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Aero 66 only builds 3lbs of boost on 09 M1000

smoothdawg

smoothdawg

Well-known member
Premium Member
I have a new pump gas OVS Aerocharger 66 series that will only build 3lbs of boost. It has a green spring with 1 shim under it wich I am told should make 5.5lbs of boost per OVS and Aerocharger. I have fuel pressure set at 36lbs and my A/F shows between 13-14.5 before boost, and apprx. 11.0-11.5 under boost. I have my veins adjusted 3 turns in after contact with diaphram. I know I could add a shim or two to reach 5.5lbs but why is it not making that kind of boost now? What kind of things should I check? I've checked the obvious stuff like tight hose clamps on the charge tube, tight airbox, no leaks or pinches in boost lines, stuff like that. What am I missing? I am a rookie to the turbo scene so I was hoping to get some feedback from some veterans on this issue. Sled runs good everywhere/no bogs or hesitations anywhere. One other thing that might be worth mentioning is the sled doesn't build boost until around 5100 rpm's. I am afraid stacking more shims in there is a short term solution, masking the real problem. Any help would be appreciated. Thanks.
 
not very familar with the aero's, but check your exhaust dounuts, and check for cracks in your pipe and y pipe. give Travis or Gar a call they might know some other common things to check.
good luck
 
There is no blow off valve. I tried calling Travis and Garr but they must be busy as they are not answering the phone. Any other ideas? I will check for exhaust leaks however this turbo kit only has about 15 miles on it so I doubt the exhaust has cracked, but I will re-verify.
 
66

Look at your rod comeing from your diaphram ,back off adj grab rod with needle nose vise grip and see if it moves in by hand then spring should move it back. If it does not move freely turbo veins will stay in one spot.Then roll turbo over an look where rod enters houseing for diaphram and make sure houseing opening is adj so rod is running stright into turbo. If not loosen two allen bolts and slide houseing to line up. I have run into this after sled has taken a tumble. I know you said it was new but mabye shiper banged it around or something.
 
Thanks 4622 I will check tonight. I know the plunger goes in and out freely as I tested that with the cover off. I never thought to look at the rod to make sure it isn't going in at an angle. Thanks, any other input would be appreciated. I'd like to get this gremlin figured out soon.
 
Mark give me a call on monday. We were testing sat and my phone has not missed any calls nor the shop phone today. The sled is to rich that could be part of the problem. If not the boost gauge could be bad or other problems don't go shooting in the dark. Call myself or garr monday. Thanks Travis.
 
You got enough springs holding your exhaust connections together?
Try doubling them up if you haven't already...
 
Thanks to all for your tips and ideas. I will tear into it Tuesday and post what I have found. Much appreciated.
 
Well I pulled the exhaust and inspected it. No cracks.
Pulled the air box to check for pinched O-rings, looked perfect.
Anybody know how to test the boost gauge?
How could I test to see if I have an exhaust leak at the y-pipe or turbo? Don't have any black oily stuff blown all over in those areas.
One other thing worth mentioning is when I pulled the air box there was approximately a teaspoon or a little more of 2-stroke oil in there. Is this normal?
Running out of ideas guys. What now?
 
Has this thing ever made the 6 pounds boost you are looking for? Does it run clean at 3psi? To test the boost gauge you will need another gauge you can trust one that goes to 10 psi, pressure up both of them on the same line, try not to put to much pressure to them or you will have 2 messed up gauges. Could be just a gauge or the turbo is not set up properly if you never had the boost up on it yet.

Good luck with it,

you will get her going
 
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try running it for a real short distance with the hose off the Vane controller and see if it builds boost
 
Travis seems to think my gauge is bad as the sled is pulling the desired rpm's with the D&D big dog weights [85 grams] and OVS torsional secondary with a 42\46 reverse cut helix. I am going to try testing the gauge at work tomorrow.
Travis has been great to deal with through this process.
I will post my results upon completion.

Thanks for all of your help!
 
Boyko, the sled runs real clean, no bogs or hesitations at all. It is a brand new kit, however the gauge has never registered above 3lbs of boost. I only have a few miles with boost.
 
Well we tested the gauge with a high end regulator and just as Travis suspected it is only registering 3.4 while the regulator is set at 5lbs. So I think we found the problem, bad gauge. It's a VDO gauge which I considered to be a good quality gauge in the automotive world. Must have got the one that fell on the floor during the assembly process.

Thanks again.
 
Thanks for the post.

Good thing you did not frick with turning up the boost, it could have got expensive.
 
Springs springs, and doughnuts !!

I cant say enough how many times my sled and my buddies sleds have blown off air pressure through or past doughnuts from the pipe. Off the Y pipe, you have to have springs doubled up. And where the exhaust enters the turbo, those ones leak too.

Hope you find the problem !

Ride safe !
 
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