Just another top mount build? ACF top mount w/ EFR 7670

[The Convert]

Quick update. Running into some problem with the fitment of the manifold and downpipe.

The shop who is working on my car just found out on Thurs that the v-band connecting the bank 1 and bank 2 manifold is short by almost 1/4". Not sure how that happened since everything fit on the mockup engine at ACF prior to ceramic coating (as you can see from my previous post). Have to cut off the vband flange and reweld it. Both my mechanic and ACF thinks the ceramic coating somehow shrunk or wrapped the manifold. But I am having hard time picturing these thick 321 stainless steel piping can be wrapped so easily...

Downpipe is also off by almost 1/2" at the mid-pipe side (sitting way too low). We have to make a new one by scratch to fix that since the downpipe that ACF made me is also rubbing on the wiring harness at the top as well. There is just no way to make the current one work, especially with the recirculated dump pipes.

Good news. Hood clearance is good. The subframe was bolted back in today and we were able to close the hood without hitting the turbo.

Pretty disappointed at the moment, since I was promised a plug-n-play kit with minimal additional fabrication involved. The weld and the craftsmanship for each parts is top notch, but they are no good if then don't fit together.

I've had a similar issue happen before with another high quality kit. I think it comes down to different cars, the work that's been done to them, and the person installing(in my case, me). If things have shifted over time one way while others have shifted the other way, motor mounts sag, new ones are put in, etc, you can have these sorts of issues pop up. Best of luck getting it fixed.

 

[cloud9blue]

I've had a similar issue happen before with another high quality kit. I think it comes down to different cars, the work that's been done to them, and the person installing(in my case, me). If things have shifted over time one way while others have shifted the other way, motor mounts sag, new ones are put in, etc, you can have these sorts of issues pop up. Best of luck getting it fixed.

well, I have fresh motor mounts... There is just no way to have the downpipe off by that much. Manifold issue is not car related either unless the engine block is messed up, which obviously isn't the case.

 

[STE92]

Have you contacted ACF?
Are they going to refund you for all the issues?

 

[cloud9blue]

Have you contacted ACF?
Are they going to refund you for all the issues?

I just did actually. Fixing the manifold wasn't too bad, but the downpipe is just unacceptable, considering I paid extra for it. Hoping I can hear back ACF soon. Maybe @Payam@BMS could help out on this as well.

 

[doublespaces]

Tubular is beautiful and can flow better, but CNC and cast manifolds get a +1 in the build consistency department. I know what I'm doing if I ever change out my kit.

 

[Payam@BMS]

Everything was fit and QC by me. Dp and manifold both fit without issues. The only variable I think is the coater. Anthony told me this was a new coater due to timing during the holidays. His original coaters lead time was way too long. Anthony should be able to help you out.

 

[cloud9blue]

Everything was fit and QC by me. Dp and manifold both fit without issues. The only variable I think is the coater. Anthony told me this was a new coater due to timing during the holidays. His original coaters lead time was way too long. Anthony should be able to help you out.

Hey Payam, I believe you test fitted the kit before Anthony made changes to accommodate the EFR turbine housing.

I understand and fully accept that the possible clearance issue I might run into with the engine harness or frame rail, since those are not things that can be checked without an actual car. But I do expect the downpipe can at least be in the correct dimension so it can be bolted to the exhaust, which obviously isn't the case here...

Anyway, I heard back from Anthony yesterday, and it looks like he doesn't want to deal with this downpipe fitment issue and claim I am more or less a guinea pig for the EFR top mount. Apparently, midpipe flange position was not tested and only "eye balled" according to the engine position for this downpipe from what he just told me yesterday. If I knew that's the case in advance, I would have come up with a better solution locally instead...

 

[STE92]

Dam... even JP refunded me for some issue I had with his kit. Doesn’t sound like he was trying to hear it.

 

[cloud9blue]

Dam... even JP refunded me for some issue I had with his kit. Doesn’t sound like he was trying to hear it.

Well, the issue is not really the refund or money at this point, but rather wasted time and missed schedule for both me and my installer because of this downpipe. Things would have been a lot simpler if ACF just told me that they can't guarantee that the downpipe would bolt on to the exhaust BEFORE we started bolting everything together.

Anyway, I keep this thread transparent and let you know how this goes. Making a new downpipe is not the end of the world and can be done by the shop who is doing the install.

 

[Payam@BMS]

Hey Payam, I believe you test fitted the kit before Anthony made changes to accommodate the EFR turbine housing.

I understand and fully accept that the possible clearance issue I might run into with the engine harness or frame rail, since those are not things that can be checked without an actual car. But I do expect the downpipe can at least be in the correct dimension so it can be bolted to the exhaust, which obviously isn't the case here...

Anyway, I heard back from Anthony yesterday, and it looks like he doesn't want to deal with this downpipe fitment issue and claim I am more or less a guinea pig for the EFR top mount. Apparently, midpipe flange position was not tested and only "eye balled" according to the engine position for this downpipe from what he just told me yesterday. If I knew that's the case in advance, I would have come up with a better solution locally instead...

The downpipe was made on the engine Jig. It was still QC again after that change to EFR. The bottom half of the downpipe should not need any adjusting. Just cut from the bend (where manifold is basically) and adjust from that end up.

 

[cloud9blue]

The downpipe was made on the engine Jig. It was still QC again after that change to EFR. The bottom half of the downpipe should not need any adjusting. Just cut from the bend (where manifold is basically) and adjust from that end up.

Payam, Anthony told me in his own email that the exhaust flange was not checked since he simply couldn't and it is up to my own fix that at this point. To quote his own message "since there is no fixture for this downpipe we just based it off the engine positioning with the turbo bolted up" I would have appreciated if he made that clear to me in advance instead of after me and my shop finding out it isn't even close to where the midpipes are.

I can post up pictures of it when my mechanic is back in town. FYI cutting it from the bend and just adjust the top is not going to fix everything.

I know both you and I were pretty excited to get this kit working. I just think better communication from Anthony's side could have prevent this whole situation.

 

[cloud9blue]

Time for an update!

Here is what I received from ACF.

Wrapped manifold, vband joints don't meet up

Anthony told me just shift the downpipe upward and everything will bolt up. But there just no space to do that. The dp is already rubbing on the wirings at the top. The only way is to remake it.

The only way to connect the downpipe is to drop the midpipes by 2-3". Obviously this aren't gonna work. The exhaust are rubbing on the rear brace too due to the drop.

Wastegate dump pipes are off as well.

 

[cloud9blue]

Have to redo the downpipe and wastegate pipes. But it fits much better now. Too bad the ceramic coating on these are just a completely waste of time and money since we had to scrap most them.

 

[135Pats]

Glad to see it all coming together despite the issues.

 

[cloud9blue]

Glad to see it all coming together despite the issues.

thanks! looking at the bright side, the kit will retain all its functionality. just a shame about the ceramic coating though. hoping to get it running in two weeks or so.

 

[doublespaces]

So have you and Anthony come to an agreement on this?

 

[Lifestyler]

Time for an update!

Here is what I received from ACF.

Wrapped manifold, vband joints don't meet up

Anthony told me just shift the downpipe upward and everything will bolt up. But there just no space to do that. The dp is already rubbing on the wirings at the top. The only way is to remake it.

The only way to connect the downpipe is to drop the midpipes by 2-3". Obviously this aren't gonna work. The exhaust are rubbing on the rear brace too due to the drop.

Wastegate dump pipes are off as well.

Not surprised that nothing fits... We have Same Nightmare Last year with AC....

 

[cloud9blue]

So have you and Anthony come to an agreement on this?

Well the last I heard back from him was in Jan. Basically told me I off on my own and it is suppose to be an easy fix. Well it is not as you can see from the pictures.

 

[sirdaft1]

Was just by the shop last night. Looks like she's coming together (albeit slowly). Perhaps I missed this if it was already mentioned... but was this kit made to fit the EFR or was it designed around the smaller Garrett/Precision type setup?

 

[cloud9blue]

Was just by the shop last night. Looks like she's coming together (albeit slowly). Perhaps I missed this if it was already mentioned... but was this kit made to fit the EFR or was it designed around the smaller Garrett/Precision type setup?

To answer your questions:

- Kit was designed around PTE turbo, just like all other top mount kit aside from the VI Engineering kit with Garrett GTW. That's why we had to modify the strut tower for extra clearance.
- I was told by ACF that the rest of the kit will need minimal modification . At most, we might have to notch the downpipe a bit for the passgener side frame rail. That clearly isn't the case since everything about the downpipe is off, as with the wastegate pipes. They don't even bolt up like they are suppose to.
- Btw, I was charged extra for the additional modification done by ACF to fit the downpipe with the EFR turbine.

Was gonna keep all this drama to myself until the car is done, so I get it all out in one post. But Payam decided to use the pics you took of this kit to promote ACF's "craftsmanship" on the other forum, while totally ignoring all the problems I have with this kit. I figure I have to say something.