Intake Manifold Mods on Evo X
So Ive been testing some new combinations of parts on the Hiboost Evo X over the last few months and appear to be making some progress. I calibrated my last dyno numbers to read very close to the VDR (Virtual Dyno Room) numbers at the time so that future changes would be within a few percent and give relatively accurate estimates. For reference STM's Mustang Dyno reads about 30% lower than Crank HP numbers.ETS Tubular Exhaust Manifold / UR O2 DP combo -vs- Full-Race Tubular Exhaust Manifold / ATP O2 DP with 44mm Tial combo
The major change since late summer was switching from an ETS Tubular Exhaust Manifold / UR O2 DP combo to a Full-Race Tubular Exhaust Manifold / ATP O2 DP with 44mm Tial combo
. My internal WG failed on the Garrett GT3076r turbo so I decided to use the ATP external WG setup which seems to be holding boost better in the 5500-7000 rpm range as can be seen in the comparison chart and analyzing my datalogs. I can now hold 27 psi to about 7k where as before it would taper about 1 psi more in that RPM range. The only reason I decided to swap the ETS (48mm runners) for the Full-Race (42mm runners) was that I suspected a crack that turned out to just be a gasket leak from loosening bolts. Still it appears that I gained some low end torque with the switch while not loosing any top end at my current power levels. Peak numbers don't show too much difference but even with the 30 F temp correction the low - midrange gains are excellent.
All runs were done at 27 psi with the same Timing Advance and 11.5 AFR tune. There may still be some power with more tweaking but I wanted to get these numbers documented first.
Peak Gains @ 7500: 8 WHP (~10 crank HP)
Best Gains @ 6500: 25 whp (~33 crank HP)
Prototype Intake Manifold
394 whp Full-Race vs 386 whp ETS.jpg [ 166.72 KiB | Viewed 890 times ]
The next comparison is the addition of a larger plenum capacity Intake Manifold
design that I'm testing for a friend of mine local to me. It's still a prototype unit and I ended up doing some portwork opening the TB side to accomodate a 64mm TB upgrade and slight smoothing of casting marks in the runners. The resulting power delivery seems very impressive. Power under the curve is up across the board with slightly more power being made as RPM's increase.
All runs were done at 27 psi with the same Timing Advance and 11.5 AFR tune. The data from these runs was only 1 day apart and the temp/baro were very similar.
Peak Gains @ 7500: 31 WHP (~40 crank HP)
Increasing gains for entire rev range of 4000-7500 rpms!
Net Gains since Late Summer 09
425 whp Intake Manifold vs 394 whp Full-Race.jpg [ 164.84 KiB | Viewed 890 times ]
The next graph shows Late summer setup that was dynoed at 380-385 whp with ETS manifold on the STM Mustang Dyno with the current setup which includes the last two rounds of modifications
. The car now spools 20 psi by 3450 in 4th gear (vs 3600) and is making the same HP about 400 rpm's sooner than before. Power under the curve is up everywhere with the biggest gains in the 5500-7000 rpm area even when you account for a 30 F temp correction. I plan on visiting the STM dyno over the next couple weeks to validate the results and then proceed to test another Intake Manifold design that has an even larger plenum capacity and ability to bolt on a 75mm Boomba Throttle Body. I'll also test larger diameter IC piping before and after to see what effect it will have slowing down the airflow to recommended levels through the TB. After running the airflow numbers I'm excited to see the results!
Peak Gains @ 7500: 39 WHP (~51 crank HP)
Best Gains @ 6500: 46 whp (~60 crank HP)
Net Gains over Stock Evo X with Mivec tuning
425 whp Intake Manifold vs 386 whp ETS.jpg [ 165.82 KiB | Viewed 890 times ]
The last comparison is a physically stock Evo X that made 240 whp with my Hiboost Mivec Maps and some basic fueling adustments and slightly lower than stock boost. The completely stock Evo X graph showed 210-225 whp but it was extremely erratic so I figured it would be a better comparison. You will notice that the Mivec tuned stock Evo X has an advantage below 3800 but after that it's all GT30 turbo land. Peak Gains @ 7500: 200 WHP (~260 crank HP)
GT3076R Turbo: 425 whp (~550 crank HP)
Stock Evo X w/ Mivec: 240 whp (~312 crank HP)
Bone Stock Evo X: 210-225 whp (~273-292 crank HP)
425 whp Intake Manifold vs 240 whp Stock X with Mivec.jpg [ 164.36 KiB | Viewed 890 times ]
Overall impressions are that this Evo X has totally transformed from it's original form. My biggest concern now is that without temp correction the raw whp numbers were at 440 whp which is about 572 crank HP and the fueling system is definitely approaching it's limits with 800cc injectors. Plans are to get a better pump solution in the 400 lph rating range along with 1200-1600cc injectors so that E85 can be an option for the future. Right now I have a feeling that installing Cosworth MX1 cams would likely add another 30-40 whp and push me over my fueling capacity so I need to plan carefully.
We may be considering making more of these Intake Manifolds for testing to see if there are repeatable gains and after I validate the results on STM's Mustang Dyno. PM me if you have interest and we'll consider options. If these do end up coming to market, I'm sure my friend will reveal his identity and become an official vendor. Either way the pricing will be much lower than the $1200-$1800 intake manifold options that are available to the Evo X right now!