Fitted a THS pipe to replace the pancake on my car (2005 LFR, 1.8T engine) and drove about 200 kms since.
Original pancake pipe is not a restriction by itself due to squashed section as previously believed. Inlet is 57mm diameter, outlet is 64mm, mid section is about 110x30mm, which gives a larger area section of about 33 sq cm (or slightly less due to rounded shape). The THS replacement pipe is 57mm diameter throughout, with a 64mm flared end to fit on the SMIC inlet and therefore its midsection area is 25.51 sq cm.
(Neuspeed pipe is 64mm for most of its length, with a narrowed end to fit the engine-side rubber hose, therefore 32.16 sq cm section area, and made from aluminium, not stainless steel like the THS.)
Restriction in flow comes from the two pressure drops the pancake shape causes, one by enlarging the midsection and changing its shape and the second by narrowing again to a smaller round shape (Venturi effect).
THS pipe does not rub the wheel at maximum left turn. Due to the shape of mounting bracket it fits ~25mm more towards the plastic panel of the engine and it has enough space between itself and the wheel to fit 2 fingers.
Changes:
- engine draws (or sucks
) easier at tickover, about -0.1 bar more on the gauge;
- boost raises and drops quicker;
- rpm climb slightly quicker;
- boost is more steady when running under boost on open road;
- acceleration is very very slightly improved, not due to power gain which I expect to be zero, but due to quicker buildup of boost;
- engine noise is slightly louder.
All changes are small and without a gauge and plenty of attention people would not notice them.
I do not understand the purpose of making the pipe pancake-shaped since it could have been made round from the start and it would fit just as well. It seems the original reason for the pancake shape was noise reduction, like a muffler.
~Nautilus