vaughnc

This was so cool, it needed to be re-featured:

Blue TII is doing a horz front mount intercooler setup on a hybrid motor setup (S4, S5, and S6 engine parts). I'm not sure if this is a daily or track car (low compression 88 rotors & huge street port)?? Let's hope his TPS will keep a good idle


Advantages of this setup:

- TMIC advantages (minimal pressure drop & less lag) with FMIC cooling advantages
- No body/frame cutting required with this setup

Setup Details:

- ECU - Haltech E6K
- Block - Street Port S5 Series5) 13B-T Pineapple block/rotor housings
- Engine Mounts - comp motor & trans mounts, custom engine brace
- Rotors - Lower Compression S4 rotors
- Apex Seals - 3mm seals (of unknown type)
- Flywheel - 11.5# alum flywheel w/ ACT clutch
- Exhaust - 3.5" SS JIC turbo back exhaust
- Turbo - OEM Turbo with BNR T04B 60-1 turbo wheel upgrade (17% more effecient)
- Intercooler Setup
-- Isuzu NPR Intercooler with modded/larger 2.5" inlet & 2.75 outlet
-- Intercooler mounted horz. between radiator support & radiator
-- Greddy POV (pop off valve boost protection)
-- Unknown BOV (blow off valve)
- Radiator - Griffin 26"x19" radiator
- Cooling Panel - CF cooling panel
- FAN - Blackmagic e-fan (HP recovery/gains by eliminating OEM belt driven fan)
- Oil Coolers - front mount- oil cooler w/ -10 AN lines
- Oil Modifcations (ie higher pressure)
- Manifolds - FD3S Manifold modifications ('93+ upper intake ported, matchported and polished runners w/ 2ndary throttle plates and bridge removed); '89+ lower intake portmatched and polished runners w/ EGR intrusion and center mounting boss intrusions removed
- Fuel modifications
-- Injectors - 720cc primary inj, 1600cc 2ndary inj
-- Fuel rail modification - K2RD rail supplied
-- SX dual port pressure regulator and Walbro pump
- Suspension:
-- JIC FLT-A2 coil overs
-- CF strut bars
-- adjustable sway bar links
-- full poly bushings
- Brakes - slotted rotors, carbon kevlar pads, SS lines
- Guages - Greddy AF, boost guages and turbo timer
- RIMS/Tires - Bronze Volk TE-37s 16x7.5" and 16x8"-
- Stripping / Lightening - no emmisions, no accessories
- Other stuff

Facts:

- TII hood fits fine
- No body/frame cutting
- reducting nose air flow into radiator, intercooler, & oil cooler lines
- nose "I've got madd power" cutout planned for intercooler








....this shows where the radiator is. The fan is directly on the back of the radiator.



I need to get a 9" cone filter now that I have room.



I concentrated on simplification and reliability mods. Everything is overkill for the 300RWHP goal.



I wrapped all the wires in aluminized fiberglass tape and re routed the harness along the top of the firewall. A partition protects the sensors/relays from the turbo heat.



It is not a unique idea- it is the set-up the fastest track FCs and FDs use in Japanese racing.

Allow myself to quote my.... self.
Quote;The stock bumper opening feeds the oil cooler and radiator ONLY. The IC is fed by the duct I cut ONLY. There is a stainless steel shroud between the two. Both ducts are sealed off/foamed in.

vaughnc

See, it does all fit under the hood (I actually tested clearances w/ the playdough method- 3/4" at closest spot.)


Here is the IC duct. It will become pretty, I promise.

I tried to light up the stainless shroud w/ a flashlight on that foam for the pic, but you just can't see in there well. The shroud curves from where the stock plastic cooling panels would be up to the top of the radiator.



Here is a better view from the front, but down more.

hypntyz7

Wow. Impressive. A pretty unique setup, for north america anyway.

I have a question, and I suppose it can only be answered by the actual owner. IF the IC sits 3/4" off the hood (as indicated above) where does the airflow go? IN other words how do you keep from building a high pressure spot and losing flow/cooling to the IC if it sits so close to the hood?

noe

very nice setup, ultimate sleeper i'd say gj.

BLUE TII

iTrader: (9)

Wow, I did not expect that kind of response. Thanks VaughnC.

I can't keep up w/ two threads to answer questions though :-).

Quote-IF the IC sits 3/4" off the hood (as indicated above) where does the airflow go? IN other words how do you keep from building a high pressure spot and losing flow/cooling to the IC if it sits so close to the hood?

Hypntyz7- there are several inches above the IC core to the hood- my metal cross over upper radiator pipe is actuall the closest spot to hood.
The IC is vented not throught the trans tunnel like a FMIC and the oil cooler and radiator, but through an CF reverse scoop in the low pressure area on the hood above it- literally sucking the heated air out. I just described a little horizontal mount theory for NZconv. in the original thread- check that for details.
Ian

Evil Aviator

I agree. A vented hood is going to need to be installed for that IC to function well. The good thing is that the the hot air will naturally rise out of the top of the IC, and a hood vent will work great because the top of the RX-7 hood is in a vacuum at speed.

Edit: Oh, I see that you already thought of that and posted as such while I was posting. Good job.

hypntyz7

Where is the other thread, so I can read up on this...

BLUE TII

iTrader: (9)

Oh crap, I already see some mistakes in info from my Sig. Like, Jason never sent my SX dual port so I bought Aeromotice dual port RRFPR.

As for the idle thing- I was friggin amazed. Rob builds a TIGHT engine. It started on 3rd crank!-The reason it took three was I had EVERY idle bypass cranked down in case of intake leaks starting the engine at a high idle. So it was crank- open up throttle plate angle a little. Crank, stumble- open more. Crank- vroooo DOH,DOH,DOH as I RAN in the house to grab the silencer insert to muffle the loud *** idle!

Projects like this are never that easy!

Oh yeah, I digress. The idle. Robs tight engine building is witnessed by this. Low compression rotors, 11# alum flywheel, stage II street port, removed 2ndary throttle plates/hogged out intake runners, 3mm apex seals and 720 primaries operating at 3% duty cycle and the idle is still strong/ fairly steady at STOCK rpms on a zero mile motor!

God damn I am impressed. Ian

luiml73

iTrader: (1)

That looks badass, I'm as we speak.

BLUE TII

iTrader: (9)

Still checking out that cool summary VaughnC did for this.

Robs oil system mods go way beyond higher pressure. Windowed/grooved bearings, ported oil passages, loop line, relocated/optomized oil cooler outlet location (allows me to more easily run dual oil coolers too as soon as I find a clean 2nd one).

The "mad power" cut out is a CF duct w/ raised lip from www.carbontrix.com on an alum NA hood- (NA hood is several #s lighter than my TII alum hood). I bought all my CF from them- uh well, all the CF I bought that was good enough to put on my car was from them.

And don't forget I have RB toe eliminators in as well as the comp rear end mount. I can't forget- what a pain in the *** to do all by myself w/ just basic tools and 1 floor jack!

Ryde _Or_Die

Where did you get the CF strut bars? Did you make them?

BlackRx7

damn damn damn, I have to ask how much did this cost, did you do the work yourself? I reeaallly wanna get this setup on my TII.

RarestRX

Yo,


Good job man! Even though it is a *cough* turbo...*grin* You're in a close battle with 1FastT2 for "Nicest S4". You two should race when your car is running!

Oh, and I still expect a full report on the FLT-A2's. My buddy has them in his GTUs and I want to see your impressions.

Anyways, excellent work. Always a pleasure to see a clean, well sorted engine bay.

Kevin
1989 GTUs "300RWHP?! That's twice as much as I got!"

BLUE TII

iTrader: (9)

The CF front and rear strut tower bars are JIC magic items purchased through Rishie (ARDT2 on this forum).

I also bought the JIC FLT-A2 coilovers, Spec90 turbo back exhaust and Volk TE-37s. He is awsome to deal w/ has great prices and he knows quality. Thanks Rishie!

Quote-damn damn damn, I have to ask how much did this cost, did you do the work yourself? I reeaallly wanna get this setup on my TII.

I couldn't keep track of the cost of a project like this- it would hurt too much. I just spent money and time on my car that would have been wasted on luxuries like food and sleep. Seriously, I have lost 30Lbs working on this car! Mainly since I always work on pieces through my lunch break at work and you burn more energy being awake 20 hrs a day than 15 hrs a day :-).

fastrotaries

Who did the welding? Very nice. Very clean.. What are you using for boost control?

BLUE TII

iTrader: (9)

Quote-Oh, and I still expect a full report on the FLT-A2's. My buddy has them in his GTUs and I want to see your impressions.

On the suspension set-up - When I first backed my car out of the garage and pulled up to the curb I swear I felt my sidewall drag accross the curb! I was like "NOOOO" and jumped out and ran to my beloved bronze TE-37s to see if they were OK. They were fine, then I noticed the tire was fine- then I noticed I was 16 inches from the curb like my normal paranoid self usually is.

Psyche- I had just gone over the maybe 1/8th inch joint betweent the blacktop road and cement gutter.

You can feel everything w/ the suspension set-up, but it is not jaring like I thought it might be- you just can feel every nuance of the road. The car feels solid and smooth.

I cranked it up to Level 10 on the way home from work and it just felt like a sports car should to me- but I haven't done any hard driving.

I guess I'm just used to driving my Honda N600 though and it is less than half the weight, on 10" rims and highly inflated Advan 0008s, so any RX-7 will feel tame as it does not get airborn off freeway reflector dots changing lanes like the Honda. Well, maybe at 17 clicks the FLT-A2s will launch the RX off of reflectors? Nah, the chassis is too flexy.
Ian

BLUE TII

iTrader: (9)

Who did the welding? Very nice. Very clean.. What are you using for boost control?

Wrightway Fabrication did the TIG welding of the conduit nipple onto the section of scrapyard found fluid transfer piping that I cleaned up and called a turbo to IC pipe (the 90 degree off the turbo- hey it was mandrel bent!), on NPR IC, on the modded TB elbow flange to tube as well as welding on the BOV flange I made (I'm a cheap bastard) and welded up the EGR blocker I made and all the ACV/EGR passages on the LIM as well as reinforcing the UIM mounting flance area for a better seal.

My boost control right now is using Hitman's 4x720cc inj. map on my 720cc primary and 1600cc secondary inj. set-up. You hit zero manifold pressure (2ndary switch on point) and the car bogs terribly. Rev limiter is set to ignition cut (perk of turbo back exhaust) and at 4k rpm incase of unforseen circumstance.

If you meant wastegate control; it is directly from the compressor housing to the WG actuator, the WG hole is slightly ported and the turbine is "O" trim.

ARD T2

iTrader: (22)

Damn. Ian, you've come a great ways since we first spoke. I give you mad props on your patience and innovation. I can't wait til you get that thing really running so we can run some events together. Great Job Ian.

So what's next. hehe.

BLUE TII

iTrader: (9)

So what's next. hehe.

You are an evil man...

BlackFC_NYC

sick set up. you listed exactly what i wish i had. =)
now you should get a hood that vents air in. I believe knight sports makes a nose with a horizonal vent for FMIC, but im sure you can get it to vent up to the IC.

i believe thats a Gerddy type S BOV, but greddy made a type R which is the bigger silver one that is usually seen on FD's with FMIC's. Hell i have a Greddy type S BOV. i think i should know. Correct me if im right though. lol

Have any exterior pics?. i wanna see the JIC exhaust and all.

Mike

RylAssassin

Ok this car is amazing its my no.1 favorite now next to 1fastT2 i love that much also.
Extremly clean. Very well thought out, Very original, Looks super fast.
What are the numbers? hp?trq? Are you going to dyno it?

Really nice work

RylAssassin

I have a question about those rims you have, First off i love those rims and always wanted em on my TII are these :Bronze Volk TE-37s 16x7.5" and 16x8 the same as the one in your pic?? If so how much did you pay for em?

1FastT2

iTrader: (1)

I dont know guys, that set up is definately awsome. Id have to say that I like it just as much as my own set up. One thing though I tried to keep mine S4 based engine wise so I do have one advantage. JK. Awsome car!

BLUE TII

iTrader: (9)

Quote-sick set up. you listed exactly what i wish i had. =)

The parts are nice, but you really have to think about how you put things together. I could make a list of nice parts that was a crummy car.

Quote-now you should get a hood that vents air in. I believe knight sports makes a nose with a horizonal vent for FMIC, but im sure you can get it to vent up to the IC.

Hood to vent air out! But, besides the CF reverse scoop, hole in bumber and stupid big exhaust tip this car is going to look like a NA.

Quote-i believe thats a Gerddy type S BOV

Yep, typeS, the way it was written in the sig was Greddy POV, BOV so VaughnC wasn't sure. I will be running conservative boost so soft spring of Type S is best.

Have any exterior pics?. i wanna see the JIC exhaust and all.

Sorry, I'm going to finish up the hood w/ vent, the nose leading edge and such before I so exterior pics. But it is a stock looking blue 87 TII w/ no wing option, bronze Volks and a silly big driver exit single exhaust.

Quote-Id have to say that I like it just as much as my own set up.

Thank you! Your car is awsome!! Mine is no where near as clean.

One thing though I tried to keep mine S4 based engine wise so I do have one advantage. JK. Awsome car!

There are certainly advantages/ disadvantages to all the common set-ups. You have to follow your priorities....and your dreams. I am Japanese wannabee for sure. Would that be Wanabe San?

Ian

BLUE TII

iTrader: (9)

Quote-:Bronze Volk TE-37s 16x7.5" and 16x8 the same as the one in your pic?? If so how much did you pay for em?

Certainly! I wouldn't tease you guys by putting things in my sig that aren't on my car!
As for price, check around for the going rate- THEN get a quote from Rishie (ARDT2 in this forum) and SMILE . Rishie has awsome communication/customer service and awsome prices- why can't every seller be a Rishie ;P.