This is how the car came in
to us. It has a built engine with the best of components, a
Motec 800 ecu. tuned by APC, over 400rwhp @ 16psi, suspension &
brakes set up for track work, Dunlop DZ02G tyres.
Trouble is, the intake temps. are high 50's in the first lap & already
in the high 70's in the third lap with the Motec triggered alarm light
on causing Terry to have to back off as the computer takes out timing &
This is what we made. It has
a 73mm core (same thickness as previously) but 20mm longer & 100mm wider
(26.5% more surface area) & a much more open fin pitch to let more
ambient air through - a case of going backwards to go forwards. Our hand
form-ed inlet tank has a different entry position for two reasons. It
gives much more even spread of charge air across the core & has a
slimmer profile which even though the core is longer, allowed us to
reposition it 70mm more rearward so the whole core is open to the vents.
This is how the three louvers
are positioned to catch the air & force it down through the core.
Without this it will be more like a heat soak. Terry didn't want his car
to look like the batmobile as it's also street driven, so we tried to
keep the louvers as discrete as possible.
The inlet tank which had to
be hand formed taking around 25 hrs & $1700.00 alone. It is low profile
but still distributes the charge air pretty evenly across the core face.
It's allot of work, but necessary for maximum results.
This pic. shows the
difference in profile of the two tanks. A fair portion of the inlet tank
volume is actually under the core & wraps around into it, whereas the
outlet tank is wholly in same plain as the core.
We had to length the air
intake to line up properly with the scoop opening. We also had to
fabricate a new air-oil separator & due to serious room constraints had
to be a stressed member of the left hand mount. Other two mounts are
We more than doubled the size
of the previous catch can fitted. I call it a catch can as it was just a
rectangular tank with two baffle plates inside - which do four fifths of
bugger all. I don't know companies can sell them as anything but a sort
of catch tank. They rely up to 90% on the filter to work.
This is the internal view of
our air-oil separator. A little of the oil drops out of the air in the
large bottom chamber, the louvered mesh catches some of the oil in the
air, the stainless turnings pull most of the oil out of the air before
it gets to the external filter. The filter on our separators takes at
least 50 times longer for the same amount of oil soak as most units -
much longer again for units like the empty GReddy unit !! A waste of
money, Japanese name product.