The results today with the amazing new BR500 turbo kit have shown me that on pump gas it runs very strong at 20 psi of boost and is very pleasant to drive

We have made recent strides in the reflash technology which allows us to re-scale the load reference to provide for higher boost applications than the stock mapping

My concept is to provide a special reflash to accomidate racers who occassionaly take the car to the track and use the carf as a daily driver most of the time

This is how it will work

most of the time you will run pump gas at 20 psi of boost max and get about 340 - 350 whp - the car will run totally smooth and will function as a stock car as far as driveability and idel is concerned

when tou go to the track you simply pour in RACE fuel - C-16 or other high octane racing fuel and turn UP the boost to the higher load refernce of 26 - 30 psi

At the higher boost settings you will have a full race tune and be making at least 420 - 450 whp

For now this dual stage flash will ONLY be offered on a custom basis

As a special promotion - I am making an offer of free race gas and no extra charge for the extra mapping to create a DUAL STAGE DYNO FLASH for anyone who books a custom tune or custom re-tune appointment with me at my dyno facility - Pruven Perfromance

Please note - this option is ONLY available with aftermarket high boost turbos such as the Buschur 440 or 500

 

 

VERY COOL
I almost bought an APR Stage 3 fo rmy 1.8T Jetta instead of selling the Jetta and getting my Evo. I loved that turbo kit because it drove like stock on the street tune - and you could throw in race gas at any time, hold down the cruise control for a certain amount of time, and it would switch to a race tune adding 50WHP+!

This, I think, is an Ideal state of tune for anyone like me. I plan on the BR440 or the BR500 next spring. Switching from 350WHP or 400WHP on pump to 50WHP more on race gas would be SWEET! I dont want to have to invest $2k in am AEM EMS and have to have it tuned all of the time....

My car is my daily summer driver and I plan on hitting up many race courses/drag strips next summer.

My only question : what would be the cost of the dual stage?

 

Of course the ONE big disadvantage with this set up would be risk of serious engine damage with over boosting.

IF you accidentally set the boost too high on pump gas it would really result in a dangerous condition with the pump gas on the race part of the map and high boost.

Therefore, as a safety measure, I would suggest an electric boost controller with a built in over boost protection and set the warning right at 22 psi. This way it would be impossible to go over 22 psi (as long as the boost controller was working properly)

While not a perfect solution, the Dual Stage flash option will provide the sportman hobbiest with 90% of he perfromance and flexability of a full stand alone system at a fraction of the price while mainatining full OBDII emissions compliance and stock like driveability.

If you are interested in trying the Dual Stage flash feel free to contact me directly to arrange a tuning session

 

Right now we are going to do it for the same price as the regular Dyno Flash on our dyno $500 with your dyno time included.

The way it works is we set your boostr to 20 psi in all gears and map the car as usual on pump gas.

Then we pour in the race fuel and turn up the boost to race settings 26 - 30 psi depending on your engine's mod level

Then we map the race segment of the map with more agressive a/f ratio and ign timing

Like I said at this point the service will be offered at NO additional charge and I will throw in 5 gallons of c-16

Later there will prob be an extra charge for an extra hour fo dyno time

At this point its just another inovative idea I want to try out

Based upon the great potential of the BR500 turbo - I think the dual stage flash is a real possibility

 

Good thinking Al. That is honestly the perfect solution. Actually GOOD DAMN THINKING. This would be a quick and easy solution on the EMS too, I can picture what you are going to do.

Normally....nevermind, I was going to go into how a tune is usually done. Let the other guys figure this out on their own.

As you said, doing a tune this way is going to require a VERY STRICT control over the boost levels that are run. Set it tune safely to 22 psi is your thought? Then set the boost at 19-20 on pump gas for some extra safety margin? At the track just get the boost anywhere over 22 psi on straight race gas and the race map will take control? Right?

You really impressed me with this idea!

David Buschur
www.buschurracing.com

 

The trick was seeing a turbo which runs very FLAT line boost from spool up to red line. The stock turbo has too much spikeing up and falling down so it was difficult to arrange a dual stage tune. Also there was not much head room on the stock turbo and no real extra power from cranking to boost.

With your BR500 the boost is flat with very little taper. Actually yesterday at 20 psi we saw the boost slightly rising - not falling towards the red line due to our higher timing up there

This kind of turbo presents us with the idea opportunity for a true dual zone tune which can accomidate bothe pump gas low boost operation and high bost race gas use

I can't wait to start woriking on revising the maps and testing this new concept on the dyno

Once we have confirmation from dyno results and testing with a few cars under our belt we will start releasing this new Dual Stage Flash in out through the mail base flashes and also possibly in the Buschur Flash upon special request

 

This sounds kew , but how would you/ecu change from pump gas tune to race gas tune ?

 

If I understand correctly, the way this would work is that there would be a specific area of the fuel and ignition maps for the load the engine would see at 20psi. When you crank up the boost to a specific level, say 28psi, the load would be much higher under WOT and the ECU would access a different area of the maps. So, basically just turning up the boost "switches" the tunes, under WOT at least. What Al seems to be saying is that the stock turbo boost output is all over the place (surge & taper), making it difficult to create two different distinct areas. The BR440 and BR500 apparently creates a very flat boost curve so it's easier to delineate between "low" boost/load areas of the map and high boost/load areas of the map.

With the AEM you have the ability to create a boost compensation curve. I know this exists for fuel, I'm pretty sure it will compensate the ignition tables as well.

 

Wow, this is indeed a neat idea.

 

I agree that is a novel idea. Good luck.

 

One question I would have is about drivability.

Presumably those top rows in the fuel/timing maps would have to cover all airflow situations greater than or equal to stock peak. So that's a pretty big jump in fuel and a pretty big retard of timing between the 2nd-from-top to top load rows.

Other question I would have is about the margin of safety needed to absolutely keep the ECU out of that top load line. How compromised would the pump gas tune be?

Still, a neat hack to support two levels of boost.

 

The main issue is DO NOT over boost on pump gas

Normally we tune in a very safe - saftey net if you will - in the highest row of the maps in case you over boost. Obviously the stock ecu has overboost ecufuel cut - which we promptly remove

So the big issue is that this path is only for you if you understand that over boosting to 26 or more psi will blow up the engine on pump gas

This is why I suggest a Electric boost controller with overboost protection warning as a back up saftey - would be a good way to keep it from going over say 22 psi on pump gas

With a flat boosting turbo like the BR series turbos there is no way you will get anwhere near the bottom / high load zone with the boost controller set on 22 psi

As far a the load refenece to hit those zones - like I said before - what makes all of this even possible is that have been able to re-set the load reference zones in the stock maps

 

sounds good al i think all the guys with the large turbos are gonna jump all over this.

 

I think it will be a good solution for a guy who wants to use the car as a dialy driver 99 % of the time and make a few trips to the track every year. Gets you 90% of the power you can get from a stand alone at a fraction of the cost and stock like driveability