5 Year Plan: An introduction, build and resurrection thread

[PringlesInVic]

First thing I would try is gapping those plugs down some. .028 would be where id start for a stage 1 car

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Easy, I'll give it a shot. Thanks

[Dan[FN]6262]

So for the Bosch plug you would suggest the FR5's on our setups? E85/F21?

It's almost time to replace the NGK's and I wouldn't mind trying those.

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For any setup I would recommend either a FR5DTC or a F6DTC.

F6DTC is one step colder than stock.

FR5DTC is two steps colder than stock.

IIRC E85 causes lower EGT temps vs regular unleaded, so you could probably run a set of F6DTCs just fine.

There are quite a few variables at play, like climate and elevation. Kinda have to try out both and see which set your engine likes better.

[Believer]

So for the Bosch plug you would suggest the FR5's on our setups? E85/F21?

It's almost time to replace the NGK's and I wouldn't mind trying those.

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From the theory I've read on these side fire plugs married with people's good experiences they seem pretty promising.

Easy, I'll give it a shot. Thanks

Np!

What's the lifespan of these plugs?

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[B5nDisciple]

For any setup I would recommend either a FR5DTC or a F6DTC.

F6DTC is one step colder than stock.

FR5DTC is two steps colder than stock.

IIRC E85 causes lower EGT temps vs regular unleaded, so you could probably run a set of F6DTCs just fine.

There are quite a few variables at play, like climate and elevation. Kinda have to try out both and see which set your engine likes better.

Thanks Dan. Yeah I was reading about the heat ranges for those. I'll probably give the 6's a shot.

From the theory I've read on these side fire plugs married with people's good experiences they seem pretty promising.

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Indeed!


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[Dan[FN]6262]

What's the lifespan of these plugs?

I replace them every year, but haven't had any failures or hiccups in that time frame. I'm probably wasting money. I know people that have ran them for 3 years on DDs and sold the car with them still in it.

I've had NGKs fail 2 days after install. I got use to popping in a new set of NGKs every oil change. Don't know why I messed around with them for as long as I did.

The FR5DTC is a OEM Porsche 911 plug. Quality.

[Dan[FN]6262]

Thanks Dan. Yeah I was reading about the heat ranges for those. I'll probably give the 6's a shot.

..

[Believer]

So some updates.

Added in the FR5DTC plugs. They are great but did not resolve my knocking and misfires.

I finally fixed my EVAP incorrect flow code. I deduced the system was not leaking based on the fact that the Group 71 LDP test passed and that instead there was a blockage somewhere in the system. 2 things were bad. The charcoal canister had some super fine white powder inside of it. I had another cannister so I swapped that in and blew out the line from the cannister to the n80 valve. Drove it a bit and the DTC returned. Blew out the last line that could be of issue from the n80 to manifold vacuum and a big ol' puff of white stuff came out. Code has not returned since.

Fixing this code resolved all sorts of driveability problems I was having, allowed misfire detection to stay enabled (would disable every time the DTC threw) and now allows limp mode to kick in properly when knocking and missing.

Dave sent me a new file tapering the boost request off a bit towards redline. I peak at 24, settle at 23 and then taper to 22. For the first time I was able to experience the actual timing request up top and my Lord it felt great. Thing pulled so hard.

Next up:



The plan is to spray between the IC outlet and TB. I'm debating on ordering Boost Juice or just using washer fluid. The objective is not really to tune for additional timing but to control the little bit of knock I'm experiencing and cooling off thos3 IATs a whole lot.

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[Dan[FN]6262]

soon to be meth addict

[Believer]

soon to be meth addict

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[Believer]

Fun times I tell ya.

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[Dan[FN]6262]

oh snap.


looks like it's time for a Gate's racing belt LOL


I wonder how that happened... would have almost had to have something fall down in there. Might be a good idea to take it apart and check it out.

Curious if an idler pulley shit. It's riding too far forward.




Don't feel too bad. I need to change my timing belt too. as well as the CCT.

[Believer]

Yea I'll find out soon enough what the cause was. No more continental belts for me. This is the second continental branded failure since I put everything back together.

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[Believer]

Well it's time for a follow up here.

First thing to mention is the CCT/VVT tensioner unit that failed after like 1k miles. In short it was leaking pressurized oil out of the solenoid. This was hands down a big issue with my loss of power down low. It was RMAd through FCP under warranty. FCP kicks ass btw.



Next I tackled the timing belt which was 100% my fault as you can see below. I got pretty darn lucky that I saw this issue and that worse didn't happen to the belt.





I replaced a failing heat exchanger for the oil as it was leeching small amounts of oil into my coolant.

Then I installed the meth kit. The controller is MAP triggered and is located in the glove box. I tapped the factory reservoir using the existing hole from the headlight washer.

I'm currently using a single D03 nozzle and spraying -20 washer fluid. I will be ordering some Snow Performance boost juice in the near future also.









Finally, I received two new files from Dave, one in July and the other in August. The focus in these revisions was to taper the boost as I approach red line. After much back and forth and troubleshooting Dave speculates that I am outflowing the turbo as it approaches 260 g/s. His goal was to try and limit the flow closer to 250 g/s. I do not have the technical knowledge to agree or disagree but I can however comment on the results which are irrefutable. Tapering the boost down to 24 in the first revision and a bit more in the second revision completely resolved my issue of 'breaking up' up top.

I drove the first taper revision prior to installing the meth kit and was still getting some break up. Since installing the meth this file now pulls hard to 7k.

The logs below are *with* the meth spraying.



Mbar x 1.2 is my actual boost pressure. This is due to the scaling using the 3bar MAP. Its odd though. I see my gauge hit 25 psi but the log says I'm only peaking at 22.6 psi.



Still exceeding 250 g/a which I think contributes to the timing falling off in the next graph.



The second taper revision added some more mid range with a little less top end. I am going to log this file today on my drive home to compare what it looks like up top vs the first taper file.

Finally after many many months of relentless issues I am running smoothly. The turbo still 'woos' at a fairly noticable level when it's spoiling. I suspect it will fail sooner than later. I'm prepared for this and to go through either a warranty rebuild or a CHRA replacement through Doug.



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[Dan[FN]6262]

good shit man

[B5nDisciple]

Yes indeed...good update! Glad to see your issues being resolved finally!

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[Believer]

Well it happened, a lot sooner than I was expecting unfortunately. My second F21 let go in the same howling fashion as before. I have yet to remove the test pipe to look at the turbine but I'm expecting it contacted the housing. Really hoping Doug gets back to me asap as this is a daily and I'm high and dry.

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[Dan[FN]6262]

Good Luck man

[genecan]

Sorry to hear about the turbo, I hope this will be a quick fix.

What belt did you go with? It is an issue for me too.

[Believer]

Good Luck man

Thanks brotha.

Sorry to hear about the turbo, I hope this will be a quick fix.

What belt did you go with? It is an issue for me too.

I replaced the Conti belt with an OE Audi belt.

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[Dan[FN]6262]

any word?

[Believer]

any word?

I got an email back from Doug asking me if I ever sent back my original turbo. Which I did so I could receive the warrantied replacement chra. My questions regarsing how I could get a turbo out to me asap and questions regarding warranty info were disregarded.

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[Believer]

Heard back from Doug today. Paid for a CHRA replacement to get something out to me asap and will send mine back for warranty inspection.

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[Dan[FN]6262]

good shit man

[Believer]

Somehow the turbo has been sitting in Memphis, TN for 36 hours. Was supposed to arrive Wednesday according to the tracking estimation. The only possible way getting my car back on the road before my wife goes back to school could have been screwed up was by a shipping mishap. Can't make this shit up

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[GOODBYNAAIR]

what format are you using in Motoza for logging mine looks different?

[Believer]

what format are you using in Motoza for logging mine looks different?

I'm formatting using Excel. I don't care for how Motozas tool formats the data it looks really odd.

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[Dan[FN]6262]

That's some shit. Good luck man.

Tell them to stop it with the drive way nonsense, you need to over night a big turbo and get this shit rolling! LOLOL

[Believer]

That's some shit. Good luck man.

Tell them to stop it with the drive way nonsense, you need to over night a big turbo and get this shit rolling! LOLOL

I called USPS this morning on my way in to work. In a nut shell the rep said we have no idea what is happening to your package, we'll open a case, which could take 2-3 business days to have an answer from. Sooo yea, probably not getting this thing back on the road for at least a week at this point.

[Believer]

Hallelujah there's movement on the turbo. Should have it Saturday.

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[Dan[FN]6262]

Badass

[Believer]

Got the turbo out this afternoon. Just as I suspected.



Will be swapping the housings over shortly and getting everything reinstalled

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[Believer]

Well it turns out the turbine housing is in pretty rough shape. Theres a crack as well as wheel contact. Is this thing toast?





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[Dan[FN]6262]

some JB Weld oughta fix her up

[Dan[FN]6262]

Joking aside....

1) Now you know what the root cause of the issue most likely is. That's a good thing and a step in the right direction.

2) Will a new turbine housing have the same defect?

3) Will meth keep the EGTs low enough that it wouldn't recur with a new turbine housing?

4) Is this covered under warranty?

[Believer]

I would hope a new housing wohkdnt have the defect. I would definitely inspect it well.

I'm not sure of what my actual EGTs are but if they correlate to IATs I would say they should be substantially lower now.

Still waiting to hear back from Doug on the housing...

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[GOODBYNAAIR]

wow that sucks, this was an F21 right ? glad you fond the problem.

[Believer]

Yea it was the mixed flow version. The housing seems to be the root cause since the first wheel died the same way. If it weren't cracked I would just clean up the housing and be on my way but that crack is only going to get larger and cause more contact with the wheel.

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[B5nDisciple]

Yea it was the mixed flow version. The housing seems to be the root cause since the first wheel died the same way. If it weren't cracked I would just clean up the housing and be on my way but that crack is only going to get larger and cause more contact with the wheel.

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Wow, that's intense. Makes me more motivated to stick with E85 to help with EGT's if that's what caused the crack. I'm interested to hear what Doug has to say about this too... Seems like the housing should be replaced under warranty too right? Or has the period passed?

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[Believer]

Wow, that's intense. Makes me more motivated to stick with E85 to help with EGT's if that's what caused the crack. I'm interested to hear what Doug has to say about this too... Seems like the housing should be replaced under warranty too right? Or has the period passed?

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I am still within the 2 year time period. I've reached out to Doug and expect I'll hear from him after the holiday weekend. My hope is that it is also covered under the warranty

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[B5nDisciple]

I am still within the 2 year time period. I've reached out to Doug and expect I'll hear from him after the holiday weekend. My hope is that it is also covered under the warranty

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Awesome, I'm sure he'll make it right. Sucks your car has been down so much though. If I ever get rods, I won't be going with a FT. Seems they might be somewhat fragile when run at their limit. I'm curious how Metalman's non-mixed flow F21 Will hold up at 25 psi.

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