I found a tiny little boost leak..no big deal.

[BigBeans]

So i've been trying to figure out why my car has been knock prone, won't take ignition timing (running 12* peak with 23psi on pump gas) and seems to be down on power.

I did a boost leak test, first pressurizing the manifold only to concentrate on that. Injector O-rings were shot. Slapped some new ones on, and everything north of the GM MAF was good.

Then i put the tester on the compressor inlet, and nothing happened. It wouldn't build/hold any pressure whatsoever. As fast as i could put air in, it was leaking out.

I could hear the intercooler hissing, so i ripped the car apart and found a bit of a crack...and by a bit i mean a 4.5" gash right through the weld on the IC end tank.

I'm amazed at how well the car was running with this issue. A week ago i jogged away from a car that traps 108 with no trouble at all. It has to be leaking a LOT of air.

This is one of the older style Buschur street cores. I haven't decided if i'm going to have my neighbor (pro welder) TIG it up, or just buy an 1100CFM monster from ETS. Either way, i'm happy i know what the problem is so i can get it worked out and make some more power.

 

[XiKeiyaZI]

xD good god man!

 

[Calan]

That usually happens from a lack of filler in the weld or poor penetration. They'll open up like a zipper on a long seam.

 

[BigBeans]

That usually happens from a lack of filler in the weld or poor penetration. They'll open up like a zipper on a long seam.

It's definitely a defect. This FMIC has like 10k miles on it, but it was purchased forever ago, so i know they won't do much for me.

I called Buschur to see if they would offer me a discount on one of their new race cores. They said they have their end tanks done elsewhere and they weren't sure if they had anymore to make a 1G intercooler.

One of the sales guys is supposed to call me back, but not surprisingly i haven't gotten a call. I'm not really sure i want another Buschur core even if they discount it.

 

[pj91gsx]

weld it. thats what they want you to do. i say weld it too. and without boost leaks it makes a huge difference. I fixed all of mine.

 

[VETTE_50_TH]

Well theres your problem. Your compressing the atmosphere faster than what it can handle. Causing your car to slow down in boost. Thatll do it!

 

[Gasolinebaptism]

What turbo are you running?
That weld should hold 5,000 PSI. You must be running like 9's!!

 

[350war]

Wow! Your turbo was working its heart out. It will be like a new car once thats fixed. That would make me question the other welds.

 

[vgknightcc]

This has happened to me many times. It is the endtank design also that is weak . The rounded endtanks dont have this issue. But hey any good Aluminum welder can fix it.

 

[BigBeans]

weld it. thats what they want you to do. i say weld it too. and without boost leaks it makes a huge difference. I fixed all of mine.

I'm going to weld it for now, and spend the money that was going to go toward a bigger FMIC on a progressive meth setup. Ill pick up another FMIC a few months from now.

What turbo are you running?
That weld should hold 5,000 PSI. You must be running like 9's!!

Only 5000psi! Damn, i guess i've got to turn the boost down!

It's only an FP3052 (30R compressor with .70 hot side). The intercooler has prob seen an absolute max of about 32psi for a second, and 23psi daily. Not exactly severe duty.

Wow! Your turbo was working its heart out. It will be like a new car once thats fixed. That would make me question the other welds.

Funny that you mention the other welds, because this FMIC is crap. One of the other welds is already developing a hairline crack, which will need rewelding.

Also, FWIW, the sales guy i spoke with at Buschur still hasn't called me back about buying a race core. I guess decent customer service is too much to expect when you're only trying to give them $900.

 

[LandoAWD]

Make sure you have them throw in a set of Buschur spec plugs if/when they respond. +80hp

 

[BigBeans]

Make sure you have them throw in a set of Buschur spec plugs if/when they respond. +80hp

I'm really all set with Buschur.

The next one will be the ETS 4" "race" core. Only decision is whether or not to anodize it black for some sleeper status.

 

[LandoAWD]

I'm really all set with Buschur.

Tongue in cheek only begins to describe where I was going with that.

 

[BigBeans]

All welded up.

I threw a thin coat of black paint on it to see if i like the sleeper look. Now i've just got to hook up the LC-1 and retune this sucker.