125shifter

I'm not setting the world on fire with this rebuild since I'm 22 months into it. I tend to get distracted easily with other projects and shiny things. I've got everything fit up on the installed engine and now it's ready to come back out for intercooler, exhaust, & A/C brackets, a final check of the fasteners, and the wiring.

Engine details:

3.4 JE pistons w/7.7:1 comp
Mahle fully finned cylinders
Pauter rods
Twin plug
Heads matched to Carrera intake
EBS perf valve job & springs
C2 cams
B&B header & custom muffler
K27HF2
Motec M600 ECU
M&W CDI and coils
Patrick flywheel
Clewett aluminum pulley
Custom 25 x 10 x 4.5 intercooler
Tial 46mm wastegate & blow off valve

PT

David,
Nice job - its better late than never, right
Quick question - what model of air filter are you using? Any idea what CFM it flows?

thanks.

125shifter

Filter model: KNN-RX-3990-1

I forget the K&N calc for CFM and I can't find it on their site anymore. It shouldn't be a restriction though. I'm expecting 500+ rwhp.

DonE

David - do you have a 90 degree bend right out of the turbo up into the engine compartment? What size is the piping up to the filter?

im4duke

Looks really nice, David.

Looking forward to hearing how well it runs.

125shifter

The intake does have a bend to the compressor just like the stock intake. It's 3" tubing, with a 2.875" ID. Stock is 2.6" ID. I figure an airflow rate of 707 CFM with a 2.0 pressure ratio (1 bar boost) so velocity through 2.875" would be 261 ft/sec. It's my understanding that you're OK if under 300 ft/sec. Does this sound right?

I've also cleaned up the welds in the tubing to improve flow.

DonE

Essa Tech does the same thing on their high HP motors, so based on that observation, you should be fine. I wish I could have done this with mine, but I could not find silicone or AL tubing that could make the severe 90 degree bend I needed with the GT35r, nor could I make a 4in hole in the engine sheet metal (needed for the GT35r) in the stock location. Is your filter positioned far enough forward to avoid water contamination (washing for example)?

Again, nice job.

125shifter

I had to cut and weld the aluminum 90 in a couple of places to get the bend tight enough. I spent an hour or so last night doing some final polishing inside the bend to help flow as much as possible.

The filter is exposed to water from the tail mesh. I may add a shield over the top of the filter although I don't plan to drive in the rain. My 280Z had a similar filter in front of the radiator and I drove it in monsoon conditions without problems. I've also raced my kart in the rain with a K&N fully exposed to water and it didn't allow much moisture into the carb. I wonder how much humidity is too much for the compressor.

slownrusty

Dave - Looks awesome man...I bet you can't believe that almost 2years of your life in the back of that car....well worth it....its beautiful and excellent attention to detail...your 500whp is definitely a dyno session away.

Keep us posted.

Yasin

JoeMag

...fyi There is a rubber 3" to 4" 90 out there. Had to make the 4" side a little shorter to make it fit. made by turbonetics i believe.

DonE

I tried the reducer, but it actually reduced the air flow and choked my intake at WOT. This was found on the dyno, so I changed over to a 4" and gained something like 30hp on top. Although the cost of the parts was not too much, I had to do this on the dyno at $125 per hour.....

JoeMag

thx for the info don. think you're flow'n little more air than I. btw-- how could you tell you were choking air flow on based on dyno?

DonE

The torque and HP curves died at (approx) 5500 rpm. We suspected the air flow was the problem from the beginning, but tried it anyway. Then I disconnected the intake and stuck the 4" KN filter on the turbo directly, then ran it again - big difference above 5500 rpm. To get correct dyno tuning, I had to install the intake system completely or the trip to FL was wasted.

125shifter

Unfortunately my inlet pipe is difficult to remove since it's bigger than stock. If I encounter problems like this, I'll have to fabricate something for a second dyno session.

Don, when does power start to drop off with the new intake?

My87Targa

looks good man