Hypergear Turbochargers and High flow Services Development thread

[t_revz]

Jez- is it just the way you set the boost controller/ tuned that e85 line isn't more responsive? Or is it a very safe e85 tune? Am I missing something. I thought most ppl gained 3-500rpm more response

[GTSBoy]

Yuh, per Jez's adendum to Stao's post, both lines are E85.

[cherring]

The green line is the low boost setting, which is basically just the actuator I think controlling the boost, the red line is the Higher boost setting, both are E85, Jez did a f**king awesome job, as usual!

EDIT: I didn't see the response from GTSBoy, I just said something because it's my car

Edited October 14, 2012 by cherring

[hypergear]

I've mis-read your comment in the dyno sheet section. the none boost controller version do appeared to be a little more responsive for some reasons. Good result nerveless.

[cherring]

Yeah I'm really happy with how that turbo goes, really good power for a small turbo, very happy! Also happy that United service station went in not too far from me

[t_revz]

Yuh, per Jez's adendum to Stao's post, both lines are E85.

Facepalm. My bad

[DVS JEZ]

The response can be missleading from run to if the exhaust temp is cooled down.

ie: the high boost run was probably the first run ater letting the car cool down etc.

hard to explain but both are the same response.

We did pick up a tiny bit of response with E85

[DVS JEZ]

Heres the overlay of 98 vs ethanol

[Manuel Kasko]

It seems to hold 20psi perfectly!

Good effort Jez!

[hypergear]

Here are some results today from using the aftermarket CN bolton manifold. There is a gain but not impressive. All three runs below are from one turbocharger.

Power wise:

Red used the lowest boost making the highest power = Brae bolton manifold (winner )

Dark blue = Ported stock manifold

Light blue = China stainless steel bolt manifold

Boost wise:

Stock exhaust manifold was the most responsive,

Brae exhaust manifold was the 2nd while stainless steel CN manifold was the laggiest.

During tuning, the CN manifold took 3 degrees of additional timing up top while stock manifold would've pin, making timing table wise identical to the $1200 Brae manifold. That is shown in the gain after 6500RPMs.

The SS2 turbocharger used today was also fitted with my twin actuator setup that had the least amount of boost drop compare to the other two.

So in conclusion while having the the highest boost level, been the laggiest, but Still not good enough beating an $$$$ hand made Australian manifold. How ever still an better exhaust manifold compare to stock. I will do one more run with in a week time using the .82 Ceramic roller SS2 against results obtained using factory manifold before making the final decision on having them imported or not.

[petero'nell]

I've got the SS1PU on stock manifold at this stage. Will there be much of a gain using your manifold?

[hypergear]

The SS1PU result that I've got was based on using this type of manifold. So there should be a 10% gain V fully standard exhaust manifold.

[jet_r31]

So you not going to test the stainless mani remade in steampipe first before delivering a verdict?..i thought it would pick up

spool made in steampipe due to retaining heat better?

cheers

darren

[GTScotT]

I think thats one of those things that is true, but not noticeable on the road or on the dyno. Negligible difference.

I can understand if Stao scraps the project if the OEM item works close to or well enough hey.. Its probably easier for fitment and a better result to hang a gate off the housing instead.

Stao why not back to back these 3:

SS2 IWG stock manifold

SS2 IWG stainless stock position

SS2 EWG/housing stock manifold

My money is on the EWG version topping them all and we wont need to test this stuff again.

[hypergear]

Well its still a dirt cheap part to buy, works out cheaper then me modifying a stock manifold. I will be doing some further evaluations and see how it goes.

[GTScotT]

No I dont mean to plumb the gate off the stock manifold, I mean to leave the stock manifold as is and pop the gate off the turbine housing.

Am confident it will work best.

[Dose Pipe Sutututu]

No I dont mean to plumb the gate off the stock manifold, I mean to leave the stock manifold as is and pop the gate off the turbine housing.

Am confident it will work best.

But if there is a restriction in the stock manifold, then plumbing it off the rear housing won't be as efficient as plumbing it off the stock manifold to relieve the exhaust pressure. It is only beneficial to plumb it off the rear housing if the manifold is not restrictive.

That's my belief

[GTScotT]

I dont think either or will resolve the restriction in the manifold, but there is also a restriction posed by an internal gate size.

My SS1PU has a MASSSSIVE flapper and port for an IWG turbo, and even then its only about 29mm.

Popping a 40mm gate (from wherever really) would reduce the restriction from the turbos side and allow you to get a little more, still working within the flow restriction of the stock manifold. It simply stops the two from compounding and becoming worse.

Doing it off the housing just means Stao can continue to supply the turbos as a kit, still fitting the OEM dump pattern and leaving the user to simply make a screamer pipe or plumb it to his existing dump.

It will also open up the market for people who want to go a .63 rear housing for mega response, and who need an external gate to bleed off the higher pressure in the exhaust.

[t_revz]

Stao why not back to back these 4:

SS2 IWG stock manifold

SS2 IWG stainless stock position

SS2 IWG v-band stock manifold

SS2 EWG/housing stock manifold

Discussed this with Stao last night as I wouldnt mind getting my dump away from air con drain and a little higher while I'm making changes to my exhaust.

Not sure if it would be better of not. Maybe only past 280rwkw would make a difference?

Thoughts?

[GTScotT]

Neg. Spool would have an effect too as it takes more mechanical effort to crack the 40mm gate than it does the 29mm flapper.

benefit you describe as 'up top' would actually start from the moment your on full boost. I am guessing you will be able to wind in more timing as pre turbine gas pressure would have a decent reduction.

please don't make the decision on my opinion alone though, as I don't want to feel solely responsible if it doesn't work as well as I might imply lol