EDIT
I have taken it a little further than expected.

Some highlights
Hood dump wastegate flames post 6
More flames...Ignition cut while on "stock ecu".. sorta post 24
Aeroturbine muffler setup out the bumper (loud turbo!) post 25
LS2/7 "truck" coil setup post 32
AEM series 2 EMS post 40



Original Post
--------------------------------
Thought I'd share where this project is at. I got out of cars briefly when I got my pilots license.... and then somehow ended up with this EVO. I was only going to lightly mod it.. so much for that. I've had a lot of wild projects in the past.. I always end up doing something a little different/nuts/borderline retarded. (for example I built a custom sideways sitting bw s366 setup on my duramax and gave it a hood stack) I didn't go as crazy on this one... but had to do something custom!

Here are some pictures of the fender exit build. I made a divorced 3.5" downpipe setup into a 3.5" Borla XR-1 (still a little louder than I hoped). The wastegate dump has 2 small mufflers (it's still a bit too loud as well). All this is hanging off a map ef4 / fp manifold combo on a built 2.4SR (head is stock other than HKS 272 cams).

Cramming all this stuff inside the bumper and keeping ground clearance was a challenge. It came out really good other than being a little loud. It spools ridiculously fast- it will reach full boost at ~3k in higher gears but it surges so I don't bother. (This ef4 has the older 11 blade turbine wheel, I had to send it back the day it showed up for this mod- map decided this needed to be done for longevity purposes... contact them for details.. so it took 6.5 weeks to get my turbo).

Anyway.. the best part is that it pulls all the way to 7800 (where I have the limiter) which for a 2.4/small cams is pretty nice!! Stock turbo was dead after 6k.

Power may look low, but keep in mind I'm at 6700ft elevation and 91 octane right now (E85 is 35 miles away, I've run it before but it was a pain having to drive that far for fuel... trying to avoid it now). So running 26psi up here is basically the same as 23.6psi at sea level.

Anyway on to the pictures / videos / dyno etc. Thanks for taking the time,
-Todd

Immediately stripped this when just getting it snug (since the drain is behind it, and it's thin, not a fun place to tap.. but it's done)



Building Stuff




Had to be tweaked from here some



KBB coated (not very good, already peeling off)



No muffler yet... Here is a video of the first startup.. running like this...


Slight muffler modification



Done!



6700ft elevation / 91 octane / 25-26psi up top (I set it up to taper upwards to help the 2.4 to rev out better, avoid clutch tq issue - got screwed by a member here, my twin disc isn't an HD like it was supposed to be)


I noticed I didn't get a pic from underneath when I was all done. But the wastegate tube runs into the stock downpipe location and has two small mufflers there....

I really thought it would make more - even on 91 octane. AFR's are at 11.0:1 and the timing is about -3 at 4500 and 13 at 7700. It doesn't seem to want any more timing down low, this motor has always been real knock prone from 3500-5000. Even with the sensitivity turned down a little. Might have to bite the bullet and go back to E85. Hoping to go with a flex fuel type of setup instead at some point.

I'd just like to squeeze a little more out of it, but it does run nicely, pulls harder and harder as you rev it out (I prefer things like this). I'll keep tweaking and update the thread if any more power can be found (I just got it together and tuned it yesterday... so there is probably some progress still to come). Thanks,

EDIT: dyno vs. stock 8 turbo.. same road, similar temps etc.

 

very sick setup, I like it!

 

thats clean for a stock turbo!!!

 

thanks guys... decided to change things up a bit. the dump tube was still kinda loud even with two little mufflers..and the v band was leaking and in a place that was a lot harder to access than I thought it would be when building it... decided to go full retard and do this:







I mean.. I have a hole in the bumper.. why not

I'll finish it up tomorrow

 

thats what I have going on, dual dumps out the hood and side exit coming soon! best way imo

 

agreed! but they are both so loud


here is a video of some flamage

video doesn't due the loudness any justice, it's actually disgusting even with the windows up

 

Just plain awesome. You get a ton of weight savings doing a bumper dump exhaust. I cut 32lbs off of my car doing it. Even more if it was a stock exhaust. I also did not have any problems road racing with my exhaust dumping near my front tire.

 

Looks beastly. Keep removing weight haha!

 

Ordered a tial mvs wastegate due to the internal flapper failing. I have driven the car 3 times. And am already out of adjustment on the internal actuator arm. Every time it gets hot, it gives and I lose pre load. And I'll I have done are single gear pulls while logging/tuning.

It's been a very frustrating few days. MAP offered to replace the housing but the thought of tearing this all apart again, plus gaskets, plus the fact it could just happen again led me to go this route. It took 6.5 weeks to get the turbo, and now this....arrgghhh... but if the turbo itself holds up, I'll get over it and move on.

Thankfully this hood dump setup will allow adding the tial fairly easily...

 

EWG is the way to go bro, much more stable and you can really fine tune it.

 

Been a frustrating week or so. After the internal wastegate failure.. I fabbed up the tial setup, and on the first drive the alternator took a crap. Turns out all the bolts that hold it together fell out lol

$330 and a 4 hour drive later I had an oem replacement... being that I have a lift, it wasn't hard to put it in from the bottom.. but still. Then the real fun began... immediately started having bad break up issues under boost.. mostly in the 4k-5k area but a little up higher sometimes. Didn't matter if I was at 22 or 27psi.. leaning it out helped some. Tried new plugs at a few different gaps.. at 17 thou and running it pretty lean it was far better, but still there. I pulled the injectors and cleaned them, tried replacing the coils 1 at a time (honda denso coils, I have 1 spare to test with). A lot of hours pulling my hair out.

Ended up I noticed I had a set of new BR8ES (non protruded tip) plugs laying around.. decided what the heck. Literally have made 25 pulls without a single issue. Pulling nice and smooth now.
Can't really explain why I am blowing out spark at relatively low boost. But these plugs must move the tip out of some of the violence inside the cylinder and it seems to work great. I read an old thread on here where there was a lot of people switching to the non-protruding tips and getting rid of misfires etc. Interesting. Boost back to 25psi tapering up to 29 and pulling strong.

Made nearly 500whp dynojet VD. Going a little lean on top...so I ordered an AEM fuel rail and bought enough stuff to rewire the pump (I have the 320 aem e85 pump and I had drilled out the small holes on the rail.. along with larger lines and my own filter setup bypassing the factory filter). Looks like I'm at the end of what the stock rail even modified will support. I actually don't need anymore power but I don't want to be riding that fence.

 

Had to work a little magic to get the dump to line up with the hole in the screen on the hood(from the internal WG dump setp). Much easier to fab the pipe, and cut the hole to the pipe.. not as much fun the other way around lol. But it came out good.

Here is a 4th gear pull (on kill, so to speak)

I didn't actually go WOT till after 4k. This turbo will spool at 3200 (full boost) in 5th gear at 6700ft elevation. But I'm on a 2.4 and this ef4 has the older 11 blade wheel. You need to contact MAP before you buy one of these, depending on your power goals they will set it up differently to try and give the turbo a longer life. Partly why it took 6.5 weeks to get this stupid thing.

Anyway.. it picked up a nice chunk of power going to e85. And I'm sure with more boost it would get pretty silly (29-29.5 up here is only about 26psi of boost at sea level)

 

Decided I wasn't happy with the xr-1 muffler. It kills the sound of the turbo, and not much else. So I built a muffler. I have a theory about the size of the holes in the inner tube. I have built several mufflers in the past, and it seemed like larger holes target lower sound and smaller wholes target higher sound waves. At least, to a certain degree anyway.

I built this last night and my theory seems to be somewhat true. It's actually quieter than I expected (quieter than the xr-1.. we'll see after it burns in though). The turbo is noticeably louder.. hopefully a little less resonance and "boominess" as well.. haven't driven the car yet there is a foot or so of snow outside. And I did a pump rewire yesterday with an 80 amp constant duty relay- and I'm getting 55 psi pressure at idle so I have to pull the tank assembly and drill the T out a little...


EDIT: modified the return T fitting. Always such a pleasure to pull the pump assembly. Anyway... it's easy to see why it makes too much pressure at idle when you see the size of that hole. I realize a person shouldn't enlarge this too much, so I didn't go nuts on bit size, bam.. back down to 45psi where I wanted it.

 

New road dyno best. (4th) In third it makes about 20hp less. This is 29.5 psi peak (dyno boost readout wrong).. so about 26psi relative to sea level. Really running strong.. of course this was after a string of other issues. Turns out my AEM pump was a little too close to the bottom of the tank and was starving for fuel. But not on every pull... the filter down there had picked up a little bit of junk, and sometimes it was sucking the filter up into the inlet and starving.. but the first pull after shutting the car off it wouldn't do this. So that took some time to figure out....

But now with the pump moved up (modified the assymbly some more to move the pump up a little higher) and the AEM rail it seems to be happy once more.

 

Car is still going lean after modifying the pump. I really don't think the regulator is to blame. I think it's the AEM pump. A walbro 450 e85 pump will be here on monday, so I'll find out then! Hopefully that fixes that issue once and for all... because