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Old 08-12-2011, 10:44 PM   #1
jockeygolfs
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Member#: 260868
Join Date: Oct 2010
Chapter/Region: South East
Location: Lake Worth, Florida
Vehicle:
2011 STI
White

Default Jockeygolf's 2011 STI Sedan Build

Current numbers Tuned by Junior2jz



ECU:



Cobb Accessport


New Block:

IAG stage 4 Extreme Block

Closed deck

O-ringed

14mm Studs

IAG custom lengthened Manley Rods

IAG custom horizontal gas ported Manley Pistons

OEM crank


Old Block at current power:

New Case Halves w/ Outfront Closed Deck, 1/2" head studs, pinned mains


Pauter X Beams


CP Pistons w/ Coated Crown


OEM Crank


12MM OEM Oil Pump

LIC Eccentric Pulleys



New Heads


Ferrea Comp Plus Standard Valves


Ferrea Dual Valve Springs


Ferrea Tooled Steal Retainers


Ferrea Valve Locks


Kelford Dual AVCS 280 Cams



Every sensor, bolt, pump, etc is brand new.

Killer B Pick up



Killer B Baffle



Grimmspeed Thermostat



Koyorad Radiator





Exhaust:



ETS Headers



ETS Uppipe Wrapped in DEI silicone coating and Titanium Heat Wrap



ETS Downpipe Wrapped in DEI silicone coating and Titanium Heat Wrap



Invidia q300 cat back



Tial 44mm External Wastegate







Intake:



2005 Impreza NA Intake Manifold

4" K&N Filter (ETS Rotated Kit)



Outfront 19mm Phelonic Spacers



ETS 4" Front Mount Intercooler



Tial Q 50mm Blow Off Valve







Turbo:



Precision Turbo 6466 BB V-Band



Grimmspeed EBCS



PTP Turbo Blanket







Fuel:



DW65 Intank



Radium Engineering Surge Tank w/ (2) Walbro 465 E85 Pump -6AN and -8 AN PTFE Lines



Fuel Injector Clinic 2150 injectors



NGK 1 Step Colder Plugs gapped .022



Fuelab High Flow Large Seat Fuel Pressure Regulator



Outfront Fuel Rails and Stainless Steel Lines



Aeromotive Billet Fuel Pump Controller

Hobbs Switch



Autometer Tach Adaptor







Gauges:



Smycluster Maker center bezel



JCS-Pods A-pillar 3 gauge pod



AEM UEGO AFR



AEM Oil Temp Gauge



Defi Oil Pressure Gauge



Defi Fuel Pressure Gauge



Perrin Oil Filter Sandwich Adaptor







Exterior:


Ebay Front Lip



HT Autos Diffuser







Transmission:



Exedy Triple Disk Clutch (cerametalic)



TIC Holy Shift Kit w Kartboy short shifter



Group N Pitch Stop



Group N Engine Mounts



Group N Transmission Mount



Whiteline Positive Shift Bushings



Whiteline Rear Diff Bushing



Whiteline Rear Diff Outrigger Bushing


Whiteline Rear Subframe Inserts







Brakes:



Stop tech Pads



Dba T2 slotted rotors







Suspension:



Fortune Auto 500 8k/8k w radial bearings



SuperPro Roll Center


SuperPro Front and Rear Trailing Arm Bushings



SPC Rear Lateral Control Arm



SPC Rear Toe Arm



Whiteline Caster/antilift Bushings



Whiteline Front Control Arm Front

Inner Lower Bushings



Whiteline Steering Rack Bushings



Whiteline 22mm Front Sway Bar



Whiteline 22mm Front Sway Bar



Kartboy Front Endlinks



Kartboy Rear Endlinks



2015 STI Steering Rack 13:1







Wheels:



Advan RZ 18x10 +35



Nitto NT555 255 35



Project Kics R40 Lugs















I have a pretty long and winded thread in the Newbies and FAQs titled "Loaded COBB AP Stage 1 93 oct in 2011 STI!! I've come a long way from that first post and want to just compile it here. I'll do my best to put everything down chronologically and with links to the photos. I want to thank all the people who have given me constructive advice etc throughout my journey on that thread. Hope you guys follow me here. I want to thank the following people/companies for all their help (if I forgot you and you want to be listed please shoot me a PM): Phatron STIMikey Jdub.csu Smeerone Tenacious Bee Xluben Themaus Wrx02ftw Rallyspec Realstreetperformance Rallysport Direct Perrin Flatironstuning Boston Motorsports IAPerformance Aquamist Howerton Engineering Bertune TAV Racing I purchased my car towards the end of September, 2010: Sitting in the driveway Out at one of my job sites Shortly after purchasing the car I began researching the possible mods that I could do but try to keep the car as stock as possible. The most obvious choice was to purchase a Cobb Accessport and flash to stage 1. I enjoyed stage 1 for probably...1 month. It was then time to go to stage 2. I purchased the following: Perrin Equal Length Headers Perrin Up Pipe Cobb Down Pipe AEM Intake At this time I knew that an off the shelf map would not do. After a ton of research on tuners in my area, I turned to e-tunes. Given the track record of this gentleman I decided that I would put my baby in the hands of Phatron of Phatbotti Tuning. This was my first time ever working on a car and thankfully a friend of mine was willing to help me. An extra plus was that his father has a garage with a lift at his house. The install occured sometime in November/December, 2010: On the lift OEM Parts a plenty Header installed Down Pipe installed Tuning commenced shortly afterwards. What an experience. We started on 2nd gear doing pulls from 2,000 RPM to 7,000 RPM. Several pulls later it was time to move to 3rd gear. It is about 9 pm and I do a pull and then...BOOM!!!!! WTF!!!!! Lights were flashing, the car was limping and I was peeing my pants!! I pull into my neighborhood and quickly pop the hood and begin texting Phatron like a mad man. All the hoses looked ok. Turns out, this was my first time experiencing boost cut! We hit 23 PSI which was what Phatron had set the cut at. Whew! When all was said and done, several nights of pulling up till 5th gear on the highway, we were done. From what I remember we were at about 280ish WHP/TQ using Airboy to calculate the road loads. A decision was then made to upgrade the stock boost control system and the By Pass Recirculation Valve sometime in December, 2010: Grimmspeed 3 port Electronic Boost Control System Forge By Pass Recirculation Valve Retune w/ Phatron. I knew this would not be enough for me. It was fun but I wanted more. Research began on what the stock engine could be pushed to. 400 WHP was the limit that I found consistently. So my focus was on a quick spooling turbo and the required supporting mods. I purchased in December, 2010: Please keep reading the following posts to see the rest of the progress. I had to chop up my original post in order to insert pics rather than just having links.
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Last edited by jockeygolfs; 02-13-2016 at 08:43 AM.
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Old 08-12-2011, 11:08 PM   #2
ljstella
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2020 BRZ
World Rally Blue

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That's a crazy build dude! Good luck with it!
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Old 08-12-2011, 11:16 PM   #3
jockeygolfs
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Join Date: Oct 2010
Chapter/Region: South East
Location: Lake Worth, Florida
Vehicle:
2011 STI
White

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Blouch Dom 2.5XT-R



Deatschwerks 850 Injectors


Walbro Fuel Pump


NGK 1-step Spark Plugs


Perrin Turbo Inlet


KStech 73mm Cold Air Intake


I was a little side tracked after purchasing these items when Invidia released their quad tip exhaust for the sedan. I had to get it and I was not going to leave the bottle neck in the exhaust so the Cobb had to be replaced by the Invidia Down Pipe. The purchase was made and exhaust installed in January, 2011:

Silicon Coated the Down Pipe


Titanium Wrap Down Pipe

Last edited by jockeygolfs; 03-07-2013 at 08:36 AM.
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Old 08-12-2011, 11:42 PM   #4
speedsnice
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Join Date: Feb 2005
Chapter/Region: Tri-State
Location: Bronx, New York
Vehicle:
2011 WRX STi
SWP

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Nice build, I have a Dominator 3.0 XTR on my 2005 STi I am not sure what to go with on my 2011 sedan.
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Old 08-12-2011, 11:51 PM   #5
jockeygolfs
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Location: Lake Worth, Florida
Vehicle:
2011 STI
White

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Exhaust Installed


More tuning with Phatron shortly afterwards.

Okay, back to the turbo and the other parts. Before I can do that I had to get an AFR Gauge. I didn't want to mount the gauge just anywhere so I had to go with something that was as OEM looking as possible. With that, I had to fill the second gauge bezzle so an Oil Temp Gauge was purchased. I know I know, an Oil Pressure Gauge will be coming soon:

AEM AFR Wideband Gauge


AEM Oil Tem Gauge


SMY Cluster Bezzle


Perrin Oil Filter Adaptor


Gauges being installed


Gauges Installed


We are now ready to go with installing the turbo now that the AFR Wideband is installed. This happened sometime in April, 2011:

Holy crap, my engine bay is a mess!


Intake Manifold is off

Last edited by jockeygolfs; 08-23-2012 at 05:37 AM.
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Old 08-14-2011, 09:57 AM   #6
smeerone
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DGM Phatbotti Tuned

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Nice write up jockey....let me know if I can help.

Last edited by smeerone; 08-14-2011 at 10:03 AM.
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Old 08-14-2011, 10:28 AM   #7
jockeygolfs
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Location: Lake Worth, Florida
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2011 STI
White

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Work is done


I tried to give the shop all the instructions on how to do the walbro fuel pump properly for an 08+ STI. They didn't follow all the directions and so the car would start poorly. Not being a gear head or grease monkey, I used my laptop and several different threads to dive into fixing my fuel pump on my own rather than go back to the shop. I lost trust in this shop so if you want to do something right it is best to do it yourself, at least for this.

I did some plastic removal on the fuel pump housing and used the double o-ring trick on the fuel pump nipple. Once all put together I fired up the car and it was as if it was stock.

More tuning with Phatron once again. This would take about 3 weeks to do. We would do a few pulls a night. Before we would do them till 2 in the morning. He is on the west coast. This time around I just could not pull that off anymore. Plus I had to switch up my places to do these pulls in order to avoid being a target for the "you know whos". At the end we were at 350 TQ, 340 WHP using Airboy to calculate the road loads.

Could we push it more? Yes. Did we want to? No. 400 WHP as a limit is known but one dyno compared to another is never the same. Knowing that this was my only car and extremely important for me to have running, Phatron talked sense into me to not go further at this time. The car has been on this tune ever since.

I made a contact with a fellow South Florida Subie owner and he pointed me in the direction of a shop that has done work on many of the local subies. Gustavo at TAV Racing in Doral. Extremely nice guy. He used to race his own open wheel car and has a beefy 2007? STI. He had this car in his shop when I went to see him:

Stroked Cosworth Long Block in a full race car. The hole thing was gutted


My first upgrade with TAV was Group N Engine and Transmission Mounts





Cobb came out with the launch control addition and I added that to my tune.


So, June comes around and I continue to do research on this forum and cannot get over the fact that my stock pistons suck so much. I decided I had to change them. But doing a swap is not what I want to do. I want to drop a short block in. This would minimize the amount of time that the car would be at the shop to swap motors. I went back and forth on buying a fully built block and building my own. In the end I decided on building my own block.

The idea was to buy parts slowly over the next few months until I had everything by Christmas. I couldn't hold back. The purchases began in late June with:

A new EJ257 block



Last edited by jockeygolfs; 08-23-2012 at 05:38 AM.
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Old 08-14-2011, 10:38 AM   #8
O.C.D.
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Join Date: Jun 2002
Chapter/Region: RMIC
Location: Colorful CO
Vehicle:
2003 WRX Sedan
WRB

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Can you please tell me where you found the "Money tree" you are picking from. Holy craptastic Batman, that is some dough, lol.

Nice to see you have the resources to build a really awesome STI! That thing was a beast but now with the built motor, my gosh.....

can't wait to see updates!
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Old 08-14-2011, 10:56 AM   #9
smeerone
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Join Date: Jun 2010
Chapter/Region: South East
Location: Miami, Fl.
Vehicle:
2010 WRX
DGM Phatbotti Tuned

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Quote:
Originally Posted by jockeygolfs
Thanks, you have been a ton of help with suggesting TAV Racing and the suggestion of Bertune for the block build. I think I will definitely want to come down and see the festivities when Phatbotti guys come down. Keep me posted!
He'll actually be down here by months end.
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Old 08-14-2011, 01:29 PM   #10
jockeygolfs
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Join Date: Oct 2010
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Location: Lake Worth, Florida
Vehicle:
2011 STI
White

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A new OEM nitraded crank


Early July I decided to get some internals:

Cosworth Parts


Cosworth 99.5 Pistons


Cosworth Rods


Cosworth Piston Rings


Late July I went ahead and ordered some supporting parts for the build. (Pics to come)

ACT Xtreme Street Clutch



OEM 12MM Oil Pump
Ribeye?



Last edited by jockeygolfs; 08-23-2012 at 05:40 AM.
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Old 08-15-2011, 02:52 PM   #11
jockeygolfs
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Join Date: Oct 2010
Chapter/Region: South East
Location: Lake Worth, Florida
Vehicle:
2011 STI
White

Default

OEM Water Pump



Grimmspeed Thermostat


OEM Oil Cooler


OEM Rear Block Seal Kit, nuts and other gaskets


Killer B Oil Baffle



Killer B Oil Pick Up


Last edited by jockeygolfs; 08-23-2012 at 05:42 AM.
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Old 08-15-2011, 06:14 PM   #12
sc00ter
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Chapter/Region: RMIC
Location: Denver, CO
Vehicle:
2014 Audi S4
DP Stage 2 (~420whp)

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Can you please save me a ton of mouse clicks and add the [img]...[/img] tags to your images for us?

I want to see this but I'm lazy.
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Old 08-15-2011, 06:30 PM   #13
jockeygolfs
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Location: Lake Worth, Florida
Vehicle:
2011 STI
White

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JDM Spec C Lower Intake (TGV Deletes)




Gates Timing Belt


ARP Head Studs


3 mm Phenolic Spacer

Last edited by jockeygolfs; 08-23-2012 at 05:43 AM.
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Old 08-15-2011, 07:48 PM   #14
rsutton1223
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Join Date: Apr 2011
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Location: Alpharetta, GA
Vehicle:
2009 CTSV 1,216whp
Black Raven

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You are using the wrong link in the [img] tags. You should be using this one...

http://farm6.static.flickr.com/5095/...0c1c38f6_b.jpg

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Old 08-15-2011, 07:53 PM   #15
jockeygolfs
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2011 STI
White

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August 11'

Engine is dead. Even on a conservative map. i was running at 21.5 PSI max. My mechanic says 19 is the max on OEM pistons. Currently waiting to be towed. I'm in the middle of nowhere. Just south of the city of Okeechobee in FL. Car was sounding awesome and then sputtering. The car was making weird sounds like playing cards in bike spokes.

I quickly took my short block parts to Bertune to have him assemble the block in case the dealership did not warranty the block.

Here's the short block, all built up!






Ended up not needing the new block because SOA decided to cover my block!!




Turn In Concept Holy Shift Set installed 10/14/11 by TAV Racing

Last edited by jockeygolfs; 08-23-2012 at 05:43 AM.
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Old 08-15-2011, 08:44 PM   #16
jockeygolfs
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Join Date: Oct 2010
Chapter/Region: South East
Location: Lake Worth, Florida
Vehicle:
2011 STI
White

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January 12'

Installed my Crawford V2 AOS. Took about 3 hours. I thought it would be faster since I did do half the work yesterday but then returned everything back to OEM since I got stuck. The Dom is really tight to the intake manifold and makes getting the crank case breather hoses out and back in real difficult. The hoses from the AOS are really thick and make putting everything back together difficult as well but it can be done. The pipe from the bottom of the AOS to the crank case is slightly shorter than what is seen in the install instructions and videos but does work. Also, being a newbie like me i did not know coolant would shoot out of the coolant reservoir to turbo hose when I removed it to reroute it to the AOS. I had to go get more coolant because i lost so much of it.

Also, if anyone has the Perrin inlet hose, you need to get a 5/8"x1/2" coupler. The vent hose from the AOS to the inlet hose comes in 5/8" size. The perrin nipple is 1/2". This was my last connection and I couldn't believe I didn't see this.

Coupler:



Installed:



Finished:





February 12'

Finally did the FPR and Dampener swap. Got the 05' STI FPR and 07 Dampeners from Bertune. Thanks Bertune!

05' FPR and Dampener:



I pulled the fuel pump fuse. Started the car till it died. Cranked it several times more. Took off the gas cap and then disconnected the negative terminal on the battery. Unfortunately I did not crank the car enough because when I pulled off one of the hoses off the supply hose a stream of gas shot out and sprayed my whole counter in my garage. I was able to cover it up before it could spill into the engine bay. I had protective glasses on as well. It was good to be prepared. I wrapped everything with a towel before pulling it apart and still had gas pour out. Not horrrible though.

11' FPR and Dampeners out:



I have a guess, no backing for it though, that the balancer hose between the supply and return dampers may be one of the reasons for the hesitation issues.

Install was pretty simple. No need to cut the existing hoses. Just used a hose that came with one of the dampeners to connect the FPR to the dampener.

Installed:



Car is running. Got a new map from Phatron with fuel compensation (I thinK) zero'd out. Going to do some casual driving and a few pulls for him to check on. Hopefully the hesitation will be gone.

Time to do the swap was about 1 hour.


Purchased Aquamist HSF-3


Purchased Howerton Engineering 2 Tank System




Last edited by jockeygolfs; 08-23-2012 at 05:44 AM.
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Old 08-15-2011, 08:51 PM   #17
jockeygolfs
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Join Date: Oct 2010
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Location: Lake Worth, Florida
Vehicle:
2011 STI
White

Default

Finally done with the wiring for the injector tank. Did a weather pack for the wires and a quick disconnect for the hose. This will allow me to remove the box without having to open the box while in the trunk.




April 12'

Here are my tank install picks. I did not screw down the tank straps yet but everything else is done.

I ran the straps underneath the foam corner piece. I scored a line further out on the trunk liner so I can fold it. I then cut a few slits in the score so that I can run the straps through it.



The trunk liner can now flap over and cover the foam piece.



Finished product. Looks like it all came OEM.



May 12'

DBA T2 rotors and Stoptech pads all the way around.






Last edited by jockeygolfs; 08-23-2012 at 05:44 AM.
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Old 08-15-2011, 08:54 PM   #18
ArSoN9
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2004 STi-

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nice car!!! 2011 white will be my next STI .. Ill check back for updates
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Old 08-15-2011, 09:03 PM   #19
jockeygolfs
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Location: Lake Worth, Florida
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2011 STI
White

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June 12'

Front lip is on! HT Auto model. The quality is great. I do not know what others are like since I've never seen the other models before but I'm pleased with this. I was worried that it would be real thin and flimsy. It isn't. Nice quality piece and all the holes line up for the clips.





I used all the clips and the extra nuts and bolts. I also used 3M double stick tape on all flat surfaces where there were no bolts or clips. This thing is on tight!!

Last edited by jockeygolfs; 08-23-2012 at 05:45 AM.
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Old 08-15-2011, 09:11 PM   #20
jockeygolfs
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Join Date: Oct 2010
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Location: Lake Worth, Florida
Vehicle:
2011 STI
White

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June 12'

Packing up the car with all the goodies for the short block swap.





Things are moving forward!!!!

My block is out of the car:





Stock pistons look pretty decent:



My new block on the stand:



Killer B Baffle and Oil Pick up installed:



Parts being installed onto the new block:


Last edited by jockeygolfs; 09-28-2012 at 07:22 AM.
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Old 08-15-2011, 09:12 PM   #21
jockeygolfs
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White

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End of June 12'

My girl is home where she belongs!

http://www.flickr.com/photos/57450230@N02/7415961286/

Installed the HT Auto side and rear skirts:















July 12'

Kartboy Short Shifter:



WRXFTW02 under the car doing the reverse lockout:



WRXFTW02 and THEMAUS swapping the shifter:


Last edited by jockeygolfs; 08-23-2012 at 05:47 AM.
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Old 08-15-2011, 09:13 PM   #22
1sick07
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2011 STI Sedan
SSM

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Amazing!!
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Old 08-15-2011, 09:29 PM   #23
jockeygolfs
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2011 STI
White

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July 12': Here is the A pillar with gauges mocked up. Install is next week.







August 12':

Meth kit is installed finally!!!! My Weather Pack and quick disconnect line is working Bertune's handiwork was well done as well. We decided to place the controller in the fuse box area on the driver's side. It is easy to access for any changes that need to be made.




I also decided on 100% meth. No need to mess with mixing. I have plenty for back up



Thank you Smeerone for coming by and dropping off some Burger King for us! I know it looked like Bertune and I were fighting a lot, we were lol. All in good fun though.

Phatron and I are currently tuning tonight. So far a cruise and 2nd gear pull. This thing is kicking!!!

August 12':

Installed HT Autos rear diffuser




Last edited by jockeygolfs; 09-28-2012 at 07:24 AM.
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Old 08-15-2011, 09:31 PM   #24
smeerone
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Location: Miami, Fl.
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2010 WRX
DGM Phatbotti Tuned

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Jockey did u do injectors ure self? I'm gonna start mine and was wondering the difficulty level

-Rob
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Old 08-15-2011, 09:33 PM   #25
wrxrono
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2002 wrx
SqC #160

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Nice Build cant wait to see some numbers
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