||Courtenay Sport Latest News and Information
Astra VXR Intercooler Revision
29 Mar 2011, 15:28
|We have recently revised our Astra and Zafria VXR intercooler pipework, after requests from customers, to improve upon an already excellent design. From its existing design, the complete kit has been tested and proven to in excess of 420bhp (the intercooler core is good for 600bhp) with the intercooler utilising 60mm pipework from the turbo (the moment we can step it up from the OE 50mm turbo outlet we do) to the intercooler 60mm inlet. The intercooler outlet was 50mm, and stepped up to 60mm by the start of the OE map sensor pipe which we made use of in our original kit.
The revised intercooler now has 60mm pipework throughout. The turbo outlet to intercooler remains unchanged. We have now modified the end tank to the righ hand side of the intercooler to fit a 60mm intercooler outlet. This is then linked to a 60mm hard alloy pipe under the slam panel and stays at 60mm right up to the end of the map sensor pipe, so we now discard the OE plastic map sensor pipe and include a hard alloy pipe from the intercooler outlet to the end of the map sensor pipe where the plenum hose joins and incorporate our hard alloy map sensor pipe into our revised intercooler kit.
This has cut down on the silicone hoses on the outlet side, instead using a 60mm hard alloy pipe with map sensor boss.
We now have not only one of (if not the) biggest front mounted intercooler for Astra VXR , but it now features 60mm pipework throughout and incorpoartes our alloy map sensor pipe.
The intercooler kit can be supplied with a polished alloy outlet pipe and intercooler, or it is available in stealth black (powder coated) finish of both intercooler and alloy pipework.
As an option the high flow plenum and enlarged hose (again to 60mm) can also be supplied.
Existing customers are able to have their current set up upgraded to the new set up if rerquired. Please contact us.
Production Touring Cars Silverstone
28 Mar 2011, 11:14
Production Touring Car Trophy - Silverstone.
Saturday 26th March marked the start of the new Production Touring Car Trophy with the opening rounds at Silverstone Circuit, using the new full GP circuit.
After some positive pre-season testing the field was assembled for qualification, with Adrian's car now wearing Number 1. New 2011 rules have allowed for changed to be made to suspension bushes (if required) along with the introduction of slick tyres to improve grip still further over the previous Direzza tyres.
With qualification under way, the full GP circuit is a long long lap, however the top 6 cars all put their fastest qualifying times in on lap 3; the pole time was 2:24.290 set by car number 1 some 2.66 seconds ahead of Carnaby's Astra VXR, Cook's Megane was 3rd, Bensley's Astra VXR 4th and Gary Duckman's Seat completed the top 5.
An eventful start saw the pole sitter in 4th place by Copse corner at the end of the start finish straight (it later transpired that the inability to find second gear off the startline was the cause of the poor start). Never the less Adrian started to make his way through the field and was in second place by the start of lap 2.
Starting lap 3, there had been a change in order with Bensley moving into the lead and Churchill close behind in 2nd place, the previous leader Cook now down to 3rd, however it was all change by the end of the lap as Churchill had taken Bensley for the lead.
Stamping his authority on the rest of the field Churchill contined to press on and crossed the line to take the race win over the second place Astra VXR of Carnaby who had passed Bensley's Atsra VXR on lap 9, with Bensley completing the podium. Cook's Megane was 4th and Gary Duckman completed the top 5. Fastest lap went to Churchill on lap 3.
Race 2 was again another eventful start for Churchill. Again being unable to find 2nd the pole sitter went from 1st to 5th by the first corner recovering to 4th by the end of lap 1. A further 2 places were made up by the end of lap 2 but by the end of lap 4 gearbox issues were starting to affect Churchill's Astra VXR and the lack of 4th gear had caused him to slip to 3rd.
The ailing gearbox wasn't getting any better as 5th become first intermittent and then eventually non existant, the best that could be managed was 7th place, with the fasest lap going to Churchill on lap 4, despite full sucess ballast of 45kgs from the win in race 1.
Up at the pointy end Cook's Megane took the race win, Gary Duckman's Seat took 2nd and 3rd went to Dan Malone in his Seat Leon Cupra. The Astra VXR's of Girling and Bensley made up 4th and 5th respectively. Carnaby's Astra VXR had a non finish due to a driveshaft failure.
Courtenay Sport Blog
23 Feb 2011, 17:29
Courtenay Sport have launched a blog, to run alongside our existing website, to keep everyone up to date with day to day goings on that don't form part of our everyday website products and development.
Our new blog can be found here Courtenay Sport Blog.
Vectra VXR Development
28 Jan 2011, 16:05
Vectra Stage 2/3 Insignia VXR Turbo Upgrade
Our goal with this upgrade was to improve the power spread across the rev range and remove the almost “diesel” like power band & delivery found in the existing stage 1 remaps, which is a direct result of the standard Vectra VXR turbo not being able to deliver sufficient boost, of any real value in the last third of the rev range.
The development car used was already at stage 1 and equipped with our uprated water radiator, FM Intercooler and a 3” front pipe, in preparation for the upgrade.
A Vectra VXR (whether standard or Stage 1) without these additional upgrades, as listed above, would still see a good power increase, with the Insignia’s Turbo, but the top end power would drop away due to flow restrictions through the exhaust and lack of inlet air cooling. We would still, however, recommend changing the water radiator, which can be an issue even for stage 1 cars when driven enthusiastically.
Installing the Insignia Turbo is a fairly easy job, but requires patience to ensure that all components required to facilitate an easy installation are removed and car is taken to prevent any damage to both the new and existing components.
Having installed the Turbo and started the car, we performed an initial run to review the results, running on the Stage 1 map. We found that the standard injectors were running out of duty cycle at circa 330 -335 bhp causing the mixture to become lean (as you will appreciate a weak mixture can cause some very serious damage and very quickly). If we were to continue on the development path, with standard injectors, the top end boost would have to be reduced for the injectors to stay within their threshold. As a result we would be back to the diesel like torque derived power curve, which was not our goal. Therefore we changed the injectors for the higher flowing Insignia VXR ones. This enabled us to hold the boost at the top end to produce a power curve that sustained good high RPM power levels (as can be seen from the graphs).
It should be noted, even though we experimented with several different types of induction pipe work, the final results, were achieved using the standard induction pipes. Even opening up the air-box and changing the pipe work to 70mm all the way from the MAF to the turbo had no effect on the peak or through rev range power band. The only noticeable increase was turbo induction noise (which actually was quiet nice, but very subtle).
This turbo will produce massive torque figures. We saw 465 lbs ft (640nm) without really trying. However, common sense was telling us that with 2 wheel drive and the fact that the standard car can struggle at 400lbs ft this figure (465 lbs ft), whilst great for pub talk, would render the first 3 gears redundant. Also it would only serve to destroy the clutch and transmission in the remaining gears. As yet we are in 2 minds as to whether 430lbsft is still too much. However a little more time behind the wheel and the owner’s feedback will assist us in making a final decision.
Looking at the graph below you can see that the big increase’s come from 4500 rpm, at which point the engine is producing an additional 40BHP, whilst at 5000 rpm there is producing an additional 52 bhp, and at 6500 rpm the engine is producing an impressive additional 62 bhp over the stage 1 remap. All this lends itself to a far more linear and sustained power delivery, feeling more like a traditional petrol engine.
Vectra VXR Tuning Packages
|All our Vectra VXR remapping is carried out serially, through OBD II/diagnostic port directly into the vehicle's ecu.
All our maps are bespoke written for us to suit our requirements. If your car does not fit into the categories listed, for example you have a different exhaust configuration, we can and will write a bespoke map and tailor it to your vehicle.
|Courtenay Sport Stage One
We carry out a full engine diagnostic test first, we check and gap the spark plugs, then Exclusive Courtenay Sport software is installed raising the boost levels, whilst optimising the fuel and timing curves. A Rolling Road calibration, set up and testing session follows. Power and Torque Graph Print Outs.
|+100 bhp mid range gain
Peak Power Increase to 295-300bhp
Torque: 400+ lb ft (540+ Nm)
140+ lb ft gain
|£590 Fitted including Rolling Road Set Up
||With our stage one ecu remap we can take the 255 and 280 bhp cars up to a peak of about 295 - 300 bhp (temperature and enviromental conditions dependent) which equates to a 40+ bhp gain on early cars and 15+ on later models but don't think that's all this is about or that our remap is not worth a second look. Whilst the peak gains are not that impressive it is not all about out and out peak power gains.............
Our stage one remap gives a massive hike of about +100 bhp in the mid range at 3,700 rpm and a gain of around +140 lb ft torque which completely transforms this car's on road ability. Mid range performance is simply breath taking!
Power Graph for Stage One
||Power graph for a Vectra 255 with our Stage One Remap. Click to enlarge.
Peak Power: 297.57 bhp.
Maximum Torque: 403.56 lb ft.
Cell Temperature: 19 degrees.
|Courtenay Sport Stage Two
We carry out a full engine diagnostic test first, then we fit a brand new Insignia VXR turbo assembly, change the oil anf filteer, check and gap the spark plugs and finally Exclusive Courtenay Sport software is installed raising the boost levels, whilst optimising the fuel and timing curves. A Rolling Road calibration, set up and testing session follows. Power and Torque Graph Print Outs.
|Peak Power Increase to 315-320bhp
||£1745 Fitted including Rolling Road Set Up
|Courtenay Sport Stage Two+
We carry out a full engine diagnostic test first then we fit a brand new Insignia VXR turbo assembly along with our extra large water radiator, check and gap the spark plugs and finally Exclusive Courtenay Sport software is installed raising the boost levels, whilst optimising the fuel and timing curves. A Rolling Road calibration, set up and testing session follows. Power and Torque Graph Print Outs.
|Peak Power Increase to 320-325bhp
||£2562 Fitted including Rolling Road Set Up
|Courtenay Sport Stage Three
We carry out a full engine diagnostic test first then we fit a brand new Insignia VXR turbo assembly along with our extra large water radiator and intercooler assembly, fit a 3” Front pipe, 3” down pipe with Sports Cat, Uprated injectors, check and gap the spark plugs and finally Exclusive Courtenay Sport software is installed raising the boost levels, whilst optimising the fuel and timing curves. A Rolling Road calibration, set up and testing session follows. Power and Torque Graph Print Outs.
Peak Power Increase up to 340bhp
Torque: 430 lb ft (580+ Nm)
|£4470 Fitted including Rolling Road Set Up
|Insignia VXR Turbo Supplied and Fitted, includes parts, labour and oil & filter change - £1155.00
High Flow Panel Filter and Iridium Spark Plugs
With any upgrade, we also suggest the addition of a High Flow re-useable K&N Panel Filter £45.95
Iridium Spark Plugs are also available (if not already fitted) at £60.00 set of six.
Fitting FREE OF CHARGE as part of a Stage upgrade.
The use of Shell V-Power 99 RON, or a similar Super Unleaded fuel, is a requirement on all remapped vehicles.
Dubai 24 Hour Race
18 Jan 2011, 14:56
|Ryan McLeod and his team from Racer Industries in Australia have just successfully completed the Dubai 24 hour endurance race in their modified Astra VXR, which was competing against a field of some considerable machinery.
The Astra 2.0 Turbo featured a number of Courtenay Sport components including our cast exhaust manifold, our VXRacing full height Intercooler, high flow plenum, lightweight LEH flywheel, race paddle clutch, brake cooling ducts and Courtenay Sport high flow panel filter.
The car was fully race prepared and fitted with a Garrett turbocharger, which with Motec management was mapped to 380bhp running a maximum of 1.2 bar of boost revving to 7k rpm, the aircon was deleted, and the sump was spaced to allow for additional oil capacity.
Ryan and the other 3 drivers Camilleri, Holdsworth and Nicholas took car number 67 to a 4th in class finish (in class A3T) and an excellent 26th overall out of 84 cars.
Congratulations to Ryan, the drivers and the whole back up team who kept the car racing for the entire 24 hour period. A fantastic result.
Links: www.24hdubai.com - - - www.racerindustries.com
|Images courtesy of Creventic and Racer Industries
Specifications - Engine, Gearbox and Exhaust
Z20LER engine, Forged Pistons, H-Beam Rods, Standard Cylinder Head, Balancer Shaft Deletion, Courtenay Sport LEH/M32 Lightweight Flywheel and 4 Paddle 'Race' Clutch, Courtenay Sport Cast Exhaust Manifold for Garrett Turbo, Disco Potato Turbo, Custom Exhaust Services twin Dump Pipe, 3" Stainless System, Courtenay Sport VXR Intercooler Kit, PWR Alloy Radiator, CDTi Air Box Conversion, M32 Stock Gearbox, Drexler LSD.
MCA Front Struts, Bilstein Rear Dampers, Kings Springs, Whiteline Rear Sway Bar
Motec M800 ECU, Complete Custom Wiring Harness (no stock wiring), Motec SDL3 dash Logger, Motec ACL Logger, Motec PDM Power Management System, Motec Shift Light Module, System controls Factory ABS and Power Steering, Custom High Energy Ignition system
Brembo Mono Block 4 piston front caliper, 330 x 32 Brembo Motorsport discs, Rear brake up grade from stock VE S" commodore,
Interior and Safety
60 lt ancillary Fuel Cell with Twin pump/ reserve system, Body Tech crO Mo FIA cage, Racetech Carbon FIA Seat, Schroth Enduro Belts, Lifeline Z360 Fire system
Wheels and Tyres
18 x 8 TD Pro Race II wheels, Dunlop 235 / 40 18 tyres
Extensive weight reduction - 1140kg dry
2011 Race Drive Available
11 Jan 2011, 19:12
Drive available for 2011 with Championship Winning Team.
Following a Dunlop Sport Maxx Championship winning season with Adrian Churchill and his Astra VXR, Courtenay Sport with Churchill Motors will be running a second fully prepared and supported Astra VXR to compete in the 2011 Dunlop Production Touring Car Trophy.
For more information please contact:
Jon Shield - Courtenay Sport - 01692 404313
Adrian Churchill - Churchill Motors - 01908 542087