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Discussion Starter #61
I'm hoping lost didn't get lost... ;) and that his Tib is still in one piece after Perfect Power got a hold of it.. :)
LOL.. Perfect Power dont break stuff. If the car is or is not in one piece it will be my fault.

But yeah. Car is going strong. 3rd gearbox now. changed the wastegate to a Tial instead of a local knockoff. 2 boost settings. 0.5 bar and 1.0 bar - fitted the fuel pressure regulator yesterday. messed up something to do with the return fuel line.. it messed a bunch of fuel out on the drive home. Need a re-tune when that is sorted out.

Otherwise all good. small steps.
 

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Discussion Starter #62
Looks like a sweet build 馃檪 I feel you're pain though with the broken gearboxes. I'm on my first replacement of the year already. I managed to grenade 4 boxes last year! With the recent breakage I was on a track day, come down the back straight at 140mph, then after slowing for a hairpin left (2nd gear job) with lots of wheel spin I shifted into third and when I reached 6000rpm... BOOM! Ripped some teeth off the gearset. More commonly though like you mention, the factory diff just can't handle excessive torque, especially when your loading just one side of the diff like when accelerating out of corners etc. I'm hoping my custom gearset + quaife diff I've put in my new box holds up better than the factory boxes I've gone through recently... If not then it's just a bloody big expense lol
Sheesh. that sounds like fun.. not.

First gearbox took out the planetary gears - second box bearings went - now third box I hope holds out till i have some cash. its a combo of the two broken boxes. Doing ok for now.
 

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Discussion Starter #63 (Edited)
And the tune results are<img src="https://www.newtiburon.com/forums/images/smilies/huh.gif" border="0" alt="" title="Huh" class="inlineimg" /> Don't leave us hanging!
I hope the pic is kinda clear. Uploaded from a cell phone. just turn your PC monitor 90 degrees to see it.. lol

This was at 0.85 bar +- .. the wastegate wasnt consistent so it was basically best of 3 yet they were all more or less the same, differed by 3 or so Kw each.

204Kw and 388Nm
273Hp 286Lbs
 

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Great job, can you tell me where did you buy your manifold flange please? I prepare my tiby with the same turbo and don't find a manifold flange (I want to build my own exhaust manifold)
 

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Discussion Starter #68
So after trying to modify the return-less fuel system on my '06.. and after suggestions made to use the older model return fuel pump housing system from the V6 / i4.. I eventually found one..

Problems started when mods were made to incorporate a rising rate fuel pressure regulator.. worked perfectly on a dyno as on the dyno, there was no movement of fuel in the tank...
The modified fuel return into the tank worked with no movement, however with pulling away and the fuel ending up at the rear of the tank, well, fuel starvation, the surging and obviously leaning out cost me a new turbo. Typical engine problems as well like heat increase, backfiring and insane temp around the turbo.

So took me an entire 20 minutes to swap the Walbro pump from the '06 container to the '03 container and fit the hoses as needed back in the tank.

Now the fuel flow is better than its ever been, smooth, instant and consistent. Going to need a tune again after this as the power curve has changed somewhat and seems to have increased slightly at the same boost pressure.

This being said, the '06 where i am is standard with return-less system so I modified the standard setup to allow return of fuel. It works, however not as great as the OEM return fuel pump housing.

So if anyone is thinking of going return on a return-less system, just source an OEM fuel pump housing and get it over with. Its a cost saver in the long term for sure
 

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I thought the stock fuel pump and return less system still flowed enough for over 15 psi ? Why did u have to go to a return setup ?
 
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