400awhp plan let me know what you think!

[DSM_Newblet]

Hey! Just picked up a 91 Vr4 about a month ago with 93k original for a steal so decided I would build it, go figure. The plan is 400awhp streetable and even, fingers crossed, daily driveable. Well here is a list of the mods, after much research, I was thinking to reach my goal. (excluding maintenance, tranny, tcase, etc. because I have already got those taken care of.) All input, advice, other options, experiences and all around comments are appriciated.

Also keep in mind I will be running e85 as I live right down the street from the pump and love the stuff!
List may be a little out of order, have spelling errors and maybeeven missing some stuff so I appologize in advance, again feel free to comment on anything.

Cams - Crower 272/272
Springs/retainers - Manley single spring and titanium retainers
Fuel pump - rewired walbro 255
AFPR - already have an aftermarket afpr on there not sure what brand, came with the car, but might keep it as it looks to be working properly)
Injectors - FIC blue max low z 1350cc (what do you guys think for e85 on the hx35?)
Ecu management - ECULink v3 full or lite(not sure if running SD or not, suggestions?) with the EPROM
Turbo - Hx35 8 blade with BEP housing (not sure how many psi I will run just yet for my goal, maybe 23-26?)
Exhaust mani - 2g ported
02 housing - MAP 38mm external wastegate recirc to exhaust ( Is this a good size or bigger?)
FMIC - ETS 10inch FMIC kit
BOV - TiAL 50mm Q recirc BOV
MBC - Voodoo MBC
Gauges - Not sure on brand yet, but wideband a/f and boost
Exhaust - No idea need to do more research of what will fit but definately 3inch no CAT

So that's about it for now, somethings may be too much for the goal or not enough so just let me know. I will continue to do more research and add to the list while also considering all input.

THANKS GUYS!

 

[WES_393]

For those who think anything more than a 255 pump is overkill for 400whp on E85, lets crunch some numbers.

To put down 400 at the wheels lets assume you need 450 at the crank. To make 450 crank lets assume you need 50 lb/min of air. To support that 50 lb/min of air safely (<80% IDC) you need 1150cc injectors. In order to support those injectors, the pump needs to at least match their maximum, combined flow rate at the maximum expected fuel pressure.

1150cc x 4 = 4600cc/min = 276lph

So in order to support 1150cc injectors at full tilt, you want 276lph of fuel. If you stay below 90% IDC then you'll only need about 250lph, but shit happens so we want 276lph. Additionally, you need that 276lph of fuel at max fuel pressure. If you plan to run 25psi of boost with the normal 43psi base pressure, your total fuel pressure will be 68psi. So we want 276lph at 68psi. Let's see how much fuel a rewired Walbro 255 pumps out:

You must be logged in to view this image or video.

At 68psi, the rewired Walbro 255 is pumping out a little over 230lph. That's not even enough fuel to support 90% IDC, and barely enough to support 80%. Would it work for putting down 400whp? Sure. And it's safer than playing russian roulette with a semi-auto pistol.

A rewired Walbro 400lph at 68psi is putting out ~320lph. Even at 90psi it's flowing more fuel than a 255 at 70psi. It's no more difficult to install than a 255 and only costs about $60 more. I wouldn't call that overkill, I'd call that adequate.

 

[92AWDHX40]

So wes to be safe what should I have a fp 255 hp pump pump rewired, and plan to get some much larger fic injectors.

 

[Kapok6]

Im no e85 pro, but will those injectors be large enough.

Change your fuel filter to something that supports e85 as the OEM one will fall apart.

And why no catalytic converter? 400whp is not nearly enough to be choked by a catalytic converter. Get a high flow one. Makes e-tests easier, makes your exhaust quieter and does that little bit to help the environment.

For what it's worth, I have 1550's and at 26 psi they are around 60% IDC.

 

[92AWDHX40]

Im looking at some blue max 1250ccs.

EXTREME PSI : Your #1 Source for In Stock Performance Parts

 

[iBoostDSM]

Vic, 1250s should be good I would think if you want to get just around 400whp. As for a fuel pump I would get something larger than a 255. I'm thinking about getting the Walbro 450 e85 pump.

 

[92AWDHX40]

Oh OK I'll look into that I'll call you tomorrow.

 

[DSM_Newblet]

With a MLS HG surface finish has to be perfect. Glass smooth, if it is not chances are not good for the HG to seal.

http://www.dsmtuners.com/forums/new...face-4g63t-cylinder-head-mls-head-gasket.html

If the HG surface looks like this...
http://www.dsmtuners.com/forums/cyl...0613-why-not-let-your-head-belt-surfaced.html

I wish you the best of luck with the MLS.

By rights for a MLS the block should be decked too.
http://www.dsmtuners.com/forums/cyl...-deck-4g63-cast-iron-block.html#post152790451


By this time in the life of a turbo 4G63 engine, chances are it has had a few HG jobs done, so the over heating, and quick cleaning methods have taken a toll on the block's HG surface.

The keyword? Simple, You said you had a head surfaced. I always like to see that.

I am a bit of a stickler for surface finishes.

Oh okay, yeah he said if I wanted the mls hg then I would absolutely have to get the head surfaced, and it is being done at the machine shop he takes all of his work to so I am assuming it will be legit.

Vic, 1250s should be good I would think if you want to get just around 400whp. As for a fuel pump I would get something larger than a 255. I'm thinking about getting the Walbro 450 e85 pump.

After much research I am definitely going with a rewired walbro 450. Even considering the fic 2150s.

Also being a GVR-4 guy, go with the ETS unit. Direct bolt on an it will be hassle free compared to piecing up a unit.
Also, compared to the 1g and 2g, we have much less room making it more difficult to install bigger turbos. The lower tranny mount will also be an obstacle. You will have to clock the HX turbo and get either a smaller radiator or one that will fit in place of the condenser.

My thoughts exactly. What do you run? and what about exhaust? i've read about people using 1g exhausts and piecing something together all over the place but no really direct answers.

Sorry dude didn't realize it was as easy as reading your mod list to answer my questions but do you run the whole ETS kit as it comes? And is your exhaust 3in? Still not sure what exhaust I will run.

 

[black97spyder]

IMO i wouldmt go with the BC 272s. They are more like 260s or so. They are cheaper for a reason. Go woth a good cam. Ilike kelford 272s and they are very street tame as well. Good drivability and last.

I agree with combs-dsm. I bought a pair of bc 280's being told they would revv high enough for my setup (which redlines at 10k rpm) and the powerband is waayy too low and stops pulling around 7500 (like a where kelford 272's start to fade off). Not real happy about that. It makes me want to try the new revised bc 288's stage 4 cams and see if they accually pull to closer to my redline than the bc 280's.

 

[DUSTIN213]

I agree with combs-dsm. I bought a pair of bc 280's being told they would revv high enough for my setup (which redlines at 10k rpm) and the powerband is waayy too low and stops pulling around 7500 (like a where kelford 272's start to fade off). Not real happy about that. It makes me want to try the new revised bc 288's stage 4 cams and see if they accually pull to closer to my redline than the bc 280's.

This is Dustin from BC.
FYI –when comparing cams always compare the duration @ .050” and the lift numbers as the advertised duration can be deceiving.
The BC0101 has a shorter [email protected]” and lower lift than some of the competition. It is more similar to the HKS profile which is a little more on the mild side.

The BC0103-2 has a more aggressive profile and if I was going to compare it to something it would be the Kelford 280.

If anyone has any questions or i can be of any assistance my direct line is 619-749-9018 ext 101 or my email is [email protected]

 

[Kapok6]

Vic, 1250s should be good I would think if you want to get just around 400whp. As for a fuel pump I would get something larger than a 255. I'm thinking about getting the Walbro 450 e85 pump.

That's the pump I have. I have stock feed and return lines, and at 30psi, I have not had any issues running out of fuel. (this is on e85).

This pump has been awesome so far.

 

[ErikTande]

This is Dustin from BC.
FYI –when comparing cams always compare the duration @ .050” and the lift numbers as the advertised duration can be deceiving.
The BC0101 has a shorter [email protected]” and lower lift than some of the competition. It is more similar to the HKS profile which is a little more on the mild side.

The BC0103-2 has a more aggressive profile and if I was going to compare it to something it would be the Kelford 280.

If anyone has any questions or i can be of any assistance my direct line is 619-749-9018 ext 101 or my email is [email protected]

Thanks for chiming in. When I need cams I'm going to call you and bug you with all sorts of questions.

 

[LandSpeed-DSM]

I agree with combs-dsm. I bought a pair of bc 280's being told they would revv high enough for my setup (which redlines at 10k rpm) and the powerband is waayy too low and stops pulling around 7500 (like a where kelford 272's start to fade off). Not real happy about that. It makes me want to try the new revised bc 288's stage 4 cams and see if they accually pull to closer to my redline than the bc 280's.

Are you trying to suggest that you are winding out to 10k rpm on a 16G or 20G and BC valve springs as listed in your profile?

If that's the case, and mind you - I am not one to go to bat for BC products, it's not the cams cutting your powerband short.

Out of steam at 7500rpm points the finger at the TD05H turbine. Granted none of those cams you listed would take you to 10k, but even BC's 288 should get close.