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  #151  
Old 03-24-2014, 07:02 PM
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Join Date: Jun 2005
Location: Beirut, Lebanon
Posts: 1,281
dux, are u still running cam advance? maybe u should not with the turbo setup, can give u better power at stock setting

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-1995 Black W140 S500 (Lady)
-1992 Black W124 E300 (Dima) (Ex-Mosselman
Twin turbo Kit).
-1988 Black W124 300 E 4-Matic.(Nadeen)
-1983 Brown W126 500SEL.(Old Lady)(Sold)
-1981 Gold W123 280CE.(Dareen)(Sold)
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  #152  
Old 03-24-2014, 07:46 PM
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Join Date: Oct 2004
Posts: 4,177
Yeah, I still run a 3 degree advance on the cam. In a lighter car, with a bigger turbo, more RPM, and deeper gears I'd tend to agree. As it sits the white whale is a heavy AWD car with an auto trans, tall gears and a small turbo. For this setup low end torque is the name of the game. Peak horsepower doesn't much interest me.

The datalog graph attached is where I had logged my first run with the EBC. It hit 20 PSI just over 2800 RPM. The dip in the white RPM line is the overboost shutoff kicking in. There is a huge sag after the peak b/c the EBC wasn't tuned where it would hold the target. Nonetheless you can get an idea of what this setup does down low, it makes GOBS of torque.
Attached Thumbnails
103 Turbo Manifold Adaptors!-20.png  
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90 300TE 4-M
Turbo 103, T3/T04E 50 trim
T04B cover .60 AR
Stage 3 turbine .63 AR
A2W I/C, 40 LB/HR
MS2E, 60-2 Direct Coil Control
3" Exh, AEM W/B O2
Underdrive Alt. and P/S Pulleys,
Vented Rear Discs, .034 Booster.
3.07 diffs 1st Gear Start

90 300CE
104.980
Milled & ported head, 10.3:1 compression
197° intake cam w/20° advancer
Tuned CIS ECU
4° ignition advance
PCS TCM2000, built 722.6
600W networked suction fan
Sportline sway bars
V8 rear subframe, Quaife ATB 3.06 diff
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  #153  
Old 04-20-2015, 08:29 PM
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Join Date: Oct 2004
Posts: 4,177
I got my hands on a part I've been wanting for a while. Its the charge cooler radiator from a 55 kompressor car. We have a guy that has a badass CLS 55 kompressor. Its super low and he had us install a camber kit in the rear. The sway bar wouldn't clear the upper arms so I made some custom sway bar link extenders in exchange for the cooler that was being swapped for a larger one at the same time. Now I just need to find the time to pull my bumper off and figure out how to mount it.
Attached Thumbnails
103 Turbo Manifold Adaptors!-20150420_182608.jpg  
__________________

90 300TE 4-M
Turbo 103, T3/T04E 50 trim
T04B cover .60 AR
Stage 3 turbine .63 AR
A2W I/C, 40 LB/HR
MS2E, 60-2 Direct Coil Control
3" Exh, AEM W/B O2
Underdrive Alt. and P/S Pulleys,
Vented Rear Discs, .034 Booster.
3.07 diffs 1st Gear Start

90 300CE
104.980
Milled & ported head, 10.3:1 compression
197° intake cam w/20° advancer
Tuned CIS ECU
4° ignition advance
PCS TCM2000, built 722.6
600W networked suction fan
Sportline sway bars
V8 rear subframe, Quaife ATB 3.06 diff
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  #154  
Old 05-25-2015, 12:51 AM
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Join Date: Oct 2004
Posts: 4,177
Finally found the time to mount the new charge cooler radiator. It was most of the day to get it installed. Took some pics along the way.

First pic is the hokey radiator I originally had wedged in between the fans and grill. It was better than nothing but not by much. I had to push the radiator and condensor back about two inches to get it in there. Out it goes.

Second pic is the new bracing for the radiator support. The front bracing got all cut out of the way so some rear bracing holds the support now. I cut a piece for both sides but only welded in the left side. Its a huge PITA trying to tig lying in the floor. I'll mig the other brace at the shop on the lift.

Third pic is the mod I did to the aux fan shroud. I cut the bottom third off for space for the charge cooler rad. I rivited a piece of angle stock in to make a new bottom of the shroud. This also serves as an upper stop for the charge cooler rad.

Fourth pic is the brackets that I fabricated to mount the rad. I used a bracket that came on the cooler. After freeing it from the rivets I cut it in two and gave both pieces a 90 degree bend. I marked where they would line up and very carefully drilled the rivit holes in the cooler. A few rivits popped and now there are brackets.
Attached Thumbnails
103 Turbo Manifold Adaptors!-20150524_122348.jpg   103 Turbo Manifold Adaptors!-20150524_133129.jpg   103 Turbo Manifold Adaptors!-20150524_165729.jpg   103 Turbo Manifold Adaptors!-20150524_181736.jpg  
__________________

90 300TE 4-M
Turbo 103, T3/T04E 50 trim
T04B cover .60 AR
Stage 3 turbine .63 AR
A2W I/C, 40 LB/HR
MS2E, 60-2 Direct Coil Control
3" Exh, AEM W/B O2
Underdrive Alt. and P/S Pulleys,
Vented Rear Discs, .034 Booster.
3.07 diffs 1st Gear Start

90 300CE
104.980
Milled & ported head, 10.3:1 compression
197° intake cam w/20° advancer
Tuned CIS ECU
4° ignition advance
PCS TCM2000, built 722.6
600W networked suction fan
Sportline sway bars
V8 rear subframe, Quaife ATB 3.06 diff
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  #155  
Old 05-25-2015, 01:10 AM
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Join Date: Oct 2004
Posts: 4,177
More pics. First up is the tabs I welded to the front of the condensor mounts that mate to the brackets rivited to the charge cooler rad.

Next you can see the charge cooler rad in place and mounted to the tabs. At this point it almost looks like it belongs there. At least until you try to put the bumper back on. The lower corners of the cooler interfere with the bumper.

Third pic shows my solution. Several 2 1/4 holes drilled in the lower section of the bumper. These serve to get more airflow across the cooler but the outer two are strategicly placed so that the interfering corners can poke through and let the bumper bolt back up.

Thats where the pics end. I ran some new hose and eventually managed to purge most of the air out of the system. I'll get a pic of the bumper mods in the daylight soon. Meanwhile I need to get the laptop charged and datalog some driving to see if it was worth all the hassle.
Attached Thumbnails
103 Turbo Manifold Adaptors!-20150524_181441.jpg   103 Turbo Manifold Adaptors!-20150524_182220.jpg   103 Turbo Manifold Adaptors!-20150524_194736.jpg  
__________________

90 300TE 4-M
Turbo 103, T3/T04E 50 trim
T04B cover .60 AR
Stage 3 turbine .63 AR
A2W I/C, 40 LB/HR
MS2E, 60-2 Direct Coil Control
3" Exh, AEM W/B O2
Underdrive Alt. and P/S Pulleys,
Vented Rear Discs, .034 Booster.
3.07 diffs 1st Gear Start

90 300CE
104.980
Milled & ported head, 10.3:1 compression
197° intake cam w/20° advancer
Tuned CIS ECU
4° ignition advance
PCS TCM2000, built 722.6
600W networked suction fan
Sportline sway bars
V8 rear subframe, Quaife ATB 3.06 diff
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  #156  
Old 05-31-2015, 02:38 PM
Registered User
 
Join Date: Oct 2004
Posts: 4,177
So the tuning laptop battery is on its last legs with a new one on order. Nonetheless I've managed a few minutes of data logging.

So far I can make a few observations. After a heat soak the MAT will fall back down to less than 10 degrees over ambient while cruising off boost. Previously it would not fall below 20-25 over ambient.

The other observation is that temps under sustained boost are within 5 degrees of the old rad. This is showing the limitations of the intercooler itself. It is an ebay cheapie after all. I am pushing a small turbo well outside of its efficiency range too.

Overall I'd say still worth all of the effort. Now I'll need to focus on compressor efficiency and intercooler capacity for any further gains.

__________________

90 300TE 4-M
Turbo 103, T3/T04E 50 trim
T04B cover .60 AR
Stage 3 turbine .63 AR
A2W I/C, 40 LB/HR
MS2E, 60-2 Direct Coil Control
3" Exh, AEM W/B O2
Underdrive Alt. and P/S Pulleys,
Vented Rear Discs, .034 Booster.
3.07 diffs 1st Gear Start

90 300CE
104.980
Milled & ported head, 10.3:1 compression
197° intake cam w/20° advancer
Tuned CIS ECU
4° ignition advance
PCS TCM2000, built 722.6
600W networked suction fan
Sportline sway bars
V8 rear subframe, Quaife ATB 3.06 diff
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