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Forced Induction, high altitude, other mods needed?

Grimmer

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I've been reading up on the forced induction options for my 2016 GT Manual. First I want to thank everyone for the incredible amount of information and help available on the forum.

I have kind of a specialized question that I've only been able to pick up indirect bits and pieces of a possible answer here and there...

First my general purpose / goal for forced induction. My car is a "fair weather daily driver", meaning that I'll drive it year round (all 4 seasons around here) so long as there is less than a 20% chance of precipitation, and in winter an adequate length of clear days following a storm to get the snow and wet removed from the roads (to avoid black ice and such). With that said, I would like to see a bump in power (of course, or why else look into FI); however, I am not power hungry and don't plan to race or track or even time runs. In reality, I would probably be just fine with the minimum amount of boost available (offset by cost, of course). And I would in fact like to minimize the additional mods required to "hold up" against the increased power. Which brings me to my question...

The '16 S550 is rated at 435 hp @ sea level on 93 octane. I live at 4,500 feet above sea level. The rule of thumb that I've always heard is a 5% reduction in horsepower for every 1,000 feet of elevation. I take this to mean (0.95^5, or 0.7738 overall). Perhaps one of you tuners out there has a better rule of thumb and can help answer the following questions. Does the same rule of thumb apply after forced induction? For example, if the FI adds 235 hp at sea level, will it also add 235 hp at altitude? Or does it reduce the 5%/1,000 ft losses and actually recover some hp and then add the 235 on top of that? Or does the 5%/1,000 loss also apply to the 235?

The reason I ask is that applying just the rule of thumb to my situation would mean that my car when NA at 4,500 feet actually only produces at best 336 hp. If the FI adds a straight 235 at sea level, and the same rule of thumb is applied for my altitude, that ends up being only 518 hp or an increase of roughly 83 hp over what the NA car does at sea level anyway. Hopefully all parts of the car were originally designed with enough engineering safety factor to handle "an extra 83 hp". If the safety factor perhaps can only absorb an addition 50 hp, is there a way to detune a FI setup to keep it under the original engineering safety factor?

I would like to get a bump in juice, but I want to limit the adverse effects and I'll need a clear idea of what additional costs will be required to keep the car in good health and up to the task of handling the "extra" hp. My car is also still under the new car warranty, so the Ford Performance Racing Supercharger Kit is top of the list for now. Alternatively, I can wait until the powertrain warranty is over (5 years) before installing FI and look at other options.

From what I've picked up so far, I might need to factor in the cost of a billet OPG and crank gear since the potential for failure there sounds like it is more related to vibrations and jarring inherent to most FI systems. Although maybe the pulley vibrations can be handled with a damper and the jarring wouldn't be too severe if only 83 hp above stock. I will probably also have to upgrade the tires because they slip a little too easily even now.

Any thoughts? Especially, does anyone know the rule of thumb for the elevation induced loss of power with forced induction? This could change the whole equation...
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cyandhappiness

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By your calculation at 5% per 1000 ft above, the average dyno whp for mustang gt is around 360, which put you at 279 whp at 4500 ft. Maybe you need a smaller pulley than you think to get that 235 hp.

Or move somewhere lower :)
 
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Grimmer

Grimmer

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Could be. I was just using example numbers based on advertised claims from Ford and Ford Performance Racing. Stock S550 @ 435 hp, then add the FPR supercharger kit claims 670 hp. I just calculated the difference (235 hp) to use as an example.

I assumed that the losses to the powertrain are basically a constant within the same car. So comparing crank hp changes would directly translate to whp changes. Although I can accept that the losses to the powertrain are not constant, but actually a percentage (or even a non-linear relationship). Which would bring the forced induction horsepower at my altitude even closer to a stock naturally aspirated car at sea level.

I think the crank horsepower increases are of primary concern when considering the necessity of upgrades to the clutch and oil pump gear.
 

foghat

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for a supercharger, to get the same psi you'd get at sea level, you will have to go with a smaller pulley. since supercharger boost is mechanical (based on pulley size), I believe a SC'd car loses about the same % (whatever that is) as NA at altitude. In a factory turbo car, the ecu will attempt to make the same boost regardless of elevation - though it gets to a certain point/elevation where the turbo just can't produce the same psi it would at sea level.

I had always heard every 1000 ft is good for a 0.1 loss at the track. Not sure what that equates to in hp.
 

v8ter

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In my case at 6700 feet I loose 20% and with boost 17%, if you have a pulley for 10psi you will see maybe 8 at your altitude, but if you pulley for 12sea level at your altitude your gona get 10psi, but the same 10psi arent gona be as efficient because of oxygen density so first your engine is making less then 435, and at 10psi its not gona increase the same hp as it would at sea level . Hope this helps
 

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Grimmer

Grimmer

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Ok, I have some follow up questions for you. In your car where you are losing 17% boosted, is that with "extra" pulley or the typical? I.e. are you compensating with pulley to get higher psi to achieve the 17 %? If I use the stock pulley can I expect similar numbers?

But the most important question is whether or not your final achieved horsepower is high enough above sea level stock hp to require upgraded internals such as the oil pump gear, crank gear, clutch etc.?

I wonder if I put on a S/C that would build 8psi at sea level without changing the pulley so I get maybe 6 or 7psi at 4,500 feet would the hp increase be under the wire to minimize additional stress over stock?
 
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Grimmer

Grimmer

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Using your same losses I estimate that the FPR supercharger claiming 670 hp @ sea level after a 17% loss would come in around 556 hp which is 121 hp over NA stock at sea level. That might still be a big enough chunk to warrant a tougher OPG at least...

Did you opt for the internal upgrades? How long/how many miles on your car after FI?
 

v8ter

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At my altitude 17% is overall, lets say at sea level wichever pulley you have and make x no hp and you go up to 6700 you loose 17% in horsepower, at your level its gona be less. And Im running a 13psi pulley only getting 9 psi though.

I did upgrade halfshafts, clutch , opg cs because I have intentions of pushing for over 700whp at my altitude but for a daily driver and you just want a bit of more horsepower and your not gona be hitting the track I still would upgrade Opg and cs, its not that expensive and I did it it my garage and for the piece of mind it's definitely worth it, stock clutch will last for a while yet but using slicks and doing 6k launches doesn't help and still I didn't have any clutch issue yet after about 7k miles but I did upgrade it and love it, its softer then stock and I have no engagement shattering issues and I use my car as my daily driver
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