Endgame setup- BW s257sxe

[iamareios]

Treadstone intercoolers are cheap inefficient cores. Perhaps part of your issue would be heat soak and cooling efficiency. On my treadstone intercoolers I had issues keeping charge temps cool anything above 23-24 psi on T04E 60 trim running pump. Some days it would be good others it would be not. When I switched to a pte (garret core intercooler) it changed everything. We were able to run 30 psi on pump and IATs were alot more stable (post intercooler). Also I haven't seen flow bench numbers but perhaps the intake does run lean in cylinders 2/3 much like the factory intake does. What sort of AFRs were you seeing overall? Perhaps run a richer tune? The evo guys generally run low 11, high 10 afrs for this exact reason unless they are running race gas. No disrespect but if I had built your engine I wouldn't warranty for the damage either. The rear main seal you have a legitimate gripe I will admit.

Can you quantify what you think is heat soak and cooling inefficiency? BAT was never a problem with the tr8 previously, let alone with the tr1035 I was running at the time. IAT was in check as well. The ST manifold has pretty damn good even airflow to all 4 cylinders. Much better than the imbalance of the oem manifold. It may not flow the most, but it's documented to be one of the most even flowing. AFR appeared to be in check and at a safe level through the tune and datalogs. However, cylinders 1 and 4 were running richer than 2 and 3 to compensate and reach target AFR

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[4dr Threat]

Can you quantify what you think is heat soak and cooling inefficiency? BAT was never a problem with the tr8 previously, let alone with the tr1035 I was running at the time. IAT was in check as well. The ST manifold has pretty damn good even airflow to all 4 cylinders. Much better than the imbalance of the oem manifold. It may not flow the most, but it's documented to be one of the most even flowing. AFR appeared to be in check and at a safe level through the tune and datalogs. However, cylinders 1 and 4 were running richer than 2 and 3 to compensate and reach target AFR

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First you need to understand where you are logging IATs. Your IATs are logged from your maf so you are not logging IATs post intercooler. I was running speed density. So I was logging post intercooler. I can tell you after hard single gear pulls I was logging 50+ degrees above ambient. Going through all 4 gears I was logging 100+. Generally the 3.5-4" garret cores you are logging single digits and around 15-30 degrees above ambient going through all 4 gears. The difference is significant. Not to mention the cheap chinese cores and treadstone cores do not flow as well either. Lots and lots of dynos out there on other platforms to prove it. Treadstone are not great intercoolers. Better than the cx racing and xs power ones IMO. As far as the ST manifold goes. Do you have any flow bench numbers? Also what was the afrs? Doesnt appear to be an assembly issue.

 

[iamareios]

First you need to understand where you are logging IATs. Your IATs are logged from your maf so you are not logging IATs post intercooler. I was running speed density. So I was logging post intercooler. I can tell you after hard single gear pulls I was logging 50+ degrees above ambient. Going through all 4 gears I was logging 100+. Generally the 3.5-4" garret cores you are logging single digits and around 15-30 degrees above ambient going through all 4 gears. The difference is significant. Not to mention the cheap chinese cores and treadstone cores do not flow as well either. Lots and lots of dynos out there on other platforms to prove it. Treadstone are not great intercoolers. As far as the ST manifold goes. Do you have any flow bench numbers? Also what was the afrs?

I understand where IAT is measured. As well as boost air temperature. No confusion there. I had zero issues with either. The ST manifold flow data can be found on Damond Motorsports website. AFR was stable at WOT and you can view the datalogs I posted previously. At this point, I find it rather weird no fault was found, but Split Second warrantied and replaced the controller.

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[4dr Threat]

I understand where IAT is measured. As well as boost air temperature. No confusion there. I had zero issues with either. The ST manifold flow data can be found on Damond Motorsports website. AFR was stable at WOT and you can view the datalogs I posted previously. At this point, I find it rather weird no fault was found, but Split Second warrantied and replaced the controller.

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How accurate is the boost air temp on the logs? because on some loads points it is showing less than IATs. That is 100% impossible on an A2A setup. It would be interesting to know the accuracy on these sensors. Any idea of what the ambient temps were during these runs? How is 9-12.4 afrs considered steady at higher RPM at high boost? Me and you have different definitions of steady. Some of your logs seem to be all over the place and very lean in a lot of high boost/high RPM areas. Running 12.35 afrs at 30 psi at 6K RPM is pretty lean in my book. When I say flow bench numbers I am asking across all 4 cylinders. Not overall. The overall flow bench numbers are irrelevant to the issue at hand. Even mild imbalances at high boost can cause damage when running lean like you are.

Here is an interesting read on chinese intercooler cores (cx racing, xs power, and treadstone etc). You will find similar stuff in the evo, and supra community as well. Just something to think about bud.
https://ls1tech.com/forums/forced-induction/1673760-intercooler-swap-gains-168rwhp-3.html

Btw. I do love your choice of turbos. I ran the s259ETT and the S362ETT back in the day as well. Love the Borgs. Next to the MIHI CHRAs they have the strongest journal bearings out there from what I have seen.

 

[L337TurboZ]

Do you think that they just sent you a replacement in order to decrease turn around time and there might have not been something wrong with the original unit?

 

[iamareios]

How accurate is the boost air temp on the logs? because on some loads points it is showing less than IATs. That is 100% impossible on an A2A setup. It would be interesting to know the accuracy on these sensors. Any idea of what the ambient temps were during these runs? How is 9-12.4 afrs considered steady at higher RPM at high boost? Me and you have different definitions of steady. Some of your logs seem to be all over the place and very lean in a lot of high boost/high RPM areas. Running 12.35 afrs at 30 psi at 6K RPM is pretty lean in my book. When I say flow bench numbers I am asking across all 4 cylinders. Not overall. The overall flow bench numbers are irrelevant to the issue at hand. Even mild imbalances at high boost can cause damage when running lean like you are.

Here is an interesting read on chinese intercooler cores (cx racing, xs power, and treadstone etc). You will find similar stuff in the evo, and supra community as well. Just something to think about bud.
https://ls1tech.com/forums/forced-induction/1673760-intercooler-swap-gains-168rwhp-3.html

Btw. I do love your choice of turbos. I ran the s259ETT and the S362ETT back in the day as well. Love the Borgs. Next to the MIHI CHRAs they have the strongest journal bearings out there from what I have seen.

It's clear that the engine build wasn't at fault here. I still don't know what the root cause was. Are you suggesting it was tune related from what you have seen in my logs posted? Everything checked out good with the DI and PI fuel delivery. All 8 injectors tested good, both DI and PI harness, and now the Split Second Controller.

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[iamareios]

Do you think that they just sent you a replacement in order to decrease turn around time and there might have not been something wrong with the original unit?

Very much so. That concerns me as I have not found the root cause yet. After meeting with Jordan, we were sure it was a SS failure.

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[L337TurboZ]

It's clear that the engine build wasn't at fault here. I still don't know what the root cause was. Are you suggesting it was tune related from what you have seen in my logs posted? Everything checked out good with the DI and PI fuel delivery. All 8 injectors tested good, both DI and PI harness, and now the Split Second Controller.

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If you have eliminated all possible mechanical or electrical possibilities then the only thing left to blame for the failure is the tune itself.

 

[4dr Threat]

It's clear that the engine build wasn't at fault here. I still don't know what the root cause was. Are you suggesting it was tune related from what you have seen in my logs posted? Everything checked out good with the DI and PI fuel delivery. All 8 injectors tested good, both DI and PI harness, and now the Split Second Controller.

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Not sure, but it does seem to point that direction. There are other things to consider though. How are you mixing your ethanol? Are you testing it? Either way I know I wouldn't be happy with how lean the car was in higher boost/higher rpm levels. Just my thoughts for whatever they are worth. Good luck.

 

[StayFrausty]

Not sure, but it does seem to point that direction. There are other things to consider though. How are you mixing your ethanol? Are you testing it? Either way I know I wouldn't be happy with how lean the car was in higher boost/higher rpm levels. Just my thoughts for whatever they are worth. Good luck.

this is late asf but here

Your Intake Manifold and You | Mazdaspeeds.org, The New Era in Mazdaspeed, CX-7 & Ecoboost Forums!

 

[4dr Threat]

this is late asf but here

Your Intake Manifold and You | Mazdaspeeds.org, The New Era in Mazdaspeed, CX-7 & Ecoboost Forums!

Yeah I found that searching around. Good info.

 

[L337TurboZ]

So what are you doing about the build now? Are you going to put another engine in it?

 

[iamareios]

So what are you doing about the build now? Are you going to put another engine in it?

Another engine is being built by Jordan. He insists on making things right for me. We're going with 2618 Manley platinums this go around. I've been at a treatment center since Feb 10th not really worrying about it. He did say he wants me to have the engine by the time I get back home from treatment. My discharge date is tomorrow and I'm doing fine and dandy (thankfully) At this point, I'm in no rush to get the car up and running as it won't be our 2nd daily anymore. I received the fortune auto coilovers I forgot I ordered awhile back lol if I change anything about the setup it would be improvements to the fuel delivery and adding a PCV plate to vent things differently. Oh, and definitely get that WOT box in and working this time!

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[StayFrausty]

Another engine is being built by Jordan. He insists on making things right for me. We're going with 2618 Manley platinums this go around. I've been at a treatment center since Feb 10th not really worrying about it. He did say he wants me to have the engine by the time I get back home from treatment. My discharge date is tomorrow and I'm doing fine and dandy (thankfully) At this point, I'm in no rush to get the car up and running as it won't be our 2nd daily anymore. I received the fortune auto coilovers I forgot I ordered awhile back lol if I change anything about the setup it would be improvements to the fuel delivery and adding a PCV plate to vent things differently. Oh, and definitely get that WOT box in and working this time!

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give me a ride when it’s done haha

 

[iamareios]

give me a ride when it’s done haha

Haha you got it brother! I'm not street tuning it this time around. Super sketchy, here in San Diego. I'll pay to remote dyno tune it lol

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[iamareios]

We'll, let's try this again.
Picked up Overspeed motor 2.0.
It's turning into a family affair now. They want to go fast as much as I do. I'm waiting on a VVT solenoid oil seal, injector seals, and pcv plate.

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[StayFrausty]

We'll, let's try this again.
Picked up Overspeed motor 2.0.
It's turning into a family affair now. They want to go fast as much as I do. I'm waiting on a VVT solenoid oil seal, injector seals, and pcv plate.

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Yessirrrrr. Crossing fingers everything goes smoothly this time around

 

[L337TurboZ]

I dig that sweet valve cover. Hopefully this one will last you a long time.

 

[iamareios]

Boring but nice update.

Cleaned the engine bay of the oil explosion that previously occurred. Clean engine bay is happy.

I cleaned up the inside of the bell housing of all the oil sludge from the rear main seal leaking. Good enough.

Just gotta pull the front end forward at this point and drop her in!

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[iamareios]

Finally installed the white line bumpsteer kit I bought years ago. Clear shot with the engine out lol

I was able to mount a 19 row oil cooler to the jbr crash bar. The inside of the bumper required some trimming, but it fits fine. I'm using a sandwich plate on the oem oil cooler and will be running 10an lines to the new cooler.

I also installed an innovate e85 percentage gauge. I'm still mocking up where I'll place the actual sensor in the return line.

Still waiting on a clutch release bearing and fork.
Maisonvi has my fuel basket to modify for the hellcat setup and I still need to run a new feed line to the front of the engine bay. I'm also waiting on a wire tuck harness. I'm targeting to get it fired up by the end of the month.

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