96 SE Gen V Supercharging 4T65 Project

[bs009]

Very cool though to see another person building a Bonne today! It'd be amazing to see this at one of the meets this year!

[Speedster400]

Updated Dyno Sheet

[95naSTA]

7.7k? Holy crap that thing must have been screaming.

When do you go back with a smaller pulley?

[J Wikoff]

That'll do.

[00Beast]

That's a screamer!!! I can't believe the 3800 can handle 7,700 rpm. I wanna know what that sounded like....

[Speedster400]

We made multiple pulls in the two days on the dyno. I started off using a 3.8 pulley and slowly worked my way down to the 3.5. However, I may back this off to a 3.6 to keep boost done a bit for street driving. Boost at higher rpm was at first a problem. At first the engine did not like going lower then the 3.8 as I tried a 3.7. However, after playing around with injector selection and fuel pressure, it started to respond. Overall, the engine was much, much happier with a smaller then traditional injector run at much higher pressure. The other item that we played around with was charge temp. I used the SIL cooling tower to control the charge temp starting out 105°F. I ended up going down to 85°F intercooler inlet temp by the final pull. I stopped at 85°F as this was the lowest real world data point I had from other projects. With the baseline call dialed in, some of the problems encountered were excess oil pressure at high rpm and excess oil temperature. Oil temp was easily resolved with an external oil cooler. My target max oil temp was 185°F and the best power was found at 135°F. Oil used was 10w40 redline. Excess oil pressure was resolved by using a stacked spring arrangement from another pump. Oil pressure at warm idle is now 25psi and high rpm is 60psi. Before the end of my session, i did start to build an E85 cal, but ran out of time. This may need to be revisited. but for now i will be satisfied with 105 calibration.

Things to be revisited at a later date:
Dual fuel calibration
E85 Tune
Alternate ECU. The delphi piece is okay, but is limiting

This weekends project will be getting the engine into the car with the final exhaust system, plumbing the intercooler heat exchanger an replacing the chassis fuel lines with stainless. But this may get put on hold as I may be getting sent out to a test site(high altitude) tomorrow and will not be back for a few weeks.

[Speedster400]

The new engine has been installed.

The weekend actually was pretty productive. I was able to get the engine installed and built mounting brackets for the engine oil cooler and intercooler heat exchanger. The radiator is actaully a GM piece that happens to fit. Thickness is 30mm. While in here, I also chose to replace the condenser as the original one looked a little rough. The oil cooler is using a modified version of the original filter head adatper. Its been modified to accept -10 Oring base fittings. I ran -10 hose from the filter to the cooler with the lines covered in fire sleeve for extra protection.


Front bumper reinstalled with 100mm LED fog lamps too. The lights actually have two modes of function. They have forward postion (low power) and on (full power). I have them wired in so that the forward postion will work with the DTRLs and the OE switch will still run the light

[Speedster400]

Somw of you may remember that I was working a true dual exhaust system for this car. I actual started to mock-up of it last fall to save me time this spring on fabricating it. Well, the exhaust system is done and hung in the car.




The system is 2.25 all the way back with a 45° X-pipe in the center. Exhaust tips are custom made and the mufflers are modified magnaflow pieces. All stainless construction. I will be using a thermal sock or wrap that will run from the two v-band at the forward bulkhead to the rear of the fuel tank. This coming week, I'll work on the fuel system. The plan is to run stainless from the tank to the foward bulkhead with soft lines between the tank and stainless hardlines and the hardlines and the engine. I will also be puting fire sleeve on the lines in these areas. I will also try to get the chiller tank for the intercooler mounted and and the surge tank mounted too.

[95naSTA]

Exhaust work looks killer.

Very curious to hear the tone and would love a sound clip of it.

[Speedster400]

Fuel Lines are installed


Being that I am replacing all the fuel lines and fuel pump, I decided to replace the fuel tank, filler tube, adapter hoses, and sender. As you can see in the pictures, I also took this time to paint the tank and straps. It was a good thing that I replaced the filler tube, as i removed it the steel tube crumbled. Only rust was holding it together. But on a good note, the rest of the steel on the chassis side was in good shape. For the send, I used three adapters to convert from the SAE J2044 tubes to AN/JIC. I now have an -8 feed line and a -6 return. The vent line is -4. The tube are 304/304L stainless with bronze/ silicone brazed on AN/JIC ends.

I also got the surge tank and chiller tank for the intercooler mounted. Early on, I was going to make my own because I was doubtful anything off the shelf would fit. However I did find these two that were close. Both required a decent amount of modification, but most of that is on the backside so it is not obvious. The only real obvious changes were the addition of the vent line bosses for both systems. Otherwise, the bulk of the plumbing is concealed on the backside of the tank.

For now, that wraps up the hard part of the project. However, I still need to check hood/supercharger clearance and build a intake system. I am looking to do the initial powerup on the car in the next couple of days to see if i have any loose ends with regards to wiring. Next week I will hopefully be working towards doing some intial driving(no high power runs) and working on getting the transmission to play nicely with the engine. I suspect that the trans cal will take somtime to get dialed in.

[J Wikoff]

Link for the fog lights?

And... wanna make a second exhaust?

[00Beast]

You absolutely have to bring this beast out to the MI Meet in June, it's in your backyard...

[Speedster400]

Link for the fog lights?

And... wanna make a second exhaust?

Fog lights are JW Speaker's Model 90.

[Speedster400]

You absolutely have to bring this beast out to the MI Meet in June, it's in your backyard...

Maybe, we'll see if I can get this dialed in by then.

...and if work doesn't have me doing long hours again this summer. I should have time as my next engine project isn't set to go to production until 7/2018ish. Even then its only a new variant of the engine that we came out with at the end of last year, not a clean sheet this time.

[harofreak00]

Subscribed!

[Pair of SSEI]

WOW, What a sleeper. Love to hear that exhaust. how about a youtude vid?

[Speedster400]

One Step closer to driving. Now sitting on GXP wheels with 245 wide tires. Its still riding a little high in these pictures as the suspension needs to be settled yet. The suspension should drop roughly another 19mm from this photo.

[WhiteArrow3800]

You absolutely have to bring this beast out to the MI Meet in June, it's in your backyard...

This is amazing man, incredible work so far!

[00Beast]

All that power and stock brakes?

[Speedster400]

Brakes are next summers project. I have somthing special planned for them and they are going to be big...