Stillen air to air conversion fabrication thread
 

Well, as some of you know, this is something that has been in the works for some time. I believe the first conversation occurred about two years ago, when I saw this supercharger kit for the first time. The time has finally come for me to work my magic, and improve on some of the engineering done by Stillen.

The tear down was rather simple and straight forward. Pull the front bumper off, remove the water/air cooler, hoses, water pump and some additional plumbing. Once all that was removed, it was time to install the
large air/air intercooler. This is the same intercooler core used on the Boosted Performance twin scroll turbo kits, but with a different end tank configuration. The core is capable of supporting 2,000cfm, so flow will never be an issue.

So step one, install the standard FMIC brackets from the BP twin scroll turbo kit, and mount the FMIC…rather simple:

http://i137.photobucket.com/albums/q...psv3clupqw.jpg

http://i137.photobucket.com/albums/q...ps2rpspxwo.jpg


The next big thing and my biggest concern with this set-up was the supercharger air intake. As it comes out of the box, a 3.5” to 2.5” reducer is used on the compressor inlet, which then goes to a 2.5” 90 degree aluminium
bend. That then goes to a Y and two small air filter. Knowing how little space there is, and me wanting to turn this in to a 3” intake, I figured it will be a challenge.

It actually went rather smooth. I used a 3.5” to 3.0” 90 degree silicone reducer, which was cut in such a way to allowed me to install it with the headlight removed (only 4 bolts):

http://i137.photobucket.com/albums/q...pstkmumdrv.jpg


Not much room to work with:

http://i137.photobucket.com/albums/q...psw0hi4paf.jpg



http://i137.photobucket.com/albums/q...psbwchjmuc.jpg


The improvement:

http://i137.photobucket.com/albums/q...pstcfptzln.jpg

3” tube hanging in front of the driver side bumper, ready for an air filter:

http://i137.photobucket.com/albums/q...ps0en7ksjb.jpg


http://i137.photobucket.com/albums/q...psdkcpznag.jpg


This configuration will allow for much better flow of air in to the supercharger. It also allows one to use a larger air filter, which is also a big plus. Should be getting some nice cold air in there now:

http://i137.photobucket.com/albums/q...psd4rm5eqz.jpg

With the intake out of the way, I was able to move on to the S/C to IC piping. That was rather straight forward. A couple of the plastic pieces between the two fans needed to be cut, as well as one fan support on each fan (there are 8 total per fan, so it is not a big deal):


http://i137.photobucket.com/albums/q...ps7wmxlg9s.jpg

With that out of the way, I was able to rout a 2.5” charge pipe all the way down:

http://i137.photobucket.com/albums/q...psmwg49rsq.jpg

From there, it was rather straight forward to get to the IC inlet:

http://i137.photobucket.com/albums/q...psiwplhxrk.jpg


http://i137.photobucket.com/albums/q...ps0d3dvqvp.jpg


http://i137.photobucket.com/albums/q...ps3v3oikrm.jpg


http://i137.photobucket.com/albums/q...psfwrniwym.jpg

Next step, getting that nice cold air to the TB’s. 3” 90 degree out of the FMIC, and through to the engine bay:

http://i137.photobucket.com/albums/q...psyb44lpb0.jpg


http://i137.photobucket.com/albums/q...psaupzcxin.jpg

Moving on to the Y section, which is where I finished the night off.

http://i137.photobucket.com/albums/q...pspew6ekgn.jpg

The plan is to install the MAF sensors in the 3” section of pipe just before the black coupler. This will allow for a proper reading of IAT’s, and will greatly improve the range of these sensors.






Some random shots:

http://i137.photobucket.com/albums/q...ps1spfdtje.jpg

http://i137.photobucket.com/albums/q...psj2gu616t.jpg



As it is built, with this air/air configuration, and a smaller pulley set. I don’t think 600whp is out of the ballpark with this kit. The head unit is certainly capable of pushing enough air, and now everything
around it will be able to support it. I will post some more pictures once I get back at this tonight.

This will be a game-changer for the Stillen guys. Very cool.

Nice work Sasha, Sub to see what happens here. :)

Man you got a lot done last night after I talked with you lol.

Super stoked for this to be done!

Not improve the engineering...

You mean, you use engineering Stillen didn't use to make this product.

Hhahah

Well he did keep the SC an manifold LOL

Dang dude did you even sleep? This went together quick. Looks nice. The way you routed the charge pipe is pretty unique.

I take it turning it down 90* wasn't possible?

So you will put 2 Mafs in one 3" pipe?

It will be interesting to see the pulley set needed to reach 600whp. This will need to push about 4-5psi more than anyone has found.

He used engineering that doesn't need CARB approval.

Yes, I worked till midnight. Just couldn't stop, it was going rather well.


Thanks, and turning the blower 90 degrees was not possible. You would end up going down and hitting the driver side radiator fan. This worked out much better, and the upgrade much simpler/easier. If I was to make this as an upgrade package, it would take about 5 hours to install...that includes a few lengthy beer breaks.

I love new ideas and especially if they are implemented!

Great Respect :tup::tup::tup::tup:

Ivo

Stillen can get a air-air system passed too, Stillen is a HUGE company. Their system is cheaper to produce.

I'm saying the air to water design is a TERRIBLE design. Especially when the contact point is on the manifold.

Is there a way to create a system where people can go back to their stock intake manifold and use a dual intake setup similar to your single kit?

subbed! gotta see if you can make 600 and make the Stillen kit reliable!!

Let me know when this new Air To Air upgrade is ready for purchase! :bowrofl:

No, There is no room to run your driver side pipe up to the TB. The blower takes up all the room on driver side.

I will be running my charge pipe in the route this kit is going with the filter. So its not a 90* per say but more like a 180.

love it, this is really cool. The relocation of the MAFs is awesome, I really hope you guys are able to take full advantage of this blower and put out some really good results on a stable reliable tune.

I have no doubt that this kit can make some serious power with this configuration. The blower is now the "weak" point (if one can say that) where as before, it was the strongest part of the entire kit.

The only potential issue is belt slip if guys try to push for high boost.

I would also encourage those who go with this upgrade to get a good flowing exhaust. A set of long tube headers will also go a long way. With these modifications the manifold boost pressure would drop, but your volume of air going in to the engine would increase...which is what you really want.

I'm with this guy

I really hope this is the case. i've never liked the kit because many members in the past who had opened up the downpipes/exhaust seemed to get worse power as a result... honestly i thought the blower was probably just a POS and wasn't strong enough to make power without a clogged up exhaust with a lot of back pressure to hold more boost.

i would really enjoy seeing this succeed. i'm sure it would be somewhat 'cheap' to offer an upgrade like this too once this is complete... plumbing, intercooler, wiring for the MAFs? and most importantly labor/know-how... $2,000-2,500 ???

Well, it is almost 01:00 AM, and the car is done. Just need to start it in the morning...hopefully the car runs on the current map. Will post a few more pictures when I get up in the morning.

I'm starting to think you like sleeping on the couch... :rofl2:

YzGyz

Hi Sasha

Pic of MAFs placement?

thanks

I love this Progress :tup::tup::tup::tup:

And i'm very :excited:

I stopped by last night at Sashas house.

The pipe he built going into the TBS is an F'n work of art. Im amazed by his welding/fab skills!

Sasha you're the FRICKEN man BTW. I know you and I talked about this over 2 years ago! My car blew up :( and you've been busy. I cant wait to see this finished and the numbers it puts down. I may go back on my word and get this kit again and buy you upgrade package :)

Props man Props!

No, my wife likes money :rofl2:

Thanks Landon.

Thanks.

This is why I'm not boosted yet!:ughdance::ughdance:

Here it is...


BOV recirculated back to intake, using the hose/hardware provided by Stillen:

http://i137.photobucket.com/albums/q...psbfhpb6d6.jpg

http://i137.photobucket.com/albums/q...psngkm7bea.jpg

All new charge pipe to the TB's. This was a pain to build. The Y section had to be carefully cut to provide the best air split between the TB's. I think it worked out very well. There is very little room there for MAF sensors, and I had to end up using some tall sensor bungs in order to have them 180 degrees apart. This was due to space on the outside, and space on the inside of the 3" diameter tube.

http://i137.photobucket.com/albums/q...pscfyxminz.jpg

http://i137.photobucket.com/albums/q...pshjqxpror.jpg

Inside the pipe (looks crooked, this was before welding):

http://i137.photobucket.com/albums/q...ps9k0kvkjz.jpg

Complete pipe kit:

http://i137.photobucket.com/albums/q...ps1kd3ixii.jpg


So, that is all folks.....short and sweet. The car fired right up after the conversion and idled just fine, although a bit richer than before at 13.5 a/f. Not a big deal at all. The car will now need a new tune.

I am not sure what the standard size injectors come with this kit. I think they are 550-600cc. I would suggest going larger than that just to make sure there is plenty of head room, especially with the smaller pulleys.



EDIT:


I am sure this question will be asked by Stillen kit owners....how much?

With everything needed to make this conversion, I am looking at about $1,750 to the door for continental US and Canada. You will have to remove the crash bar, and get the car custom tuned as well.

:bowrofl::bowrofl::bowrofl::bowrofl::bowrofl:

I don't recall anyone losing power, just pressure, which is meaningless because you still have more air going through the engine

Now we need the dyno sheet :)

booked for dyno on Aug 23.

:/ That far COME ON LOL

lol trust me, i wish it would be sooner.

Specaility z wont be down until the 23 :(

Sasha should just come up with a new supercharger kit and dominate that part of the market for the 370z. There aren't many options now since the GTM debacle.

http://www.the370z.com/2867312-post2.html

quick 3 second google. i've read this outcome on pretty much any build thread that tried to open up the exhaust.


edit - damn that's a very reasonable price, i would have overpaid by $250-$750 as mentioned above and not asked any questions.

:excited: for results

A quote from the manufacturer... Hmmmmm... If all the mfgs claims were true, no one would be fat, the average age of humans would be 200, we'd all be millionaires, and the world would be a better place.

Will the intercooler inside the manifold be removed since it's no longer in use or will it now perform as a heat sink element?

Would there be better flow without it?