Cosworth Stage 2 Install w/Dyno, Pics, Videos, Impressions

[wooly35]

cant wait to see this in person once its finally installed.

[nguyen_er]

Can't wait to see the results.

[Insurme1]

Should get mine by end of this week I hope!

[OICU812]

Sub'd and excited for you.

[Kiske]

So no install this weekend if your zombie driving Pete?

[enigma]

Originally Posted by Kiske

So no install this weekend if your zombie driving Pete?

Man! Unfortunately not. I've been so busy that I haven't had time to even change the plugs yet, let alone start the SC install.

However, my current plan is to get started Monday night and work through Tuesday and Wednesday... in a perfect world, the Cosser will be up and running by Thursday.

Fingers crossed!

[350matt]

have you got a tune and instructions now then?

[Amaya]

I want to see how this does, subbed

[nguyen_er]

Just realized you're from Olathe! I live a few hours south of you in Wichita. Haha maybe we can meet up at the track sometime.

[enigma]

Originally Posted by nguyen_er

Just realized you're from Olathe! I live a few hours south of you in Wichita. Haha maybe we can meet up at the track sometime.

That'd be awesome man! We could always use more 86 track rats around here.

[enigma]

Well, today was the day folks! The build has started! Chris @ Cosworth has been super awesome chatting back and forth with me. He got the directions out to me really quickly, and got the tune emailed over to me within MINUTES!

Her last couple pics as an NA car...





Mileage at the start













I weighed all of the parts prior to starting the install. My method was essentially weighing myself and then holding the parts and weighing myself again, as most of the stuff is pretty bulky and hard to weigh on its own.

Results came back as follows:

Manifold and supercharger: 44.6 lbs
Heat exchanger (IC): 4.75 lbs
Belt, brackets, IC pump, etc.: 7.5 lbs
IC hoses: 6.8 lbs
Intake pipe: 5.7 lbs

Total: 69.35 lbs. This total has NOT taken into account anything that I'm removing from the car (OEM intake manifold, swapping my Injen intake for the OEM airbox). I'd assume when all is said and done, the total weight added to the car will be in the neighborhood of 60-65 lbs.


I did run into a snag when fitting the throttle body onto the new manifold as the instructions seem to imply that a new throttle body gasket was included, but nowhere to be found in my various bags of goodies. I've reached out to Chris @ Cosworth to see if maybe I'm just mistaken, but I can confirm that the OEM piece definitely doesn't seem to fit. I was able to go to a local parts store and find a gasket that would fit, but will get a definite answer before doing any dynos or heavy testing of the car.

We also ended up changing the spark plugs in my car as it has 53k miles. I know they're not technically due until 60k, but I figured with as many track days as the car has seen and the fact that she's about to go FI, it couldn't hurt. We did have to loosen the motor mounts and jack the engine up to change them (Boxer engines for the lose as far as that goes). Not fun.

Lastly, the hoses don't seem to be labeled at all. Not sure if this is the norm or the exception. The instructions included with the kit seem to think that they're all labeled, but I couldn't find anything on any of my hoses that seem to imply where they all go. Doing a bit of reverse engineering and eyeballing from the included install pictures to determine it. So far, no major issues. Planning on snapping a few pics along the way to show what goes where just in case others have the same problems.

Stopped for the evening after getting the IC mounted. Hoping to finish up tomorrow afternoon!

Showing which 3 hoses are fit to the heat exchanger...






Will update tomorrow, hopefully after I get a chance to drive her! I'm also planning on taking videos, so stay tuned!

[cytack]

Looks amazing, hard to wait until tommorow

[Ernie L]

With perhaps one exception, my hoses were labeled..The labeling is molded into the hose..You need good lighting..ps the longer smaller diameter hose with the 90 degree on the end does not go to the coolers as is implied by the picture in the instructions....it's for the front pvc to cold air inlet connection (spigot on the under side of the air inlet near the throttle body.)

[enigma]

Originally Posted by Ernie L

With perhaps one exception, my hoses were labeled..The labeling is molded into the hose..You need good lighting..ps the longer smaller diameter hose with the 90 degree on the end does not go to the coolers as is implied by the picture in the instructions....it's for the front pvc to cold air inlet connection (spigot on the under side of the air inlet near the throttle body.)

Thanks for the tip! Where is the labeling on the hose? I saw the instructions mentioned the labeling was molded in, but I looked at 3 different hoses and didn't see anything... Maybe I'm looking in the wrong place?