Tuned In

• 132: The Best Stock Turbo System?

  He co-founded one of the top (and earliest) standalone ECU companies on earth, helped develop unique V10 F1 engines, created ignition systems for top-tier motorsports, and finished it all off by producing stock-frame turbocharger upgrades that push the limits of what a factory turbo is capable of.Mark Boxsell has had a varied and fascinating career in the performance industry, and he’s ready to unpack it all in this episode of Tuned In.Use GTPUMPS100 to get $100 off HPA’s Tuning Starter Package: https://hpcdmy.co/starterbHaving grown up on a farm in rural Australia that instilled a drive towards resourcefulness and ingenuity, by his early twenties, Mark Boxsell would latch on to the emerging EFI revolution and create his own fuel injection system for his personal Mazda rotary. And that was just the start.  Mark went on to invent one of the world’s first aftermarket standalone ECUs, which we all know today as Haltech. In this episode, we get straight into the mind-blowing history of how Haltech came about, discussing what was involved in creating it, the incredibly basic tools he had at his disposal to make it happen, and how it actually worked.We next discuss Mark’s stint developing a unique V10 Formula 1 engine that used rotary valves instead of the traditional poppet valves. Mark goes into detail about how it worked, and why we never saw it on the grid. Then it’s time to talk about ignition systems, which Mark knows a lot about as one of the founders of M&W Ignition — which supplies series like Australia’s top-tier V8 Supercars.We finish the episode off by moving into Mark’s current venture, GT Pumps. This company specialises in stock-frame turbocharger upgrades, which are currently aimed squarely at the WRX and Evo markets. This gets into some heavy turbo tech, covering the benefits of journal-bearing turbos, stock turbo system capabilities, and more.If you’re into tuning history and love a dose of nostalgia, this episode with Mark Boxsell is an absolute must-listen. Follow Mark here:IG: @gtpumpsFB: GTpumpsWWW: gtpumps.com.auDon’t forget, you can use GTPUMPS100 to get $100 off HPA’s Tuning Starter Package: https://hpcdmy.co/starterbTimestamps:0:00 The Best Stock Turbo System?3:43 How did you get into the automotive industry?7:57 Why did you decide to try and make your own EFI? And how?12:53 How did that first EFI system perform?15:13 How did Haltech start?23:47 How does the HC11 chip compare to modern ECU chips?26:49 Once you got the ECU working, how did you sell it?28:52 Why did you decide to use bar graphs for the interface?33:23 What were the biggest challenges building those first ECUs?36:28 Marketing first Haltec ECU continued.43:15 Why are there so many ECU manufacturers from Australia?46:05 When and how did you leave Haltec?53:52 Can you explain the different ignition systems?59:05 M&W ignition system.1:00:43 Transition from electronics to F1 engine development1:05:04 Had the rotary valve been tried by other competitors?1:09:10 Why did this rotary valve never make it to the track?1:12:25 How did your current business GTpumps come about?1:13:25 Why focus on a stock frame turbocharger?1:17:52 Are journal-bearing turbos dead?1:21:53 Are you looking to produce stock frame turbos for different models?1:28:12 Final three questions.

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• Field Report: Is This Tuning Risky Business?

  If you’ve ever considered an EV conversion but weren’t sure where to start, Ryan from ‪@rywire‬ takes us through the technical details of his incredible Honda Civic EK EV swap, showcasing the integration of Tesla drive units, AEM Electronics VCU, and CSF Radiators for cutting-edge performance and thermal management.Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-inThis lightweight (EV comparative) build features a $1,000 Tesla front drive unit and a $2,200 rear drive unit, delivering 300hp (each!) with infinite tunability thanks to a Cascadia Motion logic board. Ryan explains why switching from Tesla’s OEM controls to standalone AEM strategies unlocks full control over torque split, regen tuning, and thermal strategies—key elements in achieving high performance and reliability.Thermal management is a standout feature, utilizing CSF radiators, Freon-based heat exchangers, and a multi-directional cooling system to optimize temperatures for the motor, charger, and 400V battery pack. With insights from OEM designs, Ryan has implemented a system that ensures the batteries stay in their optimal temperature range, boosting efficiency and performance.Whether you’re interested in OEM vs. aftermarket motors, Bosch brake boosters, or regen tuning with paddle shifters, this build is a masterclass in EV conversions. With a range of up to 400 miles and a weight of approximately 3,400 lbs, this Civic is a lightweight powerhouse that sets a new benchmark for EV swaps.By the end of this interview you should understand that EV tuning is as risky as tuning your ICE powered projects, and without a high level of care for any project you undertake, you can potentially damage expensive components.

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• Field Report: What's So Special About 'Trophy Truck' Suspension?

  Off-road racing demands suspension that can handle extreme terrain, and Dane from ‪@FOXFACTORY‬ is here to break down the tech behind their world-class dampers. From remote reservoirs to internal and external bypass systems, we explore how Fox designs for the brutal conditions of off-road racing events like the Dakar, Baja 1000 and the Finke Desert Race while keeping the tech scalable for daily drivers.Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-inTopics discussed in this SEMA interview also include how heat management, damper size, and semi-active Live Valve systems let vehicles like the Ford Raptor and custom trophy trucks tackle everything from high-speed whoops to precision jumps.Also included is a quick explanation of how the system uses ECU data, including from aftermarket options, including MoTeC, rather than complicating things with their own separate electronics. This means existing sensor data is also used, including steering and throttle inputs, pitch, yaw, and of course, speed.

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• 131: UNTAPPED Potential? BOVs and Wastegates Decoded.

  Blow off valves and wastegates are fairly simple in their operation, but correctly sizing and fitting them requires a lot of careful consideration if you want to get the most out of your turbocharged engine.This week, Gregg Jones of TiAL Sport — someone who’s been in the turbocharging game since the mid-eighties — is here to get us up to speed on these simple yet crucial components.Use TIAL50 to get $50 off HPA’s EFI Fundamentals course: https://hpcdmy.co/efifundbGregg started his career in performance cars in the dark ages of turbo technology. It was the mid-eighties, and there weren’t a whole lot of good options around for the aftermarket boost industry — but working with rudimentary laggy turbos and cast-iron wastegates got Gregg thinking that he could create something much better — so he did. TiAL Sport was formed in 1993 and the company quickly blossomed as turbocharged European and Japanese imports began to filter into the mainstream. In this conversation, Gregg talks us through those early days, touching on how much room for improvement he saw and how his company was able to step up the game year after year. Gregg discusses how his products are designed, tested, and made — as well as where he sees the industry going in the future.We then move into the tech-focused section of the episode, where Gregg drops knowledge on all things turbocharging — especially when it comes to speccing, fitting, and getting the most out of blow off valves and external wastegates. There are some real nuggets of gold to be found in this conversation, and anyone who wants to better understand boosted engine applications is going to be better off for listening to it. Follow Gregg here:IG: @tialsport, @xonarotorFB: TiAL SportWWW: tialsport.com, xonarotor.comDon’t forget, you can use TIAL50 to get $50 off HPA’s EFI Fundamentals course: https://hpcdmy.co/efifundbTimestamps:0:00 UNTAPPED Potential? BOVs and Wastegates Decoded3:14 How did you form an interest in the automotive industry?8:10 Move to Florida and exposure to turbocharged vehicles10:24 Early cast iron HKS wastegate15:34 Why did it take so long for V bands to become the standard?17:23 What materials did you move to instead of cast iron?19:12 How have we overcome turbine back pressure?21:39 What was the design process for these wastegates?29:21 What are the challenges in designing a wastegate?34:13 What is the actual benefit to a blow off valve?40:52 Where’s the best place to put your blowoff valve?48:13 How do blow off valves work with MAF sensors?52:32 Do we need to tune the blow off valve for the application?54:30 Do you have a size guide for blow off valves?56:17 How do we choose the right wastegate?1:01:46 What’s the best way to mount a wastegate?1:04:36 Wastegate springs explained1:11:56 Is there still room to improve wastegates and blow off valves?1:16:05 How did you start working with Robert Young and Xona Rota?1:21:59 What’s next for turbo technology?

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  1:31:58
• Field Report: Easiest way to engine swap? | HELLTACO.

  Engine swaps on modern vehicles are no easy task, but Stewart from ‪@mesocustoms1696‬ has taken it to the next level with this insane Toyota Tacoma build, featuring a 6.2L Hellcat supercharged HEMI under the hood. In this video, dive into the challenges of integrating late-model electronics and why a turnkey Hellcat system from Cleveland Power and Performance made this swap not only possible but seamless.Use ‘PODCAST75’ for $75 off your first HPA course here: https://hpcdmy.co/hpa-tuned-inWith 800-900 horsepower on tap, at the SEMA Toyo Tires Treadpass stand Stewart explains why the Hellcat package was chosen over alternatives like the 2JZ, emphasizing the importance of retaining factory ECU integration for plug-and-play simplicity. From the OBD2 compatibility to a functional Hellcat gauge cluster and shifter, the truck now thinks it’s a Dodge—but with the soul of a Toyota.Beyond the drivetrain, we explore the custom wide-body fibreglass panels, hand-shaped and perfected using 3D scanning and CNC routing. Stewart shares how this approach not only ensures perfect symmetry but also makes future repairs and reproduction straightforward with reusable moulds.Whether you’re into engine swaps, custom bodywork, or the cutting-edge tech that bridges OEM and aftermarket, this Tacoma build is packed with ideas and inspiration.

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