Originally Posted by Leapy
A DPF is a difficult programming task...hope you've got the experience or have access to it. What are going to do with the trapped particulates?
Exhaust heat - sounds like you're planning re-writing thermodynamic law. In simple terms, 200kw is 200kw, regardless of gas velocity and back pressure. Consider this...if you've got boiling water flowing down a metal pipe are you saying the shorter the pipe the less hot the pipe gets?
I am not expecting the exhaust temperature to be lower, if anything it will probably be higher. I was working on the basis the shorter the exhaust length, would equate to less metal to radiate the heat into the engine box and the thermal wrap would also help reduce the heat radiation, hopefully leading to lower temperatures in the box.
I am still looking at the diesel particulate filter idea, my initial thoughts are to mount the filter on the transom above the Castoldi, as it is dead space. This would also get another very hot item outside of the engine box.
There is a system made by Dinex that has a removable core that you take out and clean and refit once in a while. The crap coming out of it is toxic and has to be disposed of properly. This system is designed to cope with traffic use in cars. the more stop start use will clog the filter quite quickly, requiring it to be cleaned annually. If it is used in mostly middle to high speed situations, it may only need cleaning every couple of years. 4' from the turbo is a good distance for the filter as it will burn a lot of the crap off, but will get very hot doing it. The other option is as mentioned above, to use the original car unit and mapping. The other big problem is that the ceramic based core does not like thermal shocks, such as getting dunked in a wave whilst red hot, so this will need some thought as well.
I realise that this project is all sounding a bit Heath Robinson, but I enjoy exploring options and alternatives to the norm. Most companies stick to tried and tested as it is the most economical route to go with least risk. As this is a private project for my own use, I am happy to explore an apparently dumb route on the offchance that something worthwhile can come out of it. The speed that technology jumps these days often means that what wasn't possible 5 years ago is common place now.
Thanks for your input.