Prototype Charge Pipe Kit R53 MINI - Page 3 - North American Motoring


Drivetrain (Cooper S) MINI Cooper S (R53) intakes, exhausts, pulleys, headers, throttle bodies, and any other modifications to the Cooper S drivetrain.
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Prototype Charge Pipe Kit R53 MINI

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  #51  
Old 06-30-2018, 04:08 AM
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This is a great project and I’m hoping it’ll eventually lead to another affordable mod for my car.

I can’t help with any technical info, but if anyone here on NAM knows about these engines and why things were, or might have been, designed a certain way, it would be Unbreakable Lump as he was the lead engineer of the development team for these motors.

Here’s the first part of the threads he started about the Tritec engine: https://www.northamericanmotoring.co...ec-engine.html
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  #52  
Old 06-30-2018, 04:53 AM
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With the cams and headers that we have now as well as pulleys to provide more boost, would think anything that can assist in air being brought into the system more efficiently is going to be a plus.
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  #53  
Old 07-02-2018, 10:45 AM
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So yesterday I did a bit of logging in order to see some very basic data. I used two cars for the logging. Both cars were logged the same time.
I though it will be a nice comparison as the two cars are so closed spec wise, with a small advantage on car 2. Both cars had 100 RON fuel, nearly same mileage, extremely well maintained.
Car No1 specs (that's my car) : Car No2 specs:
16% sc pulley 16% sc pulley
0% Crank pulley 0% Crank pulley
Exhaust (back box only) Exhaust ( Mynes Header, 200 cell catalytic converter and back box)
Bytetronik Tune Bytetronik Tune
550 Injectors 550 Injectors
Charge Pipewithout heatshield GP Intercooler
After market Bypass
OEM intake

Outside Temperature 26 degrees at 2 am !! It is very hot here !

Below you can see some graphs from the measurements. What you will realise is that car No1 produce more psi although is operating with increased IAT compare to car No2. To be honest I do not remember my car producing 15+ psi of boost with that heat. I could only see numbers above 15 only during the winter. I will need some time before the heatshield is going to be ready. When it will be done I will do exactly the same measurements with the heatshield on. Just keep in mind that I have not finished the data collection, I am aware that there are many things to be done. So far I am very happy with how it performs! Please guys give me your thoughts - opinions.
by https://www.flickr.com/photos/[email protected]/, on Flickr

by https://www.flickr.com/photos/[email protected]/, on Flickr

by https://www.flickr.com/photos/[email protected]/, on Flickr
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  #54  
Old 07-03-2018, 12:18 PM
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it's all absolutely worthless data comparing 2 cars with a new product vs old..............YOU MUST HAVE CONTROL DELTA's
hate to be a pain but this testing is useless unless in a controlled environment on the same car
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  #55  
Old 07-03-2018, 01:05 PM
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no you are not a pain at all !! actually thank you for the comment. It's not the only test I will do. To be honest I wanted to be sure that it performs ok.
I found a dyno that I will book to do back to back pulls with the same car, so I can have solid data concerning the delta factor.
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  #56  
Old 07-05-2018, 12:07 AM
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So I have a printed version of the heatshield but as I said I had a small problem. Well when I did the 3d scan I had the previous charge pipe version installed ( I know rookie mistake !! ) thus my fix points were a bit off. The engine bay of course remains the same but the position of the charge pipe is different. Thus I will do a new 3d scan this week and redesign the heatshield. In the pictures you see below the carbon fiber prototype is installed, that's why you see a gap around the throttle body. I think you can understand how it will look like later. In the next version everything will be in the correct position.
P.S I had to trim a bit of material, close to ECU. (when it will be in the correct position it will be ok)
by https://www.flickr.com/photos/[email protected]/, on Flickr

by https://www.flickr.com/photos/[email protected]/, on Flickr
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  #57  
Old 07-09-2018, 11:23 PM
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So I found some old logs of my car with same spec, outside temperature, fuel, driver etc and I compared them against the latest logs of the car. I could see through out the rev rage an increase in the boost level although the increased IAT (new logs are with the charge pipe but without the heatshield).
So I made a chart with the average boost level in each gear comparing the two logs. The results so far verify the feeling the car gives me , so I am very happy !!
Next steps:
New 3D scan of the engine in two days, redesign of the heatshield, print a 3d model.
Make another prototype in order to be installed in a friends car, so he can drive with it for a while and give me feedback.
Book a dyno, do back to back pulls.

By the way what do you think of the heatshield I posted in the previous post? Do you like it ?

by https://www.flickr.com/photos/[email protected]/, on Flickr
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  #58  
Old 07-11-2018, 01:19 PM
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I like it keep up the good work.
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  #59  
Old 07-12-2018, 03:58 PM
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I would tend to agree with pnwR53's comment #1, post #11.
While not for the reason he states, because in my opinion, NOT, because of the blowers rotor design, rotor quantity, pull, air flow vacuum in general, but for any round container that has a gas and or solid (air OR air-fuel) in general, will tend to swirl. Just a matter of simple physics.
I wont pretend to second guess why the Mini designers made that tube in the "shapes" that they did, but as long as the cross-section square inches (American values!) slightly exceeds the throttle body's square inches, it can any shape it wants. Again, as long as there are no excessive pinch points.

If I were doing this, I'd rather see a shape that discourages anything but a straight, full flow with no airflow rotation/swirl, and no small radius corners that will have low flow areas.
Maybe a round tube (slightly larger than the throttle body diameter) would work well with something like vortex generators in the id of the tube. This would eliminate low flow areas, keep any swirl away, help make the entire cross section of the tube flow nearly the same amount of air, rather than fast in the center and slower nearer the walls (again, physics 101).

P.E - At least you are working to better the output of the little engine.

Mike
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  #60  
Old 07-17-2018, 01:50 AM
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Nearly done with the new design of the heatshield. Some minor modifications and then I will print and test fit it.
The last days I am playing with an idea... I want the outer layer of the heat shield to be made from aluminium fiber and the inner from carbon fiber. So outer layer is the layer that we can not see (faces the ground and the intercooler horn). I want to make two prototypes one with the aluminium skin and one without and see if there is any difference with the temperatures.
More updates:
The billet air-filter adapter should be ready next week.
by https://www.flickr.com/photos/[email protected]/, on Flickr

And I also did some brackets but I have not fitted yet to see if everything is ok. Again I am thinking to use carbon fiber for the brackets, as I have done some to support an exhaust and the result was very nice.
by https://www.flickr.com/photos/[email protected]/, on Flickr
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  #61  
Old 07-18-2018, 04:04 AM
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A small update. The tapered air filter adapter is ready. A small
Air filter billet adapter. Raw finish no anodised.
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  #62  
Old Today, 05:18 AM
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This is fantastic mate. Another mod that can be added to compliment everything. Loving all the datail, and can't wait for the final results. So glad you havnt been discouraged at all either. Any idea on cost of your finished charge pipe kit when completed? Keep up the fantastic progress
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