S40 T5 sleeper project

[DaveDreads]

You have to get a mate to shoot a drive by of this car on a private road or something,
i'm intrigued to see how quiet it is with so much power.

Bloody love sleepers.

 

[The Russian.]

no, I didn't see the point in filming a noisy fan for 5 minutes!

When we going for a spin?? Would like to hear this

 

[Chrisgti6]

When we going for a spin?? Would like to hear this

Anytime you like! What spec is your new meggy?

 

[The Russian.]

Il be dropping you a txt then

It's 270bhp-300lbft mate, couple more things then il hit near 300

 

[Chrisgti6]

Il be dropping you a txt then

It's 270bhp-300lbft mate, couple more things then il hit near 300

Im aiming for 300bhp and 350+ lb-ft torque. Swapping the exhaust and Airbox should pretty much get me there.

 

[The Russian.]

Exactly same with me, Decat and itg filter, possibly 630cc injectors.

Yours is capable of a loads more power though.

 

[Chrisgti6]

Exactly same with me, Decat and itg filter, possibly 630cc injectors.

Yours is capable of a loads more power though.

I think it should be making more than it is now to be honest, the map that is on it is good for 310bhp and 370lb-ft torque, I suspect I've got something more than the exhaust and inlet holding it back.

heres the the graph from yesterday, I've clearly got something weird going on, look at the torque between 3 & 4k it drops off twice. I suspect the std boost controller is struggling to cope, I've also got a slight boost leak near the map sensor.

 

[robbie1988]

Have you checked the boost solenoid is ok? From my experience the standard ones are quite woeful, IPD make a lovely upgraded one which is a direct fit. Fitted one to mine with no further problems.

 

[Chrisgti6]

Have you checked the boost solenoid is ok? From my experience the standard ones are quite woeful, IPD make a lovely upgraded one which is a direct fit. Fitted one to mine with no further problems.

That's my first point of call, I think I'll buy Elevates. I want the elevate induction kit too, problem is the uk sellers are about 50% more expensive than the USA sellers. I'm going to contact elevate and see if I can buy direct.

 

[robbie1988]

If you try and get in on a group buy the IPD versions are superb and fully serviceable.

Never tried any of the Elevate gear though - heard some good reviews on some of there bits for the C30's.

 

[Ian_182]

Nice one chris.

Keep up the good work.

 

[_Tom]

An open filter will help massively I would expect. I hate them but even my TT saw 10bhp +

 

[mr bognor]

How is this ???

An open filter will help massively I would expect. I hate them but even my TT saw 10bhp +

 

[_Tom]

How is this ???

Just because mapped turbo's tend to run high boost. My standard air box with uprated panel filter still restricts mine.

 

[mr bognor]

mmmmmmmmmm was thinking of changing back to an air box .

Might re think this now then .

Alan

Just because mapped turbo's tend to run high boost. My standard air box with uprated panel filter still restricts mine.

 

[Chrisgti6]

I read mixed reviews, but I can't see how the current Airbox can flow enough air. For a start the actual filter is tiny, also the ECU sits partially in the Airbox. The noise alone will be worth it though, even if I don't gain many ponies.

I've gone from about 8psi to 18psi so surely a better flowing intake should help!

 

[_Tom]

I read mixed reviews, but I can't see how the current Airbox can flow enough air. For a start the actual filter is tiny, also the ECU sits partially in the Airbox. The noise alone will be worth it though, even if I don't gain many ponies.

I've gone from about 8psi to 18psi so surely a better flowing intake should help!

Plus you have a nice fmic to keep the intake temps low.

 

[Chrisgti6]

Plus you have a nice fmic to keep the intake temps low.

I sure do, it's been running 2 degrees above ambient recently (even with some hard driving) so seems to be doing a fairly good job

 

[_Tom]

That's working then! If I keep the TT its exhaust and FMIC next.

 

[Chrisgti6]

Yes or no?

also, should I remove the VOLVO, the S40, the T5 or all?

 

[DaveDreads]

Yes or no to what, the little sticker?

 

[Chrisgti6]

Yes or no to what, the little sticker?

Sorry, yes. Would have helped if I'd put that! It's not just a sticker, it's a proper badge type thing.

 

[DaveDreads]

I say yes, it's small enough to not look out of place.

 

[Cookson]

I would totally de-badge the back

 

[Chrisgti6]

I would totally de-badge the back

Hmm, I might have to 'shop it first. Can't quite imagine what it'll look like without anything.

 

[Scrooge]

All badges off except the centre Volvo one imo.

 

[Amos91]

All badges off except the centre Volvo one imo.

I'd go with this. Something about removing all the badges remind me of try hard Astra drivers.

 

[Sir_Dave]

All badges off except the centre Lolvo one imo.

Imho, with the current power this thing has, the above would be more appropriate.

 

[Scrooge]

Ha!

 

[Chrisgti6]

Imho, with the current power this thing has, the above would be more appropriate.

There's an idea! i'll see if I can pick up an extra L and switch it - maybe.

It's the VOLVO badge that annoys me most to be honest, I can't make my mind up over it.

 

[ThomasBrentnall]

Chrisgti6 Spoke to my mate at Scorpion and they don't mate exhausts for any volvo's bar the v70/s70/c70!

 

[Chrisgti6]

@Chrisgti6 Spoke to my mate at Scorpion and they don't mate exhausts for any volvo's bar the v70/s70/c70!

No worries mate, thanks for asking.

Chris

 

[Chrisgti6]

So, follow on from post #87 - The wierd boost/power delivery issue

A couple of weekends ago, after having a play with a Focus RS (the guy WASN'T happy ) all of a sudden - boom. Loss of power and warning message on screen 'Reduced engine performance'. limped it into a layby on dual carridgway to find a the intercooler inlet hose had popped off. 5 minutes later I managed to slot it back on and do the hose clamp finger tight just to get me home.

Stripped the bumper off and tightened all the clamps etc, took it for a test drive and it seems to have cleared 90% of the power delivery issue, so I assume that the hose has always been loose and been blowing. It feels like it's gained some power/torque but the next rolling road day will show that up. I'm also getting the map sensor plate welded to the intercooler endcap instead of the sealant and screw job i'm currently using, which i'm hoping will clear it up entirely.

I'm thinking about taking the resonator box out that is before the back box, but i'm worried about the noise, I might see if I can cut it so that if needed I can drop it back into place. Without that resonator it will be straight pipe from turbo to backbox, no cat etc so i'm thinking it'll be a little too loud to get past the wife!

Will update once it's been back on the rollers or if anything else changes before then.

 

[Chrisgti6]

Quick update. It's been back on the rollers at Dyno Tech. The only changes since my last run are a fixed boost leak and a new recirc dump valve. It made 281 bhp and just under 350lb-ft. Graph below. Not sure what went wrong but the power dropped off drmatically at about 5.1k whereas last run it was closer to 6.1k. Either they backed off early or the ECU decided enough was enough. I certainly don't feel the drop on the road.

My torque spikes have now gone (probably down to the boost leak I had) and if it had revved properly I suspect it would have been closer to 290bhp at it's peak.

I have some Focus RS injectors lined up, and then I also want to get the resonated Milltek system to free the exhaust up a little more. I should easily break the 300bhp barrier then, and about 370is lb-ft of torque. Still undecided what to do with the intake, I don't really want it to be noisy but at the same time I need to free it up a little. Any ideas?

There's allsorts of other bits I want to do too, upgraded boost pipes, boost controller, but before all that the brakes need sorting! I can bolt on Focus ST calipers, and the 320mm discs, but i'm toying with a kit Elevate have just released. It's using 6 pot wilwoods, and the original 300mm dics. $850 (about £500) which is not much more than it would cost me to get a good set of Focus calipers!

This is the kit

and how it would look

 

[philmots]

Good result.

i enjoy surprising people in my T5

 

[Chrisgti6]

Good result.

i enjoy surprising people in my T5

Me too, you certainly get some funny looks!

 

[mr bognor]

Power drops off quick after 5250 RPM ?

Was this done this week as I had my car on the rollers on Saturday in 23 deg heat and it did the same thing to you in dropping off more than last time so this may be down to the hot weather ???

Alan

Quick update. It's been back on the rollers at Dyno Tech. The only changes since my last run are a fixed boost leak and a new recirc dump valve. It made 281 bhp and just under 350lb-ft. Graph below. Not sure what went wrong but the power dropped off drmatically at about 5.1k whereas last run it was closer to 6.1k. Either they backed off early or the ECU decided enough was enough. I certainly don't feel the drop on the road.

My torque spikes have now gone (probably down to the boost leak I had) and if it had revved properly I suspect it would have been closer to 290bhp at it's peak.

I have some Focus RS injectors lined up, and then I also want to get the resonated Milltek system to free the exhaust up a little more. I should easily break the 300bhp barrier then, and about 370is lb-ft of torque. Still undecided what to do with the intake, I don't really want it to be noisy but at the same time I need to free it up a little. Any ideas?

There's allsorts of other bits I want to do too, upgraded boost pipes, boost controller, but before all that the brakes need sorting! I can bolt on Focus ST calipers, and the 320mm discs, but i'm toying with a kit Elevate have just released. It's using 6 pot wilwoods, and the original 300mm dics. $850 (about £500) which is not much more than it would cost me to get a good set of Focus calipers!

This is the kit

and how it would look

 

[Chrisgti6]

Yes it was done on Saturday. It could be temperature related as it was sat on the dyno for a good few minute (running) whilst they messed about with configuration etc. They didn't turn the fan on until just befor ethe runs.

I'm not sure what else could be causing it to be honest as I certainly can't feel a 40bhp drop after 5k revs!

 

[ThomasBrentnall]

Power drops off quick after 5250 RPM ?

Was this done this week as I had my car on the rollers on Saturday in 23 deg heat and it did the same thing to you in dropping off more than last time so this may be down to the hot weather ???

Alan

Yeah it was done on last Saturday (21st)

 

[JD]

Is it not the DP and cats that restrict the flow, over the OEM exhaust? I would suggest swapping those out to a larger bore version before changing the exhaust to something loud and non-sleeper-esque.