I got the stock sts-v engine cover to fit over D3's Stage-2 pipe without modding it!!

[austin]

Hi everyone,

I'm am going to have the D3 stage-1 and stage-2 pipes installed soon. So before i went to have that done, i wanted to see if i could get the stock engine cover to fit, which i did. The main engine cover photo was taking during this mock-up, and shows that the D3 stage-1 pipe is not yet installed.

What was needed to be done first was to take between 7/16" to about 1/2" off the end of each side of the stage-2 pipe, it was just simply too long (as is) to make this work (see photo). I also placed rags in both ends of the pipe, and then sealed the inside of the pipe with tape about two inches down, making sure that no debree from cutting could get in there (this absolutley has to be done first before any cutting is done to the pipe).

Then, the passenger side bracket (unknown name) needed a small piece cut out of it so that the stage-2 pipes mounting brackets could slide further back without hitting against it (see photo).

There is also one forward facing bracket located at the front driver's side of the blower that needed to be pushed back (see photo). I did not take a photo of this bracket, so i had to use someone elses off the internet.

Once all that was done, the stock cover fit without having to be cut or modded. It's a tight fit but it gets the job done!

I am also planning on adding washers to raise the rear covers mount up a little bit more. I will also use washers (maybe fender washers with the sides trimmed off) to try to grab as much of the stage-2 L & R mounting bracket holes as i can (as they no longer fit over the screws). I may also slot the holes (cut the forward facing portion off) to get more movement upon final installation.


If D3 needed to rework the stage-2 pipe to work with the stock cover, they would simply need to shorten it, and move the stage-2's mounting brackets forward with slotted holes, and also supply washers to raise the two rear facing stock cover mounts/bolts (the washers would go under the rear two of the six 10mm bolts that hold the stock pipe on).

*I will post back when final installation is done, as i will probaly tweak the fit some more (with washers). I will post a final finished photo, along with the dyno results etc.

[austin]

Worth a mention.. After cutting the end pieces off of the D3 stage-2 pipe, make sure you run a file around the edges to take care of any left over debree. Also, the front engine cover mounting post (the one on the motor), if need be, can also be unscrewed and raised up a little by placing a washer underneith it.

[Florian]

good work, Austin. Nice post. Send that over to: ctsvett@verizon.net He can post it on the faq.

F

[hodgeee1]

How come you are running the stock intake!??! except for the stage 2 pipe?

[stephenstay]

Great job. That's exactly what I have to do too. Thanks for the detailed instructions and I'll look forward to the final result.

[CIWS]

Originally Posted by Florian

good work, Austin. Nice post. Send that over to: ctsvett@verizon.net He can post it on the faq.

F

[austin]

Ok,

Here are photos of the finished product.. Few more things added... The cover fits just fine, but I had to stack two washers under the two rear cover hold down bolts, and two washers under the single left front cover hold down bolt (to raise them up higher). The front cover bolt comes off with a 10mm wrench.

On the left side (the two bolts underneith where the three map sensor brackets fit onto).. I had to take those mounting bolts out, and place 5 washers underneith them and then screw them back on (use a 1/2" open end wrench).. The sensors will sit up higher, but still plenty of clearance. The right side, and rear bolts don't need this done. The reason for this is to give clearance to the front left water tube at the supercharger. From this point you'll have to tweak it yourself as every pipe will be slightly differant. (see photo)

If you go back an look at my original photos.. You'll notice that i also had to cut the stage-2 pipe's mounting tabs down in the front (i also rounded the cut),,, If i would happen to take this apart again, i would cut the mounting hole into a slotted hole by removing some of the front, cutting into the hole for more movement (which i will most likely do).


The whine from the supercharger is only noticable under moderate to hard throttle.. At Regular or Highway Cruise speeds it is totally quiet!!


*This takes some work to do.... This is only for referance purpose to show that it can be done.. Only attempt this if you know what you are doing.. If you mess up your stage-2 pipe, or something doesn't fit right, i take no responsability what so ever.

[BMBSALES]

Awsome Post Dude!

[LITTLEELVISDAN]

I would kind of like to see D3 make the necessary changes to make this a production fix. You have proved with a little more effort it is possible to make this a turn key kit. I am buying Aero1's stage 1 and 2 intake so I will have to use your post to modify it but it really should be a turn key kit for those who order new from here on out.

[SoCal-VEE]

Good stuff austin......looking forward to a detailed performance review.