti (4th motor)
1989 6.0 lsx swapped k2500 (2nd motor)
2000 honda insight (1st motor... yay)
gunny
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« Reply #155 on: April 07, 2015, 03:40:01 PM »

I use a BFH on things I dont like too!
awesome.

Gunny
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catapultkid
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« Reply #156 on: April 09, 2015, 09:32:55 AM »

Gunny, that was my fender clearancing device... works too Smiley

Couple of photos and notes.

So Gunny, Stuart, my own brother Pat and Richardo are the Raw time contenders for the Merkur this year. Out of the 5 of us the Merkur was bettered by the M3 and Corvette. Total separation was less than 8 tenths of a second between all of us! I hope to do more driver comparing as this season progresses as it adds a personal element to it.

Here is a few of us on the same corner. Note the different lines. Richardo is fast for a reason and it ain't just that car. He visually is better prepared than Mindy and I in that turn alone.

Mindy


Richardo


Paul


The merkur lacked brakes big time, I'd mash the stop pedal wayyy to late and that became an issue very quickly at the end of the longish straight and through the finish by locking up tires. I will take some camber out of the front before next event to see if I can gain some braking. I doesn't do much for confidence when I can't trust the brakes.

The new balanced tires still kept the car neutral in the slow corners but it is still very oversteery in the fast corners. I'm not sure what to do here but next event I will try keeping the rear tires at a lower tire pressure. I think a big wing would help in the fast stuff. Mindy isn't convinced.

The new intercooler/radiator placement kept the car nice and cool (even though it was only 40* out). No leaks so far.

The new downpipe did help with boost pressures early on. The day before Richardo and Gunny drove the car and it was noticeably harsher when boost came on. We de tuned it some before Sunday but it came out a little soft for my liking at the event. It was only at 15 psi vs the 18-19 that I'm trying to run. Down 10-15 hp I'd say. Torque curve felt linearish... as much as a 80s turbo car can be...

Till next time. Thanks David for the photos as always!

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-Paul
1990 k20 swapped Gti (3rd motor)
1985 merkur xr4ti (4th motor)
1989 6.0 lsx swapped k2500 (2nd motor)
2000 honda insight (1st motor... yay)
ricardodemoraes
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« Reply #157 on: April 09, 2015, 10:48:18 AM »

Was that a compliment? Weird, usually I only get trash talk. hahaha
It's a shame that I wont be able to make the next event.
By the way the whole "So Gunny, Stuart, my own brother Pat and Richardo are the Raw time contenders for the Merkur this year." thing... CHALLENGE ACCEPTED!
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catapultkid
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« Reply #158 on: April 23, 2015, 08:09:12 PM »

Don't let that head swell too much there buddy. I'ma coming of you!

Another weekend and another autocross. This time my brother and Richardo couldn't come play so it was the boxster and corvette who remained. The course was 63-65 seconds and the merkur was once again bettered by Gunny in the vette but only by 2 tenths. Stuart in the boxster lagged behind the merkur a tad, however I know next event will see him on new tires which are by far his biggest handicap right now.

The event was at VMP which had the obligatory lane change with slalom down one side, a cross over or two and a few off set gates coming back. Typically I've found it a very rewarding setup if you get it right from the start, as soon as you get a little behind your time usually reflects it because of how easily it compounds. Also grip is down at VMP and at the top of 2nd gear with the throttle pinned most modified cars are skipping, gentle inputs are required.

The night before the event Mindy and I pulled most of the camber out of the car, raised the nose a inch or so and realigned it with 1/8" toe out. This resulted in a much more confident setup with a touch of under steer in the slow corners and a lot more stability in the fast turns. The biggest change however was the braking effects. It was like we where driving a new car. It stopped very well with only a little lock up once braking way too late for a cross over turn. 44 psi in the fronts and 40 in the rear also helped keep the car feeling precise but stable.

Thank you Laura for the photos! The look fantastic.





Now the bad news. The car still overheats! very strange so I'm working that out. So far I've tested 3 different thermostats in boiling water and the one that was in it (generic parts store) didn't start cracking open until 198-200 degrees, it is a 192* thermostat?! The OEM unit from Ford (motorcraft & also 192*) didn't open much faster however a 180* thermostat from STANT was wide open at 190ish. Looks like I need to gain more flow at 190* so I hope that is part of the issue. I also added a bleed nipple to the upper rad hose so I can make sure there is no air in the system.

Next event is VIR... more on that later.

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-Paul
1990 k20 swapped Gti (3rd motor)
1985 merkur xr4ti (4th motor)
1989 6.0 lsx swapped k2500 (2nd motor)
2000 honda insight (1st motor... yay)
sonomadrifter
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« Reply #159 on: April 28, 2015, 04:21:13 AM »

Sounds well sorted - Photos from the last RIR event:





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catapultkid
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« Reply #160 on: April 29, 2015, 03:27:51 PM »

Thanks Pat!

Look awesome.
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-Paul
1990 k20 swapped Gti (3rd motor)
1985 merkur xr4ti (4th motor)
1989 6.0 lsx swapped k2500 (2nd motor)
2000 honda insight (1st motor... yay)
catapultkid
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« Reply #161 on: May 10, 2015, 06:29:16 PM »

VIR update.

So this last weekend was pretty sweet. Great track, tons to do/see, awesome time hanging out with friends and family. This was Hyperfest's first time at VIR and all in all in it went really well. For those who don't know, Hyperfest is a NASA mid-alantic event holding HPDE levels, various races (Spec miata, Honda Challenge, E30/E36) as well as various time trials mixed with USDrift and there Hooliganism on the Patriot course all in one weekend. On top of that there was a 2 hour kart enduro, helicopter rides, rally rides, pro drifter ride alongs, burnout contest, beer garden and a car show, just to name a few things. There really isn't any other grassroots auto event that I know of state side that has the same amount of shear stuff going on.

Before getting to the even coverage I had a couple of loose ends to finish up on the car. First a bleed nipple for the upper rad hose to purge out any air. Worked very well, no leaks.



Also moved to a 180* thermostat. Notice the difference at 195*. The 180* is wide open and the OE and part store brand just started to crack open.



Then Thursday evening Justin came over and we loaded his trailer with the car and tons of tools for the trek to VIR the next day.



I didn't take any photos through the weekend so I'll keep it short and sweet. Friday Mindy and I made it to the track pretty early, around noonish. A couple of old friends of ours, Renzo, Jorge and Chris where on the way as was Justin with the merkur as well as Jeff and Audie with the integra and Stu with his boxster. We scoped out an area for us all to park. At 7 or so everyone had arrived, had a beer, I got tech'd and relaxed. Open track was on full course and we watched a few of the racers start to prep for the weekend races.

Saturday morning was like a typical HPDE, some driver's meeting along with a classroom session and such. Then by 10am it was track time. Each day we got 4 sessions of 25 minutes or so on full course.



Here is Jeff in his k20 integra following me around VIR for a bit. Every now and then you'll see a flame at a shift.
https://www.youtube.com/watch?v=EYciZbY0Pzc

Saturday evening I caught a ride with Pat, who was participating in the USDrift sector of Hyperfest, and it was epic! Before we headed to the 2 hour Karting Enduro with Mindy, Justin, Pat and I. We placed 9th of 12 teams.





Sunday was more of the same just a little less hecktic. USDrift was winding down and the crowd started to thin as the afternoon progressed. Jeff and Audie headed out a bit early due to some power steering issues with the integra. Justin, Mindy and I got out a bit after the last session.



Sunday's last run, at the end I got to play with a Cayman, other than that, clear track as you will see. I did better the cars personal best at a 2:25.9 on Saturday's 2nd session out. However with the mechanical issues I couldn't improve on that late Saturday or Sunday.
https://www.youtube.com/watch?v=MuHuolpmuBg

Currently car is under going the knife again, It felt noticable weaker through the weekend and I quickly found out that the gasket between the turbo and manifold had blown out, letting all some exhaust gas escape past the turbo. More on that later as a new turbo is being built along with what I hope a fresh bottom end. Car needs more than 160whp around VIR...
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-Paul
1990 k20 swapped Gti (3rd motor)
1985 merkur xr4ti (4th motor)
1989 6.0 lsx swapped k2500 (2nd motor)
2000 honda insight (1st motor... yay)
catapultkid
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« Reply #162 on: June 15, 2015, 06:47:36 AM »

Well it has been a month or so. Here is the latest series of events to bring this up to date.

Cliff notes: Made a CF hood.







Added studs and copper nuts everywhere:





Had an issue at VIR with the intake on number 3 cylinder. The cam lobe had a gouge in it. It also cracked the upper portion of the lifter like something had gotten between the rocker and cam. Then in compressed the lifter and smacked the valve down all the way.





So I shimmed the lifters up a bit and it ran fine, just made a lot of noise.





Had an autocross



Then took it to CMP for a track day where it didn't stop giving me motor issues. Overheating by getting air in the cooling system, turbo studs backing out all the time. Eventually the wastegate failed, it over boosted and pop! no more merkur motor. Coasted into the pits and loaded it on the trailer.








Now I'm a cross roads on what to do. I'm not sure if I'm going to finally put that 50 trim on it that I've horded with a rebuilt 2.3, I have a volvo head sitting here as well. Or say screw the turbo stuff and go V8.

For now the project will be on hold until I can get myself in a position where I can do some work in a direction that I'm certain on.

-Paul
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-Paul
1990 k20 swapped Gti (3rd motor)
1985 merkur xr4ti (4th motor)
1989 6.0 lsx swapped k2500 (2nd motor)
2000 honda insight (1st motor... yay)
MikeDe
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« Reply #163 on: June 15, 2015, 06:14:26 PM »

As long as it will live again, I can sleep at night. FMC tried to kill it in 1989 and yall loved her and gave her another life as a race car....I loved these quirky cars when I was a kid..... The XR4tI and the Mercury Capri....But then again there aren't many cars I don't love.....
« Last Edit: June 16, 2015, 03:42:05 AM by MikeDe » Logged

2008 TBSS "BEAST" / 1990 Civic SI "Fireball" / 1957 Chevy "Melissa" / 2016 "Hottesy"
(And 38 others that I have owned and loved over the years)
catapultkid
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« Reply #164 on: March 06, 2016, 10:35:35 AM »

Update:

Its been awhile and the car has gone through some small changes over the winter.

Where we left off last July was a blown motor. After that I threw together the 6.0 truck swap, did some house work and drove a combination of Jeff's civic, Gunny's vette and James si. It was really nice to have folks in the club that trusted me enough to drive there cars. THANKS AGAIN GUYS!!!

Some time in december I finally had a bit of time to turn back to the merkur. I drove to PA with Mindy and picked up a "0 mile freshly rebuilt motor" from some guy that needed money. Got it back to Goochland and a few months later with Jeff's help one night made the swap. Long story short the motor made NO OIL PRESSURE. I was a little pissed and took the next 2 months trying to figure out why. Finally I just pulled the again in February and this is what I found. I don't know how to resize the photos.

Installed the first time



Intercooler set-up. Made new piping and end tanks to the intercooler. It was a tight fit.



Removing the 2nd time



Brand new bearings already worn


Bearing clearances.... ~3/32"... support to be .0008" - .0026". No wonder it didn't have oil pressure.



Then I found out the bearing caps weren't from the same motor. There all of the tolerances where screwed up.



Here is a list of things I found where wrong.

Crank was cut .030 under
Miss matched bearings sets used (aftermarket and ford of all different sizes)
Crankshaft wasn't from a 2.3 turbo motor
Rear main cap from another motor

Free motor from Don Haulsee. Thanks DON!



Cleaning with engine degreaser and carb cleaner



Cleaned up



Cleaning pistons



Painted with engine paint


Till next time.

« Last Edit: March 06, 2016, 10:37:23 AM by catapultkid » Logged

-Paul
1990 k20 swapped Gti (3rd motor)
1985 merkur xr4ti (4th motor)
1989 6.0 lsx swapped k2500 (2nd motor)
2000 honda insight (1st motor... yay)
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