KLM IS THE EAST COAST DISTRIBUTION HUB FOR
Carli Suspension • FASS • Icon Vehicle Dynamics • Dynatrac • Fluidampr
Solid Steel • MADS Electronics • Baja Designs • Applied Rotor • Innova• Total Chaos
Crown Brake Lines • FabFours Bumpers • Hughes Racing • Scotty Air
 Edge Electronics• Centerline Wheels • Turbo Air Guide • Borgesons Steering Shafts
KLM SHIPS WORLD WIDE

The Turbo Air Guide (TAG) is a new device invented by Diesel Power Products, which when used in the intake of a turbo charger can help to get more air smoothly in to the compressor. The Turbo Air Guide (TAG) straightens air flow into a laminar flow and directs it straight into the compressor of the turbo, resulting in more power, cleaner burning and better mileage.

The Turbo Air Guide (TAG) shown in the picture above is installed in the intake of a Garrett turbo charger used on Ford Powerstrokes and is constructed of stainless steel welded honeycomb material and will eventually be made to fit many applications for most turbo charged engines, gas or diesel.

To understand how the Turbo Air Guide (TAG) works and what it does we need to look at the compressor wheel inside the turbo charger and image what it is doing. In the picture air coming from the vehicle filter would enter the compressor wheel fins from the top of the picture traveling down and being accelerated and compressed as the wheel rotates.

This air generally travels into the fins of the compressor wheel at an angle in the same direction as the rotation of the wheel, but is also turbulent from passing through the air filter and associated piping before reaching the compressor wheel.

As the wheel rotates to move the incoming air, the leading edge of the fins encounter the turbulent rotating air moving in the same direction the wheel is turning. This rotational motion of the incoming air limits the amount of air the fins can grab and the turbulence creates drag on the fins as they cut through the incoming air.

The Turbo Air Guide when placed directly in front of the compressor wheel acts to change the incoming air into a smooth laminar flow and directs the flow directly into the fins allowing for more air to be introduced into the compressor wheel smoothly, while reducing drag caused by turbulence. The results of using the Turbo Air Guide (TAG) can be demonstrated by the Dynometer chart below.

The drawing at left illustrates turbulent, rotating air entering the compressor wheel of the turbo charger. The wheel is rotating the same direction as the arrows indicate so the blades of the wheel are trying to pull in and accelerate air which is traveling in the same direction as the wheel.

The picture at left illustrates air straightened by the Turbo Air Guide (TAG) entering the compressor wheel. This allowsmore air to enter the blades of the compressor wheel in a smooth fashion greatly reducing drag and noise on the compressor wheel.

Some air flow testing has been done to determine differences with and without a Turbo Air Guide installed.

The picture shows the Pitot tube arrangement set up in the intake hose.

The sample device is placed well up stream of the turbo with the pressure tube in the center of the 4" air duct.

This is to measure the flow of air in the intake in the same location with and without the Turbo Air Guide (TAG) in place.

This photo shows the two Magnehelix units used to measure air flow in the 4" duct in feet per minute (fpm) and inches of water.

For the tests the pitot tube arrangement in the photo above remains in the same location and measures air flow before entering the turbo or passing through the Turbo Air Guide (TAG).

At relatively constant boost pressures and flow rates with the Turbo Air Guide (TAG) installed the air flow rates are approximately 200fpm higher than without the Turbo Air Guide (TAG) installed.

This about a 4% increase in total air flow at the same boost pressure. This is why many report that under highway cruise conditions the boost pressure is lower under the same load. Also with boost pressure lower the exhaust back pressure is also proportionally lower allowing the engine and turbo to operate more efficiently.

A few interesting things about air flow on our diesel trucks is that under heavy load at around 25psi boost the air flow exceeds 15,000fpm, which is about 170mph in the 4" duct.

By the time the air reaches the compressor wheel in the turbo that speed is close to 360mph.

This photo shows the pitot tube assembly installed on a 2004 Dodge Cummins to test air flow using the TAG-III.

The truck is equipped with 4" exhaust with Aeroturbine, Scotty RA-III, Cool Hose, Banks turbine outlet pipe and Banks Six-Gun in power level-4.

The same Magnehelix gauges were used as shown above for the test. The flow tests were conducted with and without the TAG-III installed.

This flow chart shows an increase of 9% using a TAG-III in a Dodge Cummins. The increased air flow provides up to a 45% reduction in visible smoke, quicker turbo spool up, increased pulling power for towing, lower exhaust gas temperatures and can increase fuel mileage. These results will vary depending on the modification level of the truck, driving habits, load and environmental factors.

The dark lines of the chart above are with the Turbo Air Guide installed and the reddish lines are without the Turbo Air Guide (TAG) installed. The test vehicle is a 2001 Ford F250, crew cab, long box 4x4, 7.3L Powerstroke, automatic transmission, 4" exhaust with Aeroturbine, aFe air intake and Banks Big Hoss level-5 chip. The area between the dark lines and the reddish colored lines represents the improvement using the Turbo Air Guide (TAG). Besides the dynometer results, the truck seems to run quieter, have quicker throttle response, less smoke and better mileage.

Turbo Air Guide Ford

We have been getting good feed back from many now using the Turbo Air Guide (TAG) in the Ford Powerstrokes. All with automatic transmissions we have heard from have reported a real seat of the pants improvement while those with manual transmissions have not reported feeling a power change or very slight power increase.

Manual or automatic transmissions have significant boost pressure reduction while highway cruising with much faster turbo response and spool up. Max boost pressure for the most part seems to be unchanged. Exhaust gas temperatures remain about the same with or without the Turbo Air Guide (TAG) installed. Most have reported less throttle position with modest mileage increases up to 2mpg. Also some have said they noticed the turbo noise to be much less using the Turbo Air Guide (TAG).

The Turbo Air Guide (TAG) has been used on stock to highly modified trucks with big, chips, exhaust and air intakes with the same kinds of results. The stock trucks have gained a noticeable seat of the pants power increase just as the modified trucks.

With a 60hp or higher chip or programmer installed it is a good idea to consider installing an after market compressor wheel with the Turbo Air Guide (TAG) to avoid any possible turbo stall or surge issues. We have also found that the Turbo Air Guide (TAG) and compressor wheel seem to work well with most any combination of chip or programmer, however some of the most impressive results have been with the Banks Big Hoss chips.

We have gotten some results back from those using the Turbo Air Guide in Dodge Cummins applications. General effects have been a lowering of boost pressure by a few points under cruise and loaded conditions on the highway and smoother running.

The most noticeable effect has been much quicker turbo spool up and a small increase in fuel mileage, 0.5-1mpg empty with increased performance unloaded.

When towing more significant mileage increases are being observed of 1-4mpg. On trucks prior to 2003 the Turbo Air Guide (TAG) does a great deal to reduce the turbo noise heard from the passenger seat and reduces visible smoke from the tail pipe. Seat of the pants performance increases are very noticeable.

The Turbo Air Guide (TAG) has been tried on one 2003 with very noticeable turbo spool up change and a 4psi boost pressure reduction cruizing on the highway. One interesting thing that was noted on the 2003 Cummins was when the truck came to a hill the boost pressure went up farther and faster than without the Turbo Air Guide (TAG) and no EGT change was noted.

Turbo Air Guide Emissions Test

This emissions test was done on a new stock Dodge Cummins truck with 6-speed with high output engine. Test was done with a Wager, Model 6500, numbers are ppm.

Record #1165, stock truck, 9-10-03, 3:58PM
Test1 11.7
Test2 7.0
Test3 7.7
Average 8.8
Spread 4.6

Record #1164, stock truck with Turbo Air Guide (TAG), 9-10-03, 3:47PM
Test1 5.3
Test2 5.0
Test3 4.9
Average 5.0
Spread 0.4

This test shows a 45% reduction of emissions using the Turbo Air Guide (TAG). Which helps to explain the reports of less smoke while towing and increased mileage under loaded conditions.

The Turbo Air Guide has broad application for most any turbo or centrifugal super charger used on internal combustion engines today. This includes over the road diesel trucks, off-road heavy equipment, stationary engines, marine engines and even the import street racers.

Though most of the testing of the Turbo Air Guide (TAG) has been on turbo charged diesel engines, it works equally well on turbo or super charged gas engines.

Even this little Honda on the dyno produced 316hp @ 10psi boost. With the Turbo Air Guide (TAG) it produced 334 @ 10psi boost. The Turbo Air Guide (TAG) is now offered in a 3" clamp inplace version for smaller turbo inlets.

Basically this idea is to use one Turbo Air Guide (TAG) near the turbo and add another Turbo Air Guide (TAG) some distance before it which is larger to create two air guides connected to each other using a velocity stack configuration. This should provide smooth directed air into the tapered stack so that it accelerates towards the Turbo Air Guide (TAG) just in front to the turbo. The directed faster traveling air from the first Turbo Air Guide (TAG) goes through the second one much easier and with a greater velocity therefor getting more air into the turbo.

Size of each air guide and the distance between them will play a key roll in how well this idea works. The drawing above shows how the two air guides may be situated in a velocity stack configuration with the face of the primary air guide (TAG1) which is closest to the turbo compressor wheel and the secondary air guide (TAG2) larger and some distance from the primary air guide. The ratio of the taper between the two air guides will also be a factor as if the taper is too steep it will interfere with the smooth acceleration of the air passing between the two air guides and create new turbulence which would counteract the effect of the secondary air guide. Also at the inlet to the secondary air guide a bell shaped edge as is currently used on standard velocity stacks would also be appropriate to help direct the maximum amount of air into the secondary air guide.

Decided to test of this new idea for the Turbo Air Guide on my 2001 Ford F250 pickup with 7.3L turbo diesel engine. The configuration of this test is using the factory inlet hose of the turbo charger as the velocity stack. This hose is not ideal by any means as it bends as it tapers from large to small and the bends will take away from the effect somewhat.

This is a side view of the air intake hose of the turbo. For the small end I used a standard Turbo Air Guide (TAG) which has a honeycomb diameter of 2.52" and for this paper I will call TAG1. The large end of the hose I used a Turbo Air Guide (TAG) with a diameter of 3.65" which I will call TAG2 or secondary air guide. The distance between the Turbo Air Guide (TAG) faces in the tube is about 6".

The picture to the left shows the location of secondary air guide TAG2 in the air inlet boot tot he turbo. TAG2 when installed in this location actually protrudes into the housing for the CCV and is secured by a molded ridge in the rubber boot.

This picture shows the installation of the turbo inlet boot and you can see the hard plastic CCV housing that connects the inlet boot to the air filter hose.

Dodge Cummins Turbo Air Guide II

The TAG-II for the Dodge Cummins is a one piece stainless steel holder with mounting flange and the velocity stack taper CNC machined into the part with Turbo Air Guide (TAG) honeycombs furnace brazed into both ends. Installation of the TAG-II is the same as the Turbo Air Guide (TAG) with the flange of the part seating into the intake hose groove and the Turbo Air Guide (TAG) projecting into the turbo inlet.

Get the maximum benefit of the Turbo Air Guide technology with our new TAG-III for 2003-2005 Dodge Cummins. The TAG-III Provides the same sorts of benefits as the TAG-II does for the 94-2002 Dodge Cummins, but is designed specifically to fit the tight space of the 2003-2006 trucks. The TAG-III honeycomb is furnace brazed to a SS support ring then inserted into the TAG-III housing.

The TAG-III housing incorporate a velocity stack to accelerate the guide smooth air flow to the compressor wheel in the turbo. This creates better air flow with even more benefit to performance and mileage.

In recent tests in a 2004 Dodge the TAG-III compared to the TAG, lowered boost pressures an additional 2psi and lowered EGTs 25F while cruising on the same stretch of freeway at the same speed and weather conditions. It also has noticeable seat of the pants gains for turbo spool up and driving performance. The engine and turbo performance gains provided by the TAG-III are smooth and across the entire rpm range. More testing and dyno results are planned and will be posted here as it becomes available.

The TAG-III is also designed to be a direct fit for use with smooth bore intake hoses and many of the after market turbos in high performance and towing applications.

This picture of the TAG-III is looking from the turbo side so you can see the tapered portion of the part that accelerates the air just as it enters the turbo. You can also see the flange support ring around the outside of the part that allows for it to be installed in the factory intake hose or after market smooth bore hoses. The relief near the support flange also allows for direct installation into after market and performance turbo charges.

Turbo Air Guide (TAG) for turbos with 5.5" hose inlet such as Holset HT-60. This TAG is very similar to the configuration of the TAG-III used for the smaller Holset turbos on the Cummins powered Dodge pickups. The 0T315 Turbo Air Guide (TAG) is now available and in production. As test results become available we will post them on this webpage.

Turbo Air Guide (TAG) Truck Test

A test Turbo Air Guide (TAG) was installed in this truck equipped with a 14 liter Detroit engine and Garrett turbo. The proto-type Turbo Air Guide (TAG) used in this truck is very similar to that shown above for the HT60, but larger to fit the Garrett turbo. Here is some of what the driver had to say.

"The turbo air guide we installed in my Detroit diesel 60 series 550hp, 18 wheeler has made this engine even more pleasant to drive!! Immediately I noticed the 3-4 lbs. of added turbo boost and was really present in the lower rpm range 14-1600 rpms. It seems that electronic diesel engines tend to drop turbo boost @the lower rpm ranges which tells the boost control in the intake manifold to reduce the fuel rate. By keeping the turbo pressure up @ the lower rpm's it then keeps the engine pulling @ full power longer and helps get those big loads over the hills without shifting that next gear! Also I have noticed a slight drop in pyrometer temp. Also an added bonus when using the Jake brake to descend those long grades the 60 series Detroit maintains an additional 2-3lbs of boost which would indicate more retarding power!!! As previously stated loving every minute of the drive with the air guide!!" --Mike

This is only the first cross country run using the Turbo Air Guide (TAG) and we hope to have more feed back and information about the TAGs results on the bigger diesel engines soon.

Turbo Air Guide to fit large turbos using a 6" connection hose. This new Turbo Air Guide (TAG) features the same velocity stack funnel used on the small TAG-III, but the funnel is long and made to fit the 6" inlet connection of large turbos such as the CAT.

• 94-2002 Dodge Turbo Air Guide (TAG) Install
  Installation instructions: Turbo Air Guide for 1994-2002 Dodge Cummins with stock turbo
• 2003-2005 Dodge Turbo Air Guide (TAG) install
  Installation instructions: Turbo Air Guide for 2003-2005 Dodge Cummins with stock turbo
• TAG-III, 94-2005 Dodge Cummins
  Installation instructions: Turbo Air Guide (TAG-III) for 2003-2005 Dodge Cummins with stock turbo and 1994-2005 Dodge Cummins with stock or aftermarket turbos
• 94-2003 Ford 7.3L Turbo Air Guide (TAG) install
  Installation instructions: Turbo Air Guide for 1994-2003 Ford Powerstroke with stock turbo
• 1994-1997 Ford TAG-II, 7.3L
  Installation instructions: Turbo Air Guide (TAG-II) for 1994-1997 Ford Powerstroke with stock turbo
• 99-2003 Ford 7.3L TAG-II
  Installation instructions: Turbo Air Guide (TAG-II) for 1999-2003 Ford Powerstroke with stock turbo
• 2003-2005 Ford 6.0L Turbo Air Guide (TAG) install
  Installation instructions: Turbo Air Guide for 2003-2005 Ford 6.0L with stock turbo

Above left is a picture of the stock Garrett housing used on the GTP38 ball bearing turbo. On the right the housing has been machined for installation of a metal deflector and snap ring.

Above left picture shows deflector installed. On the right Turbo Air Guide (TAG) honeycomb is press fit into turbo housing.