Brought in for a bottom end refresh with new bearings, crankshaft polish and mapping this conversion has a 3″ full exhaust, CSRacing full height front mounted intecooler, forged pistons, steel rods, external swirl pot and high pressure fuel pump set up and a Garrett GT3076R and TiAL external wastegate and hit 500bhp after mapping and rolling road set up. The Revolution Millennium wheels with Nankang NS-2R tyres finish the car off, and the power makes the K Sport 330mm 8 pot calipers work hard backed up by suspension from Weitec by KW and a full roll cage further stiffens the chasssis.
It now boasts Methanol injection and has been mapped to 540bhp and was the Class B winning car at Thunder Road 2015.
Another Astra H VXR in for mapping that has had a Garrett installation fitted to it. V Band Cast Manifold, Garrett GT2871HTA Motorsport Spec Turbocharger with metal bearing cage, Tial External Wastegate, AEM Dryflow Filter, 90mm AFM, 630cc Injectors, Aeromotive Fuel Pump, 80mm Inlet Pipe, 3″ Courtenay Klasen Downpipe, 3″ Courtenay Piper Exhaust System and CSRacing Full Height Front Mounted Intercooler.
Brought to us for a full conversion, this car now features a VXR engine with LEH forged pistons and ZRP Steel Rods, our V Band Cast Manifold, Garrett GT2871HTA turbo with 4″ inlet pipe, Tial External Wastegate, 3″ Courtenay Klasen Downpipe, 3″ Courtenay Piper Exhaust System, Courtenay Klasen Camshafts, CSRacing Full Height Front Mounted Intercooler, 90mm Air Flow Meter, 90mm AEM Dryflow Cone Filter and Courtenay Enlarged Plenum. Producing around 457bhp and 380 lb ft torque….. Nice.
Another Garrett build, with Garrett GT30 Turbo, V Band Manifold, Courtenay Klasen Cams and Inlet Manifold, Engine rebuild, 90mm AFM, injectors, 3″ exhaust; all the usual requirements for a Garrett conversion, previously mapped by us and making a respectable 490bhp; brought in for checking now its a little cooler. Up 13bhp to 503bhp due to the lower temperatures.
Another big power Z20LEH engine undergoing mapping this week, this time in a Zafira VXR making it a pretty quick 7 seater! Pushing around 430bhp from a Garrett conversion, with 3″ exhaust, Courtenay Klasen Cams, Nortech tubular manifold, Owen Developments GT28 71 HTA turbo, 630cc injectors, steel rods, Pro Alloy alloy water radiator, 356mm K Sport brakes, Quaife LSD. A very respectable figure for a hot summer’s day on the rollers.
Further Development of this car has seen us change the turbo to a Garret GTx3076R along with a custom made 100mm diameter inlet pipe.
Target BHP was something on the right side of 500 BHP. With 99 octane UK pump fuel we saw 525 BHP but this was on the limit of our UK fuel quality; Stephan in Germany had seen well over 550 BHP with this turbo on 102 ocatane pump fuel available to them.
At this point we thought it might be fun to add some methanol to bring the octane value up; a stainless tank was fabricated and installed with an Aquamist pump in the spare wheel well, to sit alongside the already installed swirl pot and Pierburg pump. The spare wheel well has had a number of vents installed and a laser cut acrylic panel made and installed to protect the contents and seal the wheel well off from the car’s interior. With further mapping mostly based around a much more efficient timing curve we saw the power rise to a peak of 568 BHP and finally settled with a comfortable figure of 559 BHP.
Final testing on the road proved very interesting and memorable for Mark R when he found some additional work was needed to stop the meth from puddling in the inlet manifold, which occurred on part throttle when the throttle was being feathered due to wheel spin! Fortunately the functionality and adjustability of the Aquamist ECU made this quite straight forward to achieve.
Engine Spec features numerous Courtenay core products as follows:
Ported Cylinder head
Klasen Inlet Manifold
V Band Cast Manifold
Tial External Wastegate
Custom 3” front pipe mated to a Piper 3” exhaust System
GTx3076R Turbo with Tial Exhaust Housing & 100mm inlet
Courtenay Water Radiator
Paddle Clutch plate
Reworked Sach’s Uprated Clutch Cover
To name but a few items…
Hopefully this should keep the ever power hungry Wayne T content for a while. A thoroughly enjoyable conversion to do cheers Wayne…
Spare Wheel Well with Swirl Pot, Pierburg High Pressure Pump, Aquamist Pump and Methanol Tank
Courtenay Sport Garrett Conversion. The brief was to achieve 420bhp with Garrett GT3071 turbo, tubular manifold, 76mm exhaust, 80mm air flow meter, 630cc injectors and Courtenay Sport Full Height Intercooler. The 80mm Astra VXR is maxxed out at around 420bhp so the achieved figure was the best achievable using the given components.
Astra VXR with V Band Cast Manifold, External Wastegate, Garrett GT3076 Turbo, Courtenay Sport Full Height VXR Intercooler, Courtenay Sport High FLow Inlet Manifold, Full 76mm Exhaust System, 90mm Air Flow Meter, Steel Road, Factory ECU (Bosch 7.6.3 management) bespoke mapped by Courtenay Sport
For this conversion using our new V Band Cast Manifold the brief from our customer was as close to 500bhp as possible but with usable power. We opted for a Garrett GT3076 turbocharger. The car also has our full height VXR intercooler, steel rods, Courtenay Sport High Flow Inlet Manifold and 76mm full exhaust system.
Following the introduction of our V Band Cast Manifold with external wastegate, here is an example of afinished conversions and graph on a VX220 Turbo.
The manifold has been flow tested to 600bhp and the Tial V Band flanges are much more secure and allow for easier turbo fitment.
V Band Cast Manifold fitted to VX220Turbo
V Band Cast Manifold fitted to VX220Turbo
The VX220Turbo with this V Band Garrett Conversion and GT2871 has also had a full engine rebuild and has had a full 3″ exhaust system and chargecooler system fitted, 80mm air flow meter, high flow injectors, uprated map sensor and uprated clutch and flywheel.
The build spec was for up to 400bhp, the final power output was 398bhp.
Courtenay Sport VX220 Turbo with a bespoke Garrett Build, strengthened rebuilt engine, Pro Alloy Chargecooler, full 3 inch exhaust system and full Z20LET engine management mapped by Courtenay Sport….. 360bhp