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Posts posted by MarkKassim

  1. Hi Guys,  the charge cooler has changed slightly from the link you have there , its now more compact 


    It is about 3 time the volume of the original and maintains the same flow layout, so fitting is quite easy. The water hose connections come at the standard size which i think is around 16mm.

    However Alunox can supply with larger ones as shown here at 19mm . I can only speak from my own experience , it did hold up well with new BorgWarner 6258-G turbo on the dyno running higher flow and boost.

    I don't have a photo of the original unit as yet but I will try and get one. The standard unit will be a direct replacement for the original, built to the same dimensions.

    Mark K







  2. Hi Guys, I've been in touch with Ben about another group buy for the Esprit 321 Stainless Steel Manifold if anyone would be interested. The prices Ben posted earlier in this thread are still current.

     These are the details of a group buy if we get the interest

    • 30 units in total - mixed G Car and Stevens 
    • Fitting kit - All gaskets and Stainless nuts included
    • G Car GB price including TurboSmart external wastegate £1650 normal list price £1950
    • Stevens car manifold - £1150 normal list price £1350
    • Rear system G Car 2.5” - £650 normal list price £850
    • Rear System Twin Exit Stevens car 2.5” £600 normal list price £750 - based on min 10 units
    • Rear System Twin Exit Stevens car 3” £780 normal list price £950 based on min 10 units
    • Special requests for T4 flange for turbo upgrade can be included in this GB, I will get the GB price on request

    Also the Charge Coolers can be in a separate group buy

    • Standard charge cooler £500 normal list price £750 - based on min 10 units
    • Uprated charge cooler £700 normal list price £1100 - based on min 10 units

    I will get more info on the standard unit as this is new, I believe it has the same dimensions as the original charge cooler.

    All prices are plus VAT and postage

    If you have an interest in any of the above let me know and I can create a Group Buy thread. For anyone considering the Alunox 321 SS manifold for the first time, they have been around now for about 10 years with no reported failures. 


  3. Thanks guys for your great feedback, your comments are much appreciated.

    The transition is unmodified but the clutch is uprated, Dave helped me out with the specification of this putting together some of his old parts. The pressure plate and friction plate are AP capable of holding 330 lb/ft. I may be pushing my look if I go much further with the transmission.

    Mark K

  4. Hi Robin, Yes that is a twin scroll manifold and if you have the normal Alunox manifold it is also a twin scroll as Barry has stated. My particular manifold design has been adapted in the final section (Collector) for the T4 turbo instead of the standard T3.

    This is the size of the T3 Flange vs the T4 Flange


    Sorry its not the best picture, the Collector design has been enlarged to match the bigger port sizes of the T4 flange. 



    Hope this helps,


    • Like 1
  5. Hi Thomas, Yes it is an expensive dyno that can hold static loads and so tune each speed site or cell in turn.  During part of the video you could hear him holding constant RPMs while he dialled in the speed sites. I think this formed part of the base mapping


    Later on the power runs he tunes the Boost control. I'm not running a Knock sensor so its pretty much tuned under load avoiding detonation (knock), so it may not be as close minimum you are looking for.

    I forgot to mention I am running a wide band lambda sensor and EGT sensor (PLX)

    Just out of interest what ECU are you running.

    Hope the table helps


  6. I have now fitted the plenum expansion plate, the install is easy as there is good access.I’ve ran the car hard at Castle Combe at the weekend and noticed it feels like it has more torque at high RPM and delivers it is smoother,  which would be due to the better flow distribution across all four cylinders


    The spacer is made from aluminium and has been machined to follow the contours of the plenum. The bolt holes have small counter sinks for easy location when fitting. The top section is angled to allow better flow into the plenum. The kit includes stainless steel hex head bolts and washers along with a pair of gaskets. The exiting support bar which bolts onto the engine mount can be retained, I offset it at the mount by using an addition nut. Overall it was an  easy mod with a 13mm spanner.

    The Plenum is now available to Pre-Order here on PNM's website:

    It's available as a kit or just the plate, priced at £169.95 + VAT for the plate and an additional £29.95 for the gaskets and bolts (kit) plus delivery. PNM have agreed to give a 15% discount to this group buy which will apply to the plate and kit, I will PM the discount code to the you guys on the list which is valid until the 10th June. The discount is open to another 5 if anyone else is interested. Delivery charges are calculated on the website including shipping overseas.

    Mark K

    • Like 2
  7. Hi Andy,

                  I asked the same question when I upgraded the charge cooler to approximately 3 times the volume. I was told its so small you dont notice it , and after driving with the bigger Charge Cooler I didn't notice any increase in lag. This is only 25mm deep , I've seen on other forums bigger spacers. I hope to have an updater from PNM this week.


  8. Hi Chillidoggy , I have a dyno result before and I plan to Dyno again after I fit it. It may be difficult to interpret the results due to my other modifications. I believe it increases VE at higher RPMs. My tuner at Emerald is very good at explaining the Dyno results I will ask him. Dave Changes will have the a lot of dyno info on this.

    Mark K

  9. Hi guys, I’m in the process of ordering a 25mm plenum expansion spacer from PNM engineering, Pete is having these made. It will come as a kit including gaskets and extended bolts. I can’t give an exact price at the moment, but it will be around the £150 + gaskets and bolts, possibly less if we have the numbers. If anybody would be interested in this modification could you add your name to the List. 

    1)      Mark K

  10. Hi Pan, I take it the  V band flange is for the connection of the rear system to the turbo, Leon can help you with that , you will have to send him the dimensions. 

    The difference in the pipe layout is only changed for production , they are still collect in the same order , just 2 overlaps 3 or 3 overlaps 2.

               Hi Franco, for our needs I think the internal wastegate is fine. I know the external units can have better flow ,but they are very expensive and are really used on professional 

    race cars. I know the S3 Esprits use one ,Alunox developed that set-up so it was a direct replacement. 

    After dynoing my car I found I needed the Stiffer spring in the wastegate, as the flow characteristics of the Alunox manifold blew the wastegate open. The medium spring couldn't hold it.

    If you were going for very high power say around 500BHP then maybe go for the external.


  11. Stevens Esprit 321 Stainless Steel Manifold Group Buy


    This is Group buy No 5, the 321 Stainless Steel manifold upgrade for the Peter Stevens 4 cylinder Esprit. This is a GB for 10 units which are currently made and in stock so there will be a quick turnaround once 10 people have signed up.

    For those of you who haven’t seen this upgrade before, a recap on the history of the company and the product:

     It was developed by Alunox who are a well-established engineering company that supply the motorsport industry with tailor made high end exhaust systems, made of exotic materials such as Inconel, titanium and 321 Stainless Steel etc. They also supply BAC cars with a full light weight for their current production car the Mono.

    Alunox took on the job of redesigning the original cast manifold for the Esprit due to its failure rate. But also were able to offer uprated performance using their expertise in this area.

    The manifold is constructed from 321 Stainless Steel, precision TIG welded in dedicated jigs giving a fracture proof construction. The flanges are CNC machined out of Stainless Steel to give an accurate fit, the collector uses burns double slip joints to allow movement during the heat cycle whilst being protected against shock loading by the pivoting brace mounted directly above the turbo.


    The downpipes are all equal length mandrel bent tubes to maximise flow arranged to fit within the space available. Even at normal driving speeds the exhaust gas temperatures are typically 750 to 850 °C and greater during track use. The manifold has been proven to withstand all the temperatures and conditions produced by the Esprit. The manifold is also lighter than the original cast unit weighing only 6 Kg.  All these attributes produce a durable high quality product with gains in both power and torque and lag reduction.
          It has been dyno tested as seen in the video below on a highly modified Esprit running at 424 BHP and 409 lb ft torque. Further gains have been made since the video was made taking the Power to 461 BHP and Torque 450 lb ft.

    Further in-depth technical info on this can be found on Dave Changes thread

    The manifold is has also been tested with modern twin scroll turbos yielding some great results which I will post soon.

    It has been ran on the track and driven hard without fail. Look for feedback on the forum about performance gains.

    The kit also includes all gaskets, stainless steel nuts and brace. The turbo flange can be changed to accommodate different turbos, as can the collector be made to order. These adjustments are at extra cost and can be discussed with Leon at Alunox.

    The manifold comes with 1 year warranty, this does not cover fitting and shipping.

    The normal one off price is £1350 + VAT.

    The group buy price is £1150 + VAT + Shipping & Packaging, for a 10 off.

    If you want to take advantage of this offer sign up below and I’ll add you to the list.




  12. Hi Guys,

                    Just to let you know Alunox have one complete 321 Stainless Steal system in stock at the moment for the Giugiaro Esprit if any body is interested895953703_GCar.thumb.jpg.f039d25592f58f273b3daaa37a34f1ab.jpg

    This will cure all your problems that you have with the cast unit, it won't crack or warp.

    The kit comes complete with the Turbosmart wastegate ,gaskets , brace and nuts .Ring Anita for details on 01978 8551100.or email [email protected]


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