lookforjoe Posted February 25, 2016 Author Report Share Posted February 25, 2016 On 2/21/2016 at 2:28 PM, fyrken said: Nice car! We have one working great on a 500 hp S40 T5 AWD. Also the intercooler from V40 is quite good and should be a very simple install Erik Hi Erik Do you have links to the S40 using that IC? A bunch of the guys on C30crew don't believe it. I would like to be able to substantiate the claim, so any more info on that car/build would be much appreciated :) Quote Link to comment Share on other sites More sharing options...
fyrken Posted February 25, 2016 Report Share Posted February 25, 2016 Ah, the internet doubters! Car runs a Focus RS engine with H-beam rods. Cams are Enem Y21 profile 4" Air Mass Meter/MAF/HFM (custom housing, same sensor) - really restrictive stock Turbo is an upgraded Focus RS unit (larger compressor wheel) 4" over the engine pipe (PRD Motorsport, custom) 3,5" exhaust (PRD) with optional bypass of the last muffler Elevate intake manifold Elevate boost pipes (had to be adjusted due to not so AWD compatible) Upgraded fuel pump in stock location (PEM still works) 730cc injectors E85 Dyno video: scroll down to november 5th 2014https://www.facebook.com/tmchiptuning/?fref=nf The dyno readings might be high but we have not yet tested it at PRD's new RotoTest (hub dyno which is known for beeing very accurate). This dyno pull is made in an SF-800 Superflow, which is also a nice machine. The K16 really likes good airpaths with its quite large inducer compared to exducer and it also shows in the compressor diagram. With the 4" MAF and plumbing pressure drop before compressor is very low and they really like this. The cams help with reducing boost which also improves the turbo and compressor outlet temperatures. 3,5" exhaust also helps but main power comes from the E85 fuel. Lower EGT's, lower backpressure, earlier spool and essentially the possibility to run the engine on MBT. 2 Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted February 25, 2016 Author Report Share Posted February 25, 2016 Thanks, Erik! Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted February 27, 2016 Author Report Share Posted February 27, 2016 31338236 IC arrived this morning. It is in fact brand new, so I'm happy with the price :) Side by side with stock C30 IC Fin density comparison C30 stock 31338236 Newer fin design has finer fluting to help dissipate airflow through IC I/O size difference: stock 52mm bore newer 31338236 58mm bore 2.5" Sliicone will stretch over. Think I'll look for 2.75" - 2.5" step couplers though depth 3.375" height 6" End tank - new design includes internal diverter to channel air into core :) drill 9/16" & tap w/ 3/8" npt fit cut down brass 3/8" NPT bung. cross hatch into IC tank to provide additional bite for epoxy. 3/8" bung has perfect ID for MAP o ring seal (20mm) use MAP retainer grid cut from old IC JB weld threads of bung & grid to IC tank. will be positioned thus Have to evaluate mount points to frame. Will do that when I'm no longer sick with wahtever flu crap I have now & can work outside. 7 Quote Link to comment Share on other sites More sharing options...
nocturnal7x Posted February 28, 2016 Report Share Posted February 28, 2016 Very nice. PA has the good cars. I only had to drive 2.5 hours out to get mine. Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted March 1, 2016 Author Report Share Posted March 1, 2016 Installed the IC today, temps were moderate enough to deal. Elevate IC hoses stretch OK over the 2.75" IC ports. M6 bolts through the lower mount points used to locate the stock IC One screw through the DS upper mounting point. PS doesn't align. Lower guide is snug against IC 6 Quote Link to comment Share on other sites More sharing options...
TIZIO AKA 1 HND MEC Posted March 2, 2016 Report Share Posted March 2, 2016 Quite tight fit H, seeing the pic of the C30 without the front skin is like"naah " is too early for that we are at just the 6- st page on this Album!!! Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted March 8, 2016 Author Report Share Posted March 8, 2016 Wired the exhaust cut out to the cargo area lamp & ground using the factory ground point on the DS rear panel extended the cutout exhaust flange to push the flow down below the fender liner & rear skirt 1 Quote Link to comment Share on other sites More sharing options...
andyb5 Posted March 8, 2016 Report Share Posted March 8, 2016 The cutout sounds amazing in person! Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted March 26, 2016 Author Report Share Posted March 26, 2016 28" core, 8" tall 3.5" depth, 2.75" I/O Quote Link to comment Share on other sites More sharing options...
turbobrick Posted March 27, 2016 Report Share Posted March 27, 2016 seems like it would be easier and more legit to make a pipe for the map sensor and cut the silicone vs modifying a plastic end tank?? Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted March 27, 2016 Author Report Share Posted March 27, 2016 On March 27, 2016 at 8:56 PM, turbobrick said: seems like it would be easier and more legit to make a pipe for the map sensor and cut the silicone vs modifying a plastic end tank?? More Legit? Not really. Then you need a coupler between the intercooler and the pipe, and another coupler & pipe.... The silicone hose from the intercooler to the TB doesn't have enough length before the bend to do that. Modifiying an end tank is no biggie if you are careful. 3 Quote Link to comment Share on other sites More sharing options...
turbobrick Posted March 27, 2016 Report Share Posted March 27, 2016 (edited) i've used JB weld on plastic end tanks before, don't get me wrong it will hold. But it was a temporary solution, the Oil that is thrown accumulates where ever there is any kind of crack/depression and it will wear down the plastic. Just seems like you're introducing a point of failure to the system, this is no longer fitting into a cast piece and you're pushing quite a bit of pressure at it. How did the stock solution mount in? was it threaded? I'm not being critical of your work or your solution it just surprised me this is what people opt to do when swapping intercoolers. Edited March 27, 2016 by turbobrick Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted March 28, 2016 Author Report Share Posted March 28, 2016 9 hours ago, turbobrick said: i've used JB weld on plastic end tanks before, don't get me wrong it will hold. But it was a temporary solution, the Oil that is thrown accumulates where ever there is any kind of crack/depression and it will wear down the plastic. Just seems like you're introducing a point of failure to the system, this is no longer fitting into a cast piece and you're pushing quite a bit of pressure at it. How did the stock solution mount in? was it threaded? I'm not being critical of your work or your solution it just surprised me this is what people opt to do when swapping intercoolers. If you noticed, I threaded a bung into the intercooler. The JB weld has that additional surface area to secure the outer plate. The JB weld is not securing an end tank - that would be an entirely different issue, and not something I personally would consider. The pressure over that small surface area is nothing like the overall dynamic pressure passing through the system. Quote Link to comment Share on other sites More sharing options...
WayAway Posted March 28, 2016 Report Share Posted March 28, 2016 9 hours ago, turbobrick said: i've used JB weld on plastic end tanks before, don't get me wrong it will hold. But it was a temporary solution, the Oil that is thrown accumulates where ever there is any kind of crack/depression and it will wear down the plastic. Just seems like you're introducing a point of failure to the system, this is no longer fitting into a cast piece and you're pushing quite a bit of pressure at it. How did the stock solution mount in? was it threaded? I'm not being critical of your work or your solution it just surprised me this is what people opt to do when swapping intercoolers. I JB welded a cracked oil pan on a VW years ago...Lets just say it lasted well...Years. I was a lot younger at the time and would never do that again. But It was sold two years after I used and on the pan and who really knows how long it held up for Quote Link to comment Share on other sites More sharing options...
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