SHO Noise Maker Pipe on XSport? - YUP :)

[MiWiAu]

Well ladies and germs, here's a Thursday teaser...

I got my v-band flange welded up on Tuesday and mocked up the patented AJP Turbo boost regulator mod today on my XSport. Looks awesome!!

I'm going to pick up some extra vacuum line and a tee tomorrow after work and finish my install. I did something a little different with my elbow to try and clean things up a bit; time will tell if it holds up. I'll soon put together a full write-up of my Explorer install on AJP Turbo's boost regulator mod How-To thread to keep everything in one place.

Enjoy!

 

[BlueSHO]

Nice that's some serious eye candy too..

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[MiWiAu]

Nice that's some serious eye candy too..

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IKR?! I'm super stoked! Thanks!

 

[ajpturbo]

Hell yes!..i love seeing the mod on other cars...nice welds...so how are you joining the plastic to metal?

Its going to be awsome

Way to turn a retarded eye sore into a functional piece....ford loves noisemakers lol...my mustang had a sound tube to the cabin...i turned it into a canal for my gauge wires lol

 

[ajpturbo]

Wait til you hear how much air is being bled on wot upshifts...that all just extra air pressure that would be nasty boost spikes....the more sound you hear from the new gate the more its working and reducing spikes and helping the fuel system

The more air that is bled the less the throttle needs to be used to control the spike....the 2-3 spike is the worst so that is where you will hear the best wooosh sound

 

[MiWiAu]

Hell yes!..i love seeing the mod on other cars...nice welds...so how are you joining the plastic to metal?

Its going to be awesome

Way to turn a retarded eye sore into a functional piece....ford loves noisemakers lol...my mustang had a sound tube to the cabin...i turned it into a canal for my gauge wires lol

I found a welder who does great work whom I've used for a couple small jobs. He charged me $20 for the two welds. I'm happy; it looks a lot better than I could do, and since it's pretty much right on top of everything, I wanted it to look nice.

The plastic to metal is the tricky part and what I was alluding to when I said "time will tell if it holds up". I found a  304 stainless railing adapter on kegworks.com (heh heh) that is supposed to join two 1.5" OD tubes with 0.050" wall thickness. The OD of the stainless elbow shoulder (1.390"measured) is just a hair larger than the ID of the noisemaker port (1.385" measured). I used my bench grinder and just barely skimmed the surface of the metal elbow shoulder until I had a super tight friction fit inside the plastic elbow.

The shoulder on the elbow is about 1.3" long (the part that slides into the plastic elbow), so about 1" in on the plastic elbow, I put a ring of Permatex Ultra Copper Gasket Maker, and on the rest of it I used "JB Weld Plastic Bonder" which says "great for bonding Plastic to metal" (although I have read that it's not recommended for some plastics which happen to be common under the hood...). I pressed in the metal elbow with a slight twisting motion to spread the epoxy, and I'm going to let it set up over night.

I have pictures of all this that I will put in your how-to thread to explain better.

If it doesn't hold, I have a 1.5" silicone coupler I will install, assuming the waste gate doesn't blow off and fall out the bottom of my truck. HAHA

 

[ZSHO]

Nicely done there MiWiAu....no belly pan cover underneath the Xsport ? Might need to modify one.lol. Z

 

[MiWiAu]

Nicely done there MiWiAu....no belly pan cover underneath the Xsport ? Z

Haha, nope. At least if there was one, it wasn't there when I bought it.


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[SHOdded]

Looking good :thumb: Nice work!

 

[8nutz8]

just to double up on what AJP said. i was surprised how much this mod helped maintain fuel pressure. i used to get dips of 1800-1900psi on standard fuel with the throttle closing to control the spike. now i'm on E20-throttle wide open and never below 2000psi with the wastegate controlling the spike. not to mention i set the spring rate in the gate to allow for some boost spike so i get the advantage of extra boost but the gate opens right at the point where it would hurt fuel pressure. great little mod he came up with


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[BlueSHO]

just to double up on what AJP said. i was surprised how much this mod helped maintain fuel pressure. i used to get dips of 1800-1900psi on standard fuel with the throttle closing to control the spike. now i'm on E20-throttle wide open and never below 2000psi with the wastegate controlling the spike. not to mention i set the spring rate in the gate to allow for some boost spike so i get the advantage of extra boost but the gate opens right at the point where it would hurt fuel pressure. great little mod he came up with


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I guess I need educated on implementing that blow off valve to our setup. Do you unplug or remove the factory ones? What in the tune needs changed for that?

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[MiWiAu]

I pressed in the metal elbow with a slight twisting motion to spread the epoxy, and I'm going to let it set up over night.

So, to clarify, the JB Plastic Bonder is a 2 part urethane adhesive, not an epoxy; I misspoke in my prior post.

The urethane is supposed to be better for joining dissimilar materials with different thermal expansion characteristics.

After curing overnight, I pulled (longitudinally) on the joint with all my might and nothing budged. I also applied quite a bit of torque, and no movement or perceptible noise of pending joint failure.

It will be interesting to see how this does long term under the hood with the constant vibration and thermal cycling.


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[MiWiAu]

I guess I need educated on implementing that blow off valve to our setup. Do you unplug or remove the factory ones? What in the tune needs changed for that?

No change to factory BOV. This is a wastegate that plumbs in to the intake just before the throttle body to eliminate boost spikes when shifting.

I have a link to AJPs how-to in post #1, and he explains it pretty well over there. Basically, it allows the throttle blade to stay full open, and the pressure spikes are relieved through the WG (instead of closing throttle).

At least this is my understanding.


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[8nutz8]

^Yep he beat me to it

I guess I need educated on implementing that blow off valve to our setup. Do you unplug or remove the factory ones? What in the tune needs changed for that?
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The part the OP and i installed is a wastegate not a BOV. 2 separate devices that sometimes get confuseed. Your factory BOV's are completely separate of this mod and do not need to be changed or altered to perform the wastegate mod. Here's the full writeup from the man that thought it up
http://www.ecoboostperformanceforum.com/index.php/topic,6526.0.html

 

[8nutz8]

After curing overnight, I pulled (longitudinally) on the joint with all my might and nothing budged. I also applied quite a bit of torque, and no movement or perceptible noise of pending joint failure.

It will be interesting to see how this does long term under the hood with the constant vibration and thermal cycling.


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^Anxious to see pics of this

 

[MiWiAu]

just to double up on what AJP said. i was surprised how much this mod helped maintain fuel pressure. i used to get dips of 1800-1900psi on standard fuel with the throttle closing to control the spike. now i'm on E20-throttle wide open and never below 2000psi with the wastegate controlling the spike. not to mention i set the spring rate in the gate to allow for some boost spike so i get the advantage of extra boost but the gate opens right at the point where it would hurt fuel pressure. great little mod he came up with


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I guess I need educated on implementing that blow off valve to our setup. Do you unplug or remove the factory ones? What in the tune needs changed for that?

Maybe you can clean up and return that Interceptor Sedan intake piping you just purchased/installed. LOL


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[MiWiAu]

After curing overnight, I pulled (longitudinally) on the joint with all my might and nothing budged. I also applied quite a bit of torque, and no movement or perceptible noise of pending joint failure.

It will be interesting to see how this does long term under the hood with the constant vibration and thermal cycling.


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^Anxious to see pics of this

I'll try to get my write-up completed tonight. I'd really like to get this installed and get a log back to the Warlock tonight. We're supposed to get snow on Sunday, and I'm traveling all next week for work. Bleh.



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[BlueSHO]

just to double up on what AJP said. i was surprised how much this mod helped maintain fuel pressure. i used to get dips of 1800-1900psi on standard fuel with the throttle closing to control the spike. now i'm on E20-throttle wide open and never below 2000psi with the wastegate controlling the spike. not to mention i set the spring rate in the gate to allow for some boost spike so i get the advantage of extra boost but the gate opens right at the point where it would hurt fuel pressure. great little mod he came up with


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I guess I need educated on implementing that blow off valve to our setup. Do you unplug or remove the factory ones? What in the tune needs changed for that?

Maybe you can clean up and return that Interceptor Sedan intake piping you just purchased/installed. LOL


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Lol sad thing is that might happen

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[MiWiAu]

Wait til you hear how much air is being bled on wot upshifts...that all just extra air pressure that would be nasty boost spikes....the more sound you hear from the new gate the more its working and reducing spikes and helping the fuel system

The more air that is bled the less the throttle needs to be used to control the spike....the 2-3 spike is the worst so that is where you will hear the best wooosh sound

I was getting "woosh" almost everywhere! LOL At first, I was thinking the gate was just opening early, so I tried beefier springs with no change.

Turns out the hose on my TB wasn't properly seated. DUH! That spanking new hose was a super tight fit. I couldn't see the issue from the top side, but found it when I pulled the connections to start over. Fixed this, and I'm back in business.

Working now on finishing install write-up.

 

[MiWiAu]

Post #66 on AJP's how-to thread details the boost regulator mod installation on my Explorer.