Cosworth Stage 2 Supercharger Install (Dyno,Tech,Photos,Videos)
 

Here at RallySport Direct, we have installed the Cosworth stage 2 kit. In this post we would like to share our results of this installation with photos, dyno numbers, as well as videos.








The goal of the Cosworth Stage 2 kit was to create an efficient means of gaining horsepower, increased throttle response, while still remaining to be a reliable street driving vehicle. The kit comes complete with an arsenal of parts ready for installation.

This includes:

- Positive Displacement Supercharger
- Cosworth Branded Intake Manifold
- Cosworth High Efficiency Radiator & Air / Water Intercoolers
- Pump for Air/Water Intercoolers
- Supercharger Inlet Assembly
- Intercooler/Radiator hoses
- Cosworth Front Drive Belt
- Wiring loom
- Pressure sensor
- Installation Hardware Including Fittings, Brackets, Etc.






Since we installed the earlier stages of the Cosworth packages, we had the EcuTek installed. We are currently running the off the shelf map from Cosworth.

Here are the results:

Event: Dyno Tune/ Product Testing
Location: JDP Motorsports, Salt Lake City Utah
Ambient Temp: 52.3F
Ambient Pressure: 25.72 in-Hg
Humidity: 28%
Elevation: 4,450 ft
Weather: sunny
Car: 2014 Scion FR-S
Tuner: Cosworth off the shelf tune on Mode 2
Dyno Info: Dyno Jet
Transmission: 6spd
Gear: 4th
Peak HP at RPM 93 Octane : 261.9WHP @ 7400RPM
Peak Torque at RPM 93 Octane: 206.6WTQ @ 5200RPM
Baseline hp/tq on Mustang Dyno: 150WHP/114TQ
Fuel: 93 octane with 10% ethanol



Mode 1 = 91 octane fuel.
Mode 2 = 93 octane fuel and increased rev limit in 1st 4 gears
Mode 3 = Same as Mode 2 with sharper pedal map and autoblip on a downshift
Mode 4 = Same as Mode 3 with flat foot shift and launch control






Overall we are very pleased with this kit. What do you guys think?

Couple more shots:

http://rallysportdirect.smugmug.com/...01media-X2.jpg

http://rallysportdirect.smugmug.com/..._6492media.jpg

Of course the way this kit is packaged is highly desirable, results are what I'd expect for a reliable trackish setup given the price. However it sounds like this is a 100+db exhaust setup. Sounds horrendous for street car. What is their solution for oil cooling for motor and for SC?

Still a very noticeable torque dip/jump, and peak torque isn't reached until 5k RPM. Not really impressive for a "Stage 2" roots blower even on the small FA20.

They do not provide any oil cooler in the kit, however this should work with almost any aftermarket oil cooler. We may do a oil cooler in the future as well just to make sure we keep oil temps down :)

Thanks,
Rick

Compared to what exactly? The sprintex twin screw which is supposedly more efficient in design only makes 225-240 whp on pump gas. Centrifugals which are more efficient make 250-270 whp on pump gas. Note that the baseline on this dyno is very low which means on a dynojet these numbers would likely be higher...

The "torque dip" of which you speak is maybe 5 ft-lbs? Noticeable?

Looks so stock like but the cost tho...

You can see the torque going nowhere from the 3 to 3.5k RPM range. This is part of the torque dip seen on stock cars. Most applications smooth this out better but you can clearly see torque spiking after the dip / stall in power.

That torque dip looks like the Nameless header torque curve; a lot of torque at 4000rpm. Still, it still shows that by 3100-3200rpm(ish) there is approximately more than the 114 ft-lbs of torque according to the baseline numbers, and does ~200tq from 4k to 6k... not bad. I also like these numbers a lot better than the earlier Cosworth numbers of around 290ish hp from their engine dyno (feel free to correct me if I'm wrong)?

Have to agree with Dezoris on the loudness of the whole exhaust system. I know superchargers don't muffle exhaust like turbo systems do, but he was also supercharged.

Nevertheless, nice of you to post dyno info and video. Although you did post baseline numbers, the baseline graph would be nice.

Again, thanks for posting.

Maybe I missed it, what PSI was that at?

They said the baseline was done on a mustang, they didn't say that the pulls with the supercharger were done on a mustang.

The current numbers are consistent for an a basic FI kit on an FA20 on a dynojet on 6-7psi maybe 8psi. You'd be looking at around 220-230whp if they had done the supercharger pulls on the same mustang they did their baseline on.

If those supercharger numbers were from that same mustang, I would be pretty impressed. 111whp gain?!

I agree that the baseline should come from the same dyno, but if you watch the video and look at the first pic, you see the car on the AWD dyno in the picture(most likely the mustang) and then the car on a 2wd dyno in the video(what I assume is the dynojet)

Again, Im just being skeptical, because 111whp gain is a lot for a kit that claims only an "80Hp power increase with Stage 1.3 exhaust"...:party0030:

EDIT:

I re-read again, looks like I just skimmed too fast. All the info is there.

Event: Dyno Tune/ Product Testing
Location: JDP Motorsports, Salt Lake City Utah
Ambient Temp: 52.3F
Ambient Pressure: 25.72 in-Hg
Humidity: 28%
Elevation: 4,450 ft
Weather: sunny
Car: 2014 Scion FR-S
Tuner: Cosworth off the shelf tune on Mode 2
Dyno Info: Dyno Jet
Transmission: 6spd
Gear: 4th
Peak HP at RPM 93 Octane : 261.9WHP @ 7400RPM
Peak Torque at RPM 93 Octane: 206.6WTQ @ 5200RPM
Baseline hp/tq on Mustang Dyno: 150WHP/114TQ
Fuel: 93 octane with 10% ethanol

Is this kit capable of 300whp? Im just curious if any supercharger can make those numbers without choking out up top

Yeah I see that now, different dynos...Yep their baseline number is useless.

When my kit arrives (hopefully next week), I'll be dyno'ing on the exact same dyno... So keep your eyes peeled!

Yes, the kit is easily capable of 300WHP and more. :)

Thanks,
Rick

Just to be clear the final run was on a Dyno Jet and the Baseline was on a Mustang.

Here is the Dyno Sheet as well :)

http://rallysportdirect.smugmug.com/...20Cosworth.jpg

Thanks,
Rick

Whats the real world cost (not MSRP) of the kit?

Does this mean, not paying for the Cosworth name? haha

I too would like to know this!

:bellyroll:

Seems right in the ballpark for SC systems on this car with a really nice and flat looking torque curve as well.

Super clean install too, which is always nice.

Now let's talk about price and tuning options side of the equation. A street level price would be nice.

It has an EL header, 2 resonators, a single cat, and straight-through mufflers, so probably.

At what stage will they add an intercooler? They're leaving a fair chunk of power on the table.

I haven't read this whole thread so forgive me, but what makes you think it isn't intercooled? @RallySport Direct's posts says that the kit includes an air to water intercooler.

Those two HUGE heat exchangers with the the cosworth badge might be a give away!

And very effective they are too (from cosworth):

http://i41.photobucket.com/albums/e2...ps04966e84.png

Hopefully this kit won't heat soak like the Sprintex kit does on track. Cosworth should have done it properly. Cirtainly looks that way.

More Stealth Stage 2
 

I think I remember initially that it was stated that you could get the Stage 2 kit and keep your existing exhaust system. In order to redline the car around town it would be an advantage to lose a few HP and not have the cops know you were flogging the car. The Stage 1.1 kit doesn't seem too loud although. I love a loud car, don't get me wrong. But I already have 2 other cars you can hear 1/2 mile away exceeding 100db. My FRS is the only car I can drive under the radar to redline.


I think this kit is the only way to go for me. Living in North Florida the outdoor temps can get pretty high for half of the year. So I like the whole design of the Cosworth System much better than the other ones out there. I don't need any more power than the Stage 2 gives you at this psi. I still want to have the handling of the Direzzas at 225/17 in the rear and 215/17 in the front. I have Kosei Racing wheels that are only 14lbs and the unsprung weight is 32 pounds less than stock. I love the feel of these tire sizes and any more power will just break them loose.


So here's what I'm hoping to do. Get a Stage 2 kit, and then buy later on the catback Stage 1.1 exhaust. This way I could get a little loud when I wanted to, and I could put back on the stock catback and be quiet for stealth. Let me know what you guys think of this setup, and if Cosworth will give us a stock exhaust map for 93 V Power (gas of choice).

I think cosworth re offering 3 tunes to go with the charger;
stage 2.0 - stock exhaust
stage 2.1 - catback exhaust
stage 2.3 - full exhaust inc manifold

and I think the kit gives about 7 psi

We review the Cosworth Supercharger! :)

[ame="https://www.youtube.com/watch?v=5TpEupNlVMk&list=TLXed2enS1LGc"]Cosworth Stage 2 Power Package - 2013+ BRZ/FR-S Install/Review - YouTube[/ame]

Thanks,
Rick

Rick, interesting vid as ever. Are you planning on doing a drive-by video to let us compare if the car with full exhaust is any quieter now it's got a supercharger on there?

Rick, can you convert the speeds on your dyno graph to rpm for me?

Any ideas as to what oil cooler you guys would run with this kit?

would you need one if you're not going to track it?

I am curious about this and if someone can indeed confirm that Cosworth does offer above OTS maps, it would be great.

Also, do you have to use Cosworth exhaust parts in order to use their OTS map? I want to know if their OTS map can cover the usage of other brand's header and exhaust.

Those are the tunes offered. They say their tunes are geared specifically for their exhaust parts but... it's just piping so I would assume you could. Well as for the headers, I'd still use them

I'd say as long as you're running more or less the same pipe dimensions ( the Cosworth kit is all 3") you can probably mix and match OK

if its too high a back-pressure compared to the Cosworth exhaust then it'll hamper the tune

Oh sweet. Thanks for the confirmation. I know exhaust shouldn't really matter... as for the header, I am wondering if usage of UEL header will be okay or not with OTS stage 2.3 tune. BTW, did Cosworth release any power figures and graphs for stg 2.3?

I see. Thanks for the info. Like I have mentioned in my above reply, do you think use of UEL header will be okay or not?

you might have some issues I'd say as the cam timing is going to be quite different between the 2 type
thing is if you're going Cosworth you get the tune included anyway? So there's nothing to stop you trying it and see how you get on

if it doesn't work out and you're desperate to keep the UEL header then you'll obviously need a custom tune

UEL and EL and tuning are not interchangeable @Rookie84

They graphs are on their website. As for the headers, like others may have stated, it would probably not work. I'd say at least keep the headers that Cosworth uses the same. As for the rest... well that's your choice