Probably the most exotic "tuner" build you have ever seen, or will see.

[bennyfizzle]

Highest HP 4g63 engine (from 2007) - EvolutionM - Mitsubishi Lancer and...

@Ted B (bimmerforums)

Every now and then I come across something truly impressive. This represents some of the work of Extreme Tuners in Athens, Greece, and the name is no joke. Pushing limits requires funds and skill, and these guys have both. All they do is build and tune engines. The entire lengthy discussion can be found here (http://forums.evolutionm.net/evo-dyno-tuning-results/447351-highest-hp-4g63-engine-2007-a.html), but unless you feel like reading quite a few pages of posts, I’ll post the highlights here.

FWIW, this is some of what they’ve done:

2006 - N/A ford cosworth 4cylinder 16v engine 119cui: 416hp -11,900rpms
2007 - Ford cosworth 4cylinder 16v Turbo engine 120cui: 1280hp 47psi (custom triple ball bearing 80mm turbo 119lbs/min)
2007 – Mitsubishi Evo 8 4g63 4cylinder 16v Turbo engine: 1416hp – 57psi (custom quad ball bearing 82mm turbo 132lbs/min)

So, getting 700whp/L from 2.0L @ 8500rpm is no small feat, but what do you need if you get bored and want to shoot for 2000whp?

Cast Garrett compressor wheels (right) tend to come apart above 50 psi. CNC billet aluminum wheels (middle) are stronger, but why not be different and use your own CNC billet titanium (left) compressor?

You’ll need a turbo big enough for the job, which in this case is a 108mm twinscroll T4 turbo, with custom quad ball bearing CHRA and 100psi capability.

To get enough airflow at 12,000rpm(!) to get the job done, you’ll need a skillfully ported head, complete with titanium valves and copper-beryllium valve seats:

And you’re going to need a set of camshafts to handle the rpm and withstand tremendous ramp pressures, so why not a set of hollow titanium billets with DLC at only 234 grams each?

And since there is no aftermarket rod up to the task, just ask for a set of billet mmcs-titanium connecting rods at 286g each. Rod/Stroke ratio is 2.07:

For pistons, a set of custom beryllium pistons with DLC fits the bill, and since methanol is the fuel, 13:1 SCR is fine:

A strong piston pin is needed as well:

Toss in a custom titanium billet crank:

A set of 9000cc/min injectors:

And since a factory 4G63 block probably wouldn’t hold up, just CNC machine your own from billet aluminum:

No head gasket is used:

And to put all that power to the gearbox, one needs a suitable multiplate clutch:

Yes, it is smaller than a cam gear:

An example of very efficient turbo manifold design from one of their recent projects:

And last but not least, a dynosheet from this car, running ‘only’ 48psi and hydraulic cams:

[91teg]

Wow

[bennyfizzle]

More:

@Ted B (bimmerforums)

If you look at the dyno chart, it crosses the 200whp mark around 4650rpm, which is actually pretty quick spooling for what it is. It makes so much power that the lines look vertical, but they wanted to make it ‘quick spooling’, so they did a good job.

Straight methanol stoichiometry is 6.4:1 as opposed to 14.7:1 for gasoline, so a very high volume, high pressure fuel system is needed. And since 130 octane methanol doesn’t ‘knock’, tuning in those netherworld regions is tricky.

Since some of you are wondering what this costs, I know the Ti rods are around $3250 each, and the Ti crank is around $31,000. They are now working on a CNC billet cylinder head and carbon fiber turbine housings. These guys have good connections with F1 parts fabricators.

If you want a turbo, they’ll build whatever you want, and their quad BB center sections are damn strong. GM’s 1400whp Ecotec project used one of their 80mm turbos:

If you can dream up a turbo, they can build it:

They also use straight metal matrix composite (mmc) rods, which are lighter than Ti. The problem is cost and life (120 hours). These use no rod bearing.

Not often that one sees 13:1 compression ratio beryllium pistons, much less in a turbo engine:

Ti valves and CuBe seats sure are pretty:

Some other cars laying around the shop:

1360whp 2.0L Escort Cosworth

1070whp Subaru on its way to 1500+whp:

Anyway, it just takes desire, skill, money, and maybe a kidney.

[ninety1two40]

Not to shabby

[bennyfizzle]

some vids:

@Ted B (bimmerforums)

These guys don’t have the hardcore drag scene like we have in the U.S., so they’re more constructors than racers, but they have a few videos of testing runs.

Here’s the 1200hp Escort Cosworth in the shop:
http://www.youtube.com/watch?v=TEz2Sg8Z8n8&feature=player_profilepage

And the 1200hp Escort Cosworth on the street (in Greece):
http://www.youtube.com/watch?v=Xkhgw_Ov1z4&feature=player_profilepage

The 1500hp EVO in the shop with flaming methanol:
http://www.youtube.com/watch?v=qDauSA9-FYM&feature=player_profilepage

The EVO making a ‘low boost’ (35psi) shakedown pass:
http://www.youtube.com/watch?v=9FAeElKK6Bs&feature=player_profilepage

The Subaru making a shakedown pass. It runs 8 sec ETs and makes 1070whp with only 31psi:
http://www.youtube.com/watch?v=N_2UeiIcRBg&feature=player_profilepage

[psi2high]

I read the whole thread over on evom and the work they produce is simply amazing

[KrazyKid]

weak sauce.

[GermanPSI]

Wow just wow

[ScreaminRedZ]

How do you think it handles traffic jams?

JK, that thing is nuts!

[imported_ST4TUS]

wowww

[DeathbyRT]

That is fucking insane.

[indy440]

so they must use a pressed crank with those metal matrix composite rods?

[deadbeatrec]

ive talked amongust other engineers/car enthusiasts about billet blocks but thats the first one ive actually seen. the amount of win is not measureable.

[Yetti_VR]

I just came… A LOT

[Vovchandr]

I think dividing by 0 is less impressive. :wow

[Eatonualive]

did anybody catch the fact that there is no head gasket? That’s pretty awesome. you need 2 perfectly flat surfaces for that, and its actually stronger of a seal that a headgasket. thats how we seal the turbine shells at work, if we have another machinist in here, im sure they will realize how retarded these parts are. as impressive as the power is, i think the parts and overall set up is even more insane. not to mention the cost of a tuning or assembly mistake. WOW

[ScreaminRedZ]

@Eatonualive281

did anybody catch the fact that there is no head gasket? That’s pretty awesome.

I saw that! Definitely the first time I’ve even heard of that, nevermind seeing it being done.

[psi2high]

Yea these parts are simply amazing. Such sick craftsmanship

[SRS_BZNS]

I wonder what it feels like driving to go from 300 to 1300 hp in aproximately 700 rpms?

[LKSi]

Incredible engineering… the rods and machining on the head/block are absurd