Now I know why they charge so much!

[Gly]

well had the day off work today
first good weather we've had in 3 weeks....

so what better way to put it to use...then to work on my car!

so i got up early! and went shopping....

this didnt go as planned as i originally wanted to buy stainless steel for my pipe work,

this worked out far too expensive...
went to a few other places, and they couldnt do any better...

then i got referred to a place where they make the bends...

no luck at first as they only did huge orders! Bugga!
and at that i wouldnt even save that much if i was added to someone elses order...

then the guy says we have some 3" alloy imperfects we can do you cheap,
pick what you want....

so i went home with this lot... for $200nz (less than half what i would have paid for the stainless perfects) all 3", and 3mm thick!! and one 2.5" to 3" Stainless enlarger.

uploaded/1576/1184304321.jpg

uploaded/1576/1184304348.jpg


then i proceeded to strip the car of its front end and original pipes.

the new 600x300x76mm bar/plate cooler was fitted..

uploaded/1576/1184304542.jpg

uploaded/1576/1184304586.jpg

then i wanted to fit the original impact beam... no luck!
cooler was in the way.... so it got trimmed to fit (impact beam)
i'll get a new section welded in later....

by this stage my dad had taken the original Y turbo joiner over to his friends work to get the 2.5" to 3" enlarger welded on

this was quickly fitted by me...

uploaded/1576/1184304840.jpg

followed by the impact beam...

then i looked at my pile of pipes,
hummed and harr'd....

cut and placed pieces together...

uploaded/1576/1184304967.jpg

uploaded/1576/1184304995.jpg

at this stage i stood back and looked at the huge gap on the otherside...

uploaded/1576/1184305062.jpg

dammit bugger it... its been 8 hours now.... i give up for the day, LOL!

uploaded/1576/1184305110.jpg



TO BE CONTINUED!!....

[Gly]

well heres a bit of previous progress,

an enlarged TB to fit the VR4,


its bolts on with no issues...
only thing you have to do is bore out the VR4 Intake plenum...

the TB was stolen from a 2.5L V6 legnum/galant

and it is much bigger than the vr4 item....

heres some pics,

old and new gaskit,
bored out vr4 plenum,

this will go on the car tomorrow.

[Gly]

well another hard days work...

cut up some more bends,

and got the other side pieced together...
laid the BOV roughly where i wanted it..

uploaded/1576/1184392123.jpg

uploaded/1576/1184392183.jpg

uploaded/1576/1184392221.jpg


then i marked up where to roughly drill the hole for the BOV flange,
and also where i need a bit of solid bar so i can drill and tap it.
to add the nipples for the boost controller and temp sensor for the map ecu.

uploaded/1576/1184392382.jpg


the BOV flange fitted perfectly,
and taped in place the solid bar,

uploaded/1576/1184392490.jpg

uploaded/1576/1184392512.jpg

uploaded/1576/1184392536.jpg


then the pipe work was all removed, so it can be welded on monday for me
this left it all looking bare...
time to fit the enlarged Plenum and Throttle Body...

only had to extend the return water feed from the TB to the engine so it all fitted together without any problems.

just need to fit the TPS from my original TB and it'll be good to go.

uploaded/1576/1184392784.jpg

uploaded/1576/1184392811.jpg

uploaded/1576/1184392834.jpg


in the mean time the postman had dropped off a large parcel for me...
wonder what it is?? :D

uploaded/1576/1184392957.jpg

uploaded/1576/1184392987.jpg


Yes its my cold air box to be,
the filters are a very tight squeeze.... maybe too tight??

uploaded/1576/1184393065.jpg

uploaded/1576/1184393100.jpg


and thats where todays progress ended,
now i just have to wait till monday to get all the welded pipes together.

[Gly]

ITS DONE FOR NOW....

having a couple of issues thou,
the car feels more laggy? and im hitting boost/fuel cut at 10PSI :( 4-5psi lower than it did before

apart from that nothing else wrong to report,
im gonna do something about the look of the pipe work down the track.

i think the boost/fuel cut is due to the bored out plenum and larger throtal body.

if anyone can comment on this? i think there may be to much flow at a lower PSI and the stock ECU cannot handle this?
and throwing a wobbly?? ideas suggestions??

its actually really annoying as it happend just as the powers building up!
i may have to put the original plenum and TB back on?? would this help??

its not time i invest in a wideband and a FCD (fuel cut defender)

[mpau009]

:thinking:... what psi is that duct tape rated too:P

:afro: Looks friggin awesome though, one day id hope to do the same. Could you include a list of bends / materials when your done? That would be really handy.

Also, what size pipes are you going to run on the intake side? 2.5" or bigger, and i'm assuming two HKS type pods?

Another thing, where exactly does the intercooler foul on the crash bar? I knew that the 600x300x76 causes issues, but i cant quite picture in which dimension.

[Gly]

lol, its there to hold it until its welded :D (hopefully monday)

not much of a parts list as its all scrap / imperfect bends.

but i worked out at 6 short/tight radius bends, and one long,
and a bit of straight...

silicone..
5x 3" straight joiners, 1x 90 degree joiner,
12x 3" T-Bolt clamps


also bought a steel cut off saw off trademe for $125....
i'll probably sell it on after im done with it...

has made it so much easier.


and i'll be running a single pod untill i get my cold air box (on its way),

http://www.trademe.co.nz/Browse/Listing.aspx?id=106805252


ive got 2 small simota filters... that will JUST fit in (i hope)

http://broomfish.co.nz/product_info.php?cPath=21_24_48&products_id=68


also bought a cheap set of hole saw's

and 4 x 3" pod adaptors

also got the larger Throttle Body, bored out vr4 plenum and gasket to suit.

[MarkSanne]

Nice Gly! I'm going for a large intercooler as well, and the TB mod sounds like a good idea too. Was the new larger gaskit easy to find/buy? (productnumber?)

[Gly]

fairly cheap, and can be found if you know where to look... just edited one off my reserved space's,

its the TB/gasket combo thats on the 2.5L V6's,


also the intercooler is too thick and wide to sit behind the impact beam,

so i trimmed out 2cm along the inside of the impact beam, around 650 mm long,
its mainly the corners of the cooler that fouled,

but its was easier for me to cut a long straight section out, then just try get the corners out....
this way i can get a bit of flat bar welded along the inside to box it back up.

[bradc]

Mike - do you remember what Kenneth did to his at the workshop day?

Carsten - looks awesome! Do you need any help tomorrow?

[Kieran]

Carsten - Any idea how much difference the T/B will make?

[Paul C]

make sure that al jubilee clips are easy to access when the front bumper is back on. you never know if you might want to nip them up or take them off.trust me i had a nightmare doing a couple of alterations.

[Galant_4_Live]

nicely done.... hope to see soon the new bumper on the car..

alex

[Gly]

todays progress has been added,
i feel like an old man....
probably should have jacked up the car so i didnt have to bend over so much,

oh well...

also ive decided the pipe work will get a brushed alloy finish.

[d i c k i e s]

hey bro... looking good, one question.

18512
what is this thing called? the thing that covers/blocks this pipe (where the BOV goes)

[Gly]

its a 38mm turbosmart blanking plug...

http://www.turbosmart.com.au/index.php?id=50

part# FG-ADA-BLNK38

[d i c k i e s]

awesome bro, where did u get yours? where can u get em from?

[Gly]

got mine thru a mate.

ummm trademe...

http://www.trademe.co.nz/Trade-Me-Motors/Car-parts-accessories/Performance/Turbos/auction-108767993.htm?p=44

the 35mm should fit.

[zentac]

if your going to run any serious ammount of boost I would get the ends of the pipes flared, mine use to pop off even with the mikalor clips.

[Kieran]

I see you also have a Sard R2D2 BOV - any chance of an audio clip when it's all back together? I want to hear what the Sard one sounds like.:afro:

[I-S]

also ive decided the pipe work will get a brushed alloy finish.

If this is aluminium alloy we're talking about, once the brushing is done, you will need to have the pipes anodised. Otherwise the aluminium will oxidise and turn grey/white. Remember that aluminium "grows" when anodised in case you have any very tight tolerances.

[william]

Brilliant work, GLY. BTW, do you want to sell your old elbow and seal?!! (The one that connects to the TB)

[Gly]

theres a hole in the elbow where i had a air temp sensor for the map ecu,

is the rubber seal removable?
if it is i can sell you that, send me a PM.

[Gly]

ITS DONE FOR NOW....

having a couple of issues thou,
the car feels more laggy? and im hitting boost/fuel cut at 10PSI 4-5psi lower than it did before

apart from that nothing else wrong to report,
im gonna do something about the look of the pipe work down the track.

i think the boost/fuel cut is due to the bored out plenum and larger throtal body.

if anyone can comment on this? i think there may be to much flow at a lower PSI and the stock ECU cannot handle this?
and throwing a wobbly?? ideas suggestions??

its actually really annoying as it happend just as the powers building up!
i may have to put the original plenum and TB back on?? would this help??

its not time i invest in a wideband and a FCD (fuel cut defender)

[mpau009]

ITS DONE FOR NOW....

having a couple of issues thou,
the car feels more laggy? and im hitting boost/fuel cut at 10PSI 4-5psi lower than it did before


its not time i invest in a wideband and a FCD (fuel cut defender)

Would it be anything to do with the TPS? maybe its not set correctly. I'm not surprised the car feels more laggy, considering the extra volume it has to fill before it gets to the engine, but im sure you'll be able to tune out that, and the fuel cut.

Hopefully someone will be able to shed a bit more light on what causes boost cut. From what i gather its to do with the volume of air? (ie, ecu thinks its putting in the right gas for the flow it would expect at 10psi, but yours is substantially off of the stock map?)
Perhaps if you're still running the MAF its getting some screwy signals?

[bradc]

Remember psi isn't volume, it is how much force you are pushing on the air.

At 10psi at (say) 2500rpm you are going to be moving more air now than if you were running at 15psi at 2500rpm. Therefore it hits the cut.

I guess you could try the VR-4 TB, if not it is time to start tuning with the mapecu!

It also will be a bit more laggy, Mike is right there, maybe it isn't that the lag is that bad though, it might be that when you actually do start boosting, the turbos kick in a lot harder?

[Gly]

i dont mind the lag, i was expecting that...

the TPS is set right i checked it befor i removed it from the original TB,
and set it exactly the same on the new TB,

its the cut thats annoying me....

and yeh i pretty much thou the flow would be completly different....
and not within the factory settings...

more CFM at lower PSI. which the factory ecu will not be liking.. and most likely out of its working range?

yeh time to start tuning with the map, just dont have a wideband and cant afford one for a few weeks now.
and id like a FCD at the same time so there wont be any more cut issues.

[rayray24]

That came out really good man, cheap too by the sounds of things. You made it look easy :pimp2:

Hope you sort out all of your problems and get it boosting as it was made to do.

[Gly]

well was still having issues with boost cut today,
so ive applied the MAF mod...

i wound it out half way to see if it would halp with the boost/fuel cut im having...
seams to have helped a bit, and ive now fully wound it out...
but havent been for a test spin yet.

the car feels somewhat better to drive, but cant tell if its any faster or even getting there faster? mainly due to boost/fuel cut.

[cslotay]

I think the the MAF is of Karmen Vortex type. These usually requre the air flow to be straight and even and they usually have a honeycomb section to accomplish part of this. The problem may be because of the way the pod filter causes the air to swirl and thus causes the MAF to misjudge the amount of air getting in.This may be causing the ECU to think that too much air is getting in and therefore the fuel cut. RPW have a specific rampod filter for this purpose - http://www.rpw.com.au/shop/index.php?page=shop.product_details&flypage=shop.flypage&product_id=633&category_id=221&manufacturer_id=0&option=com_virtuemart&Itemid=31

Thats my 2 cents worth. Hopefully you will find a solution soon.

[Gly]

my solution is the MAPECU thats installed,
its still in learn mode. ill set it up to run the car once i have a wideband EGO...

i still have a few things i want to do before it goes on a dyno or gets any tuning,
down pipes and intake side of the pipe work still need to be made.

[Paul C]

get a wide band and map ecu sorted then start chucking more fuel at it you might be leaning out earlier through the boost range.

[Gly]

quick change to it today...
pod filter in the box,
and a bit of pipe to get to the maf...
a hole has been sawed below the box (102mm-ish)

just need to get a feed pipe from the bumper to the box.

next mission fit my EVO 5 Style bumper to my car....

still undecided if im going to change the factory pipe form the turbos completely, or just the front turbo pipe to the factory joiner/splitter?

[SHOWVR]

Dat looks the wizz bro!! how much of a difference can you feel now that youve applied the MAP ECU? And inregards to the map ecu thats currently on trademe is says its for a evo 4? can this be used in the VR4?

[d i c k i e s]

looks nicer now.

[Gly]

Dat looks the wizz bro!! how much of a difference can you feel now that youve applied the MAP ECU? And inregards to the map ecu thats currently on trademe is says its for a evo 4? can this be used in the VR4?


no difference yet... it hasnt been tuned yet.
still want to do two more thing before that happens.
and thats my downpipes, and the turbo intake pipe behind the maf.

but the car seams to be running better with pod in the box.

he bought it for a evo 4... but there not car specific,
its needs to be wired up,
then learn a base map, then needs to be fine tuned on a dyno or road if your game.

[DefeXion]

That engine bay looks flipin techno. I think I need to start putting a bucket in front of my keyboard if you continue doing things like that

Question though... there isn't any intake pipes or gaps on the front of the c.a.b. so where are you routing the air from?

[Gly]

theres a hole below the box, goes into the guard in front of the wheel just behind the bumper... used a hole saw to cut it out

102mm diameter, there will be a pipe from the front spotlight hole to it soon.