RS7

[Paulm]

I’d love to know what you are talking about !

My take on the design. I am a grease monkey not an engineer though.

Poor design due to limited space and the desire to reduce turbo lag. Air intake pipes go directly over the exhaust manifold (almost touching) which can hit over 900DegC causing higher than desired intake temperatures. To combat this the car runs a richer Air fuel ratio to soak up some excessive heat within the combustion chamber.

Great design for quick turbo spool but poor for heat management. I guess there is always a trade off in a mass produced car.

gives me something to play with

[FrazerD]

So after your findings, what are you going to do about it? I don’t suppose there is much room for a lot. Are you planning a bigger inter cooler or is that not possible?

Cheers

[RobRS]

Will follow this thread with interest!

[Paulm]

Ideal setup would be.(in my head anyway)

Inlet pipes coming directly out the front of the engine with air filters behind the front bumper, keeps everything away from the Exhaust manifolds and excessive heat. This will require the removal of the current Charge cooler and replaced with a big Air to Air intercooler. Additionally the Engine cooling Rad and Air con rad would need to be modified in terms of overall height to allow for this. The loss in height (and area) could be compensated for by increasing the thickness of the rads.

The above is a huge and expensive job and unless you are going for huge power I am not sure its really worth it?? I doubt I will go that far.

My short term plan is,

stage 1 initially (sitting in my inbox will flash the car tonight) then do some more logging.
Order some heat shield material for the Exhaust manifolds and inlet pipes then more logging to see the difference, if any that makes.
Modify the stock air box to allow twin intake pipes with twin Air filters. Looking at the size of the stock air filter, its got to limit flow. Not sure what the CFM of the Filter is but I am sure the engine is wanting more.

[535dboy]

So lotus putting their supercharger on top (!) of the engine doesn’t do a lot for heat soak!!

[Paulm]

So lotus putting their supercharger on top (!) of the engine doesn’t do a lot for heat soak!!

Not sure what type of charger it has, but most discharge their boosted air direct into the inlet manifold so it will be bolted straight on top of the engine. Easy plumbing and easy to line up the drive pulley and belt but not good for heat as you say.

[535dboy]

This is why I put a bigger one on.

Bigger has to be better surely !

[Paulm]

This is why I put a bigger one on.

Bigger has to be better surely !

bigger is always better

[MikeFish]

Ideal setup would be.(in my head anyway)

Inlet pipes coming directly out the front of the engine with air filters behind the front bumper, keeps everything away from the Exhaust manifolds and excessive heat. This will require the removal of the current Charge cooler and replaced with a big Air to Air intercooler. Additionally the Engine cooling Rad and Air con rad would need to be modified in terms of overall height to allow for this. The loss in height (and area) could be compensated for by increasing the thickness of the rads.

The above is a huge and expensive job and unless you are going for huge power I am not sure its really worth it?? I doubt I will go that far.

My short term plan is,

stage 1 initially (sitting in my inbox will flash the car tonight) then do some more logging.
Order some heat shield material for the Exhaust manifolds and inlet pipes then more logging to see the difference, if any that makes.
Modify the stock air box to allow twin intake pipes with twin Air filters. Looking at the size of the stock air filter, its got to limit flow. Not sure what the CFM of the Filter is but I am sure the engine is wanting more.

Have you looked at the Eventuri video which went through their design process for the rs6/7? They checked the heat levels and added a heat shield and went for 2 inlet pipes with seperate filters. Not sure if there is anything there that might help you or validate your theories.

[Paulm]

Ideal setup would be.(in my head anyway)

Inlet pipes coming directly out the front of the engine with air filters behind the front bumper, keeps everything away from the Exhaust manifolds and excessive heat. This will require the removal of the current Charge cooler and replaced with a big Air to Air intercooler. Additionally the Engine cooling Rad and Air con rad would need to be modified in terms of overall height to allow for this. The loss in height (and area) could be compensated for by increasing the thickness of the rads.

The above is a huge and expensive job and unless you are going for huge power I am not sure its really worth it?? I doubt I will go that far.

My short term plan is,

stage 1 initially (sitting in my inbox will flash the car tonight) then do some more logging.
Order some heat shield material for the Exhaust manifolds and inlet pipes then more logging to see the difference, if any that makes.
Modify the stock air box to allow twin intake pipes with twin Air filters. Looking at the size of the stock air filter, its got to limit flow. Not sure what the CFM of the Filter is but I am sure the engine is wanting more.

Have you looked at the Eventuri video which went through their design process for the rs6/7? They checked the heat levels and added a heat shield and went for 2 inlet pipes with seperate filters. Not sure if there is anything there that might help you or validate your theories.

Yes I looked at that video. The issue with it is, the temp at and around the stock box is very good. Only around 5-7degC outside temp was 1Degc. All the heat (from what I can see and find) is in the intake pipes themselves.

[Paulm]

Stock Blast tonight before I put the map on. 1 DegC outside temp. Car only requesting around 1bar of boost. Timing is a bit low but could only get BP Ultimate fuel 97 rubbish!!

[Paulm]

So been doing some research. Think I will go down the ceramic coating route. My plan will be, coat the inlet pipes then look at how difficult it will be to do the exhaust manifold heat shields, might be more efficient time and effort just the use insulation on them. I will use ceramic on my down pipes when I get that far as well.

Bit stuck at the moment, managed to rip my bicep off the boneCan’t do anything with my left arm for 2 weeks and even then nothing much for 2 or 3 months

That big space between my bicep and elbow should not be there.

Was looking into bigger inlet pipes but the RS tax is crazy. Anything from £600 to £1000 for 2 pipes is just stupid. Given you will still have a big step inside the compressor housing I am not convinced they will improve flow that much on the stock turbo anyway. They will deffo cause eddies and low pressure areas so think I will stick with stock inlets for now.

[535dboy]

Yuk on the arm

Hope it recovers soon!

[Paulm]

thanks,

flaming pest. away to texas a week today on driving holiday. you could not make it up

[Paulm]

so flashed my Stage 1 last night. Very easy, about a 15 minute write with Powergate 3. Big difference in performance, prob doing around 680bhp. stock apart from Milltek cat back. deffo has torque steer now but not that bad for the power and torque. Not done any logging yet, only having one wing certainly makes things more difficult.

Going back to the torque steer, I wonder if adjusting my front toe-in/out would do anything? My cars steering is very very reactive which would suggest a bit of toe out (probably to help turn in on these big heavy cars). I wont track my car I will look to going toe-in a fraction and see if that helps. That will help straight line stability as well. the wife complains as the car needs constant adjustments to keep it straight, another indication I have too much toe-out.

I will do some logging and mods as soon as I have 2 working arms again