Integrated Engineering's "Project 2.5L Engine Dyno" Build Up Thread

[mldouthi]

Wouldn't a simple butterfly valve serve your purpose in adjusting the back pressure?

But then how would that show who is right, 2.5" making more power than 3". hahaha


This is awesome. I cant wait to see what all you guys do with this.

[magics5rip]

But then how would that show who is right, 2.5" making more power than 3". hahaha

[MK5CNY]

Wouldn't a simple butterfly valve serve your purpose in adjusting the back pressure?

Most butterfly valves will need better (Viton) seals (or remove them if you don't need full shutoff) if going over 400°F

I had the best performance out of this manufacturer, 300:1 turn down.
http://www.valvesolutions.com/pdf/Series2000.pdf
http://www.valvesolutions.com/pdf/SeriesV.pdf

Would be a good idea to get the back pressure readings across the valve while you're at it.

[pete@integrated]

We don't need anything nearly that complicated because it never needs to seal. Think more along the lines of a throttle body.

[Road Boss]

Any updates?

[pete@integrated]

Yep- we are up and running now- testing parts. I'll post a video or two this week hopefully. It's already picked up a good 40 horse or so, still on the factory exhaust manifold etc. We will be working on tuning runner lengths and such for a while now trying to get the optimum balance of torque / driveabilty and top end power.

Now we are working on solving the belt issues- first pull we did to 8k kicked the outer belt. We do not like to remove dampers so the solution we come up with will maintain the factory damper.

[mldouthi]

Yep- we are up and running now- testing parts. I'll post a video or two this week hopefully. It's already picked up a good 40 horse or so, still on the factory exhaust manifold etc. We will be working on tuning runner lengths and such for a while now trying to get the optimum balance of torque / driveabilty and top end power.

Now we are working on solving the belt issues- first pull we did to 8k kicked the outer belt. We do not like to remove dampers so the solution we come up with will maintain the factory damper.

40hp is an impressive gain, So that is just in a tune?

Looking forward to the videos!

[pete@integrated]

Nope, the tune we didn't get much- about 10hp and a decent amount of torque. Go figure- those chip tuners aren't holding out on you guys...

We are also on crappy 91 octane up here, so we can't get as aggressive with the timing as 93 octane files. The 40hp was on top of that- an intake manifold. Still tons of work to do there though. First we need the belts to stay on the damn thing.

[WOB-SH573]

Yep- we are up and running now- testing parts. I'll post a video or two this week hopefully. It's already picked up a good 40 horse or so, still on the factory exhaust manifold etc. We will be working on tuning runner lengths and such for a while now trying to get the optimum balance of torque / driveabilty and top end power.

Now we are working on solving the belt issues- first pull we did to 8k kicked the outer belt. We do not like to remove dampers so the solution we come up with will maintain the factory damper.

I'll be following your progress closely, really looking forward to putting the 2.5 in my track car!

[mldouthi]

Nope, the tune we didn't get much- about 10hp and a decent amount of torque. Go figure- those chip tuners aren't holding out on you guys...

We are also on crappy 91 octane up here, so we can't get as aggressive with the timing as 93 octane files. The 40hp was on top of that- an intake manifold. Still tons of work to do there though. First we need the belts to stay on the damn thing.

Ahh,

I wonder what is up with the belts. I think BW was getting up in that rpm range without problems, well that they mentioned

[DerekH]

Ahh,

I wonder what is up with the belts. I think BW was getting up in that rpm range without problems, well that they mentioned

Pretty sure they are running an under drive pulley.

[vr6-kamil]

Man it'd be cool if you guys find a tune or right parts to allow reving to 8k rpm wether it would need bigger injectors or not. Man reving that high and still producing power is amazing and our engines would sound great


Sent from my iPhone using Tapatalk

[pete@integrated]

Pretty sure they are running an under drive pulley.

Yep- while I could easily manufacture those- we are looking for a proper fix. Typically what we do on race engines is run a proper damper on the crank and underdrive anything we want underdriven at the accessory instead. In addition to deleting the damper, in this case you are also underdriving the water pump- which is not a good thing.

We are still running the basically open exhaust too- it'll be interesting to see if it picks up anything with some backpressure. Tons of work to do from here....

[DerekH]

Yep- while I could easily manufacture those- we are looking for a proper fix. Typically what we do on race engines is run a proper damper on the crank and underdrive anything we want underdriven at the accessory instead. In addition to deleting the damper, in this case you are also underdriving the water pump- which is not a good thing.

We are still running the basically open exhaust too- it'll be interesting to see if it picks up anything with some backpressure. Tons of work to do from here....

Agreed, a far less than ideal solution, but a solution none the less. Looking forward to seeing the way you deal with the issue. You guys have a great group of creative thinkers, so it aught be good.

[TylerO28]

why not manufacture an ac delete with a larger stepped lip that holds it in it's channel???

or somehow find a place mount up another tensioner that isn't spring operated? something like a threaded rod that forces more pressure...

and as far as the water pump with the underdrive? that is the ONLY reason i've never purchased one. i have always worried about that. and the issue with the alternator being underdriven... that could potentially cause a battery to lose life quicker than if it were getting the correct amount of juice

[pete@integrated]

We're talking about doing an AC delete- but the problem with the outer belt is the tensioner, not really the lack of flanges on the pulleys. There is a harmonic issue with the tensioner that starts right at about 7800- it goes from completely stable to bouncing around like mad.

Looking for a fix right now, I would like to keep it self adjusting / tensioning but we'll have to see. The OE tensioners are not that easy to build as they are basically a clock spring, wound up in a special fixture and welded in place.

We'll get it figured out and move along.

[pennsydubbin]

when are you guys going to tease us with some vids or dyno sheets

[mldouthi]

when are you guys going to tease us with some vids or dyno sheets

or not tease us with parts

Like the ones you didnt want to share the cam info for





Oh and what are those red things you posted on facebook??? For and 2.5L?

[pete@integrated]

Those are runner extensions for a modular development mule intake manifold... The production piece will be one piece of course.

We have peak power at 7500 right now, just tweaking the powerband and of course trying to fine tune it in some more.

I have some really cool stuff coming in the next day or two and I expect within a month or two to have that thing well over 250 bhp all motor on stock ports and bottom end.

Another thing that's becoming clear is that no header that hooks up to the stock downpipe or anywhere near it is going to do a damn thing.

[mldouthi]

Those are runner extensions for a modular development mule intake manifold... The production piece will be one piece of course.

We have peak power at 7500 right now, just tweaking the powerband and of course trying to fine tune it in some more.

I have some really cool stuff coming in the next day or two and I expect within a month or two to have that thing well over 250 bhp all motor on stock ports and bottom end.

Another thing that's becoming clear is that no header that hooks up to the stock downpipe or anywhere near it is going to do a damn thing.

So REALLY LONG tube headers. I dont mind a little modification.


I cant wait to see what you guys come up with.

[DerekH]

What about adding a ratchet type mechanism to the tensioner so it will still automatically self tension but cant bounce?

Pretty stoked to see the new gear!

[Sales@IE]

Been running this thing hard guys! Testing parts, looking for weak points, making it pretty, etc...
Took some photos so you can see what we have been working on daily for all you 2.5L guys.



















This is a great sounding engine!

[mldouthi]

I like how the main belt is missing in the last pic.

[pennsydubbin]

looks like you got a nice intake manifold on there. how about a shot of that thing

Also, what is that oil line coming from?

[Pineapplegti !]

Are those twin 54 or 60mm cis fuel pumps ?.. Kinda reminiscent of the vw motorsport rallye car fuel tanks.

[pete@integrated]

Twin bosch 044's... For when the big guns are needed haha. We don't run E85 so you're talking 1500+ crank on that setup.

Ya, the outer belt is pulley-challenged. Hahaha. Definitely shift it at 7500 if you enjoy all those luxuries like- water pumps.

The intake manifold will appear more as it gets more hashed out Right now it's running black ops style.

[DerekH]

Any chance you can give us an idea of what a 250hp all motor build will cost and what parts you will be using?

[pete@blackforest]

Great stuff guys!
I'll need some bits for the 2.5T project pretty soon..

[lessthanalex]

Any chance you can give us an idea of what a 250hp all motor build will cost and what parts you will be using?

X2 Im in love with the idea of running 2.5L NA. Imagine what this could make with a built bottom end and everything! Needless to say, Im stoked.

Sent from my GT-P7500R using Tapatalk 2

[tay272]

looks like you got a nice intake manifold on there. how about a shot of that thing

Also, what is that oil line coming from?

Im guessin its for thier oil pressure gauge but maybe not. Thats where Josh tapped my head for my gauge.

[pete@integrated]

Ya, it just goes to our dyno's datalogger.

[pennsydubbin]

ok yea I just saw the pic of the gauges - I scrolled past that the first time

[tay272]

Any updates on the progress? Havent heard anything new on here in quite awhile.

[pete@integrated]

I know- sorry! We've been slaving away testing intake manifold stuff, and there has been considerable debate about what- if anything- should be made public. In the end we are going to show some stuff. Obviously we are working on a cast 2.5L intake manifold...

Here's a few pics!







Full write up is here, on our blog:

IE 2.5L 5 Cylinder Engine Dyno Project - Part Dos

I do promise that we have some very interesting stuff coming here soon- we haven't been able to test any other power related stuff while we are doing this as it would invalidate any future comparisons, so it's pretty much on lock. However, let's just say that after this, the cylinder head needs to come apart... To make room for more LIFT.

I want to test headers as well, does anybody have anything laying around?

[lessthanalex]

This looks great. Love to see more development of this platform.