mcfly94

Well would I be good to go for a 465 with annular boosters? And ive decided im going mild xflow so would the 465 flow enougb for 300hp dont want to have to buy two carbs, will be run off aussie 4 barrel

Hey guys i made this report for my year 12 research project, my final mark was pretty high, 9/10 which was an A. It was also stated during the assignment that the intentions off the report would be to provide to the online forum , so here it is! , as you can see at the end all of this work is correctly referenced and the authors are recognised. Enjoy, feel free to add, sticky, use how the old thread was on the previous forum. Introduction Turbo charging a Crossflow in an XF falcon to produce around 300 rear wheel kilowatts (rwkw) requires a number of upgrades to the car. It’s believed that 220rwkw can be achieved reliably if the cooling, fuel and ignition system have been upgraded.[1] In order to achieve 300rwkw, research suggests upgrades need to be made to the engine, exhaust, diff and transmission, therefore most of these upgrades will be analysed throughout this outcome. TURBO CHARGED 250 CROSSLOW (Refer. http://www.xfalcon.com/forums/index.php?/topic/5118-xet-250-new-pics-added-1805/page__st__160) However it is important to note that before any upgrades and modifications are performed on a motor vehicle, it is necessary for them to comply with certain states regulations and design rules which can be sourced from your local authorities. [2] Engine Upgrades Bottom End Research shows that the stock Crossflow engine requires engine upgrades to achieve any power near 300rwkw, including a full rebuild and replacements of major components to suit turbo application.1 [3] [4]These upgrades can be performed by a reputable engine builder[5] or can be performed independently with the use of car manuals on how to completely pull down and rebuild the engine independently.[6] To build the engine, a bare Crossflow block will be needed. Crack testing and sonic testing should be done on the block[7], prior to having the block ‘zero decked’ to eliminate detonation during tuning.[8] Following this process will ensure that a safe and reliable engine is built. CROSSFLOW BLOCK (Refer. User: BGDAV [ONLINE FORUM-xFalcon.com/Newbie Info to Turboing a Crossflow] (2009) A vital key finding in research explained that many Crossflow engines had a number of bottom end upgrades for a turbo application of around 300rwkw. These upgrades included pistons and conrods.[9] 4Pistons that would be suited to a turbocharged Crossflow will have a high ‘cc’ dish, around 25+; which will help lower the overall engine compression.1Thorough research confirmed that many people who own a turbo Crossflow use two types of pistons in their engines. These pistons are either a 28cc dish piston manufactured by ACL or a 27cc dish piston by Hypatech.1, The pistons will need to have properly gapped compression piston rings suited to the engine and pistons that are going to be used.4It’s evident that using upgraded chromoly rings will also be of benefit and will last longer than standard rings.1 PISTONS (Refer. http://www.jepistons.com/PDFs/OrderInfo/custompistons-orderform.pdfs) CONROD (Refer. http://www.atomicperformanceproducts.com/images/products/conrods/EC_002.jpg) Another finding indicated that upgrading to stronger conrods will be beneficial to ensure the engine is very reliable as high rpm levels in the engine can damage the conrods when the engine tries to stretch them when the motor hits top dead centre.5Stronger E-Series falcon rods from a 4.0 litre engine can be modified through ‘shot peening’ to strengthen the conrod4 10 “The purpose of this process is to improve the resistance of the component against cracks and fatigue, which normally originate at the surface due to applied tensile stress”[10] and resizing to suit a larger diameter and stronger ARP rod bolts. Furthermore, a significant budget is needed to contact a reputable conrod builder and have a custom set of forged pistons to suit the pistons and crank as this will be a lot stronger over the E-Series rods.[11],[12] Together the whole bottom end, including the harmonic balancer and flex plate to suit a choice of transmission will need to be balanced together by an engine builder.[13] Another vital key finding is that components will need to be installed precisely and correctly to prevent any damage to either the block or components. In addition the bottom end will need all new gaskets, seals and bearings to ensure you have the equivalent of a fresh built engine. [14] Top End A number of components will need to be upgraded on the factory head to reliably to achieve 300rwkw. However, the engine will benefit from using a C-Series Crossflow head due to the larger combustion chambers, which will further lower the compression of the engine. 1 CYLINDER HEAD (Refer. http://www.atomicperformanceproducts.com/images/products/heads/IMG_8400.jpg) To get the most out of head upgrades, stainless steel valves can be installed. It is also beneficial to have valves in the head recut to a larger size.3 Members on xFalcon have found from experience that the head has benefited from back cut inlet valves to suit a size 1.84 and face cut inlet valves to suit a 1.6 size.9 Research suggests that the head will also need to have upgraded valve springs to prevent valve float at high rpm, at least 120lb rated springs with compatible collects, retainers and valve locks.3 Research indicates you should also consider upgraded roller rockers, and push rods.9 1 Camshaft and Timing Chain Upgrades over the factory camshaft will be needed to suit the engine and turbo rpm range. However the camshaft will not require a ‘high-lift’1 Many members and people with experience have used the off the shelf Wade242a cam, PSI_LTD (2012) suggests to get a custom grind camshaft from ‘Wade’ and anti-pump up lifters to match.3 Based on my findings I would recommend a double row timing chain to prevent slack in the timing chain and the timing retarding or advancing. CAMSHAFTS (Refer. http://www.atomicperformanceproducts.com/images/products/camshafts/O9I0047.jpg) According to PSI_LTD (2012), and experience by Wes (2009) using ARP Head studs should be used instead of the factory head bolts, they suggest for a perfect fit, use 308 Holden motor studs. Fuel Analysis of automotive websites suggest that with turbocharged Crossflow there are two different types of fuel setups used, LPG (Liquid Petroleum Gas) and Petrol (Unleaded)1 4. Research showed that people with experience of building a turbo charged Crossflow suggested taking the LPG pathway for fuel supply. Reasons for to doing this include that the engine will able to run over a wider fuel mixture range without detonation when compared with petrol which makes it easier to setup and tune.1 Using an LPG system incorporates a number of different mechanical objects, the tank, lines, converter, and throttle body. As research shows that standard 3/8” flex lines are proven to over 260rwkw, a larger line would be needed to produce 300rwkw. [15] Vital key finding shows that the Impco or Gas research B2 LPG converters are the most cost effective and best option for turbo charging. The converter will need to be boost referenced to compensate for when the turbo range psi increases. [16] After the converter you will need a throttle body (gas mixer), you can use a 2 barrel manifold type Impco 225, Impco 4 barrel 425 or a Gas Research throttle body. Throttle body like the Impco 425 or Gas Research will need to be used, to flow more air and fuel, to produce 300rkwkw.[17] Gas lock offs are also required for the systems, the best for turbo charged Crossflow’s are the Impco VFF30 lock offs due to their effective flowing. The lock off for the gas system will also require boost referencing similar to the converter.[18] To hold LPG you will need a LPG tank, research has shown that a stock and new model gas tanks will only provide up to 220rwkw. A 4 valve tank would be the best to use, which have two outlets however you can have a new tank made with 4 valves. Tanks for turbo charged setups require extra valves as they provide more fuel which can supply up to 440rwkw.1 The engine can be self-tuned, and to help adjust the mixtures to effective levels a wideband air flow meter or air flow ratio gauge can be used.[19] Unlike LPG setups, unleaded require upgrades to the stock fuel injection system. The stock injection system will require upgraded fuel lines, injectors, fuel pump, fuel regulator and a new fuel rail or modifications done to the existing one.4 Conclusion In conclusion a number of factors outlined in the report will need to be taken into consideration regarding upgrades to the engine, differential, exhaust and the legalities of the modification. Specifically research showed vital upgrades in the car would be needed including performance engine components and installation of a gas system to enable an easier setup to tune. Thorough research showed it was evident that when rebuilding the engine a lower compression ratio was most important to suit a turbo charger and custom exhaust with high flow mufflers. A number of sources also suggested a specific LPG gas system for a turbo setup which consisted of, boost referenced components and a 4 valve tank. Through these upgrades it is evident that a 300rwkw Crossflow engine can be reliably achieved with most of the upgrades performed independently and balancing the engine, custom exhaust, custom conrods and pistons, custom cam performed by specialists. A number of vital key findings were in subtopics of differential, transmission, Ignition and ECU (Engine control Unit), legalities and exhaust were located, however due to word limit constraints these factors could not be discussed. WORD COUNT: 1502 Reference List: Primary Source Email: Turbo Crossflow engine upgrades Books: Max Ellery’s-Falcon/Fairlane XD XE XF Vehicle Repair Manual published by M.R. Ellery Publishing Co. R.S.D. Axedale, Victoria (1995)Secondary Source http://www.infrastructure.gov.au/roads/motor/design/index.aspx http://kreraceengines.com.au/services http://www.pitstop.net.au/view/85/gregorys-manuals-information http://www.ehow.com/how_6453472_check-cracks-engine-block.html http://www.sohchonda.com/forums/topic/3775-hit-the-deck-explaination-of-deck-height-and-benefits/ http://www.wabrasives.com/index.php?pg=rubrique&rub_id=82〈=eng http://fcp-engineering.com/29-custom-size-h-beam-connecting-rods http://www.jepistons.com/PDFs/OrderInfo/custompistons-orderform.pdfs http://www.custombalancing.com/enginebalancing.html http://www.gasresearch.com.au/epg.html http://ecomodder.com/forum/showthread.php/help-needed-propane-experts-custom-v8-propane-turbo-11194.html http://www.factorypro.com/dyno/4gasEGAvso2sensor.html Blogs Entries User: MarkZE [ONLINE FORUM-xFalcon.com/Newbie Info to Turboing a Crossflow] (2009) [uSER] Morgz [ONLINE FORUM-http://calaisturbo.com.au/archive/index.php/t-94486.html] (2006) [uSER] vltrb-0 [ONLINE FORUM-http://calaisturbo.com.au/archive/index.php/t-97351.html] (2009) User: Wes [ONLINE FORUM-xFalcon.com/Project Sleeper – TURBO XE DAILY 10 Second Car (2009) User: BGDAV [ONLINE FORUM-xFalcon.com/Newbie Info to Turboing a Crossflow] (2009) [1] User: BGDAV [ONLINE FORUM-xFalcon.com/Newbie Info to Turboing a Crossflow] (2009) [2] http://www.infrastructure.gov.au/roads/motor/design/index.aspx [3] Turbo Crossflow engine upgrades [4] User: MarkZE [ONLINE FORUM-xFalcon.com/Newbie Info to Turboing a Crossflow] (2009 [5] http://kreraceengines.com.au/services [6] http://www.pitstop.net.au/view/85/gregorys-manuals-information [7] http://www.ehow.com/how_6453472_check-cracks-engine-block.html [8] http://www.sohchonda.com/forums/topic/3775-hit-the-deck-explaination-of-deck-height-and-benefits/ [9] User: Wes [ONLINE FORUM-xFalcon.com/Project Sleeper – TURBO XE DAILY 10 Second Car] (2009) [10] http://www.wabrasives.com/index.php?pg=rubrique&rub_id=82〈=eng [11] http://fcp-engineering.com/29-custom-size-h-beam-connecting-rods [12] http://www.jepistons.com/PDFs/OrderInfo/custompistons-orderform.pdfs [13] http://www.custombalancing.com/enginebalancing.html [14] Max Ellery’s-Falcon/Fairlane XD XE XF Vehicle Repair Manual published by M.R. Ellery Publishing Co. R.S.D. Axedale, Victoria (1995) [15] http://www.gasresearch.com.au/epg.html [16] http://ecomodder.com/forum/showthread.php/help-needed-propane-experts-custom-v8-propane-turbo-11194.html [17] [uSER] Morgz [ONLINE FORUM-http://calaisturbo.com.au/archive/index.php/t-94486.html] (2006) [18] [uSER] vltrb-0 [ONLINE FORUM-http://calaisturbo.com.au/archive/index.php/t-97351.html] (2009) [19] http://www.factorypro.com/dyno/4gasEGAvso2sensor.html

soon, just got to rebuild diff and then all will be focusing on motor and setup! Well you have the info to do it! get to it!

yeah they are pretty much a one piece thing, you can glass over the vinyl im pretty sure, im sure someone has before. Better off finding a method to fill the gaps between or card and pod and then have them covered in a material.

kings sell 'super low' height leafs im pretty sure, resetting standard leads can be pricey! Cost depends on what you do? You should do some new shocks along with your springs

All aus the same? Nope only 10mm over, so only needs to move 5mm

And would anyone be able to tell the dimensions of factory the factory watts link? I think I would only need to add about +-20mm of adjustment max to correct the problem, so I should be able to draw something up on cad.

Yeah sounds good, that's all we do when we reinforce 4x4 chassis after the turkeys have bent them. Can't wait to see it all come together, probably need some good bracing on them rails to make sure it stays square within 3mm

you make your own measuring tools to check square and level? also what are your plans for the plates that cover the join from original chassis to new rail? 4mm would be suffice, and why are you seam welding over stitch, also no sharp edges on the plates, all nice curves , ive picked a few things been working at a chassis repair place for past for months.

what do the annulars do?

well its an msd ripoff buy a brand no one has ever heard off. id just go buy the msd over this

Im trying to soften up my suspension as its to harsh for bumps and everyday driving. I have full nolathane through the front, all new control bushes, sway bar, ball joints, radius rod. 20mm Shock tower spacers and bump stops shortened 25mm. Shortened shocks, which I plan on replacing with koni red adjustables. Will they give me a nice ride? I also have superlow kings in the front, so im actually thinkning about raising the car up a bit. I also run 205/65 15 tyres. What else can cause such a rough ride?

Door mounted splits are simple as! Just gets slightly difficult when you want to 6.5"

Nowhere another reason I went for xe dasg

Hey guys whats the best spot, because theres nothing really to mount it to in left boot well, as theres a cavity there, I have 4 mm alloy plate over the cavity and bolted using to bolts through the boot floor but it flexes and battery isn't very secure. How did everyone do there battery to the boot in the xf's?

what are the parts in the webber to cause it too run shit? the float? the jets?

poor alignment!

ah yep! now I see! I like that, looks neat, cheers mate!

ahh, alright well now I have a few ideas to fix mine, was put in the boot because I preferred the look and wanted to give it ago!

I meant on the last collector on the extractor, so only one bank, not where the two meet.

but steve did you just put it over the cavity without putting anything there?

got a photo? im lost? is it really secure? dosent flex? well move

but how did you mount it to the body (rear quarter), mine flex's upwards, because I cant bolt it the body.

I thought they were supposed to go in the collecter? well that's where ive got mine

To be a little more guiding to my issue, it only gets real lean when cold mornings, warm day runs fine and dosent stall, just have issue with the idle mixture. Wonder if old leads would be playing a part in it, and possibly incorrectly gapped plugs.