Page 1: Modifications
Page 2: Mods - stock to stage 2 to big turbo
Page 3: Dyno/Dragstrip results
Page 4: Random Stuff
Page 5: Turbo Upgrade
Page 6: Update: New Engine Build
Here is my 2005 STi when I first got it.
For winter tires I bought Bridgestone Blizzak LM-22's mounted on ASA JH3 17" wheels.
All broken in and ready to rock!
My first mod was a Cobb Accessport running their Stage 1 93 Octane map. After that I followed up with a Helix Catted Downpipe and a Blitz NUR Spec Racing Catback.
XXTuning installed the exhaust and used hardened exhaust hangers and a ceramic-coated OEM heatshield. The fitment is perfect. This exhaust is very loud. Loud is an understatement. It is offensive. But I love it.
Here is a close-up of the Helix Catted Downpipe and coated heatshield.
Here is a picture of the engine bay. You can see, I hacked the stock intake snorkel to bring more fresh air to the K&N Intake.
It's easy to get going way too fast in this car, so I bought a Valentine-1 Radar Detector with the concealed display. I mounted the concealed display on the dashboard right under the tach. It's already saved me a couple times :)
Update June 25:
I've added a few things to make the car faster :)
First of all, I added the Cobb StreetTuner. It allows me to do just about anything I would want to do with the ECU (modifying timing/fuel/boost and datalogging). I revamped the timing maps, basically smoothed them out and added timing in some areas. At 5000rpms I added 4 degrees of timing. That had a noticable effect. I bumped up the boost to 18.5psi.
I wrapped the turbo using Thermotec Turbo Wrap. It keeps the turbo hot, drasticly reducing turbo lag. It also keeps the engine bay a lot cooler.
I also added a Perrin EBCS (Electronic Boost Control Solenoid). It still uses the factory ECS to control boost, but it makes the boost build faster and hold better.
Just today, I added a 9lb helper spring to the wastegate. This allows the car to hold more boost at high rpms. I am holding 18psi to 5000, 17psi at 6000, and 15.5psi at 7000.
Update July 1 2005:
I installed a lightweight battery today. It's an Everstart lawn tractor battery. It saves at least 20lbs off the front end of the car. And yeah, the car still starts fine... but I will probably have to take the battery out this winter.
Update July 17 2005:
I installed Hella Supertones horns in the car yesterday. They are freaking loud, 118dB's at a distance of 6 feet from the car. I left the two factory horns, and there is also one more horn for the alarm... it's loud enough to make your ears ring!
Update July 24:
I got some new stuff:
Motul 300 Gear 75W90 synthetic transmission fluid, Redline hood dampers, and the Injen "Limited" cold air intake.
I changed the transmission fluid and was surprised to see that the OEM fluid came out clean. It had 15k miles on it and looked new (smelled like **** though). The car shifts a little easier now. I changed the fluid because I had been grinding the 1-2 shift occasionally. I haven't driven the car enough yet to say if it made a difference... so far so good.
The hood dampers were installed pretty easily, it sucked having to take a power drill to the hood/fenders but it came out looking very nice, and they work great. I was able to ditch the old hood prop.
Installing the Injen CAI was also easy. Actually it was harder to remove the old K&N intake than it was to install the new one. The air filter is now located directly behind the passenger side fog light cover. The cover is removable, so I can pull it off at the dragstrip to help out with airflow and air inlet temps. While I was installing the CAI, I was able to locate a spot on the drivers side cylinder head for a grounding wire, so I added one. That makes the grounding kit complete.
Update August 2, 2005:
I installed the Perrin radiator shroud today. It cleans up the engine bay a lot, I'll post pics in a day or two. I also installed the pink STI "I" badge in the front grille. Pics tomorrow.
I installed new rear reverse lights and blinkers today. They are Chromevision bulbs which are reflective chrome when not illuminated. When lit they show the correct color (white/yellow). They look sick, although they aren't quite as bright as the stockers. Pictures really do not do them justice... they look great in person.
Update August 6th 2005:
Here is a better pic of the new rear taillights:
Here's a pic of the pink STI "I" badge and Perrin radiator shroud.
I installed Goodridge stainless steel brake lines on the car, and Hawk HPS Pads. I had the rotors turned, too. After bleeding the entire brake system a few times and filling it with Valvoline Synpower DOT4 Brake Fluid, the pedal feel and stopping power is amazing. I can get the ABS working on dry pavement now, it stops so fast that it makes you lightheaded.
I didn't get any pictures while everything was apart, but managed to get a pic with the wheel turned.
Update August 7th 2005:
I cleared the headlights today and switched to Chromevision bulbs for the blinkers and parking lights. They are reflective chrome, but shine yellow when illuminated.
Update August 12th 2005:
Here are some more pics of the cleared headlights. I also added some blue tint to the them. It looks cool but kinda ricey, I'm not sure if I will keep them this way...
I also installed the Kartboy rear diff crossmember bushings today. No pics. It was an easy install, 20 minutes tops. There is some slight whining around 40-60mph from the rear end now, and a slight rumble when the front end is pitched up while accelerating. The whole driveline feels a little tighter now.
Update August 13th 2005:
I painted my Hella Supertones so they don't stand out so much. They blend in nicely behind the grille, you can hardly see them.
Update August 20th 2005:
I installed the TiC rear diff mount bushings today. No pics. The install wasn't bad, it took about 90 minutes. The old bushings were really squishy, while the new ones are rock solid. I expected more NVH but there is none, the rearend just seems a lot tighter.
Update Sept 7th 2005:
I installed the Greddy EGT Gauge over the weekend. The install was easy. My EGT's were pretty high at first - I saw 910c at the top of 5th gear (130mph ). I leaned out my AFR's from 10.7-11:1 to 11-11.3:1 and the EGT's have actually gone down to 880c max. The car feels faster and more responsive. I have a trip to the dragstrip planned for later this week, so we'll see if the car is making more power. I'll snap a pic of the gauge install later this week. The EGT probe is mounted on the drivers side exhaust manifold, cylinder #4.
Update Sept 23rd 2005:
At my last trip to the dragstrip I kept blowing off the IC hose between the IC and throttlebody. I installed some T-bolt clamps which solved the problem.
Update Oct 2nd 2005:
I swapped by Blitz Catback for a brand new Borla Hush 3" Catback exhaust today. It's a lot quieter, but still a little louder than stock. I got pulled over 4 times with the Blitz exhaust... I don't think I'll have any problems with this one. Pics tomorrow.
Update Jan 29 2006:
In the last couple days I've ordered the next round of upgrades for the car. PE 850cc injectors, a Walbro 255lph fuel pump, and a QTP Catless Downpipe w/electronic cutout. I should have some of the parts installed next week.
Update Feb 18 2006:
I did it! I made up my mind and ordered a turbo - FP Green w/3" Inlet. Should be good for 380-400whp on pump gas and 450whp on race gas. I should have it next week sometime.
I still don't have the QTP downpipe yet. They were out of stock and said it would take a few weeks. The fuel pump is installed. I'll be ordering the remaining mods in the next week or two. Stay tuned!
Update March 5 2006:
FP told me that the turbine housing for the turbo is on backorder, so I wont have the new turbo in my hands for another week or so. I went ahead and ordered the rest of the mods that I'll need to do the turbo swap... an APS turbo inlet tube, APS CAI w/70mm MAF, SMC methanol injection kit, and a Knocklink (standalone knock sensor).
Update March 10 2006:
Check out what arrived this week.. I changed my mind and decided to go with a FMIC right off the bat, I got the entire kit but here is a pic of the IC core... it will be installed in a week or two along with everything else.
Update April 10 2006:
I finished up the FMIC install over the weekend. It was time consuming, but worth the effort. The side-splitters (below the foglight covers) are still off the car - I didn't bother with reinstalling them since I am getting new splitters. The old ones had a little curb-rash.
I also installed an XD-1 digital AFR gauge, which hooks up to my Innovate LC-1 wideband o2.
I gave up on getting an FP turbo after they told me all of their turbos would be backordered for at least another month. I went ahead and ordered the Perrin rotated GT35R kit. It includes a Garrett GT35R turbo, custom uppipe/downpipe, TiAl 44mm wastegate, 4" turbo inlet hose w/BigMAF, and all the hoses and lines to install everything. This turbo should be good to over 500whp!
Update April 16 2006:
I installed my PE 850cc injectors today. The stock injectors were 520cc. The install was not too bad, I took my time and it took 4-5 hours. I did some quick tuning and got the car running halfway decent, but it still needs more work. The idle gets rough sometimes, and at very light throttle it shudders sometimes. Everything seems great at full throttle. My injector duty cycles used to hit 96-98%, now they are peaking at 58-60%.
New injector installed:
Update April 26 2006:
I have the car tuned pretty good now for the new injectors. Today I did a compression test on the motor and installed 1-step colder NGK Iridium Plugs. The compression test came out good, 135psi on each cylinder. The motor had cooled when I did the test and I forgot to put the gas to the floor while I was craking the motor over, so the results are a little low... but consistent. The old spark plugs looked decent, there is a lot of residue on them but the color indicates that the car is running rich. The car feels good with the new plugs in! The old plugs had 27k miles on them.
Update April 28 2006:
I installed the TXS Knocklite and Apexi AVC-R Electronic boost controller today. We're going to try installing the turbo tomorrow! I wrapped the uppipe downpipe today in anticipation :)
Update May 27 2006:
In case you missed it, the new turbo has been installed on the car for a couple weeks now, there are lots of pics on Page 5. Here's a pic I took after wrapping the IC piping, coolant tank, and coolant lines. This helps with my underhood temps and looks nice too :)
Update Aug 25 2006:
It's been a while. I've installed a Forge BOV. My clutch died so I got a new one, but it isn't installed yet. I installed the Kartboy short shifter. I have new motor / tranny mounts that are also waiting to be installed, I may take a shot at it this weekend.
Update Sept 30 2006:
Well, all the new driveline mods are installed and I couldn't be happier! I went with an RPS 6-puck clutch, ACT Prolite flywheel, Cisco motor/tranny mounts, STI Group-N pitch stop, and Kartboy transmission crossmember bushings. The driveline is super tight now. The clutch is streetable, but if you get sloppy it wants to rip your head off. I'll be heading back to the dragstrip shortly...