Kappa Performance Forum
Community => Supporting Vendors => DDM Works => Topic started by: Dave@DDMworks on January 17, 2011, 07:59:20 PM
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We had a couple people ask us about what goes on when people drop their car off to have some major mods done to it, so we have a new project car in for the week and thought it was a good idea to share the build process with everyone.
The car was dropped off to us this morning and is a completely stock 2.4L other than a high flow cat and SOLO exhaust. We are installing several items on it this week including boosting it. So we will be updating this thread through the week to show pictures and descriptions of what is going into the car, how everything goes on and show before and after of how the car comes out.
Posted this over on the big board also, but I know some of you don't visit over there and didn't want you to miss it :)
Hope you enjoy!
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin_24L_4.jpg)
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin_24L_5.jpg)
(http://ddmworks.com/top_secret_stuff/kevin24build/stock_121hp_131tq.jpg)
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Thanks Dave! Looking forward to seeing this project.
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Dave@DDMWorks, thanks for letting us evesdrop on Kevin's 2.4L Build. Awesome!!!
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Thanks DDM : I like to see how these things go together and compare factory Rating change . Keep it comming . you guys are so :cool: Also :urock:
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Turbo or Super?
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Dave@DDMWorks, thanks for letting us eavesdrop on Kevin's 2.4L Build. Awesome!!!
:agree: And thank Kevin for us, too! :thumbs:
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Nice to be able to watch the progress on this kappa, coz like u said i don't visit the BB!
i wish it was my car in your shop!!!
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So we started to remove all of the stock parts that will not be re-used and pulled the valve cover for powdercoating. Also started on the VDI installation. More pics this afternoon.
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin_24L_9.jpg)
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin_24L_12.jpg)
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin_24L_8.jpg)
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That car is going to look great with the lambo doors.
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Member
tazz's Avatar
Join Date: Jan 2008
This is what I posted on the solstice forum
I hope who ever owns that car will take better care of the engine compartment, when they get it back, that was a disgrace!
Hopefully we can all agree on that statement.
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Hey, go easy. Not all Kappas are kept in garages, and sometimes it's not possible to devote all the time to keeping our cars clean that we would like.
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I believe that this SOL is from Texas. (See inspection stickers) That may explain why it is a little dirty. LONG TRIP!!
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I believe that this SOL is from Texas. (See inspection stickers) That may explain why it is a little dirty. LONG TRIP!!
You are correct, it is from Texas, and also the customer was out of the country for 6 months and it got a little dirty, but we are taking care of that :)
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Good thing you never see my car is all I have to say
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Critterman ; John isn't Def on his way back to help YOU. :gaah: :lol: Spit Shine and WAX .
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I do believe that is why he is taking a detour in his trip from the PI to Korea. What a guy flying halfway around the world just to detail my car.
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If they have been out of country my thanks and my bad.
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Yesterday the valve cover started getting prepped for powdercoating:
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin13.jpg)
and John started on the clutch swap:
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin17.jpg)
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin18.jpg)
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin19.jpg)
and the transmission finally makes its way out
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin28.jpg)
While under there doing the clutch I sneaked in around John and installed the Probeam:
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin20.jpg)
The injectors got swapped out with new spark plugs also, and then parts are starting to go back on, here is the valve cover installed on there:
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin22.jpg)
and other parts are on the table getting ready to be installed:
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin25.jpg)
More to come later!
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thx for the update Dave!!
how much do you think it would cost to ship my GT at your shop to upgrade internals and add some goodies???
:drool:
maybe it would be more cost efficient to buy a US kappa, do the job at your shop and ship it here... :gaah:
my b-day is only 6 months away kappa people (and DDM) !!
you know what i want for gift ;)
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It would be cheaper to Ship Dave there............Wait
and Ivy
and John
and Randy
and...................
Dave I see you left the heavy work for John and you take the easy-peasy work :lol:
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There actually are ways you can get Dr. Dave and his staff and family to make a house call at your home. It involves oranges, chocolate-chip cookies and proximity to Texas Mod Meets. But, that's another story... ;)
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Or Maryland ones! ;)
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You bring up a good point, they could have a European Mod meet and invite DDM, JPM, and Solo. :lol:
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She is getting close to being all done, just a little peek of how it is coming, with full pictures tomorrow of it all :)
(http://ddmworks.com/top_secret_stuff/kevin24build/kevin30.jpg)
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a helpfull hint Dave, it will get more air if you remove the plastic cover from the filter.
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Crap that's why mine is so slow and throwing all those codes ;)
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Crap that's why mine is so slow and throwing all those codes ;)
:lol:
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Dave,
What kind of turbo have you installed on this Sol?
Thanks
Jas
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Official details to follow from Dave tomorrow, but Kevin is on his way home to TX with a fun car.
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Like Randy said, Kevin is on his way back with a very different car then when he arrived here.
The car came in with only 121hp at the wheels and left with 304 at the wheels:
(http://ddmworks.com/top_secret_stuff/kevin24build/FINAL_304HP_303TQ.jpg)
And this is how the engine bay turned out after the install:
(http://ddmworks.com/top_secret_stuff/kevin24build/DSC02981.jpg)
(http://ddmworks.com/top_secret_stuff/kevin24build/DSC02988.jpg)
(http://ddmworks.com/top_secret_stuff/kevin24build/DSC02990.jpg)
(http://ddmworks.com/top_secret_stuff/kevin24build/DSC02994.jpg)
thanks again to Kevin for stopping by and allowing us to work on the car and transform it for him!
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Can you guys tell us what Turbo went in this car?.
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Love the fuzzy dice.
Flat, late(4,000 rpm)torque curve. One draw back of tuned exhaust manifold.
Looks much better than when you started and not bad for 60% gain in power.
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VERY NICE DDM!!!
CONGRATULATIONS KEVIN!!! :thumbs:
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Latinvenom - The turbo that went on the car is a Borg Warner S256, with room to grow when he is ready for more.
Normsky - Not really sure what you are talking about with "one draw back of tuned exhaust manifold". The original dyno was 121hp, so we added 151% more power to the wheels :)
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Normsky - Not really sure what you are talking about with "one draw back of tuned exhaust manifold". The original dyno was 121hp, so we added 151% more power to the wheels :)
[/quote]
I think Normsky is using the "Hahn correction factor" in his computation...
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Only makes 200 lbs torque @ 3000 rpms. That's even lower than Carl-in-Texas turbo you did years ago.
All depends on the gasoline used for the low base number. Maybe because of lower octane since most 2.4 Kappas out down close to 150, so the improvement is more like 110%.
Keep those dice dusted off. :)
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Sure is better than 150ft/lbs@3000rpm's
(http://ddmworks.com/top_secret_stuff/kevin24build/Richards003.jpg)
Seriously though, there is a big difference between runs on a dynojet (as used in the dyno above) and the dyno that we use here at the shop when it comes to turbo dyno runs. For naturally aspirated or supercharged runs it does not make a difference, but because of a turbo's inherent response time the dyno can make a difference. If you are not familier with the dynojet dyno's that are most common, they have a large 3000# roller that is used for the inertial mass. So as you spin this large roller up you can calculate the torque and then the horsepower from doing so. Typical runs on a dynojet are going to last 12-14 seconds, which gives a longer time for the turbo to come on and makes the torque curve look better than on our dyno. Our dyno is a portable unit that has 10" rollers that weigh around 700# and so the dyno runs are shorter, not giving the turbo as much time to spool resulting in what looks like a slower response then what you seen when you drive the car. Our dyno is a load bearing dyno and we could put load on the car to help the turbo spool earlier on the graph, but prefer to just run all runs in inertial mode to keep everything the same between cars/runs. As a note, Carlintexas car was on a dynojet also.
Also all of our dyno numbers use SAE correction, when you see a dyno with STD correction, it will read higher then SAE. On a 300hp car going from SAE to STD will add around 13-15hp.
After driving the car, it compares very well to other turbo kits we have driven here. The response on Kevin's was better then the other kits we have driven and with the S256 he has the capability to produce more power down the road if he chooses to. That is why we like some of the more expensive turbos out there, they can offer better spool time and provide more power.
As for the octane numbers, we didn't change gas in the car the whole time, what gas was in the car when we dyno'd it stock was in it when we dyno'd it with the turbo. Are you suggesting that we made those numbers on 87 octane? That would be impressive!
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Same gas for both runs, and I've never seen running 87 to 93 octane give ~25whp on a stock N/A system. Stock ECM's are programmed for 87oct, so going to 93 will not give any significant performance difference, at best maybe 5whp especially not 20+whp. Some cars are just low, some are high, but the average that we've seen completely stock is 130-140.
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Go with log style manifold and journal bearing turbo which costs less and makes more in the normal driving/operating range than tubular/bearing setup. Try 250ft/lbs@3000rpm's. :P
(http://i29.photobucket.com/albums/c284/Norm1988GT/300hppull.jpg)
This example is not tuned completely, so it may have more potential.
I'll give you 10-15 hp difference STD/SAE comparison.
BTW, what happened to the dyno graphs on your website for supercharged 2.4s?
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Gotcha!
Same gas for both runs, and I've never seen running 87 to 93 octane give ~25whp on a stock N/A system. Stock ECM's are programmed for 87oct, so going to 93 will not give any significant performance difference, at best maybe 5whp especially not 20+whp. Some cars are just low, some are high, but the average that we've seen completely stock is 130-140.
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Go with log style manifold and journal bearing turbo which costs less and makes more in the normal driving/operating range than tubular/bearing setup. Try 250ft/lbs@3000rpm's. :P
(http://i29.photobucket.com/albums/c284/Norm1988GT/300hppull.jpg)
This example is not tuned completely, so it may have more potential.
I'll give you 10-15 hp difference STD/SAE comparison.
BTW, what happened to the dyno graphs on your website for supercharged 2.4s?
That run you are using for a reference was made with a combination of 91-100 octane gas running dangerously lean (mid 14's air fuel) at peak torque and still made less overall power.
Also our website is being completely redone and not everything has made it back up there yet.
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Gotcha!
???
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I'm running similar boost on 92 octane without a cat. :)
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Great work DDM!!!
the engine bay looks amazing, everything seems to be in the perfect place!
great hp and torque too!!
i believe this could be offered as a DDM kit!!
i have the same dice too, in black!!!
i suppose this must be faster than lnf tuned +bolt ons
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So in your opinion the 20G is or can be better than the S256?.
I think the only way to prove that would be to have 2 cars on the same Dyno with identical equipment( except the turbo) and then tune them.
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Latin, the graph I provided is from the lessor 16G, 20G. Sure it don't hold hp up top but so little time is spent there unless your on a Dyno or the drag strip. 16G on the 2.4 is a nice bump in allot of torque down low where you need it in an autocross or just street driving.
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Dave,
Thanks for the thread to show Kevin's build. I appreciate the look into your day-to-day life without having to micro-analyse everything you did and why.
The engine bay looks much better from beginning to end (cleaner). You guys did a great job and I am sure you provided just what the CUSTOMER wanted.
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:agree:
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Thanks guys, he was very happy when he left, he was out driving it for so long on the test drive, we thought he might have gotten pulled over :drive:
Also we started a new section on the website that we will be updating with builds here. It will contain all of the pictures and dyno runs for cars that come through the shop, here is the link:
http://ddmworks.com/build_logs_home.html (http://ddmworks.com/build_logs_home.html)
Thanks!
Dave
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engine looked awesome!
Power increase doubled!
good job DDM! ;)
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Dave talk to John
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Dave talk to John
?
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Sorry should have been Mike.