Topic: LIPSTICK'S 800hp first LNF compound turbo/engine build!

[SKY888]

two EGT probes on exhaust manifold will be used to monitor heat





power steering relocated.....and Subaru reservoir will be used instead.

[SKY888]

WERKS Race Intercooler w/ vibrant 3" vanjen clamp kits to make sure that the charge pipes will not pop open during 40+++ psi of boost

[Gentleman Jack]

Does it start yet?  There is a LARGE wager on when / if this beast will fire up for the first time... 

[Sol Asylum]

That might be considered cheating GJ.

[SKY888]

Does it start yet?  There is a LARGE wager on when / if this beast will fire up for the first time... 

yeah engine started about a month or two ago.

was driven outside without boosting it.

engine was rocking a lot and discovered lots of cracking of pipes....if more braces are not installed.
Plus due to the tons of hot pipes, more heat shields need to be fabricated to avoid melting other important wires, hoses, and tubes.

Tomorrow, I'll be buying one more Vibrant boost brace, vibrant 3" vanjen clamp kit, and more DEI heat shields.

[SKY888]

even with the "turbo kits" available for the kappa platform...how long before they develop the kits?   a year? more?   
That's for a single turbo

what more with two turbos with tons of hot pipes and charge pipes....all cramped inside the engine bay?   

customizations:
- exhaust
- intake manifold
- secondary fuel rail
- fuel cell
- radiator, load support bracketry for everything that will oscillate with the engine, radiator ducting, 10,000 braided hoses support and heat shielding for said hoses, heatshielding and support for everything electrical and pneumatic
- Also building a nice, neat panel that will have the fueling controller, LED controller, the 3 backpressure sensors, tach adapter and the AEM water/meth controller
and the aeroforce EGT box


and the person who is building my car has a full time job, and work on my car on his free time.....

[SKY888]

This round of changes will have the 2ndary fuel system wired and active, and will start pushing manifold pressure beyond DI capability(with respect to fueling). If everything behaves as planned then dyno tuning will begin. Only concern at this point is where will the MAF peg. At that point ignition will be static even though the load is increasing

[SKY888]

custom lay-down radiator from scratch!
its actually 60 degree forward set-up

had  to add the tabs to hold the fan on with screws
and move the radiator neck cause it was just to damn close to the charge pipe

[Gentleman Jack]

Wow. 
I can't wait to see this in person.

[SKY888]

Wow. 
I can't wait to see this in person.

you and me both

[SKY888]

WRX power steering reservoir relocated waaaay to the other side of the engine






radiator upper brackets






grounded down all the welds of the pipes for a smooth finish.    Powdercoating begins!

[SKY888]

battery and fuse box will be relocated.
this is the area where the air filter will be positioned.

NOTE: only the GT4294r will have an air filter.   The GT2871r, instead of an air filter, will have a charge pipe connected to the compressor outlet of the big turbo.   All the compressed air will be pushed to the compressor inlet of the small turbo.   The small turbo will re-compress the already compressed air .......that's what is the compounding takes place!





if I still have extra money, BTF will be able  customize me a CF air intake w/ filter......

[SKY888]

since BTF finally wanted to finish this project.........he took two weeks off from his full time job. 



here's what he accomplished in two weeks up to date:

Street/Dynotuning (estimated, about 2hrs so far)
Build double pass radiator and mounts
Fabricate intercooler piping/Vanjen refit
Construct 2nd fuel system, re-fab cell,
route hoses under vehicle, re-fab fuel rail for FPR mounting
Remove, prep, sand, powdercoat turbos, charge pipes
Tear down turbo kit, deliver to swaintech
Reinstall turbo kit
Solve lack of bracketry for fuel pressure accumulator
relocate power steering reservoir/fab all necessary brackets
Fabricate drain tube for low pressure turbo , .085 wall 6061
layout and plumb all oil feed and water cooling lines from engine to turbo
wrap, or fab heatshieliding for most hoses, harnesses
Fabricate exhaust from supplied components, hang on car
remove backbone plate, install harness and oil in transmission
Reinstall said plate, install the clutch line. “Bleed” clutch
Fabricate,clean,pressure test -an hoses. Lots of them lol!
Fabricate radiator shrouding, relocate PS cooler
Install hood,fenders,lip etc .
Weld up the holes in intake manifold, powdercoat
Install intake manifold on car, solve design flaws WRT fit




then here's the remaining stuff to do........then dyno tuning begins:

Remove Cryo2 system
Remove old boost controller
Install Eboost 2
Install Aeroforce gauges
Install aeroforce EGT add on kit w probes
Install pressure sensor kits for turbines
Remount water injection system to suit new build
Install secondary injector controller
Fabricate brackets on intercooler for Front bumper cover
Install engine harness , re route starter cables
remove ducts from bumper cover
rewire Killerglass LED's away from heat and for new location
Remount control box for LED's in panel
Remount AEM water/meth control box in panel
Fabricate panel box for electrical components
prep&powdercoat coil cover, power steering res brackets
layout and plumb all pneumatic wastegate lines
Weld boost braces to TB, machine steel peg for compressor side
Custom machine -10 AN tee to fit in OEM drain return
Trim, install turbine blankets
Rework AMP and trunk battery locations to fit Fuel cell (scary under that rug!)
R and I valve cover to allow top coolant fitting to screw in
Replace broken fender liner, conform with heat gun to turbo kit
Relocate fuse block and battery/cables for starter
Fabricate bolt on stand for Fuse block
Fabricate air cleaner/intake to low pressure turbo
Fix the firehazard 12v passthru to the engine bay



Dyno tuning…….and fix any bugs!!!

[elff]

Thats freaking awesome

I cant wait

[Gentleman Jack]

Can the first real road test PLEASE be filmed and posted?

[Kelu]

Can the first real road test PLEASE be filmed and posted?

^^^ THIS ^^^

[SKY888]

Can the first real road test PLEASE be filmed and posted?

yup!


update:   5 bar map sensors installed

[Gentleman Jack]

5 bar?

Not enough. I'd go 10 just to be safe

[SKY888]

hahaha 10 bar?   
my block will melt first before we even get to 10 bar.....lol



BTF already turn the engine on, and drove the car on the streets (without boosting the turbos).   Just checking for any issues with the head and the bottom end.

Once the two turbos are being boosted, we'll try to post a video






kidding aside,

discovered that the  maf pegs around 500,000hz & around 115-120 lb/min

from what I gathered, the system is written for up to 512kpa only .........so 10 bar is not necessary GJ!

I believe up to around 100kpa/v

stock table reads to 912 grans/sec = around 1000+hp

[ryansalazan]

Really excited to see this on video man! Good Job and Good Luck! I'm guessing the intake manifold was able to be worked around huh? haha

[SKY888]

Really excited to see this on video man! Good Job and Good Luck! I'm guessing the intake manifold was able to be worked around huh? haha

yeah man sorry, BTF fabricated charge pipes already to make it work.  I didn't know.
I thought we'll just use the stock manifold, until recently.

[SKY888]

EGT bungs already ready for EGT sensors for each of the runners on my manifold

[SKY888]

will be rewiring a lot of wires

[SKY888]

Split second (secondary fuel controller) and Aeroforce thermocouple amplifier (EGT logging)  hooked up and tucked in underneath the glove compartment








under the hood is looking better and better everyday.....

[SKY888]

The first Tmap on the compressor measure lowside pressure/temp. the second Tmap on the charge pipe is only being used for the Thermistor as the AEM 5 bar map sensor is wired into the factory Map1. There is a second 5 bar map in the intake manifold (map 2) and the coil of copper (for cooling) that goes from the primary header to another 5 bar map sensor to measure turbine P1 on the high side. There is a port for P2 (post high pressure stage) but we are out of 5 bar map sensors