It hadn't occured until me recently, but my TT kit came with paper header gaskets. Somebody please verify for me that 30+ psi of backpressure and 1800* exhaust temps put that on the 'not a good idea' list.

What are all you turbo guys using for gaskets? I was thinking the Percy's soft aluminum gaskets might do the trick.

 

I am using the Percy composites for 2 turbos with stock TPI manifolds and .63 A/R T3 housings (high back pressure). The Percy website says they are designed for turbo apps. They have been holding up fine but I also "machined" my manifold flanges to within about .003" of run-out.

 

Cool. Are you talking about the XX Carbon gaskets? Those are actually the ones I was thinking of, after looking on their website. They sound like they're worth it. I definitely don't want to be taking off the turbo setup just to replace some stupid gaskets that blew out. The BBS header flanges aren't as precise as yours, but I'm sure they aren't too bad.

While you're in here junkcltr, I thought I'd ask about the $58. I'm about to try it out tomorrow N/A, hopefully it'll start up without much hassle. Would you be willing to send me one of your .bins to compare to incase everything goes wrong? heh
Did you get $8D boostable? I knew you were talking about it a while back.

 

Yes, I used the Carbon XX gaskets. They are definately worth it for $15 a pair. It took a few hours of hand filing and sanding to get the manifolds that flat. I didn't trust bringing them to a machine shop after all the fab & welding time I had into them.

I will see if I can dig up a $58 bin before I started modifying the code. I added a coolant fan RPM adder, a DIY-WBO2 reader/reported, etc. I will give you a bin before I added that stuff that would be stock code with just CAL parameters changed. Also check out the $59 code stuff at DIY PROM. There is a group of guys that were doing a bunch of fixes to the $58 code. I never tried it myself but the things they said they were fixing sounded good.

I have been running the BAUJP (boost AUJP $8D) in the car for about a month now. I wrote it using a testbench during March to October 06. It started out requiring an extra RAM module in the ECM, but I have re-worked it to fit into a stock 730 ECM. It is still in the design phase. I have some more things I want to add. I may release it in the Spring time if it all works out. I had to re-tune my $8D bin CAL data from before boost due to the TPI manifolds so it took some time to get it right again.

As a first start, it might be worth using the $8D to make sure you have no leaks (oil, exhaust, air, etc). Set the 2D lookup table for TPS% vs. RPM to something low like 40% across all RPMS. This will enable PE Mode if the TPS is greater than 40% and MAP is greater than 93 KPA. Set the VE table high in the 90 an 100KPA locations for extra fuel in case you get into low boost. You can also set the PE AFR richer for extra fuel. It is a quick & dirty way to run low boost with the stock $8D. Oh yeah, you can't use a stock $8D code version......there is a problem with it when doing the fuel calc. Start off with the SAUJP_V3 over at the DIY PROM board. It has the fuel calc. fixed. Without the fix, the injector BPW is limited in the code.......and will make your engine detonate.

 

Cool, I'll order those gaskets.

You really dove deep into the code stuff, that's cool. I wish I had the time.
I'll try to get ahold of that $59. I have read a lot about what those guys were doing to the $58, but didn't have my car for a long time to try it out on. It all sounds good. However, BAUJP sounds better. Be sure to let everyone know when you have something presentable! That's awesome.

The last thing you mentioned, about the fuel calcs. Is that in the factory AUJP code? I wonder if that has anything to do with my lean dyno runs today since I set the injector constant to 46.8 lb/hr (that's what I'm running now with the 54 psi base FP), otherwise it's the same decent tune I had on the 19lb/hr injectors (they were from the car's original 305).

 

I really disliked how it ran with the $58 code. That code was never intended to be run with a decent sized coolant fan and it p** me off when it would throw a fit when the fan came on. It wouldn't run singe fire injector mode properly which is needed with 42#/hr or bigger injectors and closed loop was a nightmare. The $8D is in single fire mode a lot of the time on on decel.

The BAUJP runs exactly as stock until the KPA reaches boost. Then it uses a spark subtractor, a VE adder, and a BPW multiplier....just like the $58 code would. The only difference is that all three tables are 3D lookup tables where as the $58 has 2D lookup tables. It also has some stuff for controlling a water/alky pump (3D table for water pump on time vs. RPM vs. MAP). It also has stuff to convert a DIY-WBO2 signal to a NBO2 signal that the ECM can use for closed loop. This elimates the need for a heated O2 sensor in the downpipe.

I still need to add in the WBO2 closed loop stuff for PE MODE and some diagnostic stuff if the 2-BAR MAP sensor fails. The closed loop stuff will take all winter to write and test properly because it gets quite involved. I am back working on finishing the turbo truck. I have re-fabbed the radiator support about three times now. The IC got larger (4.5" thick core) and I bought a diesel radiator for it. It never ends. The cold air boxes and dual coolant fan brackets are the only thing left to fab and then I have about a weeks worth of doing full welds and grinding. Oh yeah, then it needs rockers, doors, and some bedside work. Proabably another month of work. So I won't get back to the BAUJP until probably Christmas.

Yes, the fuel calc was for the $8D. The $8D uses pretty high TPS (70% at high RPM) values and a MAP of 93KPA to enter PE MODE. Check your TPS setting on the dyno, you might not have been in PE MODE the entire time. The $58 enters PE mode at about 55KPA. In the BAUJP I go into PE MODE at TPS greater than 30-40% and a MAP of 93 KPA. This engine spools down low so the TPS threshold needed to be reduced to 30 to 40%. I can cruise at 40% throttle and not be in PE MODE. If the MAP hits 93KPA or above it enters PE MODE.

BTW, the gaskets are coming out this winter probably when I start fabbing a single setup for the car. I will let you know how they look.

 

One other thing about the Percy Carbon gaskets. They are thin, much thinner than a paper gasket or aluminum gasket.

EDIT: One other thing I want to add the the BAUJP is a IAT predictor. Even with an open element IAT (V6 sensor) the IAT lags the true IAT when going into boost. The predictor will be NEW_IAT = REAL_IAT + (REAL_IAT - LAG_REAL_IAT) * TABLE_LOOKUP

Under steady state, the NEW_IAT will be equal to REAL_IAT. When IAT changes fast, it will be bumped up by a certain amount. This will give a more accurate IAT for the fuel eqn. when going into boost.

 

I hijacked my own thread.
I'll continue with the $58 discussion on my updates thread.

I ordered those gaskets from Summit, but unfortunately they couldn't get the stock port size until next year! I bought the 1.5" square port gaskets instead, which will be a tad bit big. It shouldn't hurt anything, I hope.