Compressor Efficiency Problem

[Killerbee]

I have a feeling JB will be better than fiberglass, at least from my study of Zytel.

had some good luck filleting the outside surface, then tooling from the inside. I am using a compound that is a polyamide resin, if that helps.

 

[Killerbee]

Checked the inside angle and it actually turns backwards. It's probably 105 degrees instead of 90 degress.

 

[Turbotug]

Don't act surprised...

 

[McRat]

Just so there is zero misunderstanding, technical discussion on topics other than proprietary information is welcomed and encouraged here.

But this is basically a commercial site to support McRat customers, and sales or offers of sales of goods is at the sole discression? of the board owners and moderators. So ask BEFORE you pick a goody just in case, unlesss it's a Garage Sale item by a private party.

 

[Killerbee]

Using a built-up stock tube, I have reached the 10% improvement point, going from 54.5 lb/min, to 59.8, 22 psi of boost constant. I have kept the tune unchanged throughout testing. The stock piece has a minimum id of 2.8". I think that is nearly equivalent to a full turbo size, is it not?

This is not the redesigned piece shown earlier. The redesign should fair better still.

I will be making an appointment for dyno testing this next week.

 

[Killerbee]

Building a prototype

This material is definately technique sensitive. Have to get it semi cured before application. This is the piece that is yielding 10-11% airflow increases. Mouth is very different compared to stock, a lot of grinding from the inside.

 

[Mike]

I wonder if turbulence can be decreased by getting rid of the pcv and resonator bung?

 

[RodZZilla]

I thought he had talked about leaving them there for external apperances (Warranty) and plugging them from the inside. Don't remember if it was in this thread or on another board.

 

[Diesel Pilot]

You just layered on a bunch of material then ground out the inside?

 

[Mike]

I thought he had talked about leaving them there for external apperances (Warranty) and plugging them from the inside. Don't remember if it was in this thread or on another board.

I see, I was just wondering what difference could be seen without them is all. I should have been more clear. Sorry bout that KB. what changes could be made to delete them, but include the bungs as dummies? Thanks

 

[Turbotug]

Dummies, but cast hallow so one could easily drill them out if they felt is was necessary or wanted it as stock as possible.

If this was swapped out by some snow bird (or a non-performance minded gent) he may not want to go through the trouble of rerouting the PCV. It will need to vent somehow.

 

[LBZ]

I wonder if turbulence can be decreased by getting rid of the pcv and resonator bung?

I thought he had talked about leaving them there for external apperances (Warranty) and plugging them from the inside. Don't remember if it was in this thread or on another board.

I agree with both of these guys!! Lets do it!! If you want to keep the PCV IMO, you don't need one of these!!

Thanks KB-Nice Work!!

 

[Mike]

KB

Will a "Banjo" style connection to the charger prove useful? I'll see if I can muster up a picture to show if we are confused about this style connection.

 

[Killerbee]

I wonder if turbulence can be decreased by getting rid of the pcv and resonator bung?

Mike, according to simulations, flaring the transitions will remove the modest amount of resistance these ports offer. The ports can be produced as dummies, should not be difficult. It is easy enough to machine them if later desired for function, like Brandon said.

I got 61.5 lb min yesterday, same tune. Up from the original 54.5

 

[Ruralgas]

Compressor efficiency

Hello Killerbee:
Finally got my duct finished. Tried fiberglass but that didn't work. Just made a mess. Cleaned it off and ended up using JB Weld. It adhered very well to the existing material and was easier to shape and work with.
After grinding and hand sanding, got the "tight" curve opened up to 2.940". I radiused the ports for the PCV and resonator. Blocked off the PCV, but left the resonator port open. Also got the curvature of the new opening much smoother. Got the PCV also rerouted with a crankcase filter on each hose end. Will see if all works in time.
Thanks and hopefully this mod makes a difference for a person that uses the truck for towing. It should.
Garry

 

[LarryJewell]

Hello Killerbee:
Finally got my duct finished. Tried fiberglass but that didn't work. Just made a mess. Cleaned it off and ended up using JB Weld. It adhered very well to the existing material and was easier to shape and work with.
After grinding and hand sanding, got the "tight" curve opened up to 2.940". I radiused the ports for the PCV and resonator. Blocked off the PCV, but left the resonator port open. Also got the curvature of the new opening much smoother. Got the PCV also rerouted with a crankcase filter on each hose end. Will see if all works in time.
Thanks and hopefully this mod makes a difference for a person that uses the truck for towing. It should.
Garry

I wonder if Acraglass would work, its used as a bedding compound in rifle stocks and it stands up to the recoil of high powered rifles and can be worked with files and sandpaper...

 

[Killerbee]

2.94" is very good! Is that the narrowest point?

Pics?

FWIW, to others, Garry stated he used the JB that says it contains a poyamide resin, as previously discussed. I mention this because there are several varieties of JB, and not sure if they all have the polyamide base.

Inspect it often.

 

[Mike]

Mike, according to simulations, flaring the transitions will remove the modest amount of resistance these ports offer. The ports can be produced as dummies, should not be difficult. It is easy enough to machine them if later desired for function, like Brandon said.

I got 61.5 lb min yesterday, same tune. Up from the original 54.5

Larry's logs have showed gains such as these. Maybe when he gets his new charger in place and makes a new inlet to his turbo, we can get an idea what he has done for these improvements.

 

[LarryJewell]

I plan on using the newly finished modded on for the new turbo for now, I cant afford for the truck to be down for any length of time waiting for a new one to be made.

 

[Mike]

I plan on using the newly finished modded on for the new turbo for now, I cant afford for the truck to be down for any length of time waiting for a new one to be made.

Oh heck Larry lighten up, Rome wasn't built in a day. Surely I didn't mean all in the same day.