Mastermind's Build

Going to be very picture heavy and not at all organized for now.

I have an IWG BNR S4 underoute setup with a DM FoST intake manifold. My goal is to have a fun DD that is reliable. The reliable part is what pushed me to get the FoST IM due to flow balance across each cylinder and since I am basically pushing the stock block with the S4 I figured it is well worth the investment.

Talking with my tuner, the plan is to drop the boost and keep the same power. Time will tell...

Making the coldside was not as bad as I thought it would be. I am planning on having a one piece welded up as soon as possible.


I pieced it together from parts from Silicone Intakes... bought enough stuff to get resale pricing... I did not want to cut the 90 coming off of the throttlebody so it does stick down quite a bit but I was able to get the skid plate back on.

The under route piping is HTP and is awesome. Fits perfectly and looks great.


Only thing I am still waiting on is the recirculation hose. The Forge V2 does not like running VTA.

In order to run the BNR S4 clocked with an IWG I had to make a new bracket for the IWG as the BNR bracket was not large enough. I did this using a piece of metal to figure out how much larger the new bracket needed to be and the position of the IWG. First attempt did not work as I didn't know exactly where the cold side exit needed to be in order for the under route piping to work. Second time was the charm.



Of course I didn't take any pictures of the actual bracket that my dad (@schmidt63) and I made because that would have been helpful.

Random pictures and videos that I have on this computer.





This last picture is of one of my runs when getting dyno tuned for E30. Final numbers were 396/420 (corrected on a mustang dyno in Denver) with CP-E TMIC and stock intake manifold.

 

Hopefully a video is attached...

 

Nice build so far! I laughed about the bracket comment. I bet you could make a batch to sell, really!

 

FYI, I am running the Forge V2 in VTA with no problem...but my MAF is after the Forge (right before the throttle body)

 

Mine is a little rough being made with hand tools but my neighbor has a cnc machine and is going to make me one.

My forge is pulling in air at idle. I'm not going to be running vta for long so I am not too worried. I'm on a safe map until I get the recirculation hose and will then start tuning with Alan.

 

looking at that set up, it looks like it would be easy to go with maf in the cold pipe.
definitely would be a lot easier than i thought to do the fost manifold swap. looks like i would need a straight and one 90 to make the conversion

 

I think the MAF wiring harness would reach but if not it is only 4 wires. I have a joiner between the 2.75" to 2.5" reducer and the blue 2.5" coupler because I thought the metal 90 deg would not be long enough. Literally, the joiner is touching the 90 and very close to the throttle body so it is adding around 3 inches. The back of the skid plate bends a bit more now towards the ground so I will try removing the joiner and blue coupler and see if it works. I also am considering rerouting the coolant line coming out of the oil filter thing*.

Also the install is very straightforward and seemed way easier on a genpu due to better designed engine/engine bay, aka more space. The hardest part by far was the damned oil dipstick tube.

*technical term

 

Funny...mine blowing air at idle (maybe turbo size makes a difference...I have a Holset HY35)

 

That is funny. Mine starts blowing... so super low AFR and -25 STFT then over like 15 seconds goes to high AFR and +25 STFT. Once it gets to +25 STFT if I place my hand over the recirc part in about 2 seconds it reached 14.85 AFR and +3 STFT. Pull hand off and goes straight back to +25 STFT.

 

Humm...anyway you should not run VTA unless youre MAF is after the BPV (blow-thru setup)!

 

I would try a stronger spring. There is always a positive pressure coming from the turbo at idle due to the fact that it is always spinning. With the tb closed the vacuum present on the opposite side of the bpv piston combined with the positive charge pressure makes the valve open slightly. A stronger spring should help keep the valve closed.

A blow thru setup would be nice considering how long of a run before the tb there is and then no fucks given about the bpv.

The oil cooler line was a pima and i will be rerouteing it when the weather warms up. FWIW a 1" Silicone hose will fit over the bpv discharge incase you want to route it up to the intake.

I would cut the 90 and keep the coupler. That coupler allows movment in the pipeing when the motor bucks between shifts. Did you bead roll the pipeing? That silicone intake AL pipe is some thick shit.

 

Now it's time to get off that stock exhaust mani

 

I have no plans to run VTA. Just trying to kill the E85 in the tank while waiting for the 28mm hose I order to arrive. Ordered it on the 23rd of December so I assumed it would take a while with the holidays. Just got tracking last night.

The oil cooler line is being pushed out of the way by the piping so I figure moving it would reduce the risk of getting a hole in the line.

The aluminum piping comes bead rolled which is why I do not want to cut it.

I have been thinking about getting an exhaust manifold... but then I would have to go EWG which would make all the bracket work for nothing. In all honesty this will probably be done in 2017. Then start saving for a built block. In the meantime a nice looking heat shield is in order.

 

Once you've got your go-fasts done, time to get rid of that wimpy stock horn, haha

 

You know, when I had the bumper off I was looking for places to mount some Hela horns. Haha

 

I mounted my hellas off the stock location; just fabbed (bent) a small piece of scrap metal to run off the original bolt location which allows both horns to be attached at the same spot. they do unfortunately point sideways, instead of forward, until I'm more motivated to do an adjustment (space was limited by CAI at the time, switched to SRI a few months back) but they're still leaps and bounds better than the squeaky little stock horn.

I also went with the sharptones over the supertones, FWIW, since I prefer the lower tone that they give (unless i got the names backwards? i can't really remember now, i just know i have the lower frequency set).

anyway, the build is looking really good! part of me is wanting my k04 to die so i can justify a replacement and start trying to keep up with those BT joneses.

 

Hard to tell from the pictures, but do you think it's possible top route intercooler pipes would work with this manifold?

 

You will have to talk to DM about that. They recommend under route hotsm side but said some top routes like cs would work. Of course cold side will be different.

 

Getting really close to having the car back on the dyno to finish tuning! The throttle response is a lot better and is spooling quicker than previously. Really excited to see how it turns out and collect data for direct comparason.

 

Hopefully the wheels stay on and the coolant lines don't blow like a hooker from Pueblo.

crapatalk, yes it sucks for free.