Has anyone else had this issue? Set up is 2.2 with a super99 with the 1.02 tial housing, single turbosmart 45mm gate with a 27psi spring. Pretty much max boost it will make is 38-40psi at which point it's making 540kw on a rolling road.
does anyone else have a similar set up? What results have you had? And has anyone else had similar issues?

 

you should be able to make more than 40.

tune
WG vacuum set up?

 

The tuner is fairly on to it so I doubt it's the tune, his shop Evo is pumping out 1300whp. I know they tried all sorts of configuration with the gate, they even put a bolt in to stop it opening all the way and are now getting 45psi. Now making 580kw which seems low for A super 99??

 

Something is up. That is REALLY low for a super99 and 45 psi. I mean 775 whp is still good power, but not for that turbo and that PSI. With saying that, there could be so many things. Starting with the tried and true, did you do a boost leak test? how is the compression? how is the overall engine health (leakdown..etc). Since the shop has a 1300whp Evo they clearly know how to tune/build...so they should be able to figure out what's going on.

 

They check boost leaks, it has those Wiggins clamps, checked bov and pressure drop accross intercooler (2psi @ 40psi boost) 45psi is with a bolt in the wastegate basically holding it shut ?!? Engine is brand new everything turbo is new everything is new.
they are back on to it on Monday I am just trying to do a bit of homework in the mean time but it's got me stumped. It's a fair way from the 1000whp I want to see

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What is the complete setup?

Engine displacement and stroke
Intake manifold
Exhaust and exhaust manifold
Cams
Cylinder head ported?
Etc...

Could be a number of things. Boost leak test being done and good points to exhaust restriction (causing back pressure), cam timing is off, bad combination of parts, etc...

 

It's a 63 block with 2.2 crank nitto long rods wiesco pistons kelford ported the head 280 kelford intake cam 288 exhaust oversize fererra valves, Hypertune billet intake with ls1 dbw throttle body. Custom headers. Side exit exhaust, turbosmart 45mm gate.
haltec full package individual egt the works, Siemens 2400cc injectors twin 044s with 044 lift pump.
its on E85 out of the can too.
I know they mucked around with cam timing and boost reference points, I know they checked for boost leaks. I'm not reinventing the wheel here so I don't know what's going on. The tuner is a fairly on to it guy I am sure he will get to the bottom of of it but it all seems a little odd. If ex manifold pressure is high enough to start pushing the gate open then with a bolt in there why wouldn't it try and over boost??
Surely someone on here has had this issue before?

 

Back pressure hurts HP, and if there's enough it will stop making more boost too.

Post pics of the exhaust manifold.

Is the boost controller plumbed correctly?

What size is the bumper exit exhaust?

Also make sure the turbo isn't hurt..

 

I am fairly sure the headers are similar to his shop drag car, fabricated by the same guy. Not sure the size if the side exit I'll ask but it must be min 3.5" because any smaller would almost fit inside the turbine. Boost controller was set up fine and it can't be that because with a bolt in the gate preventing it from opening it still only made 45 psi. It's like it has to much pressure in the exhaust pipe but I doubt he would make that mistake. Turbo is brand new but I guess could have damage? Could cam timing do this and how far out would it have to be?

 

Ok, that all seems fine. 3.5" is plenty for the exhaust. manifold looks good.

What intercooler are you running? Have you made sure there are no blockages in it?

 

Are you logging turbo speed and emap? Have you eliminated the BOV COMPLETELY and done any dyno testing ?

 

They definitely checked the BOV and checked leaks in general. I would have thought anything leaking that much would be fairly apparent? It has those Wiggins clamps.
intercooler was probably the only part of the original set up that remains so I was concerned about this and I asked the tuner to put a pressure sensor either side of the cooler and it's got a 2 psi drop over it @ 40psi.
The cooler is a bar and plate it's about 75-80 mm thick 600mm long and 300mm high basically 3" * 12" * 24"

Not logging turbo speed.

 

checking it during standard blt is different than how it acts during engine operation. But fair enough. Emap is easy to log. You can check your back pressure easily under load. I would.

 

If you have the right springs for baseline boost level, and the wastegate is blowing open, definitely emap is high.

 

Yeh measuring emap is the next step but it's a 1.03 housing