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#16 FOCA

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Posted 21 January 2013 - 08:23 AM

I have a digital electronic boost controller, so i don't have to turn the boost up in SW, it goes up to 120psi, it has 2 stages, i can turn it up or switch stages as i drive (from drivers seat) as well as the 2 stages, it has a 3rd or "stock" defeat stage, so i can compare it (or if it fails) it massively improves the turbo lag/ midrange power/ torque (hence the 5.3 second 50-70mph in top gear)

it is microprossesor controlled, and has an anti- lag programme, and transient overboost, fast target locking 400mhz bus speed etc, i have a seperate anti- lag system as well (that works even with the bosst controller switched off )

- its normally used for JDM cars (Nissan Skylines etc)

The external waterspray works well (especially in hot weather) there is something called the latent heat of evaporation (why it works) - it is safe and easy to do (unlike water injection )

i don't run an artec (or other larger intercooler) because of its large internal volume increases lag (in theory) the bumper bar on the Mondeo "masks" part of the intercooler (if it is taller than the bottom of the bumper) my intercooler just fits under my bumper - it is an all aluminium lightweight high-flow drag racing one - as far as i am aware mine is the only one fitted to a Mondeo - i would like to test it back to back with artechs etc (on "track"/ on dyno) - in theory throttle response is improved and the waterspray gives it the performance of a much larger intercooler (its bigger than stock, of course)

You probably guessed im not a big fan of turbo-lag

Yes, taking the EGR pipe off would be crazy,(sarcastic - i did a total EGR delete 5 years ago) And fitting a hybrid turbo, massive intercooler and driving at 150mph is perfectly sane! :lol:

In the UK the EGR is not nessesary for the MOT - in fact it often helps (reduces smoke, which is measured) the tester is mot allowed to remove covers (like the engine cover)

Some people (im not condoning this :rolleyes: ) have a "setup" for the MOT that is removed at other times (cats on petrol cars etc)

Most Mondeo diesel owners only do a remap / bluefin/ tuning box, a bigger IC, and the exhaust (decat , and mabee a free flow exhaust )

I like to experiment myself and get my "hands dirty" / try new things, its more for a bit of fun or an intiectual challenge, than making the fastest Mondeo diesel.

I was running a tuning box for years, i made a custom/ 1- off remote for it (to turn it up or down) the idea was i could turn the fuel up/ down with the tuning box and the boost/ air up/ down with the boost controller - i optomised these settings by timing the acceleratoin

recenty i got a bluefin to replace the tuning box, this "lost" the bottom end (car used to pull strongly from 1k or 30mph in top) but more power/ revs at the top end

Superchips did me a special map to suit my modifications and preferences, i explained i wanted maximum reliable power and was not bothered about smoke and the transmission can handle everything the engine could throw at it, unrestricted (solid flywheel, carbon fiber/ kevlar clutch upgraded heavy duty backplate, sprung plate) ive got a short- shifter, too (worth doing on the Mondeo)

The new/ revised map has made a big difference and the car is really "flying" (it has a few other modifications i have not mentioned), i don't drive as fast as you anymore, though :P

i never "got into" remapping myself, im into "old school" tuning - mabee in the next life.....

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#17 beethoven

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Posted 21 January 2013 - 07:41 PM

Now that I've read your explanation, I have learned a lot. Now, that " digital electronic boost controller" has my full attention..I am interested. Expensive? And where for sale? Is it easy to fit, how does ik work? In fact, that's all i need, it gives me the performance just the way I like it :), altough I am gonna miss the "turbo-boost"
Do you have the waterspray? Is it possible to show some pictures?
However, what does concern me is the gearbox & transmission ....How much torque can it have?
And I don't wonna change much to it. What is the weakest part of the transmission, the gearbox, I believe.
I have a FULL blankingplate in the EGR, i don't have any smoke, not a bit.
What's a short shifter? short gear ratios?
Some pictures of Beethoven's mondy included.
As you can see: a sleeper..

Attached Thumbnails

  • cockpit 001.jpg
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  • cockpit 008.jpg
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#18 FOCA

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Posted 21 January 2013 - 11:31 PM

Hello again, my electronic boost controller works by sensing the boost pressure in the intake manifold/ boost pipes after the intercooler, it has a digital microprossesor that interprets the data and controls a solenoid (at 400hz- four hundred times a second)that then controls the air fed to the pnuematic actuator and then the wastegate - it is completely seperate from the cars' electronics, but works alongside them, it has a 120psi solenoid so theoretically could work up to that PSI it has a digitally mapped - anti-lag programme built in - it outperforms any other system (in my opinion) - it was very expensive (designed for drift racing) but somtimes when you get the "best" it saves you wasting money messing about changing several "lesser" ones

the boost controller has 2 fully adjustable stages, + a defeat/ fail: safe (if the boost controoler fails/ powers down the turbo actuator still works)

Unfortunately it won't work with your car/ engine, unless you retrofit a pnematic actuator, i have seen electronic boxes that connect to the MAF sensor that "up" the boost pressure, on cars with electronic actuators

Incedentally the anti-lag system (seperate from the boost controller, which has an anti- lag programme) works by dumping the air out of the (pnumatic) actuator when i lift - off the throttle, this means when i go back on the throttle,(after a gearchange or "lifting off" ) the wastegate is always already shut, so boost can build up quicker (anti - lag)

"short shifter" "quick shifter" - the gear lever is shorter, with a shorter "throw" (often with re-positioned/ adjustable pick-up points) gears can be changed quicker, and more positively, if you are trying to change gear quickly you are also less liable to "miss" a gear, - it can reduce your 0-60mph/ 0-100mph times/ gearchange times a little (on the autobann , of course :) )



The external waterspray is very simple, it is just the same as a windscreen washer spray, but it sprays on the intercooler - i made mine out of spare parts- you could too (its easy) it does not need any special map/ setup, i saw it on "top gear" on a Mitzibushi EVO, it works well on a hot day, or sitting in traffic / waiting for your 1/4 mile run etc (reducing heatsoak)

Your car looks good! those wheels are heavy though, (22kgs, with tyres- same as ST 18" wheels), you would be better with mk3 Mondeo titanium X 18" wheels (20kgs, with tyres) or early 16" tyres (17.4kgs, with tyres) or what i run, steel wheels (also 17.4kgs)

the lighter wheels reduce the unsprung weight, and the rotating mass, narrower tyres reduce the mechanical and aerodynamic drag (but can reduce grip on takoff/ cornering) - the mk3 titanium x wheels are wider AND lighter than your wheels (by 8kgs overall) the (17.4kgs) steelies i run save 18.4 kgs (of overall weight, unsprung weight, and rotating mass)

not having the spare wheel/ jack/ brace saves another 20kgs (i use a footpump and tyre foam) and the weight off the back improves the traction

to list all the other modifications (or just the weight saving items) would take pages and pages, but briefly, the weight saving is about 150kgs, the lighter wheels/ no spare alone is minus 48.4kgs, the decat/ exhaust is minus 9.5kgs the aircon (never used it!)is 11kgs (i removed the pump and fitted a shorter aux belt - no rattling pullys now - and reduced rotating mass ) 6kgs lighter battery etc, etc

the - 155kgs increases the payload, improves MPG and reduces wear on tyres, suspension etc, the handling is transformed and it feels like a different car.

because the car is 155kgs lighter, the (stock) brakes work much better

I could take a lot more weight out, but it might affect traction, all the door cards, electric windows, trim radio, etc are still there, (remember its a "sleeper" so has to look "normal") but i plan to replace all the glass windows on the back with perspex (save about another 20kgs) (- 175kgs)

The 155kgs weight saving means it gives the equivelant power- weight ratio of a 210bhp Mk3 hatch/ saloon,(if my calculations are correct) i have a load of parts/ modifications filled, i hope to make it the fastest accelerating of its kind when im done (the in gears/ midrange is quicker than a stock st220 but not the 0-60/ 0-100/ top speed, at the moment)

ive already fitted the (elictronically controlled) electric waterpump (faster engine warm up, , less parasitic power loss, better control of temps runs independant of engine/ after shutoff if nessesary (so fan not required, again saving weight )

Im still getting 40mpg and i really enjoy driving it - it just looks like an old Mondeo estate with steel wheels (well it is) but it often puts a grin on my face in spite of (or because of) this :)

Keep in touch and let us know how you get on with your car/ project - very interesting!

#19 beethoven

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Posted 22 January 2013 - 05:47 AM

That's the difference between you and me: You want to gain "power" by removing parts :blink: :huh: :o and / or making them lighter, so the total mass of the car is less.That is not my thing: I prefer using the car in all it's comfort & add/change things to gain power.
But the main goal is that we all enjoy driving our car, isn't it?
I've already been in contact with David -SPR, the plans are ( for the moment ) : increase turbopressure (how?????) and the search of adjusted (larger) injectors. He said to me: I want to make your mondeo the fastest mondeo mk3 tdci.driving around in the BENELUX! :blink: :blink: Well, I hold him to that
For the moment, David is driving a 2.2 tdci estate black....


Best regards

Edited by beethoven, 22 January 2013 - 02:28 PM.
to keep your privacy I have removed the email address from the post, if you want to share it with a particular member, please use the PM function. this will save your email address being added to a spambot list...


#20 beethoven

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Posted 24 August 2014 - 07:54 AM

hello people, it's been a while since I've posted something. 
But we have not been idle. 
Efforts have been made to the mondy: interior (speakers KENWOOD vs OEM FORDS PREMIUM), exterior (rear bumper ST TDCi) and exhaust line has changed to COBRA & pipe instead of cath. Custom made injectors(+ 25/30% more than usual)
Further plans: soon inlet TDDI (more air volume), EGR physical removal and last but not least: "finetune" remap.
For the moment, I have about 210 hp/ 465 torque, it must go up!!!
top speed for the moment: 235/240 kms/h



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