Forged Engine & Stage 4 AVO Turbo

[ChrisD]

Originally Posted by Tim Radley

Did you get it mapped and what were the results?
How are you enjoying it so far?

The turbo bearing died when Fensport were mapping it... so had to wait a bit for a new turbo (went stage 4 instead of stage 3 this time as got a good deal on a stage 4 one).

Once that was sorted, they noticed oil building up in one of the cylinders. So I took it back to Ricky as I assumed it must be something to do with the engine rebuild, but we found it looks like the oil is coming from the intake manifold. Seems like the catch can Fensport installed as part of the original turbo installation is doing absolutely nothing (as it was bone dry and the intake manifold was covered in oil). Can even see oil stains on the inlet ports where it has run down into the cylinders.

So yeah... not having much luck so far lol Ricky has got the car this week to modify the breather system to try get this catch can to actually do its job, and also do another leakdown n compression test just to be sure its nothing internal. Then hopefully all being well, I'll get it back at the end of this week or early next week and can take it back to Fensport to get the final map done.

[spitfire481]

even if the leak down isn't the greatest, i wouldn't worry too much. the top rings still need to seat before that clears up.

[EdiVip]

What's the difference between stage 3 and 4? Where did U bought it, how much?

[ChrisD]

Originally Posted by Tim Radley

Any updates?

The oil issue was definitely because of oil being passed back into the inlet manifold through the PCV system instead of getting caught by the catch can. Engine builder quickly spotted and rectified this by changing the way the catch can hoses are set up (free of charge, even though it wasn't him that installed it originally - so thanks for that Ricky!).

Once that was all sorted it went back to Fensport for the final map. They did encounter some fuelling issues at very high RPM but got that sorted in the end and rang me yesterday to say it is all done. Apparently they've got it running 1.2 bar of boost (17 psi) through most of the rev range and said it pulls really well.

Picking it up on Tuesday and will be taking it to a rolling road day that the gt86 FB group has organised on the 27th so will see what power its making exactly. I'll update this thread with impressions of driving it once I get it back

[ChrisD]

Got it on the dyno last weekend and as you can see peak power at the flywheel was 335 bhp and 275 lbs ft of torque, which is quite a bit less than we were expecting.

Considering someone else with the stage 3 turbo running 0.8 bar of boost got 325 bhp (not sure if that was on a different dyno though) it seems odd that stage 4 turbo running 1.2 bar of boost would only be 10 bhp more. The stage 3 run was on stock compression ratio whereas I'm on 10:1, but surely the extra boost should easily make up for that and then some. Of course this is only peak power, its possible mine is making more power elsewhere in the rev range but I don't have a graph of the stage 3 to compare to.

Fensport suggested that perhaps the tyres were slipping on the dyno as this seems like a very low figure to them for the setup I'm running. We did have issues with the tyres spinning at first but the guys running the dyno strapped the rear subframe down and said they were happy that the tyres weren't spinning after that. Fensport did also say when they mapped it that they could push it and probably get another 20 bhp out of it but that they'd rather keep things safe especially as I'm going to be bouncing it off the limiter at drift days every now and then (thrashed it at a drift event just 2 days ago and it survived).

Regardless of the numbers, I'm happy as it pulls really well now - definitely noticeably faster than it was before with 0.8 bar on the stock engine. Everyone that I took out for a spin at the GT86 dyno day was shocked at how fast it was so I guess that's a good sign lol spins the wheels up easily as well and that's what I wanted.

Next job is getting an extra set of calipers mounted to the rear so we can get the hydraulic handbrake working, and also fitting a 1.5 way LSD. Fun times

[drewhusaf27]

That's awesome man! Thanks for the post the suspense was killin me waiting to see how it did. I did also expect it to do better on stage 4 than that though. Let us know what you find out!


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[spitfire481]

something doesn't seem right. i made 300whp on regular pump gas with a base avo kit around 11psi. 400whp at 18psi on e85. even with the compression drop, 17psi with the slightly larger avo turbo i feel should make way better than it did. either way, glad you got it all sorted out and running right again. numbers don't really mean a lot anyway, its how it feels

[ChrisD]

Originally Posted by spitfire481

something doesn't seem right. i made 300whp on regular pump gas with a base avo kit around 11psi. 400whp at 18psi on e85. even with the compression drop, 17psi with the slightly larger avo turbo i feel should make way better than it did. either way, glad you got it all sorted out and running right again. numbers don't really mean a lot anyway, its how it feels

Yeah that's what we were saying, people seem to make this much with way less boost and on the lower stage turbo kits, so it does seem a bit odd. Fensport also said when they mapped it and logged everything they didn't see any kind of drop off in torque towards the top end like there is on the dyno graph.

So I dunno, I could probably get better numbers if I went on a different dyno and put better tyres on and had some more weight over the rear etc etc, but I'm not bothered about dyno numbers enough to do that. It drives great now so its all good

[drewhusaf27]

That's all that matters is the you are happy with how the car drives. Numbers are all that matter to some people.


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[s2d4]

US dyno vs the world.
Their dynos read a lot higher

[totopo]

Originally Posted by ChrisD

Considering someone else with the stage 3 turbo running 0.8 bar of boost got 325 bhp (not sure if that was on a different dyno though) it seems odd that stage 4 turbo running 1.2 bar of boost would only be 10 bhp more. The stage 3 run was on stock compression ratio whereas I'm on 10:1, but surely the extra boost should easily make up for that and then some. Of course this is only peak power, its possible mine is making more power elsewhere in the rev range but I don't have a graph of the stage 3 to compare to.

0.8 bar @ 12.5:1
You are running 11.6 PSI of boost at an altitude of 0 feet. Your motor's static compression is 12.5 :1. At this boost level and altitude your effective compression ratio is 22.36 :1.

1.2 bar @ 10:1
You are running 17.4 PSI of boost at an altitude of 0 feet. Your motor's static compression is 10 :1. At this boost level and altitude your effective compression ratio is 21.84 :1.

[ChrisD]

Originally Posted by totopo

0.8 bar @ 12.5:1
You are running 11.6 PSI of boost at an altitude of 0 feet. Your motor's static compression is 12.5 :1. At this boost level and altitude your effective compression ratio is 22.36 :1.

1.2 bar @ 10:1
You are running 17.4 PSI of boost at an altitude of 0 feet. Your motor's static compression is 10 :1. At this boost level and altitude your effective compression ratio is 21.84 :1.

If its that simple then wouldn't the car be making less power now than it was before?

[Nigelr32]

Just a thought Chris, You have a Stage 4 now, but not the bigger pipework that the kit comes with? Didn't you also mention Adrian had "tuned" this turbo?

[ChrisD]

Originally Posted by Nigelr32

Just a thought Chris, You have a Stage 4 now, but not the bigger pipework that the kit comes with? Didn't you also mention Adrian had "tuned" this turbo?

nah I got the larger intercooler pipes etc installed at the same time as the stage 4 turbo. Yeah they've tweaked this turbo to give slightly more bhp at the top end. Fensport said in their logs they don't see the air flow or anything dropping off towards the top like the torque does on the dyno so that's another thing that makes them think maybe the wheels were slipping.