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Frequent flyer Gold
Posts: 1093
   
Location: An island off southern Tasmania. | Have proceeded down the path of modifying this plenum to use an intercooler.
The strategy is to create twin chambers in the center portion and direct it out the belt side through a FMIC and then back with suitable piping to the throttle body side.
Here are some progress shots.
Even a little bit of cooling will make a dramatic impact to this kit.
The intake temps often reach 90-100 degrees celsius.
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | final mockup.
The throttle body side need a 60mm elbow extension as well as being angled down at 20 degrees to clear the stock intake.
The pulley side clears perfectly as long as the connector support bracket for the crank angle sensor etc is relocated.
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | nice work |
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | Here is the finished refabricated plenum.
Cost for all R&D was stupidly cheap.
For testing I simply loop a hose from inlet to outlet....because all the air is past the throttle body...so a piece of cake.
I am hoping for some good performance out of this simple mod.
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | whats the dia of the pipe?, i m doing a modified one for my corolla, not sure it will make a diff, just doing it for the hell of it, non turbo, nice job though,will be interesting to see the performance difference |
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | thats a 2.25 inch...picked it for a variety of reasons. |
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | Got a package in the mail today.
A whole bunch of kit parts to play around with mocking up the intercooler piping.
$89 inc delivery...how in the hell do they do it?
It's chinese but it's good enough for what I am doing.
This will be fun....
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intercooler piping.JPG (110KB - 767 downloads)
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Looks flash |
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | Well spent the afternoon grazing my knuckles on the rear support bolts required to remove the plenum.
Swapped the supercharger onto the re-fabricated plenum, plugged up the LPG nozzle holes as this was my old GT plenum.
Removed the bumper bar in anticipation of fitting my cheap arsed $50 ebay intercooler that i won...( It's BIG...BIG....BIG)
Before fitting the intercooler i thought i better test my chamber-ised plenum theory to see if it runs.
Ran it up and down the road for a few kilometres and by damn it's improved even with the bit of piping.
The intake temps of theses sprintex blowers are about 95 degrees Centigrade.
Here are some pics for me to brag about how well i fluked the clearances...LOL...
Cleared the throttle body by 2mm and the drive belt by a mile.
overall very, very happy with this so far.
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clears drive belt.JPG (220KB - 1573 downloads)
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loopback chamber test.JPG (230KB - 730 downloads)
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Shes looking good, will you give it a run on the dyno to compare? Is that running the standard pulley?
Edited by wsbtt 24/6/2013 10:44
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | Nah...it's the 11-12 psi pulley (65mm) versus the stock 76mm pulley.
It also has the 7th injector removed and 6 big mother injectors instead...tuned of course with the Link Ecu and wide band O2.
That tune is the only reason it hasn't blown yet cause it's a stock engine.
Finally put it all in and she starts and runs.
I'm knackered and am calling it a day....here's the final position, just gotta fix the bonnet catch mount and power steering cooler pipes etc.
[IMG]http://img259.imageshack.us/img259/2463/5cct.jpg[/IMG]
Uploaded with ImageShack.us
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big assed intercooler running.JPG (164KB - 731 downloads)
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | It's 3am and i just came back from a test drive.
This has worked out great, it does exactly what it should...the drivers' side pipe is hot to touch, the passenger side return coming out of the intercooler is freezing.
Very, very happy with this mod...and possibly no more preignition/detonation with the sprintex kit.
One last thing to do is modify the engine cover to fit.
it's the only thing I stuffed up in my design, will have to cut a bit off the side, but should look okay....
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380 Intercooler-plenum mod-pipework-stealth mode.JPG (189KB - 710 downloads)
380 intercooler view 2.JPG (149KB - 730 downloads)
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | Today I pulled out the digital thermometer because when i put my hand on the intercooler exit pipe it was as cold as a beer out of the fridge in comparison to the inlet end from the blower.
Here are the crude under the bonnet temps of the intercooler pipes.
very, very impressive result me thinks.
46 degrees in and 25 degrees out while car is just idling....
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DSC01850 compressed heated air pipe entering intercooler.JPG (127KB - 610 downloads)
DSC01852 cool air pipe exitting intercooler.JPG (110KB - 696 downloads)
DSC01854 extractors temperature.JPG (95KB - 1634 downloads)
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Was the power comparison quite noticable , will you get it dynoed? |
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | Went for a looooong drive today with the laptop connected logging intake temps etc etc.
This Link ECU has some fantastic software, everything is viewable.
After 70klms in peak hour traffic and a good deal of start stop and occasional full boost I was sitting at the lights and here is the screen.
Note the intake temperature measured just before the compressed air goes into the cylinders.
It used to sit about 75-105 degrees C......
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Modified sprintex plenum inlet air temp fixed.jpg (248KB - 664 downloads)
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Do you think these plenums will ever be availiable again, i think this will look nice on my 6G75 |
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | I plan to fit the mod to my TMR380. |
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Yeah, nice |
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | Picked the car up from JJM Turboworld in Dandenong.
For $280 I got a very nice re-tune on the dyno for the manual VRX with S5 blower.
Previously the intake temps were horifically high, and I suspect had the potential to harm the engine in certain circumstances.
With the plenum modification all is revealed, where previously the engine would knock around 4200 rpm and needed timing pulled back holding back performance...we now go all the way to almost redline in a flat line.
A sensational 200.8 kilowatts at the wheels, repeatable...and over 500 Nm of torque at the wheels.
She really does go very well and smooth from take off to over 140km/h in 3rd gear.
The temps never go above 35 degrees (and that's pushing it damn hard).
Dyno sheet attached for your enjoyment.
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Thats awesome. |
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Frequent flyer Bronze
Posts: 34
Location: South Australia | I take it that it drives much better than before.
What sort of fuel consumption do you get now? |
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | RM380 - 26/8/2013 19:19
I take it that it drives much better than before.
What sort of fuel consumption do you get now?
Dunno...only driven it home so far.... |
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Having a go at this mod, working on these in/output plumbing , had to fab the piping as i could'nt find an extrusion this size which ended up 70mm x40mm id with the round end being 60mm id ,not sure when ill get a chance to remove the plenum to chop her up, maybe pull the whole lot off and run her with no sc for a bit, still deciding
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | you will need a stcok plenum to run her with no s/c and a smaller belt and a couple of hoses from rocker covers etc.
it's a big job to modify the plenum assy, suggest getting a pro to weld it up.
if you miss a bit of debris it WILL stuff your motor...welds have to be pretty damn good. |
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Go the stock plenum etc from my 75 for the magna, im a welder by trade , its a big job yeah, i reckon ill give it a burl though, heres some pics of how i made the oval section i used, cheers
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20130919_084901-resized-500.jpg (74KB - 726 downloads)
20130919_084705-resized-500.jpg (53KB - 754 downloads)
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | If you're a welder then my apologies.
You'll probably do far better than my attempt....
I have plenty of stock 380 plenums if you want to be slack and use one.
Have you looked at the plenum chambering pics I posted? |
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Administrator - 1/10/2013 16:47
If you're a welder then my apologies.
You'll probably do far better than my attempt....
I have plenty of stock 380 plenums if you want to be slack and use one.
Have you looked at the plenum chambering pics I posted?
All good, you effort is great , don't know why sprintex didnt think of it anyhow, especially with the intake temps so high, im pretty sure i dont want to replace the cats again or even worse a short motor, if you can spare a plenum i will take one as the one i have has been modified to go into my valiant( ha ha) yeah i have been studying the pics you posted, did mig weld it or tig ? I used the oval shape runners thinking i could get more flow |
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | It was tig...thats all i know i had an engineering company do it (Robert Lange Engineering)
300 bucks it cost... |
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | It's the best dyno result for any supercharged 380/
And it won't blow the engine. |
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Frequent flyer Gold
Posts: 1093
Location: An island off southern Tasmania. | Forgot to finish this thread....it achieved 201kw at the wheels on a stock engine....7 psi boost |
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