Worked on the pass side today and with a little cutting grinding and reshaping the inlet on the KB manifold fits great and is ready for welding.








Here you can see my clay which I used to check the hood clearance.

Here you can see my clay which I used to check the hood clearance.

 

Got the front cover chin lip and new air deflector bolted down today. When I bolted it down to the lower rad support it pulled the front covers lower lip down about a 1/2 more so even more of the intercooler will get a direct shot of cool air. The rad and fan should went in no problem, so now I'm just waiting for the welding which should be done Sat and then another day to assemble the manifolds to the compressor case. One dry time and then I'll bolt it down and prepare for smaller pullies:-)

 

I was a little dissapointed I didn't get the intakes back from the welder today. Oh well I made good use of my time polishing my kB compressor and snout and some of the pipe. The mothers ball really does a hell of a job. I did have to use my high speed buffer with some cutter on some deeper scratches, but it should look really nice when I get back together. I'll be sure to take some nice pics.
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Well here is my meth injection plan for my intercooler setup. Talked with Rodney at AIS about injecting meth through the compressor and then the intercooler and he said it was fine and would cause no harm to the intercooler. He suggested 9gph before the compressor through the intercooler and then maybe 5gph after the intercooler going to the discharge. I can't imaging I will have anymore heat issues after this and I hope to see some good power gains with the added boost and timming.

 

Worked on the bypass system today. Had to start from scratch there as The 3" inlet on the discharge took the place of the bypass. I used the same flange that led back to intake side, but cut it off, flipped it around and then angled it to fit next to the 3" pipe. Very close fit but it worked once welded up looks almost stock. The bypass itself is gonna be mounted on the side of the pipe that comes vertical from the side of the engine. It was the only place that had room to mount it. I baught a flange of ebay 1 1/2 inch ID and then cut a hole in the pipe and cut angles in the flange. Off to the welder with that.

 

Yesss....got the manifolds back from the welder and I must say I'm impressed, it looks awsome. He even polsihed all the welds and did the intakes too...wow what a guy, and all for $88. I did some more porting on the inside of the drivers side pipe where its welded to the intake from the inside just to smooth things out. There will be plenty flow through the transition from the round 3" pipe to the rectangler end of the manifold. Raising the roof of the at the end of the manifold really did it. The manifolds are all assembled to the compressor and everything fit back together nice. I'll let the gasket material dry over night and mount the KB tomorrow. The bypass bung and pipe are at the welders and should be done by tomorrow. I'll have to run to Napa and see if I can find a 1 1/2" heater hose with the proper bends to get my bypass system up and running. Then its time to fire up the beast.
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Looks good, got any vids of it running before you started??

 

god damn... i was curious how you were going to pull off adding a A2A intercooler to the KB... good job man... mad props to you.


now lets get it running!!!

 

The KB is installed and got the bypass pipe this morning from the welder. On start up it revs to about 3 grand and then cuts out, did this like 10 times. I checked everything, looked for vac leaks or unplugged sensors and found nothing. I tried holding the throttle open a bit and was able to get it run at 3 then 2k for 3 minutes then slowly let the throttle down until it finally idled. I Let it warm up and then went for a short ride. First observation was the KB's wine now is much louder, must be due to the thinner pipe comming off the manifold is resonating the sound out throught the pipe and intercooler. Sounds really sweat now, love that KB wine. The car runs well at cruise and responds well to light throttle jabs, very responsive, no stumble or hesitation. Now if I let off the throttle and coast it will sometimes stall. I'm gonna try resetting the idle and check TPS volts. I'll let you know. Its funny now it starts no problem no more high reving and cutting out. I have to burn out my old winter gas before I romp on it. I was able to get some cruise and light throttle data. Outside temp today is 52 degress, 4th gear cruise at 2500rpm showed ACT temps of 70 degress. So 19 degress above ambient, so far the intercooler really looks like its working well. I'm very happy with the results sor far. Even more interesting was how fast the ACT temps change now. When I crack the throttle open the air temp immediatly goes down, and i was only going to @ 20% throttle so I can imagine full throttle will result in even lower ACT. Stay tuned because I'm just getting strarted, havn't even tried the meth yet. :-)
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Got some pics pics of my Frankenstien Kenne Bell. Check it out.