motoring|underground  
Register FAQ Members List Calendar Search Today's Posts Mark Forums Read Blog

The Garage The place to show off your pride and joy. Show us your motoring masterpiece herein!

Go Back   motoring|underground > The Pits > The Garage
Reply
 
Thread Tools
  #106  
Old 06-05-2018, 07:00 AM
Tit's Avatar
Tit Tit is offline
μ
 
Join Date: Sep 2006
Location: Australia
Posts: 1,915
Default

Neat!
__________________

Click the image to open in full size.
Tit + Bec = '09 AB JCW // '90 964 C2 // '15 R60 CCS // Australia
Reply With Quote
  #107  
Old 06-10-2018, 04:59 AM
BlwnAway's Avatar
BlwnAway BlwnAway is offline
Y Rated - 186 mph
 
Join Date: Sep 2006
Location: St.Louis, Mo.
Posts: 1,979
Default

As a supplemental update to last weekend.
Vacuum system is now working perfectly. Ends up that with the turbo you want to either alleviate the crankcase/PCV from the system or add a vacuum pump.
Since our engines are just fine with this turbo configuration and a simple crankcase vented to atmosphere, that was the fix.

With the crankcase in the mix I was getting 1-2 psi vacuum at idle, now without, 11-12 psi.

So configuration is as follows, fuel regulator only to the factory port.
The port I added connects to the vacuum manifold with MAP sensor, Brake servo, Boost/Vacuum gauge and BOV all attached to it.

First test drive was a great success, the car runs perfectly normal and everything functions exactly as it should, both in traffic, stop light to stop light and open hwy. For normal driving, except for a code related to the change, you'd never know I did anything to the car at all.

Only issue to be addressed is heat control related, I need to add a little more of the DEI Form-A-Sheild to the cowl and bonnet.
And for anyone interested, that stuff works stellar, while the metallic side gets just as hot as you'd expect, I can actually touch the back side of the piece that rests almost right against the downpipe and it's only warm to the touch.

Hopefully I'll have time Sun to work on that and some of the other items, but tuning should commence shortly, either way.
__________________
I'll get another 3rd party hosting site eventually...

Just hope the old one dies a fiery death.
But I'm not bitter....
Reply With Quote
  #108  
Old 06-13-2018, 10:15 AM
BlwnAway's Avatar
BlwnAway BlwnAway is offline
Y Rated - 186 mph
 
Join Date: Sep 2006
Location: St.Louis, Mo.
Posts: 1,979
Default

Sundays work, the heat situation is sorted, while the ceramic heat coating works well, it alone just isn't enough for the exhaust side of the turbo, so the addition of a turbo blanket, and a strip of Form-A-Shield under the cowl has taken care of the issue.
With that done, it was time for the next phase of testing, and made a mildly hard pull in first and hard shift into second, which brought up a few issues...

First being that this wastegate actuator just isn't enough, it's only a .75 bar which translates to 11 psi max, and while 11 psi breaks the tires loose at 5200 in 1st, even doubling it with a boost controller isn't going to give me as much flexibility as I'd like, so there's a 1.2 bar or 18 psi actuator on the way.

Second and larger issue is that I miscalculated the amount of engine movement under hard shifts, (even though I'm running Ireland upper and lower bushings along with a TSW top motor mount) and the shift from 1st to 2nd pulled the upper radiator hose loose. Since I do all my testing really close to the house, the car never got above 200, but of course this needs to be addressed, so there's a new, longer, flex hose on the way as well.

Maybe not ideal the ideal result, but this is what testing is all about, esp with the amount of custom fab involved in a project like this.
Some updated pics this weekend.
__________________
I'll get another 3rd party hosting site eventually...

Just hope the old one dies a fiery death.
But I'm not bitter....
Reply With Quote
  #109  
Old 06-15-2018, 11:00 PM
werD's Avatar
werD werD is offline
μ
 
Join Date: Apr 2006
Location: In a chair, behind a desk.
Posts: 9,113
Send a message via AIM to werD
Default

Rocking that motor. Literally!
__________________
Click the image to open in full size.
Just drive dammit.
Reply With Quote
  #110  
Old 07-31-2018, 09:19 AM
BlwnAway's Avatar
BlwnAway BlwnAway is offline
Y Rated - 186 mph
 
Join Date: Sep 2006
Location: St.Louis, Mo.
Posts: 1,979
Default

Well, it's been a while since an update.
Everything is moving forward with only minor issues, but nothing more than expected.
The engine movement and radiator hose issue was an easy fix with the flex hose install.

Tuning is coming along well and hopefully won't be long until we can start on the power aspect of things.

I've been driving the car back and forth to work and I'm seeing under bonnet air temps and even intake air temps of only 10-20 over ambient with normal everyday driving, even in the 95 heat, so the I/C setup is working phenomenally.
But I am seeing under bonnet temps in the 150-175 range if sitting idle in traffic or a drive thru for more than a few min., so I'm thinking about some kind of system to help pull air from under the bonnet for those occasions, but again, space is an issue...and while it's probably not absolutely necessary, couldn't hurt if I can come up with something, I'll let everyone know if I do.

I've also added a manual boost controller and temporarily mounted it in the engine compartment, along with the new wastegate I ordered. (I still plan on an electronic controller and gauge so there's no reason to permanently mount this one)
While the new wastegate helped, I was still only seeing 16.5 psi (granted it was only with throttle in second gear) but again it wasn't what I was looking for, not with this engine, so the boost controller went in.
With the heaviest spring and opened all the way, at - throttle in 2nd gear it's giving me about 26.5 lbs, so it's just where I want it to be, and of course it can always be turned down. (Which I may just have to do, since that pull was up a ramp onto the highway, and at 5k rpm the tires broke loose.)

Had a small setback with a minor oil leak at the turbo return fitting, (the first couple of hundred miles always brings out the bugs) causing me to have to replace the blanket due to oil getting into the original one.
Pulled everything apart, and since I had to wait on parts, I also studded the exhaust manifold just to keep everything as secure as possible. While disassembly is simpler than an S/C, it's still a pain so I also replaced the two piece oil return flange and fitting with a billet part that has the fitting machined into the flange, just to alleviate one unnecessary junction point.

With the repair time slowing down the tuning, I have decided to wait on the shifter and BBK install until tuning is done, just don't want to slow things down again unnecessarily.

Next will be the W/M install and the engine cover for rainy weather, plus I still have to do the fire extinguisher brackets.

My other project at the house got more involved than first expected, but it's finally almost done so I can hopefully devote more weekend time to finishing the car at a quicker pace than lately.

Again thanks for reading, and there's only a couple of new pics because of the recent changes not really changing the appearance of things that much.

First to the left is where the AFR and EGT gauge now live:

Click the image to open in full size.

New wastegate actuator:

Click the image to open in full size.

Temp Boost controller:

Click the image to open in full size.

Turbo Blanket and new additional heat shield wrapped under the cowl:

Click the image to open in full size.

R56 turbo studs and nuts:

Click the image to open in full size.
__________________
I'll get another 3rd party hosting site eventually...

Just hope the old one dies a fiery death.
But I'm not bitter....

Last edited by BlwnAway; 07-31-2018 at 09:39 AM..
Reply With Quote
  #111  
Old 08-01-2018, 08:37 AM
MartijnGizmo's Avatar
MartijnGizmo MartijnGizmo is offline
Y Rated - 186 mph
 
Join Date: Oct 2011
Location: Almere, The Netherlands
Posts: 1,722
Default

Good to see this going stronger than ever!

Quote:
Originally Posted by BlwnAway View Post
[...] My other project at the house got more involved than first expected [...]
Don't they all?
Reply With Quote
  #112  
Old 08-29-2018, 10:29 PM
BlwnAway's Avatar
BlwnAway BlwnAway is offline
Y Rated - 186 mph
 
Join Date: Sep 2006
Location: St.Louis, Mo.
Posts: 1,979
Default

Wanted to get an update in before the holiday weekend.
Tuning is coming along just fine, with weather and my work schedule there's been a few delays, but nothing out of the ordinary.

Received an unexpected surprise last week when I did my 3rd fill up. Back and forth to work and minimal hard pulls, through 2 tanks of gas I'm averaging 36.8 mpg, and that's calculated, not with the trip computer. Never expected that at all, best I got with the Sprintex was 29 hwy / 26 around town. I'll check it again after all the tuning is done, but either way, I'll take it.

Did the first WOT pull a couple of weeks ago, pretty happy for the base starting point (basically no tuning at all and stock rev limit) 316 hp / 251 tq according to Virtual Dyno.

And yes, I know it's not that accurate, but I can't go running to a dyno after every change (since we're street tuning) and honestly all I'm looking for with it is to see gains or losses, overall, it will be what it will be. I do all my pulls at the same exact spot, the Virtual Dyno setup is the same every time and so far the ambient temps have even been the same.
Honestly, I may even wait to see if they bring back the dyno to MOTD next year before strapping it down.

I did however run across something interesting with that WOT pull. According to my boost gauge tattle tale (have to use the gauge since the MAP Sensor tops out at 19.8) and reading from my vacuum manifold as I am, I only saw 24.7 psi, and I've seen 26.5 just after the boost controller install. So it got me curious, the piping had been off and on when doing the exhaust studs and oil leak, so I figured something just didn't get put back and tightened properly.
After a little research and going through the system, I found the issue... The T-Bolt clamps.. While they got tight enough, the also slightly bent my aluminium piping so that the openings were just a little out of round. Probably not an issue if you don't take things apart much, or can perfectly align everything again, but that's just not feasible for me.
So all the T-Bolt clamps have been replaced with Breeze Constant Torque worm drive clamps, and I'm back to seeing 26+ psi.

Speaking of, as far as boost and power, I'm fine with where it's at, esp considering I'm using the 64ar exhaust housing and the full 2.5" JCW exhaust. Honestly, it's pretty much on point for what the tires can handle anyway, and the only way to give it more overall would be going to a stand alone ECU and boost-by-gear.

Here's the way I see it now...
I will be getting better tires, but not until spring, so I'll just have to deal with these for now.
As it stands, with the current boost setting, full throttle and 1st gear aren't even a thought above 4000 RPM, and once I hit full boost around 5000-5500 in 2nd it also just rolls the tires right off the pavement. But it does hold traction in 3rd and up, so I'm thinking it's just right for my setup with no boost-by-gear option, it will be really fun in 2nd, and if I want more in the upper gears, I can always spray it with a 50 shot or something.
But.... That's now, things may change with the final pump gas and esp W/M tuning. I'll just have to see how it plays out.

I should have at least 1 of the 3 days to work on some of the other things that need to still be finished, so we'll see.

Just for reference, here's a screen shot of where I was with the final Sprintex pull prior to it losing boost, and the first WOT pull with the turbo. I may try and get an actual weight on the car this weekend as well.

Click the image to open in full size.Sprintex to Turbo
__________________
I'll get another 3rd party hosting site eventually...

Just hope the old one dies a fiery death.
But I'm not bitter....

Last edited by BlwnAway; 08-29-2018 at 10:37 PM..
Reply With Quote
  #113  
Old 09-03-2018, 09:26 AM
BlwnAway's Avatar
BlwnAway BlwnAway is offline
Y Rated - 186 mph
 
Join Date: Sep 2006
Location: St.Louis, Mo.
Posts: 1,979
Default

Well, weighed the car, Holy Carp cabrio's are heavy....

Weight with me sitting in the car:

Click the image to open in full size.
__________________
I'll get another 3rd party hosting site eventually...

Just hope the old one dies a fiery death.
But I'm not bitter....
Reply With Quote
  #114  
Old 09-04-2018, 07:14 PM
werD's Avatar
werD werD is offline
μ
 
Join Date: Apr 2006
Location: In a chair, behind a desk.
Posts: 9,113
Send a message via AIM to werD
Default

Dern - a bit porky there!
__________________
Click the image to open in full size.
Just drive dammit.
Reply With Quote
  #115  
Old 11-01-2018, 06:29 PM
BlwnAway's Avatar
BlwnAway BlwnAway is offline
Y Rated - 186 mph
 
Join Date: Sep 2006
Location: St.Louis, Mo.
Posts: 1,979
Default

Finally another update, the tuning has been coming along, but remote tuning the everyday and warm idle (the closed loop stuff) is a very slow process because of all the minor adjustments, esp now that we've gotten into the extra maps available with the newer VDO ECU.

Well, come to find out the the ByteTronik team has opened a shop in Austin TX with a new Mustang Dyno, and their tuner was in the states for a month.
So.... Road Trip...

I went down the weekend of the 20th, except for my new alternator going bad, it was a pretty good trip.

Ended up taking most of the first day to iron out the afore mentioned closed loop tuning, but it's done and runs perfectly normal. As a matter of fact if it weren't for the power, it drives completely factory, you'd never know that there have been so many changes and modifications to the car.
Then after replacing the alternator, we were able to get the pump gas WOT tuning done as well.

I'm very happy with the results, esp being on a factory ECU, and can't say enough about the time and care that the guys put in to make sure everything was right, top notch, all the way around.

Only thing that bums me out is that prior to the trip I completed the Aquamist install, but because of the alternator problem, there just wasn't enough time for us to do the W/M tuning. But no problem, doing the open loop WOT tuning remotely, is much less time consuming than the everyday driving.

Only other issue was my manual boost controller was a real PITA to adjust and stay consistent, and while it's good now, there's an electronic unit going in this weekend. It will allow much simpler and more accurate adjustments when going from pump gas to W/M tunes.

Speaking of boost, we ended up running out of injector at 22psi, so that is where it will live for pump gas, we'll be able to turn it up with the supplement of the Meth, so no need to get larger injectors for now.
Besides, these 650's are supposed to be one of the most efficient available because of their spray pattern and atomization characteristics.
(I can't help but wonder if they aren't a big part of my exceptional fuel millage. While I didn't calculate MPG on the trip, I can tell you that going from a completely full tank to low fuel warning light, I was able to travel 360 miles.)
And for anything who thinks you can't road trip a car with all these modifications, except for the freak alternator issue, the trip was 1700 miles total, and everything just worked.

Here are a couple of pics of the W/
M install and some dyno graphs.
(For some reason, the final tune in those graphs is not the best number, best number was 329, but I'm not going to cry about 7 hp on a graph, you could lose or gain that with a temp or atmospheric change, if I do get that graph, I'll post it up later)
And since I won't be on that dyno for W/M tuning, I'll adjust the virtual dyno settings to best mimic the actual dyno (weight and dyno type) in order to get a good representation of the W/M changes in power.

So here's the obligatory "on the dyno" pic:

Click the image to open in full size.

This first graph is a comparison of how the car was when I first got there, running 27 psi:

Click the image to open in full size.

This is a comparison of safe boost at 22 psi, before tuning:

Click the image to open in full size.

Here are the W/M install pics, with my injector size and probably running 100% Meth, the jetting calculated out to be in the neighborhood of 1.3-1.5mm, so instead of spraying that much so close to the MAP sensor, I'm doing split delivery as suggested by Jeff Howerton, .6mm Pre-T/B and adjust the Pre-Turbo as needed.

W/M Tank install:

Click the image to open in full size.

Click the image to open in full size.

Click the image to open in full size.

New CAI Filter Positioning:

Click the image to open in full size.

Rear W/M Nozzle, Pre-Turbo:

Click the image to open in full size.

Front W/M Nozzle, Pre-T/B:

Click the image to open in full size.

I guess that's about it for now, new boost controller should be in and setup this weekend, then on to the W/M tuning, as weather permits.
__________________
I'll get another 3rd party hosting site eventually...

Just hope the old one dies a fiery death.
But I'm not bitter....
Reply With Quote
  #116  
Old 11-03-2018, 08:53 PM
BlwnAway's Avatar
BlwnAway BlwnAway is offline
Y Rated - 186 mph
 
Join Date: Sep 2006
Location: St.Louis, Mo.
Posts: 1,979
Default

Here are the virtual Dyno comparisons I mentioned.

First is the direct comparison of the before and after tuning using the old Virtual Dyno settings from the earlier posting a few months ago.

And second is an example of where the new settings need to be in order to mimic the actual dyno results.
I'll be using these settings to do further comparisons since I won't be on the same actual dyno again, while not perfectly accurate they will be close enough for my use.

Click the image to open in full size.

Click the image to open in full size.

If nothing else it's a good example of how tough a Mustang dyno can be...
__________________
I'll get another 3rd party hosting site eventually...

Just hope the old one dies a fiery death.
But I'm not bitter....
Reply With Quote
  #117  
Old 11-04-2018, 12:43 AM
werD's Avatar
werD werD is offline
μ
 
Join Date: Apr 2006
Location: In a chair, behind a desk.
Posts: 9,113
Send a message via AIM to werD
Default

Good results!
__________________
Click the image to open in full size.
Just drive dammit.
Reply With Quote
  #118  
Old 11-04-2018, 09:02 AM
MartijnGizmo's Avatar
MartijnGizmo MartijnGizmo is offline
Y Rated - 186 mph
 
Join Date: Oct 2011
Location: Almere, The Netherlands
Posts: 1,722
Default

Nice results, must feel great to drive with that top end rush!
Reply With Quote
  #119  
Old 11-04-2018, 02:22 PM
BlwnAway's Avatar
BlwnAway BlwnAway is offline
Y Rated - 186 mph
 
Join Date: Sep 2006
Location: St.Louis, Mo.
Posts: 1,979
Default

You definitely have to hold on to the steering wheel....
__________________
I'll get another 3rd party hosting site eventually...

Just hope the old one dies a fiery death.
But I'm not bitter....
Reply With Quote
  #120  
Old 11-06-2018, 09:55 PM
Samtrak's Avatar
Samtrak Samtrak is offline
μ
 
Join Date: Nov 2005
Location: Baltimore, MD
Posts: 2,861
Send a message via AIM to Samtrak
Default

killer!

keep it up!
__________________

MINI RSR- 2004 MCS______MINI....FTW !
1986 Toyota Van
1997 E36 M3 sedan slicktop w/LS1 swap
1990 R32 GTR sedan w/RB26DETT SOLD
S54/E36/8 2001 M Coupe SOLD
Slugbut the 2002 WRX Wagon SOLD

seriousrrry
Reply With Quote
Reply

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


CURRENT MOON

All times are GMT. The time now is 04:38 PM.
Powered by vBulletin® Version 3.8.1
Copyright ©2000 - 2018, Jelsoft Enterprises Ltd.
2005 motoring|underground, all rights reserved.