[ZR1] D3PE Presents: Malone Racing's Compound Boost ZR1
10-07-2015, 05:59 PM
#1
Former Vendor
Thread Starter
D3PE Presents: Malone Racing's Compound Boost ZR1
Thank you Morris, of Malone Racing, for choosing D3 Performance Engineering for your ZR1 Corvette build. His ZR1 was shipped to us with an LSX engine upgrade along with a complete nitrous plate system for which he was looking to remove and add some more power without having to refill nitrous bottles all the time. The decision was quickly made to build a compound boost setup to decrease spool up times with the factory supercharger while adding the top end power from the turbo. Our fab department engineered and fabricated a rear mount system using a Precision ProMod 88 billet turbocharger, placing the turbo in the rear of the vehicle but keeping centered to evenly distribute weight in the rear. Boost control was done with a pair of Tial wastegates with matching Tial blow off valves in the front. All hot side was handcrafted out of aircraft grade stainless steel while all the cold side from high grade aluminum.
This turbo system is completely designed with no additional intercooler system aside from the factory bricks, modified by D3PE, and a D3PE ZR1 HX System with an added ice tank used for long pulls during top speed events. We also upgraded the engine cooling system by adding our direct bolt on PWM Dual Spal Fan Shroud kit.
We upgraded the fuel system to a Fore Innovations Level 4, E85 compliant, triple Ti 267 pump setup matched with Injector Dynamics 2000cc injectors to handle the new horsepower while running Ignite E98. We also upgraded the clutch to a RPS quad carbon with Tilton adjustable slave and Tick adjustable master.
To complete the build, we added a D3PE ZR1 ProEFI package to help protect the engine as well as put the power to the ground. The standard package was installed along with a back pressure sensor (used to actively make fueling changes based on back pressure), flex fuel sensor, I-boost for on the fly map selecting, and boost control. The package also comes standard with traction control, launch control, and rolling antilag.
On our dyno this setup made 1425whp and 1198wtq at 34 psi making it the highest horsepower ZR1 in the world!
Keep an eye out for Malone Racing at all of the half mile events!
Last edited by D3PE; 10-08-2015 at 09:39 AM.
10-07-2015, 08:13 PM
#6
Former Vendor
Thread Starter
We had issues due to the DBW 108 closing, when we got back we converted the car to cable 105, everything's good now.
10-10-2015, 04:00 AM
#12
Great results! 
What were the intake temps like using the stock intercooling? Also how much boost did it take to make the power? How much boost is it making on the SC alone?
What were the intake temps like using the stock intercooling? Also how much boost did it take to make the power? How much boost is it making on the SC alone?
10-10-2015, 09:02 AM
#13
Melting Slicks
They are not running the stock intercooler setup. They are running the d3 hx kit with the addition of plates intercooler bricks and the spal dual fan set up.
10-10-2015, 12:26 PM
#14
Also I was really hoping for a F1 style twin entry turbo housings to keep everything really symmetrical. Maybe speak to Precision and see if they can't make one. There must be more people that could use them.
10-12-2015, 11:17 AM
#15
As far as boost the car is on a 2.35 upper pulley and stock diameter lower. I would suspect it would be about 10 lbs on my heads and can and header set up if it was just blower ( would be 15-16 on a stock head cam car). Turbo is putting out 23/24 lbs and it's making about 36 manifold pressure post rotor
10-13-2015, 10:29 AM
#17
Instructor
Do you have to fire ring the head to tolerate those boost levels without burning/blowing through the head gasket? I ask out of ignorance and experience with my tow rig (diesel) where I have compounds putting out 60 psi and we had to fire ring the head to allow it to survive.
10-13-2015, 11:39 AM
#18
Do you have to fire ring the head to tolerate those boost levels without burning/blowing through the head gasket? I ask out of ignorance and experience with my tow rig (diesel) where I have compounds putting out 60 psi and we had to fire ring the head to allow it to survive.
10-13-2015, 01:11 PM
#19
Was doing some test hits and checking everything out yesterday on the new tire and after a few back to back pulls with just water in the system no ice the highest it saw was 135. I haven't iced down the 10 gallon system we have in the car yet to see how much it affects the temps but once I do I will report back.
As far as boost the car is on a 2.35 upper pulley and stock diameter lower. I would suspect it would be about 10 lbs on my heads and can and header set up if it was just blower ( would be 15-16 on a stock head cam car). Turbo is putting out 23/24 lbs and it's making about 36 manifold pressure post rotor
As far as boost the car is on a 2.35 upper pulley and stock diameter lower. I would suspect it would be about 10 lbs on my heads and can and header set up if it was just blower ( would be 15-16 on a stock head cam car). Turbo is putting out 23/24 lbs and it's making about 36 manifold pressure post rotor
Don't forget it's a ratio thing not out and out pressure! If you have 10psi on the SC then the SC has a pressure ratio of 1.69:1 ((10+14.5)/14.5).
So to get to your 34psi target pressure combined you only need 14.2psi from the turbo.
It would be interesting to what the back pressure for the turbo was.