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Madison Motorsports
Next steps have been taken ! - Printable Version

+- Madison Motorsports (https://forum.mmsports.org)
+-- Forum: Technical (https://forum.mmsports.org/forumdisplay.php?fid=4)
+--- Forum: Technical Discussion (https://forum.mmsports.org/forumdisplay.php?fid=11)
+--- Thread: Next steps have been taken ! (/showthread.php?tid=2462)

Pages: 1 2 3

- WRXtranceformed - 07-23-2005

He was using the same FMIC i was going to buy, the TurboXS FMIC. I'm pretty happy so far with the TurboXS TMIC, it cools quite a bit more than the STI TMIC which apparently is highly overrated in terms of use as a WRX aftermarket part. Here's a pic of the comparison between my stock IC and the one i'm using now:
[Image: fastwrx_1855_74095402]
Stock TMIC: 297 cubic inches
TurboXS TMIC: 634 cubic inches

Some pics of the install in the next post =)

- WRXtranceformed - 07-23-2005

Removed the rubber splitter and plastic assembly under the hood scoop to fit the intercooler. The new one is about twice as thick as the old heh:
[Image: DSCF0501.jpg]
Intercooler, heat shield removed:
[Image: DSCF0499.jpg]
Water and oil lines being removed from the turbo. I literally felt like I was removing the car's heart when this thing came out ! It bled everywhere.
[Image: DSCF0502.jpg]
A random shot of the mess of hoses below the intercooler so we'd remember where they went.
[Image: DSCF0503.jpg]
New turbo on the left, old on the right. Size wise they are very similar, it's not until you look at their diameter can you see how different they are.
[Image: DSCF0504.jpg]
Not a great shot, but the bottom part of the old fuel pump assembly on the left and the new fuel pump on the right. The Walbro 255lph is about an inch longer than the old one. Again, I felt like the car was bleeding when I took this thing out, except this time it was gas all over my trunk.
[Image: DSCF0505.jpg]
New intercooler. A FMIC would have given me the overall look I want more, but I'm not willing to sacrifice performance for aesthetics (when it comes to the IC anyhow =p). Maybe someday if I drop a huge turbo in this car... which I highly doubt will happen. After a custom tune I should be more than happy with the power.
[Image: DSCF0507.jpg]
Final shot of the engine bay as is. Only thing left is an AEM short ram that i'll probably install before a custom tune. I'm a little worried about the whole setup running really lean if I installed it now.
[Image: DSCF0506.jpg]

- Dave - 07-23-2005

yeah intercooling sizing is the key. You are better off getting one cut to your specifications. Just a guess at some physics to figure out how big you need:
determine the total flow rate of the turbo at max boost. Calculate the total volume of the entire intercooling system, including pipng. If you can determine the rate of increase in flow (i.e. spooling up) as your revs increase, then you should be able to incorporate the volume of the intercooling system into that to determine the amount of lag present. Play with those volume numbers to determine which one you want, then decide an appropriate intercooler and piping size.
Given all of this and that I don't feel like trying to do these calculations, I foresee you doing more work and increaseing your turbo size in the not-so-distant future, so that FMIC isn't too far away anyways. Gerald's suggestion for an STi TMIC also sounds good as an intermediate.
Sounds awesome and can't wait to see what this beast feels like. What kind of numbers/times are expected from this setup?
edit: dammit, maybe I should have noticed that there was a second page :-p

- WRXtranceformed - 07-23-2005

Hehe, thanks for the input dave. Expecting hopefully around 300 awhp with a tune, quarter mile numbers would be dependent on my driving ability really. Mid to low 12s are what most are seeing.

- WRXtranceformed - 07-29-2005

Heading up to TurboXS tomorrow for a custom tune with some experimental new firmware ! It's supposed to automatically tune for atmospheric conditions and other neat stuff like the Vishnu tuning software is doing now on EVOs. I'll post dyno results when I get them =)

- WRXtranceformed - 07-31-2005

284 AWHP and 264 lb/ft of torque... or was it 246, I can't remember hah. I'll post the dyno graphs when I get them. Germaine and Nathan at TurboXS told me that I could have gotten more horsepower out of my setup, except my wastegate actuator was opening up under high boost (because of the porting job =/) With a helper spring adding a bit more pressure to that wastegate arm they said I could probably gain another 15-20 hp / torque. Overall I'm very very pleased.... the car pulls really hard hah.

A buddy of mine came with me today, and he put down 240 awhp and 236 lb/ft of torque on the stock turbo with just an uppipe and turboback exhaust! He's running catless, and it was really really funny to see huge frickin fireballs flaming out of his exhaust on the drive home. I mean HUGE!

I'll put up the dyno charts when I get them ^_^

- KPWSerpiente - 07-31-2005

Congrats Lee. Not too shabby for a Werx. Seriously.

-T

- ScottyB - 07-31-2005

yeah man those numbers are really nice (jealous)! i'm sure it feels like a whole new animal 8)

how is your clutch holding up so far?

- WRXtranceformed - 07-31-2005

Thanks guys, this is kinda the culmination of a lot of investing and a lot of waiting =) Clutch is holding up okay so far, it helps that I don't drive this car much. It's funny though, I'm already looking at a new turbo hah. Help me, it's a disease ! =p

- CaptainHenreh - 07-31-2005

WRXtranceformed Wrote:Help me, it's a disease ! =p

[Image: buy_valtrex.jpg]

- Nis01 - 08-02-2005

Could always go with the 20G... met a guy the other day with that set-up and he loves it... He used to have the vf34. Once the disease has you.. you are done for... Just enjoy the ride!

- Dave - 08-06-2005

nice numbers, congrats!

- WRXtranceformed - 08-06-2005

I'm going to try out a wastegate helper spring tomorrow since the IHI turbos don't have a built in adjustable wastegate spring. I'll report back on the results after I experiment with different spring tensions, etc.

Here's what it'll look like:
[Image: IMG_0496Small.JPG]

- WRXtranceformed - 09-10-2005

Update on the helper springs:

Tried a 5.25 lb spring, doesn't seem to make a huge difference, although it's slightly noticeable. Bought two springs at Home Depot the other day, and 11.something pound and a 19lb spring. Tried out the 11lb and WTF!!! The torque is unbelievably higher at the 3rd most aggressively tuned map than it ever was on the first, but I'm also pushing 25psi of boost. There's some kind of funny whistle coming from I think my wastegate now, so I've taken that spring off and am trying another spring that's about in between the two I've tried so far. I'll post an update when I finish a test-and-tune session today.

- .RJ - 09-10-2005

Isnt there a less hackjob way of regulating boost?

- WRXtranceformed - 09-10-2005

.RJ Wrote:Isnt there a less hackjob way of regulating boost?
The boost is regulated electronically through the UTEC programming and manually through the UTEC's ABC. As I said before though, this boost is bled off prematurely because of the port job on the wastegate. The point of the spring is to keep the wastegate closed a little bit longer to increase torque and hp approaching redline.

So, to answer your question, yes... boost is being regulated just fine. Its potential is just not being fulfilled. Is there a less hackjob way of doing this? Yeah, buy a new turbo without a ported wastegate.

The stock TD-04 actually has an adjustable wastegate arm in which you can do this same modification. None of the VF-series turbos have this however, so adding a spring is the way to do it.

- Nis01 - 09-11-2005

Lee... Forget the VF-series and drop in this set-up... Confusedhock:
[Image: f2785c2a.jpg]
Twin Turbo GT30's and an AMG Supercharger.
Not too shabby....

More information here: http://forums.nasioc.com/forums/showthread.php?t=840806

- WRXtranceformed - 09-12-2005

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- Jeff - 09-15-2005

Your old turbo is the same as the one on my Daytona. What is the A/R of the exhaust side and do you have a picture of it? You are doing it right, buying what needs to be had and putting it all together. You could put a bleed on the wastegate line so it dosn't open as soon. Maybe a a 2lb bleed?

- Jeff - 09-15-2005

[Image: restrictororifice2.gif]

manual bleed
[Image: turbobleed.jpg]