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

Starting this thread now because look what showed up today... You can see the rest of my build here.


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I plan on doing pictures and/or videos along the way, a before and after impressions video, before and after dynos on the same dyno (doing my last NA dyno on 3/29 actually), and will try and answer general questions along the way!

I'm super excited for this step! The car has seen a fair amount of track time (as well as being my 51k mile daily driver) and I'm really, really looking forward to seeing how this over-engineered kit lasts in the long term as a daily/track toy. She's getting her last track day as an NA car on 3/28 at Hallett Motor Racing Circuit, and I do plan on returning there after the SC to get comparison lap times.

Big thanks to Jeremy and Yo @ FT86SpeedFactory as well! They were super helpful and kept me updated while waiting for it to ship! You guys are just stellar, as always!


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Well, it's been a while since I've posted, but I have a few updates.

The good news is that the car is still running well, with minimal issue. I do have a slight issue that doesn't happen every time I drive it, but under very minimal throttle input (i.e., when the cruise control is set and the car hits a small incline), the car has an unusual hesitation, followed by a surge of power. As if the ECU can't quite figure out just how much fuel to throw at the car when barely accelerating. Honestly, I feel as if there's a chance I still have a small vacuum leak somewhere, but am unmotivated to pull the manifold back off to confirm.

In other news, she will see her first supercharged track day next Friday, so I'm a bit excited to see how lap times will compare as it's a track I've lapped NA before. The oil cooler will go on over the weekend, and then it's off to the track! Will post videos soon.

I FINALLY uploaded the dyno videos as well. It made 249 rwhp, 199 rwtq, which was a 76 rwhp, 59 rwtq gain over where the car was before the supercharger. Pretty stellar results!

Here are the three pulls. Apologies for not getting them from the very start. I had to run up the stairs to get the log started from my laptop, then run back downstairs to start filming.

Run 1:

[ame="https://www.youtube.com/watch?v=OmYEIat47SM"]2015.04.30 - Scion FR-S Cosworth Supercharged Dyno - Run 1 - YouTube[/ame]

Run 2:

[ame="https://www.youtube.com/watch?v=7xctVeDmuCY"]2015.04.30 - Scion FR-S Cosworth Supercharged Dyno - Run 2 - YouTube[/ame]

Run 3:

[ame="https://www.youtube.com/watch?v=2x4U3sRKBsc"]2015.04.30 - Scion FR-S Cosworth Supercharged Dyno - Run 3 - YouTube[/ame]


And the dyno chart:

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And the comparison from NA:

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Lucky you!!

Cosworth SC
 

I'm so excited about your Cosworth SC. I have been waiting for the real deal to come since I bought the car. I got mine the 2nd day they came out here in Florida. I am convinced that Cosworth has made the best FI System for the 86. Their approach just makes so much sense. Heat soak is my biggest worry and Cosworth has solved this problem much more than anything I've seen for our cars. I have a '12 Roush Stage 3 and I love the cooling system on that Supercharger. Down here in Florida, you really need great cooling. I don't think I have been this excited since I bought the car and put on lightweight Kosei wheels and Direzzas! Looking forward to your build with baited breath.

Subbed. This kit looks great!

Looking forward to reports on this!

nice one, what exhaust spec are you going to run? and are you running the Cosworth tune?

I just ordered mine today from SpeedFactory. Super excited to see what you get haha

fuckin blue balls man

I'm with you! Even though there were other kits available for less $ that promised marginally more power, none of them convinced me that they were as well built, tested as much, and would be able to hold up as well on a car that is not JUST a track toy, but has to hold up to daily use as well. I'm super excited to see how this pans out for the future.

Nameless Longtube Header
Motiv Overpipe
Motiv Front Pipe
GReddy CS GTS Ver 2

Definitely going to start with the Cosworth tune and go from there. I'm guessing there won't be much more power to "unlock" without going more aggressive, which might violate my "daily use" need.


My goal for the car has always essentially be like an FR-S "GT3" or "Type R." Basically I wanted something that still felt and looked like a factory car, but like what Toyota would've built had given a bigger budget to make a "track ready" version of the car. I think the Cosworth kit fit that build philosophy perfectly, which is why it's in the garage waiting for me!


NA track day Sat, NA dyno Sun, then the build starts! Stay tuned folks!

Sub'd

Good to see interest from fellow brits too.

Do you have a baseline for the stock car on the dyno you intend to take the car with the stage 2 kit fitted? Im interested to see what the whole package of exhaust (non cosworth) and stage 2 kit with the cosworth tune come out like. Judging by cosworths engine dyon Stock ~190hp, stage 2.3 ~ 290hp thats a fair increase!

Seems to be precious little info on the kit really, other than Cosworth marketing so far.. so I'm looking forward to installed reports.

looks lke there may be a bunch more on the way

https://fbcdn-sphotos-h-a.akamaihd.n...cf7d993997db59

interesting

Great looking setup. Since it's from Cosworth, I have no doubt at all that this kit has been developed and tested extensively. I can't wait to read your review. :)

BTW, does Cosworth offer OTS map for only stock + SC or do they offer OTS maps for those with SC + header + exhaust?

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

Can't wait to see the results.

Should get mine by end of this week I hope!

Sub'd and excited for you. :)

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!

have you got a tune and instructions now then?

I want to see how this does, subbed

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.

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...

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Mileage at the start
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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...

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

Looks amazing, hard to wait until tommorow

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?

That is a lot of filler rod in those heat exchanger end tanks...one of the reasons this kit is so expensive I bet. I'm surprised they didn't get an off the shelf unit but there's a good deal of volume and cooling in there for sure. If the pump holds up this should be a very solid cooling system for the track.

I've never seen a quad-pass exchanger like that as an off the shelf unit. I'm still waiting for someone to sell me one without buying the whole kit. :(

it's near the middle of the hose...they are not easy to see the first time you look for them..once you find one the others are easier to spot.

And with that ladies and gentlemen, I am a dumbass.

I can't see the hoses that we've already mounted, but literally every single other hose was labeled.

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Still not done... The black octopus of intercooler piping is going to be the death of me.

Did a coolant flush while I was under the car (had to put the new thermostat in anyways), though, so that's good.

Re-routing hosing to make room... (I know my engine bay is a mess... it's my year-round daily and Heartland Park throws up lots of rocks :()

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OCTOPUS EVERYWHERE!

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Test fitting the manifold... (and realizing that much of my IC piping was resting in the wrong locations and needed to be moved around)

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Overall, it's been taking a bit longer than expected. The majority of the hoseclamps for the IC piping BARELY fit, making every single hose fitting an exercise in patience and wiggling the clamp back and forth. I also had to make another trip to the hardware store to pickup some bolts to mount the IC water pump to the bracket as none of the bolts I had were long enough.

Instruction packet has been a bit of a pain as it's a combination of LHD/RHD instructions and pictures, so most of the actual pictures are flipped, making tracking exact hose locations a pain. These are early days for this kit, though, so it's not surprising and I can't really be mad at Cosworth seeing as their primary test bed was RHD.

Have about 3 1/2 hrs free today to try and finish this bad boy. Going to try and mount my Perrin Oil Cooler today too, which made me realize that the heat exchanger out front will now say COSWO instead of COSWORTH, seeing as my oil cooler will block it. :p

Might be done today, but wouldn't be surprised if it was tomorrow!

These octopus hoses are dumb. The included instructions also need lots of work, Cosser.

/frustration.

Don't forget to reconnect the fuel line before you do the final install of the SC. You are not going to be able to fish it under the SC...before you install the SC would be a good time to do a catch can/ Oil air separator....
what's the rush?

I'll post more when I have more time, but something finally came to life around 4AM last night...

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Initial thoughts without having the time to give a full write up? My gentlemen bits made my pants shorter while driving it. Just awesome. This is how this car should have come from the factory.

Excellent. I spoke to Cosworth (I live just down the road from them) about their testing. I asked specifically about heat soak. They said and I quote "testing on track, on a 25C day with a 3/4 mile stright where the car hit 150mph, we never saw more than 10C post charge cooler intake temp rise above ambient". Cracking bit of kit. Now they just need to sort out the instructions and jobs a gooden.

so now you've driven it a bit , what do you think - other than Cosworth need to add more detail to the instructions

throttle response good? driveabilty OK? is it too loud? or not loud enough?

Videos?! :)

I'm pretty happy with the power delivery. It's very linear and literally feels like a small V6 was dropped into the front of the car. Throttle response under load is good, and it certainly gets to redline quicker (because POWAH!), but I have noticed that I've had to adjust my rev matching because the car actually revs slower when between gears. I assume this is because of the parasitic drag that the supercharger puts on the motor. No big deal, and it's not massively different, but it is worth noting.

Oddly enough, the car actually got quieter after install. I'm not sure if this has anything to do with the supercharger though, as I did find a small exhaust leak at the overpipe. It does drone less though, and the actual exhaust note is slightly different (even other 86 owners noticed this at our meet today).

I have had an annoying, though seemingly minor issue pop up today though. The car doesn't seem to drive any differently, and it still develops good power, but it's making this squealing noise at idle. When you rev it, the noise goes away, but returns as soon as it settles back in @ 800 rpm. Under load, the noise is gone as well. After the turn the car off, the noise persists for a few seconds and changes pitch before going away. It seems like it's coming from the backside of the engine bay on the driver's side.

I had company coming by to watch the F1 race, so I didn't have much time to mess with it today. We initially thought because the noise persisted, that one of the vacuum lines was loose. Thought maybe the rear crank breather hose had come loose, but reaching back and making sure it was tight didn't change anything.

Guess I'll take a peek sometime tomorrow if I get some time.

[ame="https://www.youtube.com/watch?v=lHbSJ4zxoCw"]Cosworth supercharger noise - YouTube[/ame]