Sometimes I lose things in the garage, then find them again. Bearing accidently pushed off the bench
There you are
Hmm HKS
Shiny HKS Silent Hi Power Exhaust
Machine tig welding on the resonator
Hangers mig welded on
Pipe mig welded on
Flange mig welded on
Machine bender marks on the outside of the bend
JASMA approved
Wrapped some carpet around the resonator to protect while I installed. Tip, easier to drop the subframe slightly to help get the pipe over the subframe.
Have to line up the resonator bracket with the bracket on the body
And installed. What surprised me was how low the resonator hung down from the heatshield. If I build an exhaust system, I'll be mounting the resonator higher to prevent dragging the resonator on speed bumps
Accessories provided with the exhaust system
A bit of lube before putting the rubber hanger bushes on
Build quality of the HKS system is okay. Pipe doesn't sit flush with the flange. Some peneration of the weld into the pipe
The pipe sits very close to the subframe reinforcement bracket
I help my friends out on occasion. Richard's engine mount on his honda was broken, time to replace.
Picked up a 2nd hand manifold with gen 3S mounting flange. A HKS pod filter adapter came with the manifold.
Design is a 4 into 1. You have probably seen this design on 4AGE or 4G63 applications. Driven Performance in NZ sell this unit in stainless. Schedule 40 black pipe so built strong.
Pipes are not elongated to match the ports.
Merge collector is not the greatest, but taking into account the age of the manifold, we have come along way in terms of our thinking regarding exhaust gas velocity and direction.
Merge is pretty reasonable on the inside
Time to remove the studs. Cleaned them up a bit before getting some nuts on them for removal
Double nut trick works to remove the stud
Manifold mounted. Some thoughts about this manifold.
Location: Manifold locates turbo to centre of the engine. Factory position is offset to allow more room for the dump pipe relative to the AC pump. Have to also take into consideration the location of the water pump inlet from the radiator.
Wastegate outlet: the outlet being on the gearbox side of the engine is not optimal. It means either routing the WG piping between the block and turbo, or routing the pipe between radiator and turbo. In NZ, it is a requirement to have exhaust gases recirculated back into the exhaust sytem. This does means that the WG piping has to go either front or rear of the turbo. Front side routing may interfere with fans, rear side routing may interefere with oil feed to turbo and/or the oil return back to the sump.
So I have a manifold that doesn't provide optimal position of the turbo, at least for the Holset HX35 I plan to use. Hmm
Next fun part. To mount a nut to this stuf is almost impossible. Also can't use a ratchet or torque wrench and can only use a spanner..
Test fit of the Holset with an adapter on the factory manifold. Turbo position allows for better routing of the dump pipe.
But problem with the adapter. Pushes the turbo out too far (or I have very large turbo..) and would interfere with the radiator. I did consider relocation of the radiator under the support panel, or in front of the panel (which may interfere with the radiator latch vertical support)
Main issue is that the factory twin scroll exhaust housing is rather large. Research showed that while the 12cm housing would be good for response, I'd still have to weld the WG flap shut and use an external wastegate for more optimal control as the factory wastegate actuator is between 17 and 23psi. A bit much for me at this stage.
Second issue, compressor housing hits the gearbox and would prevent the clutch release actuator from being mounted. Repositioning the actuator still wouldn't prevent the compressor housing hitting the box
Friends use my garage. This time it is to fix an exhaust leak. Leigh scavanged some metal from my scrap pile and got to work
clean up metal before welding
Tig time!
While Leigh fixed his exhaust, I installed the bearing that I found. Trick: tap the seal in with the handle side of a screwdriver, moving slowly around the seal to gradually put it in. Works a treat every time.
Leigh still at work..
Using the aftermarket manifold, the holset didn't fit on to the head. as it interfered with the oil cooler. I borrowed Nick's exhaust housing from his HX40. Firstly, test fit to ensure no intereference with the oil cooler - check
checking the position of the turbo and if it would interfere with the gearbox and clutch fork actuator - seems like it would fit
And plenty of room for the compressor housing.
Side trip - got to visit a local industrial park and what used to be our national industrial research labs. Interesting note, they had a wind tunnel which I was curious about as Jonno was exploring downforce for his car due to our interest in Time Attack. Little did I know that the wind tunnel was for scale models.
Here are some of the models they used to test wind effects in city scenarios.
To get the correct velocity of the wind, the tunnel is a long straight which feeds air into a little control room where they setup the models for testing. Testing costs were $1200 a day.
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GT Four
Adovansu
"I want to enjoy the powerful and nimble agility behavior."