Well I have finally finished my car and looking forward to getting back to the tracks...
Wanted to give you guys some info I thought interesing during this build. First of all, my last motor was a 302 stroker and I would never recommend that stroke for anyone. With anything over 298, you have to lose your knock sensors and that feature is just too valuable not to have. That's why this motor is now a 298ci and I have the knock sensors completely operational.
Second, I love the PH (powerhouse) turbo kit but from the beginning I was a little concerned the 67mm wasn't enough for me. On the 67mm with my AOD transmission, I was making about 400 rwhp at 9 psi and the I made about 640 rwhp at 17 psi but the unit was definitely losing all it's efficiency and being maxed out at 17 psi. In fact, I only made 10 more hp at 17 psi than I did at 15 psi.
So the first order of business was to switch to a 76mm. Many claims have been made on the internet that it is a simple swap and no modification is needed to convert to a 76 mm... not true. Although nothing 'MAJOR', you will have to cut the turbo piping and smooth it out and then resize it up to the 76mm unit because since it is bigger than the 67mm (by far) the kit piping is too long for it. The size of the housing is much larger than the 67mm and it literally rests right up against the CAM sensor. So what you have to do is hardwire your CAM sensor in. Here's a pic...
The wastegate of the PH kit is a really good one and the BOV is okay for the standard kit but I wasn't completely satisfied with it or the placement of it. PH has the BOV placed on top of the intercooler so the boost isn't released until after all that heat passes through the intercooler heading for the turbo. I did not find this very effeceint at all. What I did was use a tial 50mm BOV and mount it in front and before the intercooler so that hot boost is released before it even gets to the intercooler. I really think this is what is helping me see much more power at lower boost levels. Here's a couple pics...
So how much better is the 76mm over the 67mm? Well I already said on my set-up I saw about 400 rwhp at 9 psi on the 67mm. I am at 9 psi right now on the 76mm and I am seeing about 500 rwhp. Bear in mind I have a 4 speed AOD transmission so I lose about 25% from the fly so these numbers would be considerably higher on a manual trans.
I beleive this 9 psi set-up is good for high 10's or very low 11's at the least and will find out this week. I'll post some vids up this week. I plan on staying at 9 psi for 500 miles and a couple dozen passes and then upping the boost to 14-16 psi for 500 miles and a couple dozen more passes. I'm just taking baby steps right now to break this thing in right. Once I've got that time under my belt, I'll go ahead and crank it up to 22-24 psi and look to be deep into the 9's.
Based on what I have seen on my car, I really like the 76mm single turbo for us. It makes the power range that most are striving for (450-500 rwhp) at very conservative boost levels. (8-9 psi)
I should also point out that these pics are very deceiving. After I took them, I had to run back and look at the car again to make sure...lol The BOV and piping is actually less than a 1/2" lower than the intercooler and nowhere near as low as it looks in the pics. There are no issues what-so-ever with the height - it is just an illusion in the pics.
Mark
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05 Sonic Blue Roush GT
Daily Driver KB Blown 298 built SB with Livernois heads, 4 speed AOD - 6.68@105....10.52@129 - Built by ST Motorsports
That looks nasty bad. You did the install by yourself?
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07 GT. Exterior mods n/a. Engine mods, see profile.
One of the more powerful cars around.
One of the slower cars around.
Makes me feel like a kid every time.
He hasn't yet and I suspect it's becasue it's not as simple as he thought. The blocking of the cam sensor is a very hard thing to overcome in a kit. I had to hard wire it and it's easy but it would be diffcult to incorporat a fix in a kit.
Adam at ST did all fabrication minus the cage in my car.
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05 Sonic Blue Roush GT
Daily Driver KB Blown 298 built SB with Livernois heads, 4 speed AOD - 6.68@105....10.52@129 - Built by ST Motorsports
very nice. What was your driving impression of the PH 67mm kit? that is the one I'd been leaning toward.
also, what's the purpose of the fan over the new BOV?
very cool man. Look forward to some vids of the car. Can't wait to hear that beast.
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2005 Satin Silver GT 5spd, IUP, ICAP, bullits, active alarm, lug locks, side a!rbags, shaker 500, XM Roady 2, JLT cold air, Xcal2 w/ SCT 93 oct tune, & custom fab'd ram air duct, BMR Sway Bars, Hurst Competition plus shifter
Custom blackout on hood and trunk with Steeda street wing and Ford Racing hood pins
very nice. What was your driving impression of the PH 67mm kit? that is the one I'd been leaning toward.
also, what's the purpose of the fan over the new BOV?
very cool man. Look forward to some vids of the car. Can't wait to hear that beast.
I like the 67mm and still think it is a great kit overall. I just tested it's limits and found it maxed out at 17 psi ad lost all effeciency. At 17 psi, I only made 10 more hp than a 15 psi. It's a great unit for the street but just not enough if you are looking for some big power (600+) The fan over the BOV is my trans cooler and was the only place I could find to put it...lol
If you plan on being in the 450-500 rwhp range, I think the PH 67mm kit is a great choice and can get you there on 9-10 psi.
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Hi Mark can you please clarify the difference betweek the 298 stroker vs the 302 stroker.
What bore and stroke did each have?
My thoughts were that the 298 was a 3.552 bore = 9.9091 cu. in. x 3.75 stroke x 8=297.27 cu. in.
and that the 302 was the 0.020" overbore 3.572 = 10.0210 cu. in x 3.75 stroke x 8= 300.83 cu in.
I may be mistaken.
You are pretty much correct but the konck sensor availability also has to do with your piston choice and how they are matched to the block. It's the piston height in the stroker kit that effects the knock sensors. I checked around and all the popular choices (Manley, JE, Probe, & mahely, etc. etc.) don't accomodate the knock sensors above a 298 kit.
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Again Mark, NICE!!
I e-mailed Mike a few months ago asking him to price the kit with a 76... no reply...
You reall think you lose 25% into your tranny? The stocker drop less than 20%...
Oh yeah, I'm sure of it. A C4 or AOD is a big difference from the stock auto. But the loss isn't really a loss cause it's only on the dyno. An AOD or C4 trans may show less dyno HP, but will be faster than a manual or stock auto with signifigantly more dyno HP. Don_W is another good example of this. Granted, he still has the stocker but it is rebuilt and functions more like a C4 with an overdrive (if you can imagine that) and at around 450 rwhp, he is running low 11's. The torque multiplication down low is insane with it as well. Even at only 500 rwhp, I cannot go more than 1/2 throttle in 1, 2, or 3rd, or I go instantly sidewayz on the street. This coupled with the turbo makes a mean torque combination and it hits hard and fast as soon as you step in it. I would strongly steer most away from this type of set-up cause it's honestly not that fun on the street cause you have to baby it. Yeah, great if you're a track guy like me but if most of your driving is on the street, I would not recommend going with an AOD or C4 espcially with a turbo or TS.
Mark
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05 Sonic Blue Roush GT
Daily Driver KB Blown 298 built SB with Livernois heads, 4 speed AOD - 6.68@105....10.52@129 - Built by ST Motorsports
very nice. What was your driving impression of the PH 67mm kit? that is the one I'd been leaning toward.
also, what's the purpose of the fan over the new BOV?
very cool man. Look forward to some vids of the car. Can't wait to hear that beast.
The PH 67 kit is fantastic if you plan on staying with stock internals for awhile. You have to keep in mind Mark's borderline modding psychosis ( ) makes him my idol but not exactly your average street mustang guy. He's right on target with the rwhp numbers... I was 460 on a 93 octane tune, 16 deg, 9lb spring in the wastegate (never measured actual boost pressure's, probably 8.5ish range) The car is easily streetable as a DD although I don't use mine that way. If you're going turbo, it's my recommendation over the other kits, not only from personal experience but also from the experiences of others that I have read about.
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06 Tungsten Manual, Powerhouse Turbo ,Hurst, Eibach Pro-Kit, Tokico Ds, Powerslot rotors, FR Sways, FR Strut Tower Brace, CHE poly Panhard, CHE poly LCAs, CHE DS Loop, CHE Axle Brace with LPW diff cover, Powerhouse DS, SOS triple pod pillar, Autometer FP/DPSS, Innovate LC-1/XD-16, MRT hood struts, MGW, underhood line locks, Stefs slop bucket
Well said. I did a lot of research into the available turbo kits and I still feel the PH kit is the hands down best choice. My point of the post was to show that with the PH kit as a starter, you also have the ability to go much much farther if you ever choose to.
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05 Sonic Blue Roush GT
Daily Driver KB Blown 298 built SB with Livernois heads, 4 speed AOD - 6.68@105....10.52@129 - Built by ST Motorsports
2005 Satin Silver GT 5spd, IUP, ICAP, bullits, active alarm, lug locks, side a!rbags, shaker 500, XM Roady 2, JLT cold air, Xcal2 w/ SCT 93 oct tune, & custom fab'd ram air duct, BMR Sway Bars, Hurst Competition plus shifter
Custom blackout on hood and trunk with Steeda street wing and Ford Racing hood pins
what a monster! talk about sick..now thats sick! awesome man!
I saw that article on Adam in 5.0 nice write up.
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Saleen S/C 3.2 pulley tuned by JDM Engineering, GT500 pumps, CHE goodies on the rear, 4.10's, KOOKS/ high flow catted X pipe with PYPES Violators, Spydershaft, TCI 3500 stall, PA deep tranny pan. Meziere w/p,M&H 325/45/17 DRs.
future mods.... a 3.0 pulley
How to make your turbo kit 'better' 
) makes him my idol but not exactly your average street mustang guy. He's right on target with the rwhp numbers... I was 460 on a 93 octane tune, 16 deg, 9lb spring in the wastegate (never measured actual boost pressure's, probably 8.5ish range) The car is easily streetable as a DD although I don't use mine that way. If you're going turbo, it's my recommendation over the other kits, not only from personal experience but also from the experiences of others that I have read about.
,Hurst, Eibach Pro-Kit, Tokico Ds, Powerslot rotors, FR Sways, FR Strut Tower Brace, CHE poly Panhard, CHE poly LCAs, CHE DS Loop, CHE Axle Brace with LPW diff cover, Powerhouse DS, SOS triple pod pillar, Autometer FP/DPSS, Innovate LC-1/XD-16, MRT hood struts, MGW, underhood line locks, Stefs slop bucket
