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Having A Grand Time: Pt 1

Want to build a 1,000hp 327? We thought so!

This pressure-to-power conversion works at elevated power levels as well, which is why we chose to increase the power output of the normally aspirated motor in the first place. If we run 14.7 psi, we essentially double any power gains applied to the normally aspirated motor. An example works well here. Suppose our test motor produced 400 hp normally aspirated. If we applied 14.7 psi to the 400hp motor, we would expect something near 800 hp. If we upped the power output of our normally aspirated motor to 450 (a gain of 50 hp), the same 14.7 psi would give us something closer to 900 hp. If we take this scenario one step further, we can see that a 500hp normally aspirated motor will produce near our magical 1,000 hp at just 14.7 psi. Had we tried to produce 1,000 hp with a 300hp motor, it would take over 34 psi of boost, with a 400hp motor we could lower the boost to 22 psi, while a 500hp motor reduces it to the aforementioned 14.7 psi. Less boost means a lower charge temperature, although we planned on running a rather efficient intercooler regardless of the eventual boost pressure.

The solid roller profile ensured we had plenty of rpm potential, as we planed to buzz the turbo motor to 7,000 rpm. The XR286R cam featured a .614/.621 lift split, a 248/254 duration split (at .050) and a 110-degree lobe separation angle. The street roller cam was actually installed as our backup cam after discovering that our initial choice (.675 lift, .245 duration and wider 114 lobe sep) resulted in a piston-to-valve clearance problem. We liked the custom cam spec'd by Comp Cams for our turbo motor, as we felt the motor would benefit from the additional lift and wider lobe separation angle. We did not have time to notch the pistons for the bigger cam before running the test, so in went the XR286R grind.

We elected to forgo the throttle body casting, as our turbo motor incorporated a Vortech Mondo air-to-water intercooler, which mounted right onto the carburetor pad of the Spyder intake. The Spyder allowed us to run the motor in carbureted and injected form with the same intake. All we had to do was plug the injector bosses when running the carb. The Spyder also allowed the motor to run effectively in our chosen rpm range. Remember, it is important to match the effective operating range of the cam and intake. It does no good to choke off an 8,000-rpm cam with a 5,500-rpm intake.

With the success of our baseline behind us, we installed the new HP turbo kit. We say new kit because HP sent us one of their race kits. The race kit consisted of larger diameter primary tubing along with repositioning of the turbo to the driver's side. The merge from the cross over tube to the turbo flange featured a true Y connection, something that aides exhaust flow to the turbo. The new street kits also employ a similar Y connection, but the turbo is still positioned on the passenger's side. Installation of the HP portion of the turbo kit was pretty simple, not unlike bolting on a set of headers. What took some time was fabricating the inlet tube running from the discharge side of the turbo to the inlet of the Paxton carburetor enclosure. The fabrication required utilization of a V-band clamp to secure the inlet tube to the turbo. It was also necessary to connect the 5-inch (that's right) exhaust tubing to the turbine housing, a situation cured in haste by tack-welding it to the turbine housing. Not ideal, but it would hold for the dyno sessions.

While we recognized that the boost was creeping, we ventured off and performed a few tests anyway. The motor was run from 4,000 to 5,600 rpm and eventually to 5,900 rpm before the fuel system would call it quits. With the waste gate set to open at 7.5 psi, the carbureted turbo stroker was run from 4,000 to 5,600 rpm. The lambda meter indicated the motor was leaning out near the end of the run and the boost gauge showed that the boost began at 5.6 psi and ended at 9.8 psi. The Innovative turbo was obviously on the job, as the motor produced 714 hp at 5,600 rpm and 669 lb-ft at the same rpm. The fact the horsepower and torque peaks occurred at the same rpm was an indication we had not revved the motor high enough to find the power peak. As we would find out, we had not revved the motor high enough to find the torque peak yet--this motor was going to make some serious power.

We tried a larger carburetor, but even with the boost-referenced regulator, the fuel pressure was not rising. The culprit turned out to be the fuel pump. Apparently it was internally regulated to bypass (or dump) fuel at 16 psi. With 8 psi of static pressure, once we reached 8 psi of boost pressure, the pump would sign off fuel supply to the carb bowls. The motor would exhaust the supply of fuel in the bowls and then lean out. Our day with the carbureted turbo motor was done.

Steve Ridout from PowerTrain Dynamics was on hand to burn chips for our custom application, and his fabrication talents were called on to build the discharge tube to connect the turbo to the repositioned throttle body inlet. Steve also configured an inlet system to connect the 96mm C&L meter to the 5-inch compressor housing. The C&L meter was used in conjunction with electronics from a 90mm Lightning meter and a set of 150 lb-hr injectors. Is it any wonder we needed Steve's help in calibrating the turbo motor?

Lucky for us, John Pizzuto from JS Electronics was on hand during the testing. John came equipped with one of his sophisticated knock sensors to monitor for any trace of detonation. We had obviously made every effort to eliminate detonation. Our efforts included 118-octane Pro Stock Race fuel courtesy of Union 76, a rich 11.5:1 air/fuel mixture and a conservative amount of total timing. Steve from PowerTrain had the programming set to provide just 25 degrees of total timing. Tossing on a big turbo like our Innovative GTB-88 (with taking the aforementioned steps) and hoping for the best is a sure-fire recipe for disaster. John from J&S indicated there was some trace detonation present during our last run, so Steve pulled 2 degrees of timing from the program and richened the mixture further. The air/fuel was reaching 12.0:1 up near 6,000 rpm, so we decided to put it back in the safe zone. We also upped the boost pressure to 11.4 psi. So equipped, the 327 produced 803 hp at 6,700 rpm, but the motor was pig rich. The drop in timing negatively affected the turbo response and overall performance. Combined with the additional fuel, the result was an air/fuel ratio of 10.5:1. Did the air/fuel and timing changes hurt power? The torque production was down by nearly 100 lb-ft from the previous run. It was time for some more tuning.

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The 1,000hp motor started... 
   
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The 1,000hp motor started out with a suitable short-block. Our 327 test motor sported an A4 block, billet crank and forged rods and pistons.
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The short-block was augmented... 
   
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The short-block was augmented with a Comp Cams Xtreme Energy XR286 R Street Roller cam. The Street Roller designation meant the cam did not require a bronze distributor drive gear.
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The roller profile required... 
   
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The roller profile required dedicated roller lifters. Important note: Roller lifters can only be installed with the head removed!
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The 327 short-block was topped... 
   
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The 327 short-block was topped off with a set of AFR 205 aluminum cylinder heads. The AFR heads featured full CNC porting, an extra thick deck surface and additional exhaust porting to further improve the flow rates.
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Fel Pro supplied all the necessary... 
   
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Fel Pro supplied all the necessary gaskets for the buildup including a set of 1011-2 head gaskets and 1262 intake gaskets. Note the ARP head studs used to retain the AFR heads under all that turbocharged cylinder pressure.
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Comp Cams also supplied a... 
   
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Comp Cams also supplied a set of Pro Magnum 1.6 ratio roller rockers for our 327. Stock stamped rockers have no place on a 7,000-rpm turbo motor.
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Coast High Performance supplied... 
   
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Coast High Performance supplied a Spyder (converted Victor Jr.) for our 327. The CHP Spyder allowed us to run the motor carbureted and injected with the same intake.
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The motor was run in normally... 
   
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The motor was run in normally aspirated trim before installing the HP Race turbo kit. The AFR heads, Comp roller cam and Spyder intake upped the power of the normally aspirated motor to 470 hp at 7,000 rpm.
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The HP Race turbo kit included... 
   
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The HP Race turbo kit included a set of 1 3/4-inch headers and crossover pipe. The system was configured to mount our large-frame Innovative GTB-88 turbo. Unlike the street turbo kit tested earlier, the race version mounted the turbo on the driver's side of the motor.
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We ran the GTB-88 turbo with... 
   
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We ran the GTB-88 turbo with a 5-inch exhaust system for maximum flow. On street/race applications, the exhaust would simply dump downward, but this was not possible on the dyno.
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The highlight of the turbo... 
   
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The highlight of the turbo motor was, of course, the turbo itself. The Innovative Turbo GTB-88 turbo was reportedly capable of over 1,200 hp--more than enough for our 1,000hp needs.
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The carbureted motor was initially... 
   
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The carbureted motor was initially run with one waste gate, but a second Innovative waste gate was added to gain control over the boost.
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Once again we relied on the... 
   
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Once again we relied on the Paxton carb enclosure and Mighty Demon carburetor for our initial testing.
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We attempted to control the... 
   
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We attempted to control the boost using the Turbo XS waste gate controller, but it wasn't until we installed the second waste gate that the controller became effectCarbureted Turbo 327 2.3 psi, 9.8 psi and Boost Spike.
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On the dyno, the carbureted... 
   
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On the dyno, the carbureted turbo motor proved to be too much for the (dyno) fuel pump. Even though boost referenced, the electric pump was unable to supply the necessary pressure to supply the fuel needs.
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Knowing we needed plenty of... 
   
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Knowing we needed plenty of fuel for our 1,000hp 327, we selected a set of 150 lb-hr injectors from the Ford Racing catalog.
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CHP supplied an extruded aluminum... 
   
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CHP supplied an extruded aluminum fuel rail with pipe fittings to feed the injectors. Note the trick retainers used to secure the rail in place.
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Trial fitting the Vortech... 
   
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Trial fitting the Vortech Mondo intercooler resulted in an interference problem with the MSD billet distributor.
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A carb spacer was employed... 
   
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A carb spacer was employed to raise the Vortech intercooler abovet the MSD.
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The Mondo air-to-water intercooler... 
   
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The Mondo air-to-water intercooler was selected to cool the inlet air temperature. Using the supplied bottom section, the Vortech unit bolted right to the CHP Spyder intake (with spacer). A pair of electric water pumps was used to circulate water through the intercooler cores.
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John Mihovitz of AccuFab not... 
   
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John Mihovitz of AccuFab not only supplied a 90mm billet throttle body but also helped locate the necessary V-band clamp section to complete our discharge tube. Thanks for the help, John!
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The big Innovative turbo and... 
   
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The big Innovative turbo and Vortech Aftecooler required a custom discharge tube. The discharge tube required a V-band clamp at one end to mate up with the compressor section of the turbo.
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Our engine management system... 
   
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Our engine management system consisted of a C&L 96mm mass air meter and an EEC IV with custom chips burned by Steve Ridout of Powertrain Dynamics.
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After a lot of head scratching,... 
   
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After a lot of head scratching, we eventually removed the EFI turbo motor and contacted Ford Racing about a new wiring harness. With the power output up near 800 hp at very low-boost levels, 1,000 hp should only be a matter of finding the injection problem and getting it back on the dyno.
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Feeding our beefy fuel rail... 
   
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Feeding our beefy fuel rail was an Aeromotive EFI pump capable of 1,500 hp.
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N/A Carbureted 327 Head, Cam... 
   
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N/A Carbureted 327 Head, Cam and Intake Upgrade
The first step in our quest for 1,000 hp was to improve the power output of our normally aspirated motor. The 327 stroker was upgraded with a new roller cam, CNC-ported AFR 205 cylinder heads and a single-plane Victor Jr. intake manifold. The upgrades not only improved the power output, they allowed more usable engine speed, something that would come in handy when searching for four-digit power. The upgrades increased the peak power from 392 to 470 hp. The peak torque improved by 10 lb-ft, from 386 lb-ft to 396 lb-ft, but the peak shifted by a good 1,000 rpm.
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Carbureted Turbo 327 2.3 psi,... 
   
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Carbureted Turbo 327 2.3 psi, 9.8 psi and Boost Spike
Before installing the fuel injection, the Innovative turbo 327 was set up with the Mighty Demon carburetor sealed in the Paxton carb enclosure. Initial attempts resulted in just 2.3 psi and 475 hp at 5,600 rpm. The culprit turned out to be two missing plugs in the carb bonnet and two oxygen sensors in the exhaust system before the turbo. Plugging these four holes resulted in much more boost, to the tune of 9.8 psi. This increased the power output to 675 hp, but the air/fuel mixture was starting to get lean near the top. One final run to 5,900 rpm resulted in 850 hp at over 15 psi, but the dyno fuel pump could not keep up with the fuel demand of the turbo motor. We never got a clean run (even at low boost) to 7,000 rpm.
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EFI Turbo 327 6 psi, 9 psi... 
   
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EFI Turbo 327 6 psi, 9 psi and 11.6 psi
This graph illustrates the great thing about forced induction, the ability to improve the power output by increasing the boost pressure. The three lines represent the injected 327 turbo motor run at roughly 6, 9 and 11.6 psi. Note the dramatic difference in power along with the fact none of the runs ventured any higher than 6,200 rpm. With Steve from Powertrain burning chips to control our timing curve and 150 lb-hr injectors, the motor was making some serious head way before the injection called it quits. After a lot of head scratching, the turbo motor was removed and our 1,000hp goal will have to wait for another issue. We'll get there, it will just take a few changes to the factory wiring harness.

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