Possible spec for the proposed 910 engine - hopefully I can swing the forged conrods..
I agree that John's turbo will provide a big chunk of the extra power; so I will focus more on the reliability. The standard induction system is quite restrictive and while a bit of detailed work in the diffuser, plenum and intake manifold makes a big difference there isn't really any point in going for a seriously ported head: I could do you a head that flows 180cfm; but what's the point if the induction system will cap the flow at 150cfm?
I would therefore propose a head with just +1mm inlets - like the S300, a bit of tidying up on the short side of the port and some matching of the inlet manifold. I'd rather save the money and use it towards a crank or dry sump.
Regarding transaxles; the V8 version or the GT3 one are the strongest - they had a different material specification for the gears to the Renault versions. I suspect that 500hp will standard transmission quite quickly. The Derek Bell conversion seems to me a rfeasonable upgrade at sensibe money. I have however just read an article about "isotropic superfinishing" ; it is a new finishing / stress-relief process that is heavily used in high end motor sport and military applications (helicopter gears); it is not expensive and it apparently works wonders on gear sets ; extending lifespan massively; it's not particularly expensive; if you were to rebuild a stock transmission, put in a quaiffe LSD and superfinish the gears; it may well solve the problem at reasonable cost.
I think I would build you an engine from scratch; the other engine would need too much stripping down; I may as well start again. In terms of tuning it would be similar to the one advertised; but I would include some additional items:
ARP heads studs,
Iron liners or closed deck block,
10 dowelled mains
10 dowelled head gasket joint,
Extrude hone your exhaust manifold,
high quality balance of reciprocating components
I'd like to include steel rods, steel crank and dry sump; but that collectively will run to around ?3500; so we can't have them all. I suspect that the rods will have to go and possibly the dry sump.
I would therefore modify an S4 sump and a set of standard rods - I can lighten the rods a little and polish and shot peen them. The sump I can add extra baffles; maybe a windage tray and do some extra work to the oil system.
Garry
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