Buschur's dyno testing......never ends.
 

Back on the dyno today with my RS. The quest to improve what we do and how we do it never ends.

Most of you know at the end of this year my RS ran a 9.04 at 159.64 mph. The car at one point was making power in the 680 whp range on our dyno. The car was getting tired I suppose and we changed the header configuration, turbine housing, 02 housing and a few other things. As the dyno testing kept going on and on and on I was losing power. I finally decided to just take the car to the track and forget about what the dyno was telling me. By the time I had given up on the dyno I was in the 630 whp range. That's quite a ways from the 680 whp I was at. The dyno I guess lied to me because it ripped off the multiple 9.0 passes:)

After the racing season was over we pulled the head off and I pulled the pistons/rods out of the engine in the car. A quick inspection showed everything looked good but the rings were showing some signs of not sealing, probably from the cam sensor failure that hurt the head in August at the shootout. Anyway, I touch honed the cylinders and put a fresh set of rings and bearings in the engine.

While the timing belt was off the car I decided to have the guys finally install the 12 tooth crank trigger that I had been looking at on my desk for months. This new 12 tooth wheel takes the place of the stock crank disc. There is modification needed to the cam sensor trigger. Then of course there is quite a bit of set up required in the AEM EMS. The purpose of this new crank disc it so the AEM has a better signal from the crank sensor. It will allow the AEM EMS to sync instantly and the car starts faster. It does work, 100% as advertised. There seems to be some other benefits to it as well that I am seeing in the logging on the AEM. I'm not going into all that. The part is available direct from triggerdisc and we have been autorized to sell them as well. I'd suggest if you are going to do this to do it when you have the timing belt off for something else.

Next up I wanted to get some better temperature readings for the cam sensor shield. I did a pull, checked my log and then hit the header, shield and cam sensor with the laser heat gun. The header tube was 370 degrees at the point closest to the carbon fiber cam shield. The cam sensor shield at it's closest point to the same header tube was 165 degrees. The cam sensor itself, only 126 degrees.

Let's step back for a minute to when I was dyno'ing the car and swapping parts. I went from the header I had built for the car to the one Ron Shearer and I worked on together for the forward facing kit. When we made the header swap I also changed turbine housings. There was a loss of low and mid range when the headers/turbine housings were changed. I chased this for quite some time and that is what I was chasing when the power started falling off that I was talking about earlier. Tom Powell and I were looking over some of the parts I used on my car when we were deciding what to run on his car. Tom noticed that the turbine housing I was using on the header I built was completely different than the housing that was on the car after the header change. Some measuring showed a large difference in the actual physical size of my old turbine housing vs. the new PTE .82 4 bolt housing I was using after the header swap. After making some phone calls I found out that the PTE housing and the standard 4 bolt housing we generally use from Garrett (T31 housings) are old school, basically. The housing I had been using (on the header I had built) was the new Garrett GT turbine housing. It got my brain churning and since I just couldn't get the low/mid range back I had lost I figured it had to be in the turbine housing. Problem was there just wasn't enough room with the forward facing turbo to fit the Garrett GT turbine housing. You know what they say, "You have to pay to play." I like to play so I bought 5 of the Garrett GT housings and had them machined to work/fit with our forward facing kit. That brings me to the next part of the testing.

I made the base pulls with the PTE .82 turbine housing on the car. Which BTW, performed better than the standard Garrett .82 turbine housing by a slight margin across the board. After I had a good baseline this morning I swapped the PTE housing over to the GT .82 turbine housing we had machined to fit. I found my losses or I should say most of them that I had encountered when I swapped headers. The gains were most notable from 4300 to 5800 where they hovered in the 20+ HP/FT LBS. The largest gains were close to 30 hp/ft lbs. Peak numbers didn't change much, 8 ft lbs and 6 whp. A heck of a nice gain for just swapping the style of turbine housings and keeping the same A/R's.

The next test was to run our standard Race FMIC against our new BFIC. Before I even started I have to be honest, I wasn't expecting much as the air intake temps were in the low 50's to begin with. I was correct the gains were not noticable. I keep extremely good notes of my own car and the changes I make. I note the AIT's, AFR's, the RPM the car reaches 20 psi, rpm it reaches peak boost and the boost at 8,000 rpm. The increase in temperature across both the race and the BFIC was only 6 degrees F on a 3rd gear pull at 41 psi of boost. The difference to reaching 20 psi was only 55 rpm. Peak boost was the same and boost at 8,000 rpm only varied by .13 psi. I believe in order to actually see the difference between the two intercoolers we would need to test in some hot weather and in some more extreme conditions.

Last but not least. DEI just released a new turbo blanket. I've seen a lot of these through the years and they were all junk to be honest. Hard to install, looked like crap, couldn't really re-use them after removing them once etc. This new product from DEI is just flat out SWEET! It is perfectly formed and sewn to fit the T3 housings. The material is actually made of Lava rock and there is an inner padding/insulation that is made of silica and has a temperature rating of 2,000 degrees F. The turbo blanket has three heavy duty metal bosses embedded in the material so you can safety wire the blanket to the turbo. The install, seriously took me 3 minutes, including twisting the SS wire with the safety wire pliers. I did the dyno pull, Trent stood in front of the car with the laser heat gun. Immediately following the pull he took a temperature reading of the turbine housing, 693 degrees F. The turbine housing, obviously at that temperature was so hot it instantly burns you. I worked on the car that hot. Right after it was installed I ran the car again, identical dyno run. Trent took another temperature reading and at the end of the pull the outside of the blanket was only 260 degrees. That's a drop of 433 degrees. After a few minutes of Trent and I talking about the results he happened to hit it again, the temp had already dropped to 130 degrees. I told him, "If that's right I should be able to touch it and not get burnt." I took the plunge, it was correct. I could lay my hand on the blanket no problem.

This is huge for heat control under the hood. That is a lot of heat gone from the engine bay. DEI is releasing a complete kit that will include the turbine housing blanket, a 2"x15' long roll of titanium wrap (made of the same lava material), ss wire ties for the wrap and safety wire for the blanket. This kit and the turbo blanket by itself will be available next month. Anyone interested we are going to offer both the blanket and the kit at 20% off for pre-orders. The blanket alone is $230 retail, it will be $184 for this introduction. The entire kit is $251 retail and will be $200.

Here's a picture of the turbo blanket on my RS:

http://img.photobucket.com/albums/v2...rboBlanket.jpg

Last but not least is the final dyno sheet from all the work today. Considering the car ran 9.0 with the power levels in the 640 range, this new power and improvement on the power curve should put the car well into the 8's. It's going to be a hell of an exciting year next season!! Final numbers, 677 whp/536 ft lbs.

Here is the dyno sheet:

http://img.photobucket.com/albums/v2...hur/rs1210.jpg

wow, impressive. :)

what are the major differences between the 2 housings you tested? the new and the old

David, you have a PM with my order. I've seen this blanket in person and it fits like a glove. Don't sell my housing either! As usual, if it wasn't for your testing, we'd all still be wondering whether something works or not. Thanks for your time and testing.

dave .... stop the testing already all the money i keep making you make me keep wanting to spend it ...lol keep up the good work..

09 is gonna be a sick year....BR FTW

this thread is the reason why I <3 BR soo much! IT just never ends, constant development.

^ then switch that AMS IC out for the BR race core

The main difference is in the two housings is the actual area of the snail portion of the housing.

9sec9, I've always got parts for you buddy;) Glad I can be of assistance. You are still kicking my butt by about 45 whp! I compared our dyno sheets today, again;)

Good stuff David,

That is the finest looking turbo blanket!!! Good find and great results out of it , over 400 deg. Wow.

That has to help with IAT's

Congrats

Very nice!

Do they make a turbo blanket for a T4 TS housing?

looking forward to 09

Thanks

Evan Smith

I will after I buy drop ins and my BF272s that I already have get installed. Work is stupid slow right now in the auto business. I was hoping to already have the money by now. Atleast i havent been layed off. Pretty much only going to get stuff from Buschur anymore. The only place that Ive delt with that gives you what you expect for a good price and sound advice with expeirence.

Back on topic now. David is this still the FS635 that you were using during the turbine housing tests?

Yes, they make T4 blankets. These things are quality plus. Not something that just wraps around the housing and is just 'OK'. I spent quite a bit of time at this booth looking at these. REALLY nice product. Also, David, I have a sneaking hunch that you can find that 45 whp difference. I think I know, but I've got to keep an Ace in the hole. LOL. Since I know what's in developement AND what next years plans are, I would say that REAL FUN is just around the corner. STAY TUNED!!!!

I can't wait till spring can we just rent Norwalk already haha.

Me too. I was talking to Curt Brown today and told him how much I really missed being around the 'group'. These guys are so much fun to race with and just hang around in general. I don't think I ever expected to find friends like all these guys. I've met so many good guys this year that I'm still in shock at how down to earth they all are. Names that were only legends to me. This next year, we'er going to have so much fun that we'll all mark it down as the Year of the 4G63. Mark my words, fun is coming.

I'll be happy with a 9 second pass next year! You guys are going to be running 8's .....grrrr.... stop going so fast.

Thanks David for everything!!! Next year is gonna awsome for everyone:D

David...that's is just sickening!!! winter needs to be over with!! :D

You guys can always pack up and come south! It was 70 degrees today. It would definitely be easier to get some touch up tunes, parts, etc...

Yeah....yeah....yeah.... Lecon.... rub it in why dont you. :lol:

It was 26 here today. :crap:

My Ace! What's up, Jarrod? Nice vids by the way. Sorry, had to throw out this freakish weather we're having. Still, tracks are still open, weather's nice, just have David bring his laptop! {thumbup}

I cant wait for next year allready! My car should be back together this weekend and on its way up tou you guys next week! Ill have to put my order in for the blanket kit and cam sensor shield while Im there. Damn you guys just keep taking my money!

Nice job again Dave. As usual, the BadBish just keeps pulling away from the rest of the group. haha

Great stuff Dave....{thumbup}.

Do they make this blanket to fit a stock turbo?

that's a sick setup

Whats up buddy! Thanks man! I appreciate it.

Heck the windchill here on Saturday was 0 degrees. :crap:

I think its time to move. :)

Yeah to Vegas:)

I am gonna be the 1st in the 9's on 91 pump;)

wow love the numbers i cant wait to bring my car to u guys i want the same setup

:confused:

I applaud your guys testing and commitment - never stops.

A note on those heat gun readings, they are largely influenced by the emissivity of the material you probe. In simple terms two things the exact same temperature will read different on a laser temperature gauge if one part is dull rubber and the other is polished aluminum. Good laser temp guns allow you to manually enter the emissivity value and include a reference list for a range of materials. If your carbon heat shield had the reflective tape on it, and you didn't adjust emissivity, you got a bogus reading from the gun.

To test the impact the shield is having on the cam sensor you should use thermocouples mounted on the senor body and do a before and after. Not that your results are necessarily incorrect, just pointing out some things I've learned in doing a lot of documented and scrutinized testing as an engineer.

Keep on testing{thumbup}

GTFO!! :lol:

So I guess the test where Dave put his hand on it was the most accurate :D

Nice post Dave good luck with your goals.

crcain, Where "Higher Sensitivity" is required, David doesn't do the testing with his hand. That's what he has Trent for, but then again, Trent was the one using the 'Gun', so I guess once burned, once learned.:lol:

"Me too. I was talking to Curt Brown today and told him how much I really missed being around the 'group'. These guys are so much fun to race with and just hang around in general. I don't think I ever expected to find friends like all these guys. I've met so many good guys this year that I'm still in shock at how down to earth they all are. Names that were only legends to me. This next year, we'er going to have so much fun that we'll all mark it down as the Year of the 4G63. Mark my words, fun is coming. " 9sec9

If they only listened to our phone conversations :lol:. They have no idea what's on the other side of the fence :eek:.

David, Thanks for the tip on the custard from Kansas. Fed Ex rules!

Tom, Here is the photo of the high speed low drag Petco dog bed.

From page 1, the turbo on the car for these test were the HTA86, same one I ran 9.0's on.

9sec9 says DEI is making the turbo blanket in T4 sizing, I am not aware of that, as far as I know it is T3 only for now. I could be mistaken. On that same subject it is not available for the stock turbine housing and won't be but honestly, I bet the T3 housing blanket is an excellent fit on the stock housing. I do not have a spare to check it and don't want to take mine off but I am sure it will fit well. When they come in I can check it.

I gotta be honest, as good as this year went, it's going to be hard to ever beat it. This year was for sure a high point in our 20 years of building 4G63's.

Thanks to all of you who have supported us!

Nice David! That blanket actually looks good!

We should all chip in and buy 42. Put some underground water heating in and we could race year round.

Just make it indoors!! :D

Dave, we all have to thank you also! Without you guys being there to build our cars and you being the great guy you are, we wouldnt have been able to have this year either!

And yes, Buschur Quarter would be amazing! lol And indoor would be rediculous!

That would be sick:eek: How much we talkin? Imagine the MPH in this cold ass weather:lol:

^word, thank YOU david and the whole crew at BR. i wouldnt be where im at today without your products powering my car.

Dave, mark me down for one of the blanket kits.

You can put yours on my car if you don't want to wait for them to come in. :santa:

Excellent work as always!

I believe this next season will be even better. There are some real fast cars in the making:D

Thanks David for all the testing. We will get in touch soon.

wow, that blanket looks way better than I had imagined...tastefully done and appears to fit tight. Thanks for sharing the info David, good stuff.

p.s. This Saturday is the last TNT of the year at Memphis Motorsports Park, I won't be ready (tranny is out) but I heard they open back up in February so that will give me some time to perfect the HTA86 pump and race gas tune :)

david im a fan of a ceramic coating called swain tech. you also offer some type of coating. how do you feel this blanket will work along with a coating on the hotside???

Great job as usual with the testin of new parts, we are seein some serious science comin out of BR. 09 should be really fun

Thanks guys, I really mean thanks when I say it. You guys don't owe me the thanks though,we owe you guys for the support and letting us do your builds. 2008 was a kick ass year. Trying to some how imagine 2009 being better is extremely hard to do!

Where the hell are we going to go after a year like this? Faster?! I better get started turning the engine the other way in the black car!;)

My english is not so good so im going to ask,from what i understand,the problem was the PTE housing? i thought it was one of the best housings available.:crap:

:eek: Uh OH! I bet I know what that means!

Turn it!

somebody can answer my question? im a bit morron.

There's no need for that. There is another second to be knocked off those 1/4 mile times yet.:beer:

There was no problem with the PTE housing. The Garrett GT housing has the best power curve and that is what I am always looking for.

Ron, you better come and get this car then;)

Youll make me so happy and envious if you spin the motor in the black car.. I wanted to do it so bad but i just cant take the leap just yet.. It is hard to imagine 09' being better but i am sure it will be since you and I both live for making these Evo's faster and faster!!! {thumbup}

I don't!:spin:





































































Quicker is much more fun!:drink:

Thanks for doing all this testing and posting it up. It really helps all of the rest of us!!! It's really guided me in my car decsions lately.

Have a question about the DEI turbo blanket and forgive me as I'm a newbie to this stuff. I know it'll drop temps but does that make hp/tq? I assume it would help with reliability but not sure about power.

Awesome results Dave and we all appreciate everything you do for the Evo community and always bringing new products to the table for us. Can't wait to meet you and the BR crew this spring!

from my understanding anytime you lower engine bay temps, then you'll make more power.

but how much more power, I don't know...

In theory and I suppose somewhere someone has test results to go along with it, the more heat you can keep in the header/turbine housing the faster the turbo will spool up. That would of course make for a fatter curve on the dyno. In the case of the blanket, I looked at logs before and after and I can't see anything in the logs. Now, any time you can drop underhood temps the car is going to produce more power if that's where the incoming air is being drawn from.

Ace, you're welcome. Thanks for taking the time to recognize what we do.

nice dave,

i saw the blankets at PRI..

im going to use one on the TA along with swaintech coatings (which we use on everything high performance)

cb

Makes sense, thanks for the explanation Dave!

Thanks for sharing your test results with us Dave, as usuall- bringing the facts to the table!!!{thumbup}

Looks like there will be more 5-bolt housings up for sale this season!! :lol:

8.80's for the street rs next??

Hey Dave, I was wondering how that 12 tooth trigger disk worked out? How much better did it start? Maybe we can get a video on it. Anyways I was wondering how much you are selling them for and if you have them in stock. Also will be assisting with the AEM setup?

bump

Yes, I'm guessing there will be more 5 bolt housings up for sale this year, haha. This particular housing is really sweet, it's just expensive.

The 12 tooth wheel worked out really good. It's on my car now. If you buy one the instructions come with it to set up the AEM. You can thank Brad Brooks for that, as far as I know he wrote them. I believe the wheel is $110, I'm not at the shop and can't remember off the top of my head.

The car does fire instantly with the wheel.

Thanks for that info on the 12 tooth wheel, David. Looks like I'll have this added when my car makes the trip to you guys again this year!

Fu*kin 5-bolt housings, I hated that little bastard when it was on my car:lol: Finally got RID of that sucker lol

with my old turbo kit I couldnt even switch from .63 a/r to .82 a/r lol

I'm now using the same housing that was tested in this thread{thumbup} thanks for doing all the testing!

yupp.. it never ends, just keep going and going LOL

Thank goodness it never ends. I'd hate to have to wait on other shops to do testing to find out what works and doesn't. haha

That is some really nice number!!!

Dave, another question about the 12-tooth disc... what are you guys using as far as balance shaft goes... it says it cannot support the balance shafts. Do you guys use a stub shaft or do you think it would work with the AMS eliminator kit (i know they arent your favorite)?

We use our balance shaft eliminator kit in all of our engines. We do not have any problems with them. I have cars with 100,000 miles on them running the kits in them. I am not familar with the AMS kit, I don't have an answer for that.

How much does one of your balance shaft eliminator kits cost?

I think it's $75 for the kit.

Yes as David said its $75.

That is really interesting information regarding the GT turbine housing.

I am fortunate to have great friends that pitched in to buy me a GT turbine housing (0.82) for my birthday present.
Thanks for posting up this information david. Hopefully I WILL have a nice gain in through my powerband ( I will be going from the 0.63 T31 turbine housing to the GT turbine housing (standard gt35r Turbo)

A quick question though. Have you placed the Turbo blankets on your site ?, As I have not seen them on there.

Turbo blankets are not on the site yet. If you'd like to get one please give us a call. We are still waiting for them to come in.

wonder if the turbo blanket works better or simillar to jet hot coating?

Better than coating.

Excellent david, I will give you a call shortly regarding the blankets