24 replies to this topic

[stickle]

Have had a Courtenay Stage 3 for a couple of years and thought it would be good to get a bit more “pep” now Although there is some final work and mapping still to do to get the most out of it, I thought you would like to here where we are so far: In short: 280BHP (but with more to come, see below) Over 300 lbs torque across wide rev range peaking at 349 lbs in the mid range! To go into more detail, here is a list of what work was done, over and above the CS3, Nitrons, Mintex etc already fitted: Forged steel con rods Low pressure forged pistons Under piston oil spray jet cooling Lightened flywheel Polished head Removed counter balance shaft New Modified VXR Astra Turbo VXR injectors Probably something else I have forgotten! We still have the original Courtenay Charge Cooler fitted which was only ever designed for 280 BHP (ish) and so need to get fitted the new larger CC fitted as the air intake is peaking at about 4000rpm and strangling the last 20-30 BHP. This was something Jon thought may need to be uprated but we need to do this work in chunks! So how does it drive? The CS3 was already superb, but even unfinished as it is the CS5 is simply mind blowing! As desired, driveability on the road has been retained and the turbo spools up really quickly with very little lag. In fact, I may ask Jon to make it a little more progressive as on track it may be hard to balance. So we still need another trip to Courtenay’s for final mapping and need to decide when to fit the bigger CC. Have also have added the Speedline Magnesium Alloys and Yoko A048’s from Plans, but that’s another story…..!

[super fandango]

Sounds fun.. It's possibly my next mod after the CS2 when the car runs out of warranty in Sept. With regards to the conrods, pistons, polished head etc, I believe these aren't part of the standard CS5 package so do you believe it's a pre-requisite when tuning to these kind of levels? Cheers Matt

[Mr_M]

Respect

[dw1]

Nutter I live in Surrey, so might see you one day as you screeeam past my Stage 2 VXT in blink. And please tell us the other story...

[stickle]

With regards to the conrods, pistons, polished head etc, I believe these aren't part of the standard CS5 package so do you believe it's a pre-requisite when tuning to these kind of levels?

Cheers

Matt

Looking at Courtenay's website they do not list the Stage 5 yet! I could have jumped the gun as it looks like I have a stage 4, plus the flywheel & Clutch option, PLUS all the internal engine works.....so perhaps that makes it a Stage 4.75 or something!

The engine internals are not ESSENTIAL with this turbo & map, but with 50% more power over standard I wanted to make sure the engine was as safe as possible. I guess Courtenays will need to do a few more Stage 4's before we know if the internals have actually increased power and/or driveability.

[M3 BFG]

Hi, I have a CS 4 also with early CC set up, light flywheel/clutch which made 291bhp/316lb ft. Courtenay applied the "low torque" map, so it looks like you must have the "not so low torque" map Do you think the stage 4 map is a little smoother than the stage 3 map, particularly coming off boost and on part throttle? I have had no trouble with this car on road with the early CC, having done 4K standard, @8K on stage 3 and 4K on stage 4 Looking forward to hearing more about the Courtenay stage 5...................

Edited by M3 BFG, 24 May 2007 - 07:52 AM.

[Guy182]

CS5 sounds mad im just fitting the new proalloy/courtenay chargecooler at the minute and then i'll be back at courtenays for a CS4 remap.

[speedster]

Cool! An NA turbot! Nice torque Any mods to shift engine bay heat?

[stickle]

Hi, I have a CS 4 also with early CC set up, light flywheel/clutch which made 291bhp/316lb ft. Courtenay applied the "low torque" map, so it looks like you must have the "not so low torque" map

Do you think the stage 4 map is a little smoother than the stage 3 map, particularly coming off boost and on part throttle?

Hi M3, Yeah, the torque is amazing....I think they can squeeze a few more BHP out through final timing/mapping etc but the CC is ultimately a big limiting factor due to high intake temps.

The map I have feels much smoother throughout the rev range, but is harder to balance on part throttle. As mentioned though, this is only the first "default map" applied so has not been fully Courtenay'd!

[stickle]

Cool! An NA turbot! Nice torque Any mods to shift engine bay heat?

None yet but am considering some fat pipes cut into the engine bay, through the boot and venting out the back. Do not want to lose the boot completely. Also thought about the raised engine cover....looks cool too.

CS5 sounds mad

IT IS

[Winstar]

Cool! An NA turbot! Nice torque Any mods to shift engine bay heat?

IIRC the courtneay CC system removes the standard IC thus allowing the airflow from the drivers side ear into the engine bay which should aid cooling considerably.

[stickle]

Just had confirmed that it is DEFINATELY a Stage 5 It uses the brand new K04 Race turbo which starts life as an Astra VXR turbo, half is thrown away, is enlarged, 6mm bigger impellers fitted, new bearings etc. Peak boost is 22psi holding at just under 20psi! This explains the massive torque figure and shows why I need the latest CC to release the remaining BHP. Apprarantly this is 1 of only 3 made so far

Edited by stickle, 24 May 2007 - 01:09 PM.

[vxr36]

Congratualtions! I have been waiting for my TMS stage 5 to be finished since January. At the moment all I have is empty pockets from the engine mods but there is no firm visibility about when the turbo and manifold will ready. Very jealous.

Edited by vxr36, 24 May 2007 - 12:25 PM.

[Thorney]

Sounds great, mind you just delivered a VXR220 with a 'humble' stage 4 and that ran 308llbs of torque Our stage 5 (yes I know its taking a while for the turbo to arrive Andrew, sorry) runs over 440llbs

[MAP18W]

Just had confirmed that it is DEFINATELY a Stage 5 It uses the brand new K04 Race turbo which starts life as an Astra VXR turbo, half is thrown away, is enlarged, 6mm bigger impellers fitted, new bearings etc. Peak boost is 22psi holding at just under 20psi!

This explains the massive torque figure and shows why I need the latest CC to release the remaining BHP. Apprarantly this is 1 of only 3 made so far

You are indeed correct the essential full engine rebuild forms the basis of the Stage 5 (high yield forged pistons with teflon coated skirts, steel rods, arp rod bolts, new shells, water pump, oil pump, lightened and balanced bottom end incl lightweight flywheel and clutch, deletion of balancer shafts etc etc) and then you have the K04 Race turbo with different internals which is very limited in numbers at the moment! I did think the other night when I drove it is was quite quick!!

However if anyone really want bundles and bundles of torque and power beyond all rational means you could always try our manifold and GT28R........ If you really enjoy going sideways!!!!!!!

Like this one we're fitting.....

Edited by MAP18W, 24 May 2007 - 02:56 PM.

[paulf-cam]

Our stage 5 (yes I know its taking a while for the turbo to arrive Andrew, sorry) runs over 440llbs

Thats lbft right, not Nm?

Edited by paulf-cam, 24 May 2007 - 02:36 PM.

[Thorney]

Yep, we're limited on bhp in the race cseries so we developed it for torque....its a bit silly

[stickle]

Let's not get into the mine is bigger than yours thing, not before it is finished anyway!

Sounds great, mind you just delivered a VXR220 with a 'humble' stage 4 and that ran 308llbs of torque

M3's 'humble' stage 4 from Courtenay is 316 lbs ft

Mine currently peaks at 347 lbs ft right at mid range, and sustains over 300lbs across a wide rev range. Will post graphs but don't see the point before I have uprated the CC.

Our stage 5 (yes I know its taking a while for the turbo to arrive Andrew, sorry) runs over 440llbs

The one they are bringing out (when it is finished) pumps out a squillion lbs No seriously though, we had the option of strapping a bigger Turbo on for even more grunt but wanted to stick with modified original equipment as much as possible

[Code Monkey]

engine mods sound amazing, not sure would enjoy being a passenger think would almost hurt if not ready for the acceleration. But with reference to this thread, felt like had accidently logged onto a gay site with all the willy waving, mine is bigger, no look i have an extra 8 on you, yes but mine is thicker in the middle. FFS! Just the proven available yes you can have it now, information on it all please.

[AndyVXT]

Hmm, So when are we going to get a dyno shootout with a cross section of these different cars? Appears there are some mad cars out there since the last one was done. Claimed figures are just that until they can be stacked up side by side. Actually some in-gear measurements through a v-box or similar would also be interesting.