Andy
08-08-2011, 04:02 PM
Nope, it isnt a Jeep, but we are getting close and well Im excited so here are the details on what we had to change around.
1. Air Filters: They attached like a dryer hose and with enough boost, they actually suck themselves closed. The fix is a filter mounted directly to the turbo.
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/AirFilter.jpg
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/AirFilter2.jpg
2. The scavenge tank setup: Oil drains out of the turbo and into a tank. There is then an oil pump that pumps the oil from the tank back into the crankcase. This design is a nightmare and if the pump were to fail, so would the turbos. You also have to add a timer to keep the pump running for 30 seconds or so after the ignition shuts off in order to completely get all the oil out of the turbo so that it doesnt leak past the seals. My fix was to replace the Turbonetics turbos with Comp oilless turbos that do not use engine oil and are cooled via engine coolant.
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/OilTank.jpg
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/2011-05-19_13-40-09_170.jpg
3. The 2.5" piping: Might be ok for 500rwhp, but its way too small for high boost applications. Replace all this piping with true 3" piping instead. With my new turbos, we spec'd them to have a 3" V-Band outlet to make mating with the down-pipes easier.
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/2011-05-19_13-39-26_686.jpg
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/Piping.jpg
4. Wastegate Ventilation: With the 2.5" down-pipes already being too small, the last thing you want to do is add even more exhaust gas into that pipe via the wastegates especially at a 90* angle like this. With the 3" pipe, it may be OK, but I have chosen to vent the wastegates directly to atmosphere. If this is too noisey for you, you can route the vents into the exhaust, but do so at an angle so as not to disrupt the flow of the exhaust.
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/Wastegate2.jpg
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/Wastgate.jpg
5. Intercooler: The standard 3" thick intercooler doesnt cut it at high boost. You need a 4" intercooler. To make it fit, you simply notch the bumper support and your ready to go.
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/167216_10150373441860391_897475390_16714436_448458 1_n.jpg
With all these changes, you will have yourself a 1000hp or more capable system. I hope to have finalized dyno results for you guys in the near future. As of right now, we have seen right at 850rwhp with the down-pipe, intercooler, wastegate modifications but this particular car is still using oil fed precision turbos.
http://i861.photobucket.com/albums/ab175/PW-Racing/Dyno/johnstwinturbo91octane.jpg
‪300c srt8 twin turbo dyno‬‏ - YouTube
My conclusion is that the Hellion kit is great up to about 650rwhp. If you wish to make more than that, I would consider having a local shop build it for you (Stage 6, Mr Norms, Juniors place, etc.).
Some side notes:
The standard Hellion kit at 15psi had 40psi of back-pressure on a 392
The standard STS kit at 9psi had 42psi of back-pressure also on a 392
Both of these kits are probably great on stock engines with low-boost, but once you start cranking it up, thats when issues begin to pile up.
1. Air Filters: They attached like a dryer hose and with enough boost, they actually suck themselves closed. The fix is a filter mounted directly to the turbo.
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/AirFilter.jpg
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/AirFilter2.jpg
2. The scavenge tank setup: Oil drains out of the turbo and into a tank. There is then an oil pump that pumps the oil from the tank back into the crankcase. This design is a nightmare and if the pump were to fail, so would the turbos. You also have to add a timer to keep the pump running for 30 seconds or so after the ignition shuts off in order to completely get all the oil out of the turbo so that it doesnt leak past the seals. My fix was to replace the Turbonetics turbos with Comp oilless turbos that do not use engine oil and are cooled via engine coolant.
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/OilTank.jpg
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/2011-05-19_13-40-09_170.jpg
3. The 2.5" piping: Might be ok for 500rwhp, but its way too small for high boost applications. Replace all this piping with true 3" piping instead. With my new turbos, we spec'd them to have a 3" V-Band outlet to make mating with the down-pipes easier.
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/2011-05-19_13-39-26_686.jpg
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/Piping.jpg
4. Wastegate Ventilation: With the 2.5" down-pipes already being too small, the last thing you want to do is add even more exhaust gas into that pipe via the wastegates especially at a 90* angle like this. With the 3" pipe, it may be OK, but I have chosen to vent the wastegates directly to atmosphere. If this is too noisey for you, you can route the vents into the exhaust, but do so at an angle so as not to disrupt the flow of the exhaust.
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/Wastegate2.jpg
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/Wastgate.jpg
5. Intercooler: The standard 3" thick intercooler doesnt cut it at high boost. You need a 4" intercooler. To make it fit, you simply notch the bumper support and your ready to go.
http://i861.photobucket.com/albums/ab175/PW-Racing/Hellion%20Kit/167216_10150373441860391_897475390_16714436_448458 1_n.jpg
With all these changes, you will have yourself a 1000hp or more capable system. I hope to have finalized dyno results for you guys in the near future. As of right now, we have seen right at 850rwhp with the down-pipe, intercooler, wastegate modifications but this particular car is still using oil fed precision turbos.
http://i861.photobucket.com/albums/ab175/PW-Racing/Dyno/johnstwinturbo91octane.jpg
‪300c srt8 twin turbo dyno‬‏ - YouTube
My conclusion is that the Hellion kit is great up to about 650rwhp. If you wish to make more than that, I would consider having a local shop build it for you (Stage 6, Mr Norms, Juniors place, etc.).
Some side notes:
The standard Hellion kit at 15psi had 40psi of back-pressure on a 392
The standard STS kit at 9psi had 42psi of back-pressure also on a 392
Both of these kits are probably great on stock engines with low-boost, but once you start cranking it up, thats when issues begin to pile up.