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MANDALAY
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RE: Checkin 2012/07/05 18:30:22 (permalink)
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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


MANDALAY
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RE: Checkin 2012/07/05 18:41:12 (permalink)
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So im going to use the Turbosmart Hypergate 45
 



MANDALAY
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RE: Checkin 2012/07/05 18:42:16 (permalink)
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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.



cogs
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RE: Checkin 2012/07/05 21:01:19 (permalink)
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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!
post edited by cogs - 2012/07/05 21:10:56

1990 SW20 GT
MANDALAY
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RE: Checkin 2012/07/05 21:16:22 (permalink)
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:)
 
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.
MANDALAY
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RE: Checkin 2012/07/05 21:19:32 (permalink)
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Got it !

rikkir
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RE: Checkin 2014/02/18 20:34:37 (permalink)
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Time for more updates!
MANDALAY
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RE: Checkin 2014/02/19 13:02:42 (permalink)
+1 (1)
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 
 



 
MANDALAY
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RE: Checkin 2014/02/19 13:03:59 (permalink)
+1 (1)
Thought you guys might want to see the progress of the 5-axis machining on the Intercooler end having the WG and BOV connections




MANDALAY
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RE: Checkin 2014/02/19 13:05:10 (permalink)
+2 (2)
A few more hrs on the mill. Its at the finishing stage as most of the aluminium has been taken off




MANDALAY
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RE: Checkin 2014/02/19 13:39:14 (permalink)
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The end air tanks to the inter cooler have been milled. Here it is taped up.

Unlike the very hot exhaust manifold where Waste Gates normally reside mine is on the cold side. To guarantee a perfect seal like the BOV i milled a slot for an o-ring

Waste Gate and BOV clamped on

The 2 nipples supply reference air one for a second MAP sender for pre throttle and the other nipple is for the MAC electronic Waste Gate control
  As a comparison to the current inter cooler it is much bigger , however even with the E153 bigger gear box and bigger Rotrex it still all is under and hidden by the intake plenum.
All i had to do was relocate the coolant overflow bottle to the rear quarter in the trunk

MR2QIK
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RE: Checkin 2014/02/19 15:40:05 (permalink)
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Top quality work.

MR2QIK - "The Little Car That Could"



320rwkw @ 19psi (pump fuel, no giggle gas)
11.96 @ 116mph (with 228rwkw)
rikkir
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RE: Checkin 2014/02/19 20:02:35 (permalink)
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I'd love to be able to do something like this!
kameleon
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RE: Checkin 2014/02/19 22:07:23 (permalink)
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Nice CNC work there.
B24
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RE: Checkin 2014/02/20 10:17:51 (permalink)
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It's pretty amazing effort. Can't believe you have machined that from a solid block of alloy!
Have you considered fitting a dry sump? There is a company in the USA which sells a billet alloy dry sump pan with the pumps bolted directly to the pan. Compact and effective.
 
I think you should bring this to the MR2 Trackday Challenge. Robk needs some competition. 
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