Mojojo's Tinkerings


mojojo
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On 6/19/2022 at 9:18 AM, mojojo said:

I decided to put the RN manifold project on hold so that I could get the car back on the road. Unfortunately, I'm not sure how long it'll be on hold. Seems like it may be a better idea to figure out a custom manifold setup with the combination of short runners and large(er) plenum. We'll see.

Nonetheless, the P2R air box is in, battery relocated to the trunk, PCV system upgraded to 12AN hose.... and new cam hubs installed. I took the car out for a test drive last night and I'm happy to report no more flow restriction through the air box, like was the case with the 850 box. 👍

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Still to do: work on the inlet adapter for the air box to accomodate the 3" hose from the bumper inlet.

 

I have always been told the stock airbox on P80s will support over 400hp, is that just not the case from what you found?

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Posted (edited)

I'm running a 1/0 marine grade tinned copper cable from the starter positive terminal, around the passenger side of the engine bay - following the main harness into the cabin. The cable passes through the factory access point and down along the passenger rocker panel, finally into the the trunk where I've placed a 150A circuit breaker. The battery has been mounted on the passenger side of the trunk. I'm not really happy with my solution for the original battery... so still thinking how I would like to improve it. Maybe I do end up with an optima and billet hold down.

Here's some pictures I took when plotting the route. I removed the cable to cover it with a conduit before finall install.OAO3wJH.jpg

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I'm not sure that I've ever seen 400 whp flow through the stock box... Mine basically started having issues around ~300 whp. You can see in my graph on page 1, my RPMs were increasing, but airflow was staying the same or dropping.

Edited by mojojo
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Happy to announce the P2R setup is finally in. Findings are promising. Previous max from 1078 kg/hr with the open filter, to a new peak of 1105 kg/hr! Needless to say, the car is running well... and it's getting closer to the switch to e85!

I've already incorporated some QoL changes to the air box snorkel for a v1.1 that will reduce the amount of filament to print it, increase the size of the opening into the air box, and result in a much better overall install and polished product... including addressing the odd mounting bolt location as seen inside of the air box.

also upgraded PCV lines to 12an fittings. There's still a restriction (relative) to being true 12an at the catch can - I'm using 10an orb to 12an male fittings. Perhaps, down the road, there's a better breather box in the works.

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Looking great, love seeing other people 3D printing bits for their P80s.

Is there a reason for the right angle bump in the printed housing where it meets the airbox? I'd want to smooth that out if possible.

EDIT: Appears to be for the mounting bracket. I'm sure it'd be strong enough with that clearanced to make a perfectly smooth routing.

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You're exactly right - the mounting bracket on the box. This is v1.1 - v1.2 has even less of an impact to that area, but does still have a clearanced area.

I'd say you're probably spot-on about modifying the box bracket as well. Perhaps a v1.3 is in the pipeline - I've also thought of remixing this with a 4" opening vs. the 3" that is currently.

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I have no intentions of ever getting rid of this car. I think at current power levels, it wouldn't be unreasonable to think this combo would make ~400whp with the move to e85... which is more than I'd want to daily drive and beat on a completely stock engine. Future plans include new intake manifold, larger (Garret/EFR) turbo, and building a more robust engine to handle those.
...ultimate want would be to do an AWD conversion ala simplyvolvo.

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21 hours ago, mojojo said:

I have no intentions of ever getting rid of this car. I think at current power levels, it wouldn't be unreasonable to think this combo would make ~400whp with the move to e85... which is more than I'd want to daily drive and beat on a completely stock engine. Future plans include new intake manifold, larger (Garret/EFR) turbo, and building a more robust engine to handle those.
...ultimate want would be to do an AWD conversion ala simplyvolvo.

I think rods would be a safe bet if you haven't done those yet, I know many recommend rods at 350+ hp just to be safe on the N engines.

I would love to see a madman such as yourself do a RWD 850 build. There are a few out there, none in the USA though.

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To be fair, I'm using a B5234T9 - so I've already got the best rods/crank from Volvo... and improvement upon the 850 lump.

But, I agree, rods would be a good durability investment. I just don't want to deal with anymore downtime. I'd like to build that engine on the side.

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On 6/21/2022 at 1:50 AM, mojojo said:

I'm not sure that I've ever seen 400 whp flow through the stock box... Mine basically started having issues around ~300 whp. You can see in my graph on page 1, my RPMs were increasing, but airflow was staying the same or dropping.

I know it's anecdotal, but mine, which was close to or slightly over 400 bhp, ran the stock airbox. I've not noticed it being a restriction at the time. I was hoping you'd have some strictly before-and-after numbers on your box, it's easy to have something 'feel' better after you tinkered with it or crediting it to a change when you did other stuff in the meantime. Clean numbers are key.

With the setup you have now, it might be interesting to on the same day do a few runs, log the average KG/hr, then change only the airbox back the original and immediately do another few runs. Then you'll eliminate all other factors, which should be a very good gauge of the actual increase of your new box.

Edited by Boxman
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