Alan,
Apologies..... just re-read your post. I must of skipped a couple of words when I read it the first time round.

 

Is everyone friends now then

 

Shaun and I are old buddies, and we've ALL done that one, where you speed read, then bang off a reply from "Mr Angry of Tooting" only to feel the slow creep of egg on face later on.

We're all fascinated with the outcome of your build now, so I'm really keeping tabs on this one!

 

So .. can we now get back on track ............ please ............ ?

 

Nothing's happening now until it's all been checked out by Iain, go have a cuppa or something..

 

It has been that bad has it!

Keep us updated Tim

 

Will do! There won't be anything to report for a few days, until the car is up with Iain and he's had a chance to look at it

 

Just spoke to Tim .... he's having pizza waiting for the AA truck to arrive a bit later and take him up to drop the car off to Iain's tonight. Silly people went and sent him a patrol vehicle at the appointed collection time ... ..

Tim's going to be very tired by the time he gets home

Also just spoke to Iain ... he's got the basic map in on mine .. and the 'bum dyno' apparently say ... "it pulls like a train" ... but he's waiting for the rear brake work to be completed tomorrow morning before completing the full mapping. So I'll be off to Iain's to collect mine tomorrow night ....

I can't wait .. and I am sure Iain can't wait for me to stop pestering him on progress either

Oh and Iain's R2 courtesy car is a little pocket rocket .. supercharged 650cc with semi automatic gearbox ... great fun .. although not to be pushed in corners !!

So .. more updates close ........

 

it will be great to see some positive results posted up. Good Luck mate. Oh, and welcome to the R2 club
Andrew

 

Bet Dyno about

LOL I've also been in the R2 Club great fun but speed limiter (don't tell Jenny though



Tony

 

Update - turbo is off and on its way back to TD. At first glance it looked OK, but has been returned to them for proper checking.

And. more interestingly, Iain has found a crack around the turbo mounting flange of the Milltek downpipe which could easily account for the late spool and lower-than-expected performance

Maybe these Milltek's don't like being removed

More news tomorrow, we hope, from TD on the turbo, and Milltek on what they're going to do to rectify the downpipe...don't want to exchange it really as it's been ceramic coated.

 

How bad is the crack i take it that it's quite big letting a lot of pressure/gases out?

 

Not seen it myself, but I have seen another cracked one before now, and that one was pretty bad

 

an interesting read...from someone waiting to purchase one of these turbos, i await the results.....looks like they have found the problem by the sounds of it....

 

Well ...... evening all . guess what is sitting on the drive now .... ? Yup .. a superdooper machine !!

No dyno figures I am afraid as Iain ran out of time to get it done but Iain reckons it is around 410 bhp/380lbs with a conservative map with loads of scope for more.

Remember I've added a cat and am still running normal induction and topmount on a 2.0ltr MY05 JDM STi.

Forgive me if I've got this wrong but I am pretty sure Iain says he's set the :

• fuelling at 11.2 ie quite rich
• boost at 1.55 when it can take 1.65 easily
• ignition at 21 degrees and he thinks it might take another 3 or so

So he thinks there is potential for probably another 30 odd hp

As for the drive .. well .. most of my journey has been motorway and its been wet and its dark .. so I have been very restrained, and haven't really had the opportunity to put it through it's paces yet, but here are my observations so far :

1. It is super smooth ... I used to get a horrible flat spot at around 3.2k revs if I accelerated hard in 6th from below 2.8k revs ... no more ... just smooth increase in power all the way from low revs in 6th to peak boost at around 3.4k at which point acceleration increases dramatically .. but not neck snappingly so ... the boost is then just held all the way up .. and very noticeable compared to before when in the lower gears
2. If I dropped it down from 6th to 5th .. it took off very quickly, much more so than before
3. If I dropped from 6th to 4th ... I got pushed right back into the seat as the front lifted and the rear sunk and it belted off
4. With the old turbo it used to start to run out of grunt about 6k revs .. not this baby .. all the way to red 8k line and much stronger feel to the power
5. The de-acceleration when coming off full boost suddenly caused massive neck snapping !!
6. It was lovely to just apply a little pressure to the accelerator peddle to hear the turbo whistle

So .. all in all I am very pleased so far .. just need to get some daylight and some normal roads to try some 'spirited driving'

Also saw Tim's downpipe this evening too and it is definitely blowing through the welds at the flange/neck - but no-where near like mine was before I had it repaired. Hopefully it's as simple as that for you Tim.

 

Well this great news! Glad you are enjoying the new turbo, waiting patiently to hear the full report after some good spirited driving and some dyno sheets.

 

Good news which turbo did you go for?

Tony

Ps Tim hopefully won't be too long

 

420 ... power level originally based I believe on what Iain expected out of his MY08 JDM STi with FMIC and Induction Kit .. but I could be totally wrong .. any way .. am off to bed now .. night all

 

There should be no pressurte in a downpipe and w2hen they crack around the flange which has happened on several that are ceramic coated the effect is more noise but performance is not effected to any noticable degree.

 

I dont like the quality of welds & workmanship on Milteks anyhow but they do seem to be popular?

 

Well thats that then.......... Where`s my credit card!

 

if a car is setup and THEN the dowonpipe cracks around the flange then no it will have little effect..

If it is cracked when it is being setup then the fuelling measured after that crack will be wrong as the exhaust gas passes air will be sucked into the exhaust under certain cricumstances.. the wideband then reads leaner than the engine is actually running and it gets setup richer..
depending on how bad the crack is it will also effect spool as the flow in the exhaust is distrupted also.

Simon

 

I believe Miltek make the revolution exhaust and that was very poor quality of welds.

 

Came across this photo of a Milltek downpipe that also had a cracked flange. This was one I bought second hand - the fault only came to light when we tried to fit it. I know of 3 now, so it does rather suggest that the welding is not as good as it could be

 

The figures sound very similar to what the hybrid turbo offers. Whats the difference between the two. To be honest am not really fussed about the figures it's the spool up response how does it compare to the standard set up?

I don't want to go for more power and sacrifice the driveability and the current spool up response.

Need as much info as poss as am trying to decide what turbo to go for and don't want to spend 3k then end up changing and spending another 2-3k to do so.

Immy

Immy

 

Hmm a bit worried about mine now!!! As i also have a Miltek system on mine and with the new turbo going i hope Iain doesn't run into any trouble with my downpipe fingers crossed.

T20 - glad your enjoying yours, now i cant wait to get mine back and mapped.

Lol only 2 more weeks before its all done
Will post up the results once all finished.

Mel

Soon to be LM450-S60'd

 

As per feedback Immy .. have not really had the opportunity to put it through its paces yet. May well try to go out at lunchtime

Generally speaking though .. the response seems very marginally slower when in higher gear ... but as good as the same when above 4k revs ... but much more powerful and goes on longer

But to your point Immy .. mine is just one implementation and model (420). Sounds like you need a few more feedbacks to help. Remember too that Iain developed the Hybrid and so he is best placed to discuss what the differences are.

More to follow when I have it ...

Chris

 

Your cracks aren't anywhere near that bad Tim ... more like hairline ones ... 3 I think ... but you can clearly see where the soot has blown through them

 

Thankks Chris...so still to be determined whether they were enough to cause the poor spool and reduced performance. There's also the very smoky exhaust that I experienced to be explained.

I remain patient, and am 100% confident that Iain and/or Len will sort this

 

Glad you like the car Chris
The remit from Chris was to produce a comfortable 400-410bhp as it will be his daily driver, track day toy and would be running the standard top mount etc. However the turbo is more than capable of supporting 420bhp+

Tim, I’ll try and get some pictures of your downpipe time before if goes off to Milltek. They will repair it under warranty and send it back tomorrow. I must say they are an excellent company to work with as you can imagine we have used a huge number of their exhausts on our all our cars and we have only had a handful of warranty claims in over 8 years.

Turbo Dyanmics are testing the turbo now but initial inspection is that it’s fine