Hi again,, good news!
Been out testing a bit today, still not fully tuned yet.
Had some problems getting it sealed properly at throttlebody as i have ported the manifold to 78mm, same as throttlebody.
Airmass meter is still std size, will build new one at about 80mm

However..
First test with everything sealed up correct.
Took a ride, crazy rich at full throttle, 10-1 in AFR.
back home, installed the aem piggyback again.
Took a ride, yes!!
as suspected it maximised the airmeter, output was 4.97volts
I dunno about my tuned chip in my std ecu, but it seems like it just floods the engine with fuel when hitting somewhere above 4.95v

Anyway, i pulled off 10% fuel at full throttle in piggy, now it was about 11-1 in afr.
Still rich but better.
Stopped by the road pulled off another 5%(15 total), now the engine starts to talk to me.
tested the performance in an telephone app, (perfexpert)
And yes!!
even thou it´s still rich the app says a healthy 23hp increase.
I then was about to test a 1/8 mile run,, but,, rain.. fall in sweden is tragically boring.
But it´s another day tomorrow

I will tune the car to about 12.9-13 in afr, by then i should receive a couple of more hp.

Even thou i know the app isn´t the truth, a verifying test as i did should be as close to a dyno as i can get without having it in an real dyno.

And, (don't take this as the truth) the app shows me now 493hp in engine.

And, reflections in drivability?
No loss nowhere, gains everywhere, and above 5000rpm the engine really kicks ***.
cruising in 55 mph and doing an overtake is much easier now then before.
And just cruising you need to be very very lightfooted, you can´t almost not touch the accelerator to run at 55mph.

And the sound!!! ohhh yes!!!
sounds almost like an sls blackseries.

so,, stay tuned!

 

Great write-up and glad to hear you saw gains everywhere!!

Looking forward to further updates and the possibility of us getting our hands on one!!

 

I´ve been out doing the 'last' on the fuelmap today.
Some finetuning left, but it´s minor.
Now i run 12.9 AFR and now the **** really hits the fan.
It´s sadfully quite cold weather today, fall is coming on hard in Sweden now.
No use of testing, no traction at all.

If i'm allowed to guess i´m way past 500hp at this point.
But i have been let down before

Rgds

 

looking awful.
almost ashamed.
But,, when developing a prototype i find it useless to put effort in finish, if the result was bad.
In this case, result is really really good.
but remember, i got longtube headers,ported heads,100cell cats, underdrive pulleys, 'needswings' bigger throttlebody(78mm)
Now i feel the restrictions is in airmeter, and the 'knee', still oem, only mod here is no 'mesh' in airmeter and a small velocitystack inside the Y-pipe do guide air into airmeter.



A little downside effect thou.
Ticking from injectors are louder, seems to be resonance in new inlet.

Next mods: 82mm throttlebody and bigger airmeter.
Need more air
But this will be an 'wintermod'

 

Looks awesome! Nobody is going to judge the prototype, function is the most important. Great work. How are you going to do a larger airmeter? Put the stock one in a larger pipe and retune?

 

Yes.. first a 135degree 84mm siliconebend hose.
then a pipe with suitable diam with a bracket to hold meteringunit.

Notice, i will go up in diam a bit in the bend, this is because i want to lower the airspeed.
this to get it to go round the sharp bend more easily.

Did a little bit of research today, 82-84mm throttlebodies are quite cheap.
Just look for Audi and Porsche on Ebay.
Some say the pinout in connector might be different.
but i suspect this is an easy fix, more on that later when it´s reality.

 

The Audi/Porsche throttles require swapping two pins. The Mercedes 82mm is plug and play. The Mercedes also has the PVC vent port, while Audi throttle you gotta drill and install a barb or do other tricks to fix up the pvc. On a side note the PVC requires suction, and a simple breather filter is no Bueno.

 

Is the mesh before the airmeter easy to remove?
Can I put it back if the idle is too affected?

 

Looks amazing. We need to get these printed. We should get a list of who is interested.

1. Sick430
2. TW2
3.
4.
5.
6.
7.
8.
9.
10.

 

Swedepat, I see you removed the secondary air injection, how are you running the egr valves? Also what's the gauge you have right under that?

 

I would be interested.

 

You have to pry and bend a little bit.
But it should popout without damage.
and yes, you can put it back.
Mine idles just fine =)
But you might get problems.
as mine doesn´t idle fine with std airbox.

 

Yes fill in this, it might just come true =)

Another reflections on poweroutput:
with std manifold the maxpower is somewhere around5600-5800rpm in my case.
But now with having it leaned off to about 12.9-13 in AFR the peakpower is around 6400 rpm.
And three different phoneapps and also including Gtech says the car is 3-5mph faster trapspeed in 1/8mile(actually tested early this morning, about 4 am ).
That equals more power in my book.

Really nice sound it delivers too, it screams up to 7000rpm on 2nd and 3rd before shifting with a nice 'braaap' in exhaust between shifts.

I´ve got bluetop solenoids and eurocharged tcu software and raised rpm in engine software.

Dbilas camshafts on top of this would be really really nice

 

Oh... forgot.
the secondary airpump is just relocated to behind drivers side headlight.
this is because supercharger setup isn´t completely gone yet.
I will relocate the fuelregulator instead and move the airpump back this winter.

Rgds

 

Thanks

 

Do you think it's possible to run 2 mass air flow like a c63?

 

Why? The issue where is the volume of air that can flow through the opening in the manifold. we need to increase the size of that opening and run a larger throttle body. Having a larger mass air sesor casing would be nice as well.

 

I'm in if it shows results, looks professional, and priced right!
I would also want the larger TB and mass air flow..

 

Larger throttlebody isn´t my piece of the cake..
It is mounted in lower piece of manifold, and i don´t make any mods on that(as i need to have that piece here).
secondly, the max throttlebody you can use is just 74mm if you don´t upgrade the airmeter.
The airmeter is 74mm and with meterunit inside a bit more restriktive than an straight pipe.
My setup as is now have 78mm throttlebody with grinded shaft to make more area when wide open.
This results in that i topping out the airmeter and ecu maximises fuel.
I have adjusted this with my piggyback at this point, but i´m about to make a bigger airmeter(84mm) to get more flow and lower airspeed through metering unit, and in that case lower the fuel amount.

I´m excited and can´t almost wait, i will try to make this next week before i put the car away for the winter.

And yesterday i spoked to my friend that´s really really good at 3d modeling in Autocad.
He is willing to help.
Babysteps

 

Sounds great!!!! Once we have a CAD model I can ask a friend about the 3D printing

 

testing testing.. today has resulted in off and on with new intake to verify.
I suspekt a little problem in my setup.

This is a 'road dyno program' that seems to aaaalmost tell the truth
A lot of friends cars that we have dynoed in dynapack seems to match this app quite good if you put in correct data and using it correct.
this curve is direct with no fueladaptations and std inlet manifold:

 

After a couple of hours of driving, adaptations end at about 10-20hp more.
My top result after all adaptions are done is 476hp and 612Nm.
Still with std manifold.

Now to the problem:
If i mount the special manifold i can drive a couple of hours and do a couple of 1/4runs.
Then,, suddenly as a lightning from clear blue sky, no performance at all

I did a 'dynorun' and it showed low 290hp.
I tried on and on, no!
No more power.
I had topresult before this happened at 497hp and 629Nm(with custom inlet).

So i figure this is happening:
Doing some runs and cruising around a couple of times, the fueladaptations starts to get perfect, and suddenly it hits torquelimit in tcu-box.
And it doesn´t allow more than ~290hp.

With this in mind i went out logging throttleposition, and yes!
It doesn´t reach 100% open.

Unhooking battery for a while(clearing adaptations), and yes! it allows 100% a couple of times, then it starts to adapt againg and BAM! it hits the wall again.

I need to remap tcu, i´ve got eurocharged tune at this point, but i need to raise the limit more.
Is there anybody out there that can customtune tcu?

Rgds
Patrick

 

So...
One question.

Are you ready for an custom tune in dyno?
As you can´t benefit fully from this inletmanifold without it.

 

On a tune from OETuning. Once I have this then I will go back and have them retune the car. Would also love to add long tube headers.

Liran

 

I'm in ProjectC55 but skeptical about it coming to fruition for the masses just saying! Would be nice to have though.