Just got car back from my friend (he a mechanic )
He's fixed injector light problem, which was the throttle position sensor has never been connected since rebuild, there must have been a break in the wire somewhere!!

He's also fitted my larger turbo elbow and larger blue flame decated full system i bought off eldinho on here!

Finally got rid of all Blowing issues with the new elbow by cleaning up the the welds and also using some good old exhaust paste!!
after that was sorted it still felt and sounded like it was blowing down by the elbow??
This turned out to be a hairline crack in my 6 month old tubular manifold...
Not gonna say where i got it from but NOT HAPPY!!

Anyways had that re welded today and finally all blowing has dissapeared!!
feels loads more responsive now TPS has been sorted, also turbo is coming in a little earlier.... and there is definately more power as i can no longer get grip (at all) in 2nd gear once reaching max boost (1.2 bar)

Once i got a little more dough together i will pay a visit to Flea as i've spoke to him about running a little more boost and my programme at the mo is still for 440 injectors... but i'm now running 630 ones!!

Nick

how you finding the exhaust Nick?

the blue flame doesn't seem all that different in sound to my old system, (standard downpipe, decat and peco back box), if anything a little quieter on idle and low revs which is a good thing as peco was very loud! i've had neighbours knock my door before now, when i've started car in morn and left to warm up!
Think it sounds much nicer when opening her up tho, alot smoother!!
can't wait to get back on the rollers once Fleas had a fiddle!

Nick

Good stuff, look forward to seeing the results

Interesting, as i don't hold out much hope for mine then

yeah i thought you might comment on that..

I've been assured of a massive discount next time i purchase anything!!!

Back on topic, just want to say that this exhaust system is probably the best mod i've done, Can't believe how much of a difference its made and if i ever modify anything again the exhaust system will prob be the first thing i do, Not the last as i have done on the coop!! DOH!

At power station a fews months back i only made 265 bhp (cracked manifold and standard exhaust)...
Today i've had a play with a Boxter S (looked newish) and he ate dust from a 30 mph rolling start (me behind) prob pulled about 2-3 car lengths by the end of half mile dual track!! Chuffed!!!

Nick

Good to hear it is running right.

The standard exhaust is really restrictive and I suspected after all your other mods you would notice a big difference, good you have

I would be very surprised if you aren't over 300bhp now, especially with the few issues you found, like the exhaust leaks and the TPS

If the map you are running is for 440cc injectors and you have 630cc ones I would guess you will be running really rich so there should be a bit more to come from here as well

So, when are you getting on a RR?

Money is the issue at the mo saint... Dubai has cleaned me out!!
Next step is paying Flea a visit and he is hopefully gonna tweak one of Vas's maps for me, hopefully gonna up boost a little to... from 1.2 to 1.4!!
then i'll get back on the rollers... may even try to organise that for the same day??

I believe i am running quite rich at mo so if i get fuelling right and tweak the boost i reckon i could see 325-340 bhp.... still with 48ar exhaust housing!

Nick

how do you think i feel going back to the standard exhaust

hope you are happy anyway! i spent a lot on that exhaust and glad its going to be used properly

its sound mate... thanks very much!!

Nick

Nick

Just a thought, if you are going to get Flea to map it it maybe worth looking at changing to a 2bar map sensor (I think cosworth is the same model but 2 bar) - flea may know.

It will give you more headroom for extra boost in the future (as you have the forged bottom end) and I see the 20vt guys are running between 1.5 and 2bar these days

Your call but something I had considered if I got my car mapped with larger injectors, to handle the extra boost

Not sure if flea has worked on the cosworth stuff before (same ECU I believe 16VT to some cosworths) but if you can't track it down try Vas as he mentioned it to me

Cheers

You must have read my mind saint... been thinking of doing that for a while now!
what does changing the map sensor involve??
is it just a case of a straight swap then obviously re map with more boost???
will ther be much point in alot more boost as i'm still on 48ar exhaust housing... heard that 330 bhp will be pretty much as far as i can go with that housing??

Nick

yeah - as I understand easy as that, just change the sensor on the firewall, and map for that sensor

I know what you are saying about .48a/r but you may not stay with it long term (or go stage 2 or 3 turbine (i have gone stage 2) and also will peak power may be limited top end you might decide you want to run 1.6bar in the mid range or similar. that housing will restrict your max top end power but mid range you may still be able to run more

Anyway, I would talk to flea and see if there are any negetives (ie loss of resolution on the sensor) if there are no negetives apart from the money to swap it (small amount) then it might be worth doing

think i may change to a 2 bar sensor then....
any ideas where could get one???

oh yeah, i forgot to mention... I don't think its just the exhaust thats made the difference lol... Glanced at boost guage when gunning it in 5th gear today and it overboosted to 1.5 bar then sat at 1.4 for a while (didn't cut out tho)..... Then i remembered i had a fiddle with the actuator rod when turbo was off, shortened it by 2 turns.... Naughty!!

Nick

Just checked boost in 3rd&4th and it still only 1.2 bar... just seems to overboost to 1.5 bar in 5th??

just done 60-100 test as trying to guague new bhp...
did it in 5.8 secs...
According to fleas PERFORMANCE CALCULATOR (i know its only an approximation) that would give me around 325 bhp???

Could sorting leaks (manifold crack & manifold gasket), sorting TPS sensor error and larger exhaust really give me around an extra 60 Horses???

Nick

Anyone know what the max bhp anyone has run on 48ar exhaust housing???
Think i am gonna go for larger map sensor and have a play with upping the boost...(Well flea can!!)

Nick

thats a hard one to answer, I have heard some people say 300bhp is the max (thats why I went to a stage 2 turbine) but then again I can point you to a dodge neon site where they have made 450whp on a .48a/t T3 (this is a 2.4l 4 cylinder motor)

I did start a thread on this exact same question

it's a differrent motor I accept but if the turbo was that restrictive how would they get that much power, given the engine is effectively an air pump and the air for those numbers can get out and a 2.4 isn't that much bigger

BTW - i have been trying to find the answer to this same question for months

Well we'll soon see when the boost get wound up!!
think my compressor side would be maxed by 400 bhp anyways??
hopefully gonna sell my saxo this week so will have some cash to get map sensor and then hopefully see flea!!

we're hopefully gonna run my current set up on rollers first, to see what exhaust has done for me.... then put the larger injector programme in and let flea work his magic!!!

Nick