more on the ducting

So I picked up a Aluminum sheet metal and started to draw out my patterns and started
cutting away.


Cutting took some time, cause I first started using a dremel w/ a cut off wheel, I later on changed to a angle grinder which was much faster but not as clean.

One thing I realized I could really use is a sheet metal break.

So I took a break in making the inlet pieces and started making the pieces for the bumper beam deflectors.

To get the curvature I rolled the piece over a 3.00" tubing.




Inserted the deflector into the bumper beam.

Another angle on how the deflector will work when air is traveling through the bumper beam. Looks like a success.

All and all I feel very content on the progress, and hope to have more updates. Note to self that I need to remember to take pics when I'm working so I can show the progress.

Autox at Great America

I recently had the opportunity to go auto crossing and one of my buddies allowed me to use his gopro on my last run. This run was my second fastest time of 46.709, my fastest lap time was 46.667.



My first two runs were in the 48 sec realm, and on my 3rd run someone asked me what did I do differently to break into the 46sec realm, and I told him that I turned earlier to compensate for the understeer I was encountering.
After this auto cross I noticed that my rear sway bar endlink was off, which I hope will allow me for faster times.

Some updates

So its been along time since I have updated on progress on my build. Some current things being developed is a integrated brake ducting system and a wind splitter. I wanted to create ducting system that is not of the typical design, instead of running hoses along the underside of the car, I wanted to integrate the ducting within the frame of the car. I got the idea from some Subaru race cars.


I know ducting is probably the last thing I should consider when upgrading brakes. I know that going w/ different fluids, and pads would be sufficient enough. BTW I'm currently running Hawk HP plus, which are great pads for my usage. The Evo X is no light weight, and weights in a 3500lbs so ducting was something I just wanted to do since I plan on doing a track day in the near future.

The inlet part of of my design I had an idea of using some preexisting holes located in the front part of the bumper.

This picture shows the holes are bring used for the inter cooler which will now serve as the ducting inlet. But to do this I will have to modify the front bumper beam and create an air deflector so it will direct air in the proper location.

So I hacked the bumper beam up in 3 section. I wanted to try and keep majority of it, since it has brackets for the inter cooler and bumper. Hacking the bumper beam may not be the safest thing or even blocking part s of the inter cooler, but I think the benefits out weight the drawbacks.

Taking apart the bumper I noticed in order for my design to work I would need to cut some holes to allow the air to flow to the brakes.




I drew up a template for the inlet deflector.






This is what I hope it will do. Still another deflector will needed along the bumper beam to get the air to travel from bumper beam to the frame of the car. But all and all I am pretty happy w/ what I have so far.

Some updated picture for the Cold Air Intake

So I finally got a chance to take some pictures where the filter is located with the bumper off.




The clearance is excellent. On another note I had the opportunity to check out an EVO X MR and found out that the transmission is allot larger than the standard GSR which covers the entrance where the CAI would go, so making a CAI work on a MR would not be possible.

Time off

So I know it has been awhile since I have last blogged but its because I have been doing some testing and remeasuring the stuff I have created. I am looking to produce some of my things ever since I have been getting lots of response from the evoxforums. Some of my plans are making a cold air intake for the Evo MR, new mirror mounts so that people can get rid of that truck size mirror, and I still need to blog about my Tune by Mike Croutcher and his friend Mike. So much to do and not enough time.

Some things to come.

So some things to come and look forward to:
1. Blog about tuning by D.S.S. (Diamond Star Specialist) Mike Croutcher and Mike the Tuner
2. Catalytic Converter modifications
3. Brake Ducts
4. Front End Wind Splitter

Below are some drawing made on Solidworks that I am currently working on.

Brake duct that bolt to the caliper bracket

Front end air splitter frame work.

O2 Housing/Downpipe

So I was graciously given an ATP O2 housing down pipe. This is one part I did not make. The difference between this down pipe compared to the normal down pipe is that this one attaches to the turbo housing, while other ones attach after the O2 housing. The one I received has pluming specifically for the waste gate which is to prevent turbulence to the exhaust flow.

A couple of pics on the O2 housing down pipe.


This is no easy install, took me a total of 5 hours. When first installing the down pipe I had an exhaust leak coming from the band clamp for the waste gate, I removed the band clamp around making sure it is fully wrapped around and had re torque the band clamp. I am also trying to reuse all of the heat shield components, but noticed that some of the threads that hold the heat shield were on the O2 hosing. Because the bolts can not all be installed to hold the shield it is causing a rattling noise, which can be heard inside the cabin. I am currently debating on keeping the heat shield on.

Although the install was a pain, the down pipe does fit in nicely. Power difference is very noticeable, boost comes on stronger, and there is a slight increase in exhaust noise. By the way I must note that I am still running the stock catalytic converter. I am trying to really strive in keep pollution to a minimum. The factory catalytic converter does have a higher load of precious metals compared to any aftermarket catalytic converter and should be able to handle the additional of horsepower which can and will increase the rate of HC, CO and NOx. Maybe especially on NOx you may see a increase since its endothermic due to the increase of boost.