I'm at the limit!!.........

Gerry H · Post by **Gerry H** » Mon Dec 22, 2008 12:02 am

If you remve the headers, you may see a carbon line on the flange where it bolts to the head, at each port. Then it's a case of working with a die grinder to remove the obstructive flange material so you have a matched port opening that blends to the i/d of the tube.

In other words, remove any step in the direction of the gas flow. Same for the header to up-pipe.

ScoobieWRX · Post by **ScoobieWRX** » Mon Dec 22, 2008 1:10 am

I thought that might be the case as i remember when i first fitted the headers i thought the tube ID seemed a bit bigger than the exhaust ports.

I think we have the same GT spec GenII type headers so no issue with the uppipe to headers as they should already be matched although i will be porting the turbo exhaust inlet to the uppipe as i'm sure there is a big step there.

Gerry, thanks for the advice on this, it's much appreciated. :thumb:

duncan · Post by **duncan** » Wed Dec 24, 2008 10:43 am

Finally hit my ceiling today - CEL came on at 550 gram/sec

I cant raise that ceiling any higher in the software

gary@apt · Post by **gary@apt** » Wed Dec 24, 2008 10:53 am

buy a proper ecu then :-D

duncan · Post by **duncan** » Wed Dec 24, 2008 11:03 am

gary@apt wrote:buy a proper ecu then :-D

all in hand sir

ScoobieWRX · Post by **ScoobieWRX** » Wed Dec 24, 2008 12:15 pm

Duncan, I take it you're using a big maf?

550 g/s

All that air you're sucking in, there won't be enough left for the rest of us. :lol:

Which ECU are you buying??

duncan · Post by **duncan** » Wed Dec 24, 2008 4:03 pm

yep - 70mm ID Cold air induction kit - it gives an extra 17% flow (ish ... it isnt quite linear though)

Was a bit of a surprise when the CEL came on though. I have never had that one before (have had most of the rest

)

ScoobieWRX · Post by **ScoobieWRX** » Wed Dec 24, 2008 11:29 pm

:lol: I've had a few of those myself as i've gone along. Lucky i can just untick the box and disable what isn't required.

There are benefits to being able to flash in public!!

Nice one Duncan!! :thumb:

ScoobieWRX · Post by **ScoobieWRX** » Sun Jan 11, 2009 11:23 pm

Having spent the holidays messing about with my car i'm happy to say i've finished doing any modifications for now. This is what i did:

- Removed headers and ported them to the same ID for each port as the holes in the gasket so there is a smooth flow with no obstacles in the way.

- Ported exhaust outlets (on each head) which weren't concentric as Paul at Zen said they wouldn't be, so they are now!! Again ported to the same size ID as the gasket and now a perfect match for the headers.

- Ported the headers exit (3 bolt flange end) to match the gasket ID.

- Ported bottom of the uppipe to match the 3 bolt flange.

- Ported the uppipe exit as much as i felt was safe to do without compromising the integrity of the pipe, again following the shape and ID of the uppipe to turbo gasket.

- Turbo: Hot side inlet and oulet.

- Wastegate ported (keeping within wastegate flapper OD limits)

- Turbo: Cold side inlet and outlet ported and polished for increased flow (every little bit helps)

Downpipe entry ported to match turbo exhaust oulet.

...and if that wasn't enough!!

- Purchased and fitted a new silicone turbo inlet hose from RCM. No inlet header removal required. Excellent fit and top quality product!! New silicone turbo oulet to intercooler hose and silicone intercooler to throttle body coupler, and silicone airbox hose and Aluminium coupler to turbo inlet hose.

It was an interesting experience and a task not to be undertaken by the faint hearted. To be honest without all the right tools and bits for porting it would have taken me weeks to do just using normal grinding stones so i invested in some proper carbide burring tools to remove the bulk of the metal, then different grades of stones to get the shape and smoothing of the internal surfaces, finished off by using fine grit flappers and fine wire brushes.

Baring in mind this was all done by hand the key thing here is that without jigs and machinery to set everything up the best advice is to go carefully and take your time!!

Having done some logging today just to get an idea of what needs to be done mapping wise i was chuffed to see i'd pegged the MAF good and proper!!

I have decided to start mapping from absolute scratch all over again now as the car feels completely different to drive and feels like the turbo could handle a lot more.

It doesn't spool up much earlier but when it's on song it does so more quickly and solidly. It's holding boost 1.3bar right up to the redline and that's just with the old map so we'll see how well i can exploit that further. It seems to me that i can now dial in whatever i want up without fear of making the turbo a flamethrower. Right now my only limitation is the MAF.

400bhp here we come!!

:D:D

:thumb:

Post by **Stuart** » Sun Jan 11, 2009 11:26 pm

Good results Sir.