2012/07/05 18:30:22
MANDALAY
Went past the engineering shop and he me modeled the air intake tank to the intercooler from the piece i made. He scanned it a got tandem points
His CAD drawings are unreal. Note this is not a square design so the lines are flowed.
Lets see what it will cost


2012/07/05 18:41:12
MANDALAY
So im going to use the Turbosmart Hypergate 45
 



2012/07/05 18:42:16
MANDALAY
So with a few guys pitching in with comments and the recommendation of a Rotrex guru

So i went with this this solenoid to run my Turbosmart wastegate



It also includes a sintered vent/muffler if i chose not to run that line to the air box

Leads are 18" long.
 12 volt DC , polarity not sensitive.
5.4 watts
10-90% duty cycle
1/8" npt ports
compatible with many & most boost controllers and ECU's : AEM,Autronic,E-boost etc,Neptune, Hondata,ECtune,Megasquirt,VEMS.
(4 ) 3/16" bhose barbs nipples
(1) sintered vent/muffler
This is an industrial quality valve, Autronic,e-boost and AEM have been using them for years on everything from rally cars to drag cars, there is a reason they use this valve, it is very durable and responsive.
This valve can be driven by many stock ecu's as well as many aftermarket stand-alones and regular stand alone boost controllers.


2012/07/05 21:01:19
cogs
Uhh, hang on, this is a turbo wastegate setup.  Is there something you're not telling us???
 
Edit: Ahh, never mind, just Googled it.  Seems that Rotrex 'extremists' are using turbo wastegates to bypass compressed charge air back to the 'cold' side for boost control.  I guess it works, but also introduces inefficiencies to the system.  Basically you're compressing more air than the engine's consuming, and this requires more shaft power supplied to the Rotrex.  Conversely, it should allow more boost at lower engine RPMs, with the high range boost limited by the wastegate.
 
Interesting idea!
2012/07/05 21:16:22
MANDALAY
:)
 
Nah. Thing is im using the biggest SC from Rotrex. No-one has put one of these on a Beams. We arent to sure how much psi it will develop , depending how much air the Beams can swallow.
See ive geared the pulley for maximum + 5% over drive at 7,600 rpm so as to get the most down low.
 
Now i dont want to add water/meth injection so if the engine comes to close to knock i need to limit the pressure.
 
The BOV takes care of closed TB.
 
It has been recommended that i do it buy another guy who has done a lot of work on this SC.
 
Another alternative which i have done before was to restrict the inlet. I prefer not to do that.
 
The other reason is i have no option to increase my tyre size and if i do happen to loose traction i can always do boost by gear.
2012/07/05 21:19:32
MANDALAY
Got it !
2014/02/18 20:34:37
rikkir
Time for more updates!
2014/02/19 13:02:42
MANDALAY
Way too much and its been some time, but here are a few
 
We did some solidworks drawings for the intercooler as all the pieces were going to be machined 
 



 
2014/02/19 13:03:59
MANDALAY
Thought you guys might want to see the progress of the 5-axis machining on the Intercooler end having the WG and BOV connections




2014/02/19 13:05:10
MANDALAY
A few more hrs on the mill. Its at the finishing stage as most of the aluminium has been taken off




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