i am pulling the plug on stage 2 development
after many days of working with both the aftermarket header and the modified oem header, i have come to the conclusion that there is not enough gain to be had relative to the amount of tuning that will need to be done, and additional parts that would need to be added, to justify that i pursue any further work - at this time, the problems that exist as a result of the increase in flow create such a risk of long term engine damage that i am not prepared to deal with the inevitable complaints and resultant political backlash from having people run such a setup
any higher output kit would require a bigger supercharger - i can't spin this one any faster - it's at its maximum now - besides, it will not increase power much but would seriously increase temps, as the efficiency would drop dramatically
bigger injectors don't help much - neither does more exhaust flow - been there - done that - not good - the motronic can't keep up and the mixture becomes completely erratic - the only solution was to fatten it up to the 12s everywhere and that will kill an engine subjected to low load levels and lower rpms - it makes more power like that above 3k, but the fuel wash will really tear up the cylinder walls over time, and given how these engines are designed to use oil, the fuel mixing with the oil won't be good on the bearings either
essentially it looks like there is maybe 25hp on the table, but at the expense of probably about 50k miles of engine life and any chance of civility of driving, leaving it only for track use
it would take a LOT of track testing to see if this even worked on the track, and i'm just not prepared to do that
i took a detour to try to see what could be done, but i put a lot of homework into the design, and determining the maximum efficiency and boost levels took a good amount of math - as it turns out, i chose right the first time - all of this just verified it
basically the kit works as it should, and taking it any further will only result in more problems and unhappy people, just like the other kits have done - i want no part of that
sorry guys - i'm leaving the kit alone and will be doing no further development, at least not until if and when i decide to build a new toy