Another KB install

Aussie MustangGT · 18-12-2007, 09:51 PM

First up I would like to thank Chris and Paul for all their help and input on the intercooled KB install in my 2004 GT-P. My original background is one of a fully qualified motor mechanic and mechanical engineer, having worked on all sorts of cars in my own business during the 60's through to the early 90's with great success. The 60's and early 70's involved preparing sports cars for circuit racing up to a big 7 litre hemi Ramcharger for drag racing, having hillclimbed and drag raced myself over a 7 year period. I absolutely loved this period and wanted to revisit the experiece one more time by completely re-building the engine in my 2.75 year old, 3300km GT-P in readiness for supercharging, totally by myself. The engine was fitted with forged Manly forged H-beam conrods, forged Manley 9.0:1 std pistons, Ford Racing MMR high pressure oil pump, MMR billet timing wheel, steel timing chain tensioners and new std ACL Racing bigend bearings together with ARP studs and bolts throughout. The whole assembly was internally and externally balanced, crankshaft journals polished and bores honed to exactly .004" clearance, etc, etc, by Russell Jones Engines. I replaced the exhaust with a complete 4 into1 Herrod stainless steel quad system. Finally I fitted the complete intercooled Bluepower Kenne Bell supercharger kit and Chris's legendary CAI kit. I bought a map 2 sensor plug with 30cm harness from CAPA which made the job of installing the supercharger assembly infinitely easier for one person. There is a lot more to this story which I propose to detail here at some future time for those that would like to undertake the project totally by themselves. The car goes like a absolute rocket with Chris's preliminary tune and I can't wait for him to come to the Gold Coast and finish the tune to the order of 400rwkw and untold amounts of flat torque. Even now the car idles as smooth as silk. I am definitely one happy chappy.
Thanks again Chris and Paul. You are both legends in my books.
Ian
PS. The picture titled "Engine out" shows how clean things were as the car has never been out in the rain. Made things a pleasure to work on.

JOSH · 18-12-2007, 10:24 PM

What pictures

Aussie MustangGT · 18-12-2007, 10:26 PM

Quote:

Originally Posted by JOSH

What pictures

I had a lot of great pictures but I can't get them to show up. Damn!!
Ian

JOSH · 18-12-2007, 10:27 PM

if you email them to me i will post them up for you if you like

Aussie MustangGT · 18-12-2007, 10:41 PM

Quote:

Originally Posted by JOSH

if you email them to me i will post them up for you if you like

That would be great. PM me your email address. I think I need an alternative site to post them at as maybe the total size of the files is too great to post them directly here. There are 8 pics totalling 800kb.
Ian

Aussie MustangGT · 18-12-2007, 11:06 PM

I'll have to come back tomorrow if any one has any ideas. I have not heard from you Josh.
Ian

LUXO_8 · 18-12-2007, 11:37 PM

go to www.photobucket.com and sign up an account..
load the pictures onto there (its very easy), then paste the links that appear below your image(the ones with the [IMG][/IMG] ) into your thread.

they will then appear when you submit the thread.

i hope that helps, i would love to see the pics

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Road Games · 19-12-2007, 12:01 AM

Me too.... or email can.dazzler@bigpond.com and i,ll post them as well .

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Aussie MustangGT · 19-12-2007, 12:53 PM

Thanks everyone for your help, Josh included, but I am going to have one more go myself with the pictures,
Ian.

JOSH · 19-12-2007, 03:28 PM

very nice mate, i bet u love driving it. how many k's r on your car

JOSH · 19-12-2007, 04:07 PM

Here is a couple more photo's that The Old Hoon had me put up for him. they are very sweet and i cant wait till i get mine.

Grum · 19-12-2007, 04:42 PM

I love the idea or a BPR-KB but (I know i'm in the minority) I don't like the look or the KB unit much. Has anyone made any attempts to fit the factory engine cover? Part of the reason is I would like a KB and a shaker

AGRO · 19-12-2007, 10:45 PM

Quote:

Originally Posted by Grum

I love the idea or a BPR-KB but (I know i'm in the minority) I don't like the look or the KB unit much. Has anyone made any attempts to fit the factory engine cover? Part of the reason is I would like a KB and a shaker

Yes mate. The factory cover can be modified to go back on. All you need to do is cut out a section at the front of the plastic cover for it to fit. It then hids most of the fuel rail.
Regards
AGRO.

WOLF · 19-12-2007, 10:58 PM

Quote:

Originally Posted by AGRO

Yes mate. The factory cover can be modified to go back on. All you need to do is cut out a section at the front of the plastic cover for it to fit. It then hids most of the fuel rail.
Regards
AGRO.

I would imagine someone has tried this....pics would be great

LUXO_8 · 19-12-2007, 05:16 PM

following my instructions earlier will show the pics full size...

Aussie MustangGT · 19-12-2007, 06:53 PM

Quote:

Originally Posted by LUXO_8

following my instructions earlier will show the pics full size...

Thanks mate. Will remember that for next time.Just didn't have time today.

Grum · 19-12-2007, 11:05 PM

Thanks AGRO, Is Craig keeping you on the pay roll for forum time???

AGRO · 20-12-2007, 07:39 AM

Quote:

Originally Posted by Grum

Thanks AGRO, Is Craig keeping you on the pay roll for forum time???

I'd like to be on Craigs payroll....lol.
Been on night shift last few weeks....have plenty of spare time.

"I would imagine someone has tried this....pics would be great."
I have some somewhere mate, I will try to dig them up. If not, I will set one up and take some pics.

Ian, beautiful looking car mate, It looks a treat. Just wait till you get it tuned properly.......

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Regards

AGRO.

Aussie MustangGT · 20-12-2007, 09:59 AM

Quote:

Originally Posted by AGRO

Ian, beautiful looking car mate, It looks a treat. Just wait till you get it tuned properly.......

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Regards

AGRO.

Thanks mate. I think the intercooler radiator being black looks more sophisticated IMHO. What do you think? Can't wait for the final tune from Chris as I have already gotten used to the amount of power that I have, but then you and Chris both warned me of that.......lol. His words were " You'll find that it will become addictive". He was sooooo right....hehe. Once again, thank you so much to the both of you. By the way did you notice my comments above re insurance?
Cheers, Ian.

Scott · 20-12-2007, 10:10 AM

Great setup Ian and the car looks a treat. Interesting comment re insurance, can I ask how much shannons are charging? Before I bought another mortgage I got pretty keen on the s/c idea and checked pricing with insurers. No suprise NRMA weren't interested but Rhino would do it for about $1k with s/c, exhaust & tune. Their normal price was about $650.

Aussie MustangGT · 20-12-2007, 04:24 PM

Quote:

Originally Posted by GTP006

Great setup Ian and the car looks a treat. Interesting comment re insurance, can I ask how much shannons are charging? Before I bought another mortgage I got pretty keen on the s/c idea and checked pricing with insurers. No suprise NRMA weren't interested but Rhino would do it for about $1k with s/c, exhaust & tune. Their normal price was about $650.

Thanks. I tried Ryno and they would only insure me with a supercharger if it was "state legal". As we all know they are not legal in any state if they weren't fitted to the car as original equipment as is the case with most mods. You would have to get an engineers certificate on your supercharger install stating that it met all emmission ADR's and that the driveline and brakes, etc could handle the extra power. God knows what that might cost. Shannons insured the GT-P as a "highly modified" vehicle with supercharger, etc, for $1435 incl.GST with an agreed value of $53000 and maximum no claim. I must admit I forgot to ask what the excess was, but under the circumstances is probably academic. That is also only taking the car out 2-3 times per week. RACQ on the other hand was insuring the car for $1201 at market value which they said was currently $43000 and maximum no claim and NO supercharger allowed, but naturally could take it out as often as you liked. I still think total ADR compliance would be the way to go, but in the meantime I am insured. Just have to make sure I am not pulled over by the police or Transport Department. Jeezuz life is difficult for the enthusiast. Not like the good old days.
Ian.

XRQTOR · 20-12-2007, 05:45 PM

Quote:

Originally Posted by The Old Hoon

Thanks. I tried Ryno and they would only insure me with a supercharger if it was "state legal". As we all know they are not legal in any state if they weren't fitted to the car as original equipment as is the case with most mods. You would have to get an engineers certificate on your supercharger install stating that it met all emmission ADR's and that the driveline and brakes, etc could handle the extra power. God knows what that might cost. Shannons insured the GT-P as a "highly modified" vehicle with supercharger, etc, for $1435 incl.GST with an agreed value of $53000 and maximum no claim. I must admit I forgot to ask what the excess was, but under the circumstances is probably academic. That is also only taking the car out 2-3 times per week. RACQ on the other hand was insuring the car for $1201 at market value which they said was currently $43000 and maximum no claim and NO supercharger allowed, but naturally could take it out as often as you liked. I still think total ADR compliance would be the way to go, but in the meantime I am insured. Just have to make sure I am not pulled over by the police or Transport Department. Jeezuz life is difficult for the enthusiast. Not like the good old days.
Ian.

Chris can slap me if im wrong but the BPR kit is has passed all ADR's.

The Lone Ranger · 20-12-2007, 06:10 PM

And correct me if I am wrong also but I am sure that CDAA (Colville) has just been through this very same thing with the Whipple setup and passed everything and IS legal in the state of South Australia. Not sure about the KB though.

Darren

Aussie MustangGT · 20-12-2007, 06:45 PM

Quote:

Originally Posted by ENIAL8

And correct me if I am wrong also but I am sure that CDAA (Colville) has just been through this very same thing with the Whipple setup and passed everything and IS legal in the state of South Australia. Not sure about the KB though.

Darren

What you both have to remember is that the ADR's in regards to emissions has changed over the years covering percentage of gases such as CO and NOx, etc, so depending on the year model of your GT, we have pre 2007 and post 2007. Then think of the engine and exhaust as being a unit putting out a percentage of the above gases. Now depending on your engine modifications and the boost of your supercharger kit, you can have an infinite combination of percentages of the above gases, with one percentage that complies with the relevant ADR emissions. So one version of say the KB kit with say 6psi boost might be made to comply with a completely standard engine/exhaust setup. Change the exhaust for example and that same kit may no longer comply. Or change the compression ratio and it may no longer comply, so to have a kit that is guaranteed to comply, you can only have one set of conditions under which that KB kit was submitted to the relevant testing authorities. Any other combination needs to be re-submitted.
Ian.

Jason50 · 21-12-2007, 01:31 PM

Quote:

Originally Posted by The Old Hoon

Thanks. I tried Ryno and they would only insure me with a supercharger if it was "state legal". As we all know they are not legal in any state if they weren't fitted to the car as original equipment as is the case with most mods. You would have to get an engineers certificate on your supercharger install stating that it met all emmission ADR's and that the driveline and brakes, etc could handle the extra power. God knows what that might cost. Shannons insured the GT-P as a "highly modified" vehicle with supercharger, etc, for $1435 incl.GST with an agreed value of $53000 and maximum no claim. I must admit I forgot to ask what the excess was, but under the circumstances is probably academic. That is also only taking the car out 2-3 times per week. RACQ on the other hand was insuring the car for $1201 at market value which they said was currently $43000 and maximum no claim and NO supercharger allowed, but naturally could take it out as often as you liked. I still think total ADR compliance would be the way to go, but in the meantime I am insured. Just have to make sure I am not pulled over by the police or Transport Department. Jeezuz life is difficult for the enthusiast. Not like the good old days.
Ian.

Are you sure your vehicle is really insured ?

I got a quote from Shannons for my car which has the KB kit like yours, but when I told them it is not engineered yet and I wanted that stated on the policy they backed out on me.

They are happy to take your money, but don't ask many questions of their own, like "do you have an engineers report". Beware...

Aussie MustangGT · 21-12-2007, 03:41 PM

Quote:

Originally Posted by Jason50

Are you sure your vehicle is really insured ?

I got a quote from Shannons for my car which has the KB kit like yours, but when I told them it is not engineered yet and I wanted that stated on the policy they backed out on me.

They are happy to take your money, but don't ask many questions of their own, like "do you have an engineers report". Beware...

Ryno specifically states that it has to be legal "in your state" whereas I haven't seen that mentioned on Shannons site. They (Shannons) told me that I would have to disclose all facts relating to all their questions and I told them that I had supercharged the engine myself and fitted a Herrod quad exhaust. They said that they would then have to classify me under "heavily modified" and at no stage did he say that the mods would have to be legal. I will wait until I receive the disclosure statement and then comment further, but I believe I have not held anything back and he made no mention of exceptions. In the new year I plan to look into getting an engineers certificate. I have been told by a reliable source that as you get the CO gases, etc, to compliance levels on the dyno the NOx gases will increase above compliance level. There are supposedly devices that can be fitted to the end of your injectors which will bring down the NOx gases to compliance levels and certainly worth investigating. I will report if I find there is any such devices.
Ian

Jason50 · 21-12-2007, 04:47 PM

Thats interesting information about the correct C0 levels leading to acceptable N0x levels. NSW do the test for free unlike Victoria, but getting an indication before the test could still save a lot of driving for repeat tests for me.

Look forward to hearing more about how you go with all this.

Cheers,

Jason.

baboon · 20-12-2007, 12:26 PM

They are fantastic pics. Nice and neat. Looks very clean. I admire you alot! Looks like a nice sleeper from the outside shot!

superpursuit83 · 20-12-2007, 06:54 PM

I suppose the beauty of the KB kit is you can take it home and in 4 hours or so have the engine back to stock.

Aussie MustangGT · 20-12-2007, 08:06 PM

Quote:

Originally Posted by superpursuit83

I suppose the beauty of the KB kit is you can take it home and in 4 hours or so have the engine back to stock.

Providing your engine was stock to start with. Mine unfortunately runs on 9.0:1 compression and has a non standard exhaust, but I get your point.
Ian