A while ago a good customer came to us with his brand new completely stock 2006 STI and told us he wanted to add some more power and better handling. The first thing we recommended was a stage 2 power package. His response to me was I was looking for a little more power then stage 2 so I asked how much more he said about 500 whp and so this project was born. After over a year a lot of money and a lot of hard work this project is coming together and nearing completion. This customer is a stickler for details and wanted nothing but the highest quality parts for his car so COBB, APS, KW and many more suppliers were called on to deliver the car you see below.

Engine:
COBB pro-series sleeved short block.
COBB pro-series stage 3 CNC ported header with bigger valves
Cosworth 274-278 cams
Cosworth 12mm oil pump
ARP head studs
APS DR725 FMIC
APS TSR 70 turbo kit
APS rotated mount intake
APS BOV
APS fuel rails
APS aux fuel rails
APS 3.5in turbo back
APS header with header wrap
APS TGV deletes
Tial 44mm waste gate
COBB main pulley
PE 850cc primary injectors (4)
Bosch 600cc aux injectors (4)
walbro 255lph fuel pump
Aeromotive A1000 external fuel pump
Aeromotive external fuel filter
Aeromotive fuel pump controller
Aeromotive adjustable bypass regulator
FLI custom fuel surge tank
FLI custom reverse intake manifold pipes.
LINK G4 stand alone ECU
Aquamist HFS-5 kit
Spec-C 12 liter tank


Suspension:
KW V3 coilovers
COBB front and rear sway bars
Whiteline Anti-lift kit
Factory BBS wheels for now



http://fliblog.files.wordpress.com/2008/09/_empty_enginebay_withfmic_.jpg
Old engine out of the car and APS FMIC core mounted

http://fliblog.files.wordpress.com/2008/09/_block_21.jpg
COBB Pro series motor. This motor uses 100mm Forged JE pistons, COBB rods, COBB main and rod bearings, darton sleeves and is balanced and blueprinted.




http://fliblog.files.wordpress.com/2008/09/_head_2.jpg
http://fliblog.files.wordpress.com/2008/09/_head_3.jpg
http://fliblog.files.wordpress.com/2008/09/_head_1.jpg
COBB CNC heads with the Cosworth cams


http://fliblog.files.wordpress.com/2008/09/_engine_bare_long_block_3.jpg
Completed and assembled long block


http://fliblog.files.wordpress.com/2008/09/_engine_6.jpg
Engine all the way back together for the most part and the start of the reverse intake manifold mock up.





http://fliblog.files.wordpress.com/2008/09/_rfmic_0.jpg
http://fliblog.files.wordpress.com/2008/09/_rfmic_12.jpg
http://fliblog.files.wordpress.com/2008/09/_rfmic_main-blog1.jpg?w=475&h=357These are some of the pic of the revers intake manifold being built by us here at the shop. On one of the pipes we made some notches to accommodate keeping the AC and still leaving no chance of it rubbing on the hood or the AC. All pipes have been sent out for final powder coating and will be back shortly.



This brings you up to date on what we have done with the car so far I will be updating this thread as the days go by and we make some more headroom. As always if you have any questions about the car or anything we have done please let me know.


Ryan
Fine Line Imports
www.finelineimports.net

WOW. talk about uh.....$$$$$

Nice build. Thats going to be a monster.

$$$... worth every penny :)

car is looking good. there are a lot of builds shown online now! this is a good thing, keep the updates coming!

really nice work!!!!
:eek:

Nice build.
<-- Same turbo kit, same FMIC, same heads/cams, different bottom end and I opted not to go with the reverse mount IC piping.

What hotside are you planning on running? The .82 is a spooly, quick beast, but puts the brakes on around 6700RPM. The 1.06A/R housing (now an option direct from APS [I had to source mine elsewhere and get some custom work done on the outlet to get the 3.5" Vband DP to mate]) won't thin out unless you take your foot off the gas. :)

Nice build.
<-- Same turbo kit, same FMIC, same heads/cams, different bottom end and I opted not to go with the reverse mount IC piping.

What hotside are you planning on running? The .82 is a spooly, quick beast, but puts the brakes on around 6700RPM. The 1.06A/R housing (now an option direct from APS [I had to source mine elsewhere and get some custom work done on the outlet to get the 3.5" Vband DP to mate]) won't thin out unless you take your foot off the gas. :)



This is the .82 hot side right now. If for some reason we don't hit our hoarse power goals or he decides to upgrade we will put the larger one on. We are at the current time trying to keep lag to a minimum as this is more of a daily driver/weekend track car.

thats gonna be pretty nice when its all done. wish i had that kinda doe

What made the customer choose a COBB engine over others? Any idea? Or even you guys stage 3 block?

The reason I ask is because in the past I heard their motors had reliability issues?

What made the customer choose a COBB engine over others? Any idea? Or even you guys stage 3 block?

The reason I ask is because in the past I heard their motors had reliability issues?

At the time we ordered the engine we were still working on our own stage 3 motors and they were not ready to be sold. In the past several of us here at the shop including myself have run COBB engines as well as our customers and ran into no problems what so ever. It was only the next logical step having good luck with there motors to have them build the one for this car.


Ryan
Fine Line Imports
www.finelineimports.net

Cool thanks for the clarification Ryan

Wow....thats Nasty......how long did this take?

Wow....thats Nasty......how long did this take?



Well it took the better part of two months just to get the short block here. I would say we have had the car here for a little over a year now. Its one of our longest term projects we have ever had.


Ryan

Looks stunning mate. Really nice job :D

Would like to see some side on pics of the throttle body pipe to see just how its shaped around the alternator. Looks good though.

thats gonna be pretty nice when its all done. wish i had that kinda doe

you have spent more into yours, you just spend it over time :)

how come in the other picture, the nice polished pipe is different bends than the new one you put on with notches? and wont those notches cause a flow issue...?

how come in the other picture, the nice polished pipe is different bends than the new one you put on with notches? and wont those notches cause a flow issue...?



In the beginning we had a different plan on how we were going to make the IC piping so we were using part of the APS kit later on we realized to make it fit properly with the AC still there we would have to completely make both pipes from scratch. the two notches on the back of the pipe are not so drastic that I am worries about air flow into the motor. The over all size of the pipe is decently big as well.

Ryan
Fine Line Imports
Ryan@finelineimports.net

how big is the piping? how long would it take you guys to fab me some ic piping if i have it all there and it's just a couple of pieces and the section to clear the alternator?

Looks stunning mate. Really nice job :D

Would like to see some side on pics of the throttle body pipe to see just how its shaped around the alternator. Looks good though.



At the time I do not have those pictures. The pipes are out getting powder coated crinkle red along with the intake manifold and intake so there all one color. When they get back ill snap some pictures for you.

Ryan
Fine Line Imports
www.finelineimports.net

Nice build Ryan!! You guys always perform such clean work!!

you have spent more into yours, you just spend it over time :)

haha true bro

Id go straight to the 1.06 housing the backpressure is too high on a built camed 2.5 to have anything smaller.

how big is the piping? how long would it take you guys to fab me some ic piping if i have it all there and it's just a couple of pieces and the section to clear the alternator?


shoot me a call at the shop and I can see what we can work out for you.


Ryan
Fine Line Imports
707-525-1536
www.finelineimports.net

im interested in the piping

Update 10-02-08: It has been a busy couple of weeks at the shop but we did manage to make some headway on the STI. All the injectors and fuel rails are installed and the fuel lines ran. We got the IC pipes back from powder coating and installed those as well. Next on the list is tackling the fuel system from the trunk to the engine bay. Below are a few pictures from the final installation of the IC pipes and the two sets of fuel rails and the 8 injectors.




http://i15.photobucket.com/albums/a388/FLIWRX/_FLI_HHP_fuel_system_18.jpg?t=1222968877
APS aux fuel rail kit installed onto the APS TGV deletes with the Bosch 600cc inj.



http://i15.photobucket.com/albums/a388/FLIWRX/_FLI_HHP_fuel_system_15.jpg?t=1222969009
Both sets of APS fuel rails one set holds PE 850cc and the other the Bosch 600cc secondary set.



http://i15.photobucket.com/albums/a388/FLIWRX/_FLI_HHP_fuel_system_13.jpg?t=1222969087
Aeromotive adjustable bypass regulator



http://i15.photobucket.com/albums/a388/FLIWRX/_troy_rfmic_red_6.jpg?t=1222969215
The reverse intake manifold pipes all done coated and installed.



http://i15.photobucket.com/albums/a388/FLIWRX/_troy_rfmic_red_10.jpg?t=1222969305
This is the notches we made in one of the IC pipes in order to clear the alternator and still keep the AC.



http://i15.photobucket.com/albums/a388/FLIWRX/_troy_rfmic_red_2.jpg?t=1222969394
http://i15.photobucket.com/albums/a388/FLIWRX/_troy_rfmic_red_18.jpg?t=1222969453
Some other pictures of the IC pipes.


If you have any questions please let me know.

Ryan
Fine Line Imports
www.finelineimports.net
http://fliblog.wordpress.com/

:lol: This is a great build.

If it were me, I'd have that 1.06A/R housing on the standby just in case. I have a feeling that 500WHP just isn't going to happen on the .82A/R housing... especially considering the potential with the insanity of all that fuel lol.

What kind of dyno will this be tuned on? Any idea on stock STI numbers on said dyno?

:lol: This is a great build.

If it were me, I'd have that 1.06A/R housing on the standby just in case. I have a feeling that 500WHP just isn't going to happen on the .82A/R housing... especially considering the potential with the insanity of all that fuel lol.

What kind of dyno will this be tuned on? Any idea on stock STI numbers on said dyno?

This car will be tuned on our in house mustang MD500 dyno. On the average a stock STI makes around 240ish WHP on our dyno. If for some reason we do not make the numbers the customer is looking for with the .82 housing the 1.06 will not be far behind.


Ryan
www.finelineimports.net
http://fliblog.wordpress.com/

Very nice...

How are u controlling the 8 injectors?? i also bought the APS housing for the additional injector ports..

Im doing the same thing with my motec M800.. running 8x wrx top feed decapped injectors..

I had to get hadwired new imputs into the main board then feed them off to each injector.. Should hopefully work...


Do u think the notch in the IC piping will create turbulence of flow??

Very nice! I was thinking the same thing as Tino said about the notches causing turbulence, but I'm sure you guys have it all figured out..

Sick build, APS FTW!

You dont need to notch the piping to clear the a/c or alt. Theres a reversed manifold thread in the 2.5 liter forum. I would have tapped another port for the brake booster so you dont run all the way across the engine bay (thats what I did) Looks good other than that. Im still with my first response with you need the 1.06 housing.

I have NEVER been so jealous in my life- SWEET build

can i get a redo :)

Yeah I'm wondering if those notches will hurt airflow by causing turbulence. What's your input on that subject?

Yeah I'm wondering if those notches will hurt airflow by causing turbulence. What's your input on that subject?



I am not worried about the notches at all creating turbulence. As far as not needing the notches there is minimal clearance with out them so to make sure there is no rubbing what so ever we added them.


Ryan
Fine Line Imports
http://fliblog.wordpress.com/

Very nice...

How are u controlling the 8 injectors?? i also bought the APS housing for the additional injector ports..

Im doing the same thing with my motec M800.. running 8x wrx top feed decapped injectors..

I had to get hadwired new imputs into the main board then feed them off to each injector.. Should hopefully work...


Do u think the notch in the IC piping will create turbulence of flow??

We are controlling the injectors with a Link G4 stand alone which has outputs to control them. We converted the APS kit over from batch firing and will wire them into the stand alone.


Ryan
Fine Line Imports
www.finelineimports.net
http://fliblog.wordpress.com/

this car better make more that 450whp.... i wanna see 550

i always see these badass motor builds and then the car only makes 450whp....

but great job guys, nice collection of parts

Will you care to elaborate why you are not worried about the notches? I just want to understand it.

THanks.

I may have missed it, but the 500WHP goal is on what octane fuel?

Also, I'm still trying to understand the need for that much fuel? 850cc injectors with injection has enough headroom (personal experience, not talking out my ass)... I'm curious why you need 850ccx4 and 600ccx4 for fuel? If it's run primarily on race gas, then it's run leaner anyway and requires less fuel.

Anyway, just curious. Thanks.

I may have missed it, but the 500WHP goal is on what octane fuel?

Also, I'm still trying to understand the need for that much fuel? 850cc injectors with injection has enough headroom (personal experience, not talking out my ass)... I'm curious why you need 850ccx4 and 600ccx4 for fuel? If it's run primarily on race gas, then it's run leaner anyway and requires less fuel.

Anyway, just curious. Thanks.



We will make a 91oct map as well as 100oct with meth and 91 with meth. I am pretty sure this car will most of the time run on 100oct with meth. On smiler equipped cars that we have done we have run out of fuel with PE 850cc injectors before. For the most part this car will be a weekend track car and wanted to make sure that no matter what we did with the car fueling would not be a issue.

Ryan
Fine Line Imports
www.finelineimports.net
http://fliblog.wordpress.com/

^Cool. Thanks for the answer. Good luck with the rest of the build and the tuning.

How are you going to make sure that IC piping doesn't hit the alternator pulley? It looks awfully close to making contact. You should add a bracket that secures it to the alternator.

I want an clarification as to why the notches aren't going to affect anything.

I want an clarification as to why the notches aren't going to affect anything.


On a turbocharged (force inducted) vehicle, the intercooler piping has a constant charge when the turbo is in boost and a constant vacumme when not. This means for example, 15 psi is 15 psi with or without notches.

Notches effect air flow near the turbo inlet and near the Mass Air Flow (MAF) sensor. If these notches were on the intake system (to the turbo) or near the MAF sensor then this would affect how the MAF reads which in turn would affect the fuel curve of the ECU map. This is because the ECU looks at the MAF sensor data to determine what the mass of air is when entering the engine.




I hope this anwsers your question.


Miles
Fine Line Imports
www.finelineimports.net
http://fliblog.wordpress.com/

On a turbocharged (force inducted) vehicle, the intercooler piping has a constant charge when the turbo is in boost and a constant vacumme when not. This means for example, 15 psi is 15 psi with or without notches.

Notches effect air flow near the turbo inlet and near the Mass Air Flow (MAF) sensor. If these notches were on the intake system (to the turbo) or near the MAF sensor then this would affect how the MAF reads which in turn would affect the fuel curve of the ECU map. This is because the ECU looks at the MAF sensor data to determine what the mass of air is when entering the engine.




I hope this anwsers your question.


Miles
Fine Line Imports
www.finelineimports.net


Yeah that makes sense. I'm just thinking about the swirl and airflow going into the heads but that matters at the runners. I see your point now.

You guys gonna start selling these notched pipes as a kit?

Yeah that makes sense. I'm just thinking about the swirl and airflow going into the heads but that matters at the runners. I see your point now.

You guys gonna start selling these notched pipes as a kit?




If we get some demand for them we will. Its hard sometimes because everyone's turbo kit and intercooler combination is different so it throughs the measurements of the pipes off a little bit. We are thinking of making turbo kit specific ones like for TSR70 ktis with the APS front mount or the Perrin kit with the APS front mount.

Ryan
Fine Line Imports
www.finelineimports.net
http://fliblog.wordpress.com/

Care elaborating how you did the notches so i can do mine when I get to that point? They don't look to be welded on.

Care elaborating how you did the notches so i can do mine when I get to that point? They don't look to be welded on.



They are welded what we did was once the pipe was finished we measure out and cut the wholes then heated up the pieces of metal that were cut out and bent them upwards then welded them back into the place. The overall diameter of the pipe is 2.5 in at the top of the notch its a diameter of 2.3 inches so the notch is not is not that big but just enough to make sure that while the engine is vibrating and moving it does not rub against the inter cooler pipe. Shoot me your email and I can send you some more pictures that I do not have posted here.


Ryan
Fine Line Imports
http://fliblog.wordpress.com/

PM sent

PM sent


Email sent to you.

Ryan
Fine Line Imports
www.finelineimports.net
http://fliblog.wordpress.com/

insane build, can't wait to see the numbers. keep up the good work!

very very clean build. id like to have something like this one day.

Wow :)

very nice build :)

UPDATE: 10-16-08


Here are some updated pictures of the fuel system for this car. In this first set of pictures you can see the distribution block installed and most of the lines ran into it. The block sits on a custom bracket so there is no chance of it movies or coming loose.

http://i15.photobucket.com/albums/a388/FLIWRX/_fli_hhp_fuel_system_18-1.jpg?t=1224179183

http://i15.photobucket.com/albums/a388/FLIWRX/_fli_hhp_fuel_system_19-1.jpg?t=1224179219

http://i15.photobucket.com/albums/a388/FLIWRX/_fli_hhp_fuel_system_20.jpg?t=1224179269


Next up on our list was fabricating the fuel surge tank and the mounting tray for the tank, A1000 pump, fuel filter and Aquamist pump. After some thought this is what we came up with.


http://i15.photobucket.com/albums/a388/FLIWRX/Copyof_fli_hhp_fuel_system_012.jpg?t=1224179474

http://i15.photobucket.com/albums/a388/FLIWRX/Copyof_fli_hhp_fuel_system_11.jpg?t=1224179517

http://i15.photobucket.com/albums/a388/FLIWRX/_fli_hhp_fuel_system_15-1.jpg?t=1224179570

If you have any more questions please feel free to ask. You can also check out more pictures and updates about this car and other project cars on our blog.


Ryan
Fine Line Imports
www.finelineimports.net
http://fliblog.wordpress.com/
707-525-1536

Wow.....nice work as I said before.

No good way to change where that bracket attaches at the intake manifold? Kind of an eyesore (I'm anal like the owner probably) in an otherwise gorgeous engine bay.

wish i could have something like that in the near future

dream set up:)

UPDATE 1-09-09: These are some of the last pictures we took of the car before the customer came and picked up the car to put the brake in miles on it. When he returns we will finish up with the power tune. The car will have a 91oct map, 91oct with meth and a 100oct with meth map. While the car is back here for the tune we will finish final installation of the fuel system and a few more odds and ends.



http://i15.photobucket.com/albums/a388/FLIWRX/p1010176.jpg?t=1231542352
Fuel tray back from power coating. We also had the surge tank coated as well.


http://i15.photobucket.com/albums/a388/FLIWRX/p1010183.jpg?t=1231542445
Another side shot before installation into the car.


http://i15.photobucket.com/albums/a388/FLIWRX/p1010192.jpg?t=1231542492
The start of the installation. Running the wires to the fuel pump controller and the lines for the fuel system. All the fuel lines are NHRA approved Aeroquip lines.


http://i15.photobucket.com/albums/a388/FLIWRX/p1010255.jpg?t=1231542612
This is where we left off with the installation. No fuel is running though the secondary injectors or the surge tank at the moment. The car is out getting the brake in miles down then the trunk will be buttoned up once and for all when it comes back. More to come on this project over the next few weeks.


Ryan
Fine Line Imports
www.finelineimports.net

Nice and clean. I like.

Nice work, subscribed. Liking the ''mission control" in the trunk. The powdercoating came out sweet.

subscribd on crazee build

I have a question....

who makes the fuel block being used?

I have a question....

who makes the fuel block being used?

The Fuel block is actually for a Chevy big block motor that goes in a boat. We ran accross it at the performance marine store here in town and used it.

You guys are doing a great job! That is such a nice build!!!

That fuel system is ridiculous. I love it. I also want a dist block similar to that one bad as a mofo haha. Very nice work so far.

What happened with this car? The Shop last Updated in January

very nice

update thou long over due

Bump for an update please ;)

That is one clean engine/bay

what was the total hours and costs of this project?

nice work fellas, looks clean as hell

A while ago a good customer came to us with his brand new completely stock 2006 STI and told us he wanted to add some more power and better handling. The first thing we recommended was a stage 2 power package. His response to me was I was looking for a little more power then stage 2 so I asked how much more he said about 500 whp and so this project was born. After over a year a lot of money and a lot of hard work this project is coming together and nearing completion. This customer is a stickler for details and wanted nothing but the highest quality parts for his car so COBB, APS, KW and many more suppliers were called on to deliver the car you see below.

Engine:
COBB pro-series sleeved short block.
COBB pro-series stage 3 CNC ported header with bigger valves
Cosworth 274-278 cams
Cosworth 12mm oil pump
ARP head studs
APS DR725 FMIC
APS TSR 70 turbo kit
APS rotated mount intake
APS BOV
APS fuel rails
APS aux fuel rails
APS 3.5in turbo back
APS header with header wrap
APS TGV deletes
Tial 44mm waste gate
COBB main pulley
PE 850cc primary injectors (4)
Bosch 600cc aux injectors (4)
walbro 255lph fuel pump
Aeromotive A1000 external fuel pump
Aeromotive external fuel filter
Aeromotive fuel pump controller
Aeromotive adjustable bypass regulator
FLI custom fuel surge tank
FLI custom reverse intake manifold pipes.
LINK G4 stand alone ECU
Aquamist HFS-5 kit
Spec-C 12 liter tank


Suspension:
KW V3 coilovers
COBB front and rear sway bars
Whiteline Anti-lift kit
Factory BBS wheels for now



http://fliblog.files.wordpress.com/2008/09/_empty_enginebay_withfmic_.jpg
Old engine out of the car and APS FMIC core mounted

http://fliblog.files.wordpress.com/2008/09/_block_21.jpg
COBB Pro series motor. This motor uses 100mm Forged JE pistons, COBB rods, COBB main and rod bearings, darton sleeves and is balanced and blueprinted.




http://fliblog.files.wordpress.com/2008/09/_head_2.jpg
http://fliblog.files.wordpress.com/2008/09/_head_3.jpg
http://fliblog.files.wordpress.com/2008/09/_head_1.jpg
COBB CNC heads with the Cosworth cams


http://fliblog.files.wordpress.com/2008/09/_engine_bare_long_block_3.jpg
Completed and assembled long block


http://fliblog.files.wordpress.com/2008/09/_engine_6.jpg
Engine all the way back together for the most part and the start of the reverse intake manifold mock up.





http://fliblog.files.wordpress.com/2008/09/_rfmic_0.jpg
http://fliblog.files.wordpress.com/2008/09/_rfmic_12.jpg
http://fliblog.files.wordpress.com/2008/09/_rfmic_main-blog1.jpg?w=475&h=357These are some of the pic of the revers intake manifold being built by us here at the shop. On one of the pipes we made some notches to accommodate keeping the AC and still leaving no chance of it rubbing on the hood or the AC. All pipes have been sent out for final powder coating and will be back shortly.



This brings you up to date on what we have done with the car so far I will be updating this thread as the days go by and we make some more headroom. As always if you have any questions about the car or anything we have done please let me know.


Ryan
Fine Line Imports
www.finelineimports.net

oh my...i thought this was supposed to be a 600hp project? =)

This makes me jealous