My New Turbo Problems.. Options

[Rollout]

I've kept it kind of on the low up until now, but I recently (finished totally today) installed a super16g on my car, w/ tubular manifold.. Check out my garage for pics and what not on that:
http://www.dsmcentral.com/invision/index.p...&CODE=12&CID=17

But... ever since the install I've had hella problems...

#1, the manifold (I believe it was a prototype KOU manifold) isn't aligned perfectly, so everything is crooked, all the oil lines had to be fabricated, and new fans had to be perchased.. Luckily all these problems appear to be fixed with some serious help from Carl Crawford (Owner of Speed-Source). Can't express how helpful he was with the installation and letting me use his shop + lift to do it.

#2, this manifold gives off some serious heat.. On top of that, it puts the flange where the manifold mats to the turbo about 3 cm from one of my new fans.. I'm afraid it's going to melt, I've already smelled burning plastic when stepping out of the car, and that hasnt even been during serious driving... The only ways I can think to fix this problem are:
a. Thermal wrap, but I'm afraid the manifold will crack...
b. Heat sheild (at least in front of part of the fan), this seems like the best solution, but there really isnt much room to work with there... and two it will block some airflow..
c. Put the factory manifold back on, but this would mean im stuck with a tubular manifold and O2 housing, and plus i would need to purchase a HRC O2 housing..

#3, I'm having boost problems... I'm thinking it is because I am still running the stock downpipe and just having serious boost creep.. I have the AVCR set at .65 bar.. I would assume that is somewhere near 10psi or less.. Actually, I'm not even sure this wastegate will allow for any less then that, but none-the-less, the turbo should not be seeing levels of 16 psi when its set that low... Tomorrow I'm going to bypass the controller, and just route a line from the wastegate to the turbo for now, just to see what the minimum boost is, and to keep things under control until i can get this thing properly tuned.

#4, I cant tune this thing, i dont have a datalogger or cable..

Other then that, seems to run good, I'm just freaking out

[SCCA Stang]

boy I hope I don't have those kinda problems when I install my new ceramic coated tubular header and EVO III 16G.... was your header ceramic coated??? if not winners circle can send it off to a company that they seem to be satisfied with near Joliet.... it costed me $125.... good luck to you and I hope I have better luck than you have had so far.

[cjk123]

boy I hope I don't have those kinda problems when I install my new ceramic coated tubular header and EVO III 16G.... was your header ceramic coated??? if not winners circle can send it off to a company that they seem to be satisfied with near Joliet.... it costed me $125.... good luck to you and I hope I have better luck than you have had so far.

No its not coated, check out the pics in my garage, 125$?? hmm, couldnt that also cause it to crack?

by the way, this is Rollout

[SCCA Stang]

boy I hope I don't have those kinda problems when I install my new ceramic coated tubular header and EVO III 16G.... was your header ceramic coated??? if not winners circle can send it off to a company that they seem to be satisfied with near Joliet.... it costed me $125.... good luck to you and I hope I have better luck than you have had so far.

No its not coated, check out the pics in my garage, 125$?? hmm, couldnt that also cause it to crack?

cause the manifold to crack.....???? I wouldn't think so but it will help keep the heat in the exhaust system instead of letting it loose in the engine compartment.
that will help keep the heat from melting his fan

[natedogg]

Your boost problem is probably the stock downpipe. Once you upgrade to a larger downpipe, you should have less backpressure and your wastegate should have an easier time bypassing exhaust gasses to keep your boost where you want it.

[Rollout]

was the manifold portmatched to the 16g? If not, expect some lag.

Yep it matches up, I'm pretty positive its the downpipe now that nate supports the idea, the O2 housing is like 2.5 and the stock pipe is like 2

GSXracer, if u can pm me the number of winners circle and some info about them/the ceramic coating that would be awesome... thanks

[SCCA Stang]

GSXracer, if u can pm me the number of winners circle and some info about them/the ceramic coating that would be awesome... thanks

you have a PM!!!!

[Super16G]

Ran friggin strong as hell on my car......You need a diggity down pipe

[SCCA Stang]

I got my new header back from winners circle today and it looks great, they really did a nice job ceramic coating it, I just hope now that it doesn't explode in a fireball like the prototypes that some of the other guys got... Marcus and I compared the two and it looks like there was a lot more planning involved in the design... wish me luck guys!!!

[xian 1g]

hey roll out, this may be to little to late, sorry i brain farted about it earlier, but here's a huge write up on that manny, dyno graphs are available and vid's too... just let me know

manny

[Rollout]

Thanks

[ncgalant]

was the manifold portmatched to the 16g? If not, expect some lag.

Yep it matches up, I'm pretty positive its the downpipe now that nate supports the idea, the O2 housing is like 2.5 and the stock pipe is like 2

GSXracer, if u can pm me the number of winners circle and some info about them/the ceramic coating that would be awesome... thanks

In my experience the opposite happends. I have very low boost with excelent control before upgrading my exhaust. The second my 3" downpipe went on my boost shot up.

You said you have a super 16g. Don't those have a 15psi spring in the wastegate actuator? I'm assuming you are talking an HRC super 16g.

[natedogg]

The HRC super 16g's have 10 psi actuators.

As far as boost creep goes, it can happen either way. It all depends on the wastegate. Intuitively, one would expect a larger downpipe to allow more boost creep because of a larger pressure differential and this does happen. The problem that the small stock downpipe presents is the smaller pressure differential created by it applies just as much to the wastegate as to the turbine outlet. And the exhaust gasses would rather travel through the turbine outlet than the wastegate outlet because it is the path of least resistance, since the pressure on the turbine inlet is increased indirectly with the increased flow from the 16g compressor. A few Evo owners have run into this problem by slapping a larger turbo on the stock downpipe.

Like Spy alluded to, it all comes down to matching. Port matching the exman to the head, the turbine housing to the exman, the O2 housing to the turbine housing, and the downpipe to the O2 housing. Consequently having the correct size wastegate outlet to match the turbine outlet makes a difference as well, but that isn't really flow matching, more like flow resistance matching.

[Rollout]

interesting.. I'll let u know how it works out, the dp should be here by the end of the week hopefully.. I plan on putting the 550's in then, but im not sure at all how to tune the AFC without a datalogger.. I'm going to be completely blind

[mark95turbo]

interesting.. I'll let u know how it works out, the dp should be here by the end of the week hopefully.. I plan on putting the 550's in then, but im not sure at all how to tune the AFC without a datalogger.. I'm going to be completely blind

You can get a datalogger and cable on ebay for dirt cheap. Like around $100- $150. Just search aroune a bit. It will be my next and probably one of my most important upgrades. Good luck!