Benzo's new ride

[Benzo4gT]

I was advised to go long and have a nice 45º merge, hence the setup. But I haven't run it yet so I suppose I'll find out LOL
The usual issues I've heard of are lack of fine waste gate control, I'll be running a 100 cell cat just after the merge so it should have a bit of back pressure, plus I have an EBC that lets me adjust duty etc. every 500 rpm so I think I should be ok.
If I have any issues I can easily make it shorter

 

[evo-gsr]

Less talk..more fitting.

 

[Benzo4gT]

I'm on it man, did the welding for the W/A IC mount today.

I'll post some pics of the progress. I'll have it up and running by easter weekend.

 

[evo-gsr]

Good shit....cant wait to see how it goes!!

 

[Benzo4gT]

Today's progress. Lots of fiddly work, I extended the MAF wiring the suit the new location, and got the intercooler and fuse box in position. I'll weld the brackets for the washer bottle tomorrow after work. I'll run the IC hoses through and put some shields up for the MAF.

 

[White Knight]

Looking good Benny!!!! Top effort bro.

 

[evo-gsr]

Good to see some progress.

 

[Benzo4gT]

I finished the IC outlet to TB today, It's functional but not a fancy as I was intending it to be. I went with form over function, welded the whole thing from a mild steel 3" doughnut so I could get the sharp turns needed.
I still have the air filter shields to figure out, and the W/A radiator and pump should be all done by tomorrow night. I think the flow of the pump might not fit the requirements that I need, but I have a temp gauge to let me know what's going on at full load, so running it hard will be the only way to determine if a higher flow diaphragm pump will be needed.

I still need to get a ring welded on to make the TB have a 3" sized outer, and I need an oem oil filter housing gasket.

 

[grndsm]

I'll be running a 100 cell cat just after the merge so it should have a bit of back pressure

That stinks . Are your laws/inspections are so strict that you can't get away without one?

 

[Benzo4gT]

A lot of guys go without one, but it is illegal in all states. It's perfectly ok to put in a test pipe or run half an exhaust system for a track day.

The cops over here have a nasty habit of waiting outside a drag strip or a track day and pulling everyone over for a roadworthy inspection on the way in. I drive past an inspection station a few times a week so I want mine to be 100% street legal regarding cat converter and proper ride height, pod mounts, wheel size etc.

 

[evo-gsr]

Especially when it stands out the way it does!

 

[grndsm]

We have all the same laws in US, some are federal and some are state. Since emission controls are federal laws and all police force works ether for state or cities/towns, cops very rarely enforce cat laws. However, what they do in my state is even worse, we are not allowed to modify our exhaust louder than stock! And some cops are very strict about it! That is why I have 3" downpipe that goes into 3" electronic cutout, connected to a stock Summit exhaust . So my Summit has two modes: stock quiet or OPEN DOWNPIPE!

But that aside, would cops really harass RVR? To most of them, it is just another minivan and who would modify a minivan

 

[Benzo4gT]

I'm probably paranoid because I go past the inspectors so much. I have faffed about with some flanges and am welding up a dump for any drag day I can get to, not as fancy as an electronic cutout though

 

[grndsm]

This my "cat" . Only $160 on eBay and had been working flawlessly! Aside from leaking a bit...

 

[Benzo4gT]

NICE!! I might have to get one of those.

 

[TBOWGN]

Haha, epic Leon :w00t:

Nice work Benny! I might be a bit slow on all this, but whats the box all about?

 

[Benzo4gT]

The box in the engine bay?

That's the water to air intercooler, it will make sense after I hook up the piping.

 

[TBOWGN]

Ahhh nice, thought it was initially but then saw the pipework still go down the front.... What's the benefits? Quicker boost?

 

[White Knight]

Cause race car!!!! Ha ha ha.. Had to.

 

[Benzo4gT]

Ahhh nice, thought it was initially but then saw the pipework still go down the front.... What's the benefits? Quicker boost?

The pipe comes up from the turbo, the front housing is rotated to face the outlet up instead of down.

Boost will build faster because there is less space it has to fill up, but it's not going to be and earth shattering difference, the main advantage of a W/A system is the thermal conductivity of water compared to air. The heat will transfer from the boosted air into the water better than it would to air of the same temperature, as in the case of a front mount IC.
Water also has a really high specific heat capacity which means it will absorb just over 4 times more heat than air will.
The downside is that once hot, water will stay hot for a long time, so it's more suited to short bursts, not really suited to track racing...............but on saying that, I have a huge radiator for it, and a 10lt reservoir that I can put ice into......................AND an additional small radiator inside the car that I can lay a block of dry ice on top of to really pull the temps down for any track/powercruise type work.

I don't know of anyone anywhere that has made a setup like mine, and I can't wait to see what the intercooler water outlet temps are with some mountain driving. I plan on doing a full write up with data once I have tested it's limits.
But in the meantime here is a pic of the intercooler radiator, it's a modified CC lancer A/C condenser which sits in front of my oil cooler.