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-   -   Accelerated Performance 2013 BRZ - FRS Turbo Kit Designing (https://www.ft86club.com/forums/showthread.php?t=9942)

Don@Accelerated 06-26-2012 09:18 PM

Accelerated Performance 2013 BRZ - FRS Turbo Kit Designing
 
Accelerated Performance 2013 FRS/BRZ-300 Turbo Kit
Direct Link to Classifieds
http://www.ft86club.com/forums/showt...062#post333062

Kit Includes:

Turbocharger:
-Garrett GT28RS (up to 350HP w/ supporting modifications)
-Tial Stainless Steel V-Band Turbine Housing
-Tial MVS 38mm External Wastegate

AP Overpipe/Uppipe:
-Schedule 10 (.109" Thickness) 304 Stainless Steel
-Integrated 2.5" V-band for Easy Removal (No need to Lift Engine)
-Fabricated and Fully Tungsten Inert Gas Welded In House

AP Downpipe
-2.5" 304 Stainless Steel (.065" Thickness)
-304 Stainless Steel V-Band Turbine Outlet
-2.5" 304 Stainless Steel 2 Bolt Flange (No need for aftermarket Exhaust)
-Stainless Steel UEGO Oxygen Sensor Bung

Intercooler
-Tial Q Blow Off Valve
-AP Air to Air 350HP Bar and Plate Intercooler
-Tungsten Inert Gas Welded w/ Cast Aluminum End Tanks
-Billet Aluminum MAF Adapter Plate
-6061 Polished Aluminum Tubing
-4 Ply Reinforced Silicone Couplers
-301 Stainless Steel Worm Guide Clamps

Intake
-AP 3" 6061 Polished Aluminum Tubing
-K&N 3" Filter
-4 Ply Reinforced Silicone Couplers
-301 Stainless Steel Worm Guide Clamps

AP Stainless Steel Teflon Oil Feed Line and Fittings
AP Stainless Steel -8 Oil Drain Line and Fittings
AP Oil Filler Turbo Drain Return Cap
Turbowerx Oil Scavenge Pump
Plug and Play Wiring Harness for Oil Scavenge Pump

All Gaskets, Hardware and Instructions Included


Heres a teaser pic. People kept asking me why I had the bumper off driving it around. Well for starters I was testing another intake setup. But honestly it was just for this :popcorn:

http://i1128.photobucket.com/albums/...rton/ICPic.jpg

Don@Accelerated 06-26-2012 09:18 PM

Pics

http://i1128.photobucket.com/albums/.../turbopic1.jpg
http://i1128.photobucket.com/albums/...-27-36_283.jpg
http://i1128.photobucket.com/albums/...-28-25_159.jpg
http://i1128.photobucket.com/albums/...4-13-23_94.jpg
http://i1128.photobucket.com/albums/...9-27-28_55.jpg
http://i1128.photobucket.com/albums/...-58-57_814.jpg
http://i1128.photobucket.com/albums/...-50-22_748.jpg
http://i1128.photobucket.com/albums/...-10-28_415.jpg
http://i1128.photobucket.com/albums/...-30-26_404.jpg
http://i1128.photobucket.com/albums/...-30-52_139.jpg
http://i1128.photobucket.com/albums/...-28-58_771.jpg
http://i1128.photobucket.com/albums/...-30-20_170.jpg
http://i1128.photobucket.com/albums/...-30-20_170.jpg
http://i1128.photobucket.com/albums/...-38-31_656.jpg
http://i1128.photobucket.com/albums/...8-09-58_32.jpg
http://i1128.photobucket.com/albums/...09-58_32-1.jpg
http://i1128.photobucket.com/albums/...6-21-02_48.jpg
http://i1128.photobucket.com/albums/...-48-06_352.jpg
http://i1128.photobucket.com/albums/...00-41-31_2.jpg
http://i1128.photobucket.com/albums/...-28-19_971.jpg
http://i1128.photobucket.com/albums/...-28-29_703.jpg

Don@Accelerated 06-26-2012 09:18 PM

vids in order!

[ame="http://www.youtube.com/watch?v=JwjqJqDWJ_k&feature=g-upl"]Accelerated Performance 2013 Brz TURBO - YouTube[/ame]
[ame="http://www.youtube.com/watch?v=Qycuyi6FPzo&feature=g-upl"]Accelerated Performance 2013 BRZ Turbo - YouTube[/ame]
[ame="http://www.youtube.com/watch?v=12NYUHr8p3c&feature=g-upl"]Accelerated Performance 2013 Turbo BRZ - YouTube[/ame]
[ame="http://www.youtube.com/watch?v=90rKAvzOG-0&feature=g-upl"]Accelerated Performance 2013 Turbo Brz - YouTube[/ame]
[ame="http://www.youtube.com/watch?v=yiiHeJHWsjI&feature=g-upl"]Accelerated Performance 2013 Turbo BRZ - YouTube[/ame]
[ame="http://www.youtube.com/watch?v=M3Y79zXOR34&feature=g-upl"]Accelerated Performance 2013 Brz Turbo - YouTube[/ame]
[ame="http://www.youtube.com/watch?v=WPtvSZskocQ&feature=g-upl"]Accelerated Performance 2013 Brz Turbo - YouTube[/ame]

Newest Vid

[ame="http://www.youtube.com/watch?v=D7_2QSLelY8&feature=plcp"]Accelerated Performance 2013 BRZ-300 vs. 2013 Scion FR-S - YouTube[/ame]

LivingLegend 06-26-2012 09:32 PM

AWE YEAH! Can't wait to see it!
Wished I still lived in Ohio to stop by at take a peep lol

Polac_Rudie 06-26-2012 09:34 PM

My prayer's answered :D lol

kmbkk 06-26-2012 10:26 PM

Very nice! Can't wait to see what you do with it.

iggy 06-26-2012 10:39 PM

What will you be using the handle the ECU?

spiller 06-26-2012 10:43 PM

subscribed! funny how subaru and toyota said they couldnt find a place to "package" the intercooler as to their reasons for not going turbo, yet you've managed to comfortably find a place there it seems haha.

Silverdub 06-26-2012 10:48 PM

Booyah andsubscribed. Whats the tuning your going to useis my biggest question

bakerr6 06-27-2012 07:58 AM

hmm, well that settles it, I may have to just stop by the shop and see what's going on haha

UncleFester 06-27-2012 08:09 AM

Quote:

Originally Posted by bakerr6 (Post 281751)
hmm, well that settles it, I may have to just stop by the shop and see what's going on haha

Take your camera with you...tehe

slow_frs 06-27-2012 08:11 AM

Quote:

Originally Posted by spiller (Post 281012)
subscribed! funny how subaru and toyota said they couldnt find a place to "package" the intercooler as to their reasons for not going turbo, yet you've managed to comfortably find a place there it seems haha.


considering that subby likes top mounts and toyota likes side mount i can see how they claim they couldnt find a spot for it, and considering the way radiator only gets air from the lower grill im gonna go and assume they didnt wanna try a front mount because of the restriction of airfolow to the radiator...intercooler-ac condenser-radiator, yes it may still get its air but not the same fresh air it would normally get, no i dont see any issues with this setup just trying to see in from the manufaturers view

spiller 06-27-2012 08:19 AM

Quote:

Originally Posted by slow_frs (Post 281766)
considering that subby likes top mounts and toyota likes side mount i can see how they claim they couldnt find a spot for it, and considering the way radiator only gets air from the lower grill im gonna go and assume they didnt wanna try a front mount because of the restriction of airfolow to the radiator...intercooler-ac condenser-radiator, yes it may still get its air but not the same fresh air it would normally get, no i dont see any issues with this setup just trying to see in from the manufaturers view

That's a fair point but plenty of turbocharged cars come with factory front mounted intercoolers (including a few toyotas). Sure, it does come into consideration though, perhaps weight distribution does also as an intercooler in that position adds a chunk of weight in front of the axle.

Don@Accelerated 06-27-2012 08:29 AM

I have something that I'm working with. I'm really not going to take any control from the ecu. The direct injection and the port injection work with each other and I see many issues with trying to fool with them. I'm just taking it one day at a time. Honestly I would love to just remove that direct injection bolshit!


Quote:

Originally Posted by iggy (Post 281008)
What will you be using the handle the ECU?


Don@Accelerated 06-27-2012 08:30 AM

This intercooler is quite small. I'd be suprised if that was 10lbs.


Quote:

Originally Posted by spiller (Post 281775)
That's a fair point but plenty of turbocharged cars come with factory front mounted intercoolers (including a few toyotas). Sure, it does come into consideration though, perhaps weight distribution does also as an intercooler in that position adds a chunk of weight in front of the axle.


Don@Accelerated 06-27-2012 08:32 AM

Well the car already doesn't want to get up to temperature for starters. The I/C is not completely filling the the front bumper area. I don't think we'll have any issues with airflow. I've been driving it with the intercooler blocking that area for a few days and I haven't noticed anything yet. I'll keep an eye on it.




Quote:

Originally Posted by slow_frs (Post 281766)
considering that subby likes top mounts and toyota likes side mount i can see how they claim they couldnt find a spot for it, and considering the way radiator only gets air from the lower grill im gonna go and assume they didnt wanna try a front mount because of the restriction of airfolow to the radiator...intercooler-ac condenser-radiator, yes it may still get its air but not the same fresh air it would normally get, no i dont see any issues with this setup just trying to see in from the manufaturers view


spiller 06-27-2012 08:37 AM

Quote:

Originally Posted by Don@Accelerated (Post 281797)
This intercooler is quite small. I'd be suprised if that was 10lbs.

Then toyobaru were taking us for a ride with their comments :D

Don@Accelerated 06-27-2012 08:38 AM

Well as far as a factory engine goes. The basic kit will be low boost and a marginal gain. The 12.5 compression does not scare me at all. I have a few toyota engines that are 11-12:1 that make nearly 1600whp. The problem I have with the stock subaru design is the upper most ringland at the valve relief. It looks like trouble from an engine builders perspective.

I have considered the basic kit being upgradable just by adding a remote fuel system w/ e98 or e85 capabilities just for boost fuel enrichment. (This of course would be the stock engine internals) Should allow a far amount of increase over the std pump gas fuel.

Now for the persons who are real serious, we'll just use our drop in pistons we have. I'm also in the process of Billet drop in connecting rods as well.


-Don



Quote:

Originally Posted by Roadstercycle (Post 281135)
I know you don't have all the answers
yet but I am curious as to what your going to do about the 12.5 to 1 compression issue. Do you think it will be a bolt on with piston swap?
or just low boost???????


Don@Accelerated 06-27-2012 08:43 AM

Quote:

Originally Posted by spiller (Post 281811)
Then toyobaru were taking us for a ride with their comments :D


Without cutting the front bumper support. Theres no real room for even a 500hp core intercooler. For the purpose of this kit, I'm going to make it 100% no cutting involved.

I can remember when I had my greddy front mount for my wrx. I had to hack a brand new car all to hell and it pissed me off. Now for those persons who are going to do pistons and rods. We'll be hacking that sucker up :bonk:

spiller 06-27-2012 08:49 AM

Yeah I really like the sound of a kit that doesnt involve any cutting. It seems a shame to take to a nice new car like that, even if you are already forcing air down its lungs!

I have no experience with F.I. on high comp motors but I guess running it on corn juice would be a very sensible way to run higher boost levels without as much risk of detonation? Could you fit a thicker head gasket to lower the comp ratio?

titusdrake 06-27-2012 08:59 AM

Nice. Love the turbos :thumbup:

Sent from my DROID RAZR using Tapatalk 2

slow_frs 06-27-2012 08:59 AM

Quote:

Originally Posted by Don@Accelerated (Post 281814)
Well as far as a factory engine goes. The basic kit will be low boost and a marginal gain. The 12.5 compression does not scare me at all. I have a few toyota engines that are 11-12:1 that make nearly 1600whp. The problem I have with the stock subaru design is the upper most ringland at the valve relief. It looks like trouble from an engine builders perspective.

I have considered the basic kit being upgradable just by adding a remote fuel system w/ e98 or e85 capabilities just for boost fuel enrichment. (This of course would be the stock engine internals) Should allow a far amount of increase over the std pump gas fuel.

Now for the persons who are real serious, we'll just use our drop in pistons we have. I'm also in the process of Billet drop in connecting rods as well.


-Don

so for the basic bolt n you will likely use some maf trickery =P(smaller maf housing) and for the mild you will use a fuel injector in the intake for e85 =D hmmim pretty good with this

slow_frs 06-27-2012 09:00 AM

for those that dont know, making the size of the maf housing smaller makes the ecu read MORE incoming air thus allowing more fuel to be added, as well as it retards timing

Don@Accelerated 06-27-2012 09:05 AM

No i'm not planning on using any kinds of a smaller inlet. The compressor inlet is 3" just like the factory and I intend to still keep it that way if allowable.



Quote:

Originally Posted by slow_frs (Post 281841)
so for the basic bolt n you will likely use some maf trickery =P(smaller maf housing) and for the mild you will use a fuel injector in the intake for e85 =D hmmim pretty good with this


Don@Accelerated 06-27-2012 09:07 AM

You could, but i'm pretty sure the piston is going to be a weakpoint. It would most likely require a HG to thick to bump down far enough. We'd be talking about 4mm+


Quote:

Originally Posted by spiller (Post 281829)
Yeah I really like the sound of a kit that doesnt involve any cutting. It seems a shame to take to a nice new car like that, even if you are already forcing air down its lungs!

I have no experience with F.I. on high comp motors but I guess running it on corn juice would be a very sensible way to run higher boost levels without as much risk of detonation? Could you fit a thicker head gasket to lower the comp ratio?


slow_frs 06-27-2012 09:07 AM

oh ok well ive been debating slapping on, one of my many old turbos that ive ran on my tc running bout 5-6psi and using a SAFC to make the maf think more air, i only plan on fabbing this up testing then ditching it i dont see it being the reliable way in the long run but will be nice for the week of testing

Don@Accelerated 06-27-2012 10:22 AM

Just wait a little while. I'll put together something real nice everyone can enjoy reliably.

Don

Quote:

Originally Posted by slow_frs (Post 281853)
oh ok well ive been debating slapping on, one of my many old turbos that ive ran on my tc running bout 5-6psi and using a SAFC to make the maf think more air, i only plan on fabbing this up testing then ditching it i dont see it being the reliable way in the long run but will be nice for the week of testing


kmbkk 06-27-2012 10:51 AM

Quote:

Originally Posted by Don@Accelerated (Post 281814)
Now for the persons who are real serious, we'll just use our drop in pistons we have. I'm also in the process of Billet drop in connecting rods as well.


-Don

Don, which aftermarket pistons fit our car?

eikond 06-27-2012 12:45 PM

This is my new favorite thread..

I must stop by to visit one of these days.. too bad I usually pass through Toledo in the evenings..

I'm very excited to see how this turbo kit turns out. I'm glad to see you doing one of the first.. I'm confident that you'll make sure to keep it safe and reliable. Which is something I'm not so sure of from some other shops out there.

Looking forward to seeing your exhaust manifold design.

Any thoughts on converting from MAF to MAP or does that require ECU tuning to acheive?

That IC core looks more than adequate. I find it comical that people use such huge tanks for low hp turbo kits.

Should be intersting to see what turbo you chose and when the boost kicks in. Ideally I'd like to see boost kick in right at the point that the torque dip starts.. that would make for a very linear powerband. But, I'm concerned that it might take a big turbo get the spool to kick in late.. isn't the torque dip around 3200 rpms? But you'd have to limit that turbo with a low boost wastegate. The big turbo would not be as responsive as a small turbo..

I'm really intersted in seeing how you design this thing.

I'm very to see you working on it Don! Keep up the great work!

Don@Accelerated 06-27-2012 12:48 PM

That would be our piston Set Custom made for us by Wiseco


Quote:

Originally Posted by kmbkk (Post 281971)
Don, which aftermarket pistons fit our car?


kmbkk 06-27-2012 01:10 PM

Quote:

Originally Posted by Don@Accelerated (Post 282166)
That would be our piston Set Custom made for us by Wiseco

Will those be available for us to purchase?

Dimman 06-27-2012 01:15 PM

Quote:

Originally Posted by slow_frs (Post 281766)
considering that subby likes top mounts and toyota likes side mount i can see how they claim they couldnt find a spot for it, and considering the way radiator only gets air from the lower grill im gonna go and assume they didnt wanna try a front mount because of the restriction of airfolow to the radiator...intercooler-ac condenser-radiator, yes it may still get its air but not the same fresh air it would normally get, no i dont see any issues with this setup just trying to see in from the manufaturers view

I think it has to do with crash standards. Something about the cost of damage in a 5mph front collision or something...

RRnold 06-27-2012 01:17 PM

'scribed!

Can't wait to see the final pics and performance gain. :happy0180:

Don@Accelerated 06-27-2012 02:34 PM

They will be, but are currently not for sale. I won't consider selling them until i've beat them to death first! I want to make sure the changes we've made from the stock piston design will be enough for longevity and durability.

Most likely it will be, but i'll error on the side of caution momentarily.

-Don

Quote:

Originally Posted by kmbkk (Post 282213)
Will those be available for us to purchase?


Fenrir 06-27-2012 02:41 PM

Definitely interested to see where this goes. I'd love a nice small turbo setup for a modest increase in power, as the car (much like miata's) doesn't need much help really :)

Don@Accelerated 06-27-2012 02:57 PM

I'm looking to have full tq by 3-4krpm

Quote:

Originally Posted by Fenrir (Post 282394)
Definitely interested to see where this goes. I'd love a nice small turbo setup for a modest increase in power, as the car (much like miata's) doesn't need much help really :)


kmbkk 06-27-2012 05:07 PM

Quote:

Originally Posted by Don@Accelerated (Post 282378)
They will be, but are currently not for sale. I won't consider selling them until i've beat them to death first! I want to make sure the changes we've made from the stock piston design will be enough for longevity and durability.

Most likely it will be, but i'll error on the side of caution momentarily.

-Don

Any ETA on when they may be available and an estimated price?

sdlynx 06-27-2012 05:26 PM

Definitely interested! Subscribed.

:thumbup:

Don@Accelerated 06-27-2012 05:45 PM

Not sure yet. I'm guessing 3-4wks before we test.

Quote:

Originally Posted by kmbkk (Post 282682)
Any ETA on when they may be available and an estimated price?


OldSkool86 06-27-2012 05:46 PM

With the factory compression, tuning would be key even with boost. I think the D4S with 8 injectors is what is allowing the motor to run such a high compression. When in doubt, add more fuel lolz.


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