scalbert

Now that I have seen it I feel very comfortable with using the radiused edges versus the air horns. I would have liked to use air horns but the spacing would not have allowed it. Plus, this is a boosted engine, not a 9000 RPM NA motor so this should be more than adequate. It is actually better than what the factory uses anyway.

The owner of the machine shop is still shocked at the bulk of material I am using. He thinks it is an overkill to use such a thick base. I explained to him that the thicker base was used to gain height to clear fuel rails and heads. It is also the main support for the whole system so the firmer the better.

Plus he thinks that the 1/4 inch aluminum plate for the walls might also be an overkill. But we can always back off later. I'd rather be sure it is strong enough for continued future use. The front wall and drivers side wall really need to be this thick to support the studs and vacuum port fittings. The rest could be thinner but I'm sticking with the same thickness for the rest anyway. But as he put it, this thing will be stout.

However, I may need to have another base made. I bought 7075 aluminum for the base which might not weld up well with the 6061 plate I am using for the walls. But for the test fitting this should be good enough. I’ll probably have to go back and get it all made out of 5000 series aluminum be we’ll see. I have heard that a good TIG welder should be able to mate the 6061 and 7075 just fine especially considering the thicknesses being used. But for the final units I will use whatever they suggest.

ferizzo

After seeing that and reading this thread all I can say is:

Blow Me!

scalbert

I'll leave that up to your northeastern couterparts...

ferizzo

Steve, Thats awesome what you are doing! I love seeing innovative people trying to help out fellow ACL members! Like I said, I wish I were blown now! Gotta start saving!

Caddy©

So...forgive my ingnorance, but Intercooler is Only for those with SC--Correct ?

Wait: I found Intercooler Site Info: Let me educate myself !

http://www.gnttype.org/techarea/turbo/intercooler.html

99%StockAV6

Any reason you didn't machine the EGR hole?

Zootking

Steve, did you ever dyno your car again? Just curious if you were gonna do it again before the intercooler install.....if you're gonna be up this way on Oct. 11th, we've got a dyno day at a local shop...wouldnt mind seeing some other CL's around....

scalbert

I didn't have it on the original drawings because I was sure how I wanted to incorporate it. I wanted to try and evenly distribute the gases which would require passages to be cut or plumbing installed. But more than likely I'll just drill a hole and let it fill the chamber.

It may not be even distribution but it is the way it works on the GM L67 motor. Plus, this would be the easiest solution and keep the EGR system intact.

scalbert

I haven't yet but I will want to and maybe on the same day I test the IC.

Nope, I won't be up in that area then so no good for me. Ya'll have fun...

types1967

steve im coming down for the install lol lol

ModAddict

just curious,...

scalbert

Nothing yet, they have been busy. I was going to wait until Friday and run by there.

But that brings up something else I needed to talk to you about. When ready from them and verified on my car I would like to send it up to you for a test fit on your TL; that is if you don't mind.

The TL has a different hood so I need to make sure it also clears.

ModAddict

I thought about that too. I was banking on the TL having more room rather than less, but a test fit would be great, and eliminate any doubt. A nice hood scoop and a CF hood would be cool, but my :-* might just kick my ass on that one.

ModAddict

She might not notice a bulge instead of a scoop.

scalbert

That's just a power dome...

I'll send it up when ready.

scalbert

BTW, I stopped by the machine shop Friday and all the peices are cut. They were waiting on me for a change I made to the drawings which I never sent over. :o But that is taken care of now and should ready to go soon.

They have a welder lined up for this who is waiting on all of the peices. I'll stop by tomorrow to verify that there is nothing else needed. So hopefully soon I can test fit it on my car and send it off to Brad to test fit it on his TL-S.

ModAddict

scalbert

I went by the machine shop and the pieces are all cut and machined now and he just needed my approval before going to the welder. It should be welded up at the first of next week with test fitment shortly there after. Once verified on my car it'll be sent up to Brad for test fitting on his car.

Then the next step is purchasing the main IC and having it welded up.

As ususual, this is taking longer than planned but should be an excellent system when completed.

ModAddict

Steve, your IC design is a super clean setup! I don't think anything could top it.

scalbert

I just picked up the main plenum a few minutes ago and boy is it stout. It should support the IC very well. As previously mentioned, I'll test fit it in the next day or two and if it fits fine without any modifications I will pack it up and send to Brad for testing fitting on a TL.

When that works out I will go ahead and order the intercooler and get it welded up.

I took a few quick pictures with a Web Cam I have here. I'll take better picture later tonight and post them.

ModAddict

looks like "a better moustrap"

scalbert

I'm really looking forward to getting the intercooler hanging off the back of it. BTW, we should have enough intercooler to support 750 HP.

ModAddict

Do you think that'll be enough?

Smitty

u r nutz

types1967

i just need enough to compete with the concord lol

ModAddict

I'm curious to see if the psi goes up, or down, at all with the new manifold. I would think with the cleaner path to the runners it would go down a bit, but you still need to go thru the same runners, so.....

If we added the IC with our current setup, I assume would we have fuel problems.

Chemmech

Wow HBP in Cal is an option then? Are you considering selling kits?

scalbert

That is precisely what I was thinking about the boost. Actually, we are going through only 50% of the factory runners; the injector base only. Plus, it is a straighter path. So IMO, boost may drop some. How much we'll have to wait and see.

As for fuel, I dunno there too. Certainly with the e-Manage we can do what we need to run with the IC. But without the e-Manage we'll have to see. I'm moving the IAT sensor after the IC so it will see the cooler temps and should adjust fuel delivery. If this is enough I can't say but it might be adequate.

scalbert

I had planned on building only mine but then ModAddict, types1967, and Smitty wanted one so I went a step further. If one were to be done it would have been manually machined. But since multiple were needed I did up CAD drawings for all parts and the pieces were CNC machined. Now a couple of other may want this system as well once the results are in and it shows the expected gains.

So yes, it will be available and it should allow you to run the HBP in Ca. In addition, with the e-Manage as well, you might be able to run up to about 8 PSI boost by backing off on timing a little more.

RUF87

Real , but I IT!

Ruf

Ogolden1

Scalbert, please add me to your list as well...

IT'S A DEFINITE !!!

scalbert

I just did the test fitment. It turned out well but did require and will require a few minor grinding points. I'll adjust the drawings to account for this. There was less clearance at one point that I care for. But the whole unit had another 1/8 inch to play with and could be ground down another 1/8 inch. This will be fine giving a final clearance of about 3/8 inch. But the rest, excluding this one point, had more than enough room and fit great. The other measurements also looked good.

I'll make the slight changes needed and get it shipped out to Brad early next week. Once confirmed on Brad's car I will go ahead and order the IC and get it installed.

BTW, in the view from the driver’s side; two of the holes are for threaded fittings for vacuum connections. One other is for the IAT sensor. The top left area is the mount for the MAP sensor.

ModAddict

Gaaaawwwwwdayammmmmmmmmm that is fvcking great!!!!!!!!!!!

scalbert

I may be able to expedite things and avoid sending Brad the unit. Any chance you can place some clay at the four corners of the upper manifold cover and see how tall each point is with the hood closed and revved a few times??

ModAddict

EGR simm?

scalbert

I really wonder how unmanageable this car will be with 380+ WHP, maybe 400+ WHP...

I was driving into work this morning at about 6:00 AM and the temps were about 35F; the coldest I have been in with the blower. I rolled on the throttle in 2nd and it broke loose easily; this was at 45 MPH already and without any clutch input. I have 235/45 ES100 tires and had been on the interstate so they were warmed up. Another 60 - 80 WHP is bound to create traction limitations well into 3rd. :o

scalbert

Nope, the EGR system will be fully intact. So it will comply with all emission guidlines.

mattg

that is awesome steve. can't wait to see the finished product.

we still on for the intake swap?

ModAddict

Sure thing! Not the black plastic cover, you want the smaller cover that covers the inner plenum, right?

scalbert

Correct, the light gray one with the ten bolts (eight bolts and two studs on your car ). Also, the upper portions of it; the highest elevation sections but still at the corners.