TweakGames

iTrader: (3)

ohhhhhh that's a stage 3?! I thought it was a stage 2! Sorry, yeah I guess I would be a little disappointed also. hmm... well, we will have to see what happends when you turn up the boost. What psi do you think you will run?

Eternal_Gamer

iTrader: (10)

What do you guys think I can do on a dyno and 1/4 mile with a streetported s5 with bnr stage 3 running on wolf 3d v4? It has a rich tune at the moment, but drives really good. Give me your opinions.

boost_its_what_for_dinner

id say low to mid 12's @112-118 mph

but hp @10 psi prolly around 280-340 within factors of how big streetport and tune?

i ran a 8.1 @91 mph inthe 1/8th this past october the car had more but my tune and launches were pretty weak.. thats on s4 t2 big streetport and s5 bnr stage 1 @15 psi(peak)12psi steady)and mods in the sig.

Eternal_Gamer

iTrader: (10)

wow. low-mid 12s and 280-340whp sounds pretty cool. mid-high 12's 280-300whp is good enough for me. I am not sure on the size of the streetport. What did you run in the 1/4 mile and what did you get on the dyno with the BNR Stage 1? I am switching to the stage 1 after a little fun with the 3.

bigdv519

iTrader: (3)

Ok its Sunday night and I finally have time to share my numbers.

Relevent mods for those just tuning in:

K&N filter, BNR stage 4, R-Spec 2 row intercooler, custom piping, ported and polished throttle body, stock manifolds, stock intake ports, ported exhaust ports, Racing Beat downpipe.

This is an S5 motor with lapped irons, Pineapple Racing oil pan, gilmer drive pulley set, no AC/PS, RX-8 e-shaft, RX-8 stat gears.

Walbro pump, -6AN lines in engine bay, stock rails, 720cc prims, 890cc secs, 1:1 FPR, APEXi PFC.

80psi oil regulator, Royal Purple 20w50.

I think thats all the relevent stuff.

Dyno'd at rx7.com on Friday.
Injectors are nearly maxed out at 92% duty cycle and we didn't want to go any higher. We drove home with 346rwhp at 14psi. We actually made 355rwhp on one run but we didnt feel too safe with that so we backed it down a bit.

Sorry for no sheet, but as soon as Chris e-mails it over, it will be posted.

So, then we went to the track today, and I've discovered I have a small exhaust leak and boost is just marginally lower...maybe 13.5 psi...definitley not the 14psi it was registering before. But oh well we ran it anyway.

The only relevent run of the 5 was a 12.1 @ 116 with a 1.9 60'. Tires are 235 Falken FK452's on 18" rims. Car weighs 2520lbs without me. I weigh 240lbs.

Suffered some bad wheel hop on the first run, dumping clutch at 5500rpms, and loosend up the rear-end a little. All runs after that involved no clutch dumping.

Going back to rx7.com in a couple of weeks with 1600cc secondaries. Then back to track with MT ET's on stock convertable wheels.

Thank you Houston RX-7 Club, National RX-7 Club, and Chris, Ari, and Mary at RX-7.com.

TweakGames

iTrader: (3)

wow very nice!

What is your review on the turbo compared to the stock one? What RPM do you go positive pressure, and when do you hit ~14 psi?

Do you feel as though the turbo is running out of breath at 14, or do you think with the injectors you will easily be able to break 400 rwhp?

Do you like the turbo in general? Any spiking issues?

How big is the RB DP?

Thanks for sharing with us! You are a great help!

P.S. WOW nice 1/4 time! How did you get your car so light?!

bigdv519

iTrader: (3)

Well, I ran the stock turbo on the previous setup and it ran near its limit. I would run it to 12lbs, then it would fall to about 7 or 8 psi by 7k rpms. I ran a 12.9 with the stock turbo.

This turbo begins to see positive pressure right at 2k rpms. I see about 5 lbs right at 3k rpms, and full boost by 4k rpms.

Turbo is definitley not running out of breath at 14psi. I literally expected the car to have plenty of power in the 6000 to 6500rpms range, but it pulls so hard between 7000 and 8100rpms.

I think the hybrid package is a great bang-for-the-buck. I didn't have to buy another exhaust manifold, nor re-do my intercooler piping, nor buy an aftermarket wastegate. Bryan Nickell also gave me a great deal on the turbo and I plan on ordering another for a buddys car. I haven't seen any spiking issues yets.

The Racing Beat downpipe is also a good bang-for-the-buck, even though the mating flange to the turbo was slightly warped. This is only one of 3 Racing Beat downpipes that I have seen warped at the flange so they are .750 on the downpipes with me.

I've done a lot of weight reduction items. The car still looks completely stock in the interior and exterior. You would never know it weighs 24xx lbs with bbs rims. How's that for all the "10th Anniversary-are-pigs" sayers.

Side note: Going back to the track with 235 60R15 MT ET's. Will post times soon. Also going back to Garland, as soon as the 1600's come in the mail.

bigdv519

iTrader: (3)

*Rephrase 3 paragraph*

Turbo is definitley not running out of breath at 14psi. I literally expected the car to ONLY have power in the 6000 to 6500rpms range, but it has plenty of power from 5k rpms up, and pulls so hard between 7000 and 8100rpms.

TweakGames

iTrader: (3)

Very nice very nice. I looked up the RB down pipe, and all I found was a 2.5 inch. Are you running that down pipe and still getting that early of boost? I think a 3 or 3.5 inch DP would really help you out, but I could be mistaken. Is it even possible to mount up a larger downpipe on the stock/hybrid turbo? Yaa, you must be able to, because blue is using 3.5 inch I thought. I can't really argue with the numbers you are throwing up though!

When do you think you will get the dyno sheet posted btw?

Also, are you using s4 or s5 turbo manifold and/or turbo?


Thanks again!

You're getting me all excited to send brian my turbo!

blmcquig

iTrader: (15)

dude, you have no freaking idea!!!

im SO excited to get my turbo back....

should be just a few more days!! (or like 2 weeks. whatever)

gxl90rx7

iTrader: (1)

RB sells a 3" downpipe.. but come to think of it, ive always had a small exhaust leak, i think my rb downpipe probably has a warped flange too

oh and forgot to mention, mine was an S5 turbo and manifold, S4 block. I ordered a boost controller this week, im going to turn it up and get ti dynod again at 10-12 psi soon

junito1

NICE!!! I have the bnr stage 4 myself, but i am limited to 9 psi at the moment, due to not having proper fuel/ignition supporting mods.

Cant wait to get EMS and installed along w/ the injectors i have laying around.

BLUE TII

iTrader: (9)

Yes, I also had exhaust leak at turbo to manifold w/ RB 3" REV 2.

Some of the 3 1/2" JIC Magic Spec 90 front pipes need to be modded for the BNR Stage 4 as some like mine had a flange opening made for the stock turbo exit diameter and then a velocity stack. Others had RB style larger than you need turbo flange (but pressumably without the RB signature leak).

I am so unimpressed by RB quality compared to Japanese (weight/bad material spec, cheated bends, bad welds, but great flanges and mufflers.)

I like the stock look and sound of the 3" REV 2 rear section, so I put up with it.

Someone recreate the KnightSports true dual turbo back PLEASE!!!!!!!!!!!

TweakGames

iTrader: (3)

So, would it just be better and cheaper to have a custom 3.5 inch down pipe made? Blue TII, do you have any pictures on how the 3.5 inch DP looks connected to the stage 4? Is hole in the back of the turbo even 3.5 inches? O.o

gxl90rx7

iTrader: (1)

thats what sucks, the stock turbo outlet is only like 2.5"

TweakGames

iTrader: (3)

Yeah, that is what I thought. I am really interested to see how he mounted a 3.5 inch DP to the 2.5 inch turbo outlet. I am intrigued.

bigdv519

iTrader: (3)

I'm using the 3" downpipe.

Here are a couple of screen shots from the day. Theres a couple of 34x hp pulls in there.

BLUE TII

iTrader: (9)

TweakGames
gxl90rx7

My Spec 90 had 2.5" ID flange to velocity stack to 3" pipe for first bend at downpipe to 3.5" pipe for rest.

I have seen other Spec 90 that had 3" flange.

BNR Stage 4 turbo outlet ID is bigger as it is bored to minor diameter of whatever exhaust wheel you choose ("O" trim, "P" trim).

So, I had to port the 2.5" flange larger to match the Stage 4, but it left a venturi where flange met velocity stack.

Later, I welded pieces between the flange and pipe so I could eliminate the venturi restriction everywhere but where the 2 top bolts are. Umm, I can see where a pic would help :P



Nice numbers bigdv519! Stock ports and internal wastegate no less?!

Is it S4 or S5 based? That is about the same spool I had with restrictive RB 3" exhaust as well. Better w/ bigger downpipe.

TweakGames

iTrader: (3)

Yeah, I definitely need a picture! haha sorry Is this something brian could do right off the bat so that I wouldn't have to mod/risk breaking the turbo myself?

bigdv519

iTrader: (3)

Yes stock intake ports and internal wastegate. Turbo and manifold are S5.

What gasket do you use to mate the downpipe to the turbo since it is bigger than stock. I know my gasket is extending into the path of exhaust flow about 2 or 3mm all the way around.

BLUE TII

iTrader: (9)

I tried several gasket ideas out.

Two things that actually worked well are-

1) Take a stock S5 laminated stainless gasket and cut it to larger inside diameter. This eliminates the sealing "fire ring" but works great anyways. I also had to do this to my turbo to manifold gasket.

or

2) Take very thin copper sheet and cut it to correct gasket shape. Stack 4-6 of these up for the gasket. This works great UNLESS you get any exhaust leak at the flanges and then they will quickly burn through one at a time.

I stack the copper sheets, screw to work table and holesaw the ID, drill the 3 mounting holes and then cut out each outline individually with scissors.

Heatcycling the copper caused the nuts to loosen or the studs to loosen when the nuts were jam nutted- which caused exhaust leak. I used high grade bolts in place of studs on the turbo to downpipe connection with high temp antisieze and safety wired the bolt heads together and that fixed everything.

So, bigdv519- is there anything special done to that S5 Stage 4 to stop boost creep? Which size exhaust wheel?

bigdv519

iTrader: (3)

BLUE TII: I am at such a loss for an answer when it comes to what size exhaust wheel it is. I basically asked Bryan to make it a beast, and that I'll be shooting for a quartermile record with his turbo.

After further analyzing some of the footage shot at the dyno, there is an obvious boost creep issue. As stated before, positive pressure is seen right at 2k rpms. Then about 7psi right at 3k rpms. That holds until about 4100rpms, where boost starts to increase. Then about 10psi right at 5500 rpms. Then 12psi by 6k rpms. Then ~14.5 by 6500rpms and holds that until 8100rpms.

The quoted statement above is incorrect and based on looking back and forth between the gauge and the increasing faster approaching road ahead.

As for the exhaust leaks. I had a whole bunch. I had exhaust leaks between the motor and exhaust manifold; between the exhaust manifold and turbo; and between the turbo and downpipe. I hate to say that I believe they were all caused by the copper lock nuts I used. Anthony and I removed all the exhaust components and using the best gaskets we had laying around. After tightening everything back down with lock washers and original Mazda nuts, the PFC is registering much more boost that normal. I was tuned at max boost of 1.02 bar (14.79psi) @ ~93% injector duty cycle. The PFC is now registering 1.15 bar (16.679psi) @ ~97% injector duty cycle WITH THE BOOST CONTROLLER OFF. I even scared my self a little while ago, when I looked at the max pressure on the PFC and saw 100%. This is a mistake on my part and is not to be blamed on RX7.com nor BNR Turbos. I will cruise the car around for the next week or so until I make the short trip over to RX7.com.

TweakGames

iTrader: (3)

I know this is semi off topic, but I am sad. My engine blew today (this morning) when my front primary injector stuck closed while I was in boost. I am rebuilding as we speak. If someone could post up a cool bnr hybrid fact, dyno, or video it would really make my day better.

Thanks
~Tweak

P.S. btw, saying you really do have boost creep, didn't help. :P But keep the info coming.

bigdv519

iTrader: (3)

I think I got something that should cheer you up. Follow this link.

https://www.rx7club.com/build-threads-294/project-10th-ae-turbo-ii-391031/

gxl90rx7

iTrader: (1)

tweak, what seals and mileage were on the motor? how did you know it was a fuel injector?

anyway, to cheer you up, heres some crappy videos of my dyno at 7psi:

3rd gear, 253whp
http://www.youtube.com/watch?v=WO8gIGjhuZ0

4th gear, 255whp
http://www.youtube.com/watch?v=Wc33lFL7s3E