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Old 11-21-2006, 01:31 PM   #1
AZ04STI
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Smile My pain is almost over! !!!UPDATE I RAN 10's!!!!

After almost 1 and a half years and being humped in the butt so hard by a local shop I am still bleeding (and so is my wallet) My project 04 STI is almost finished, Thanks to the hard work and uncompromising talent of Robert and Chris @ Forced Air Technologies.

Long and the short of it all, in Sept of 2005 I dropped my car off to Vivid Racing Here in AZ, to have my motor fully built, after 4 attempts $12,000.00
and 12 months time, I got the car back, broke the motor in and headed to DynoComp for a tune, on the Dyno the car would not make over 400hp to the wheels and the SR55 would not hold more than 22lbs of boost??? upon further investigation the passenger side cam was advanced 7%, easy right? A slipped tooth on the timing belt. After taking the motor apart and checking the timing marks everything matched up??? Did a leak down test and every single cylinder came back erratic??? Pulled the motor and upon removal of the passenger side valve cover the cam saddle fell on the ground at our feet WTF???

I then called Vivid, they said they would send there mechanic to were my car was at to take a "look see" When Pat (vivid mechanic) got there he took a look and said and I quote "Yup I ****ed up" I called Vivid and told them I was done with them, and I was taking my car somewhere else.

My car was already at Forced Air Technologies, so after talking with Robert the owner he promised me that he would make things right. So 4 months later this is the results, I am truly speechless when it comes to what he was able to accomplish with my car and the custom fabrication that took place when designing the turbo kit, exhaust system, fuel system and oil pan.

I have included a list of mods and buildup, and some recent pics of the motor and fab work. If all goes well I will be driving my car next week. Something I have not been able to do for over a year and a half...


Garret GT40r Twin Scroll Turbo .72 AR
With anti surge compression housing
Tial 44mm Waste Gate
Tial BOV
Custom Intake
Custom up pipe
Custom Down pipe
Custom Header
Custom 4 inch exhaust
Custom Oil Pan
The Header, up pipe and down pipe have all been ceramic jet coated to reduce heat
Custom Fuel System
Aeromotive Fuel Pressure regulator,
Aeromotive External Fuel Pump,
Aeromotive Fuel Filter -
all fuel lines are now 3/8 inch braided stainless with AN fittings)
All the Custom work was done by Robert at Forced Air Technologies (FAT Racing)

This is what's done already

FAT Stage 5 block, sleeved and ringed (Balanced and Blueprinted)
CP pistons (ceramic coated head surface, Teflon coated ledges)
Custom Rings (I can't remember the name of the guy that actually assembled the short block, but he built the rings himself)
Pauter Rods
Cosworth Billet Crank
Cosworth Big Bore CNC Heads
Cosworth Cams 272 intake 274 exhaust
Cosworth titanium Springs and retainers
Cosworth inconel Valves
Cosworth Oil Pump
Greddy Kevlar timing belt
ARP oversized head studs
APS DR725 Front Mount Intercooler
APS TGV Deletes (with spare injector port)
Power Enterprise 850cc injectors
Perrin Fuel Rails
Perrin Crank Pulley
Perrin Radiator Hoses
Zero Sport Thermostat
PWR Radiator
AEM overdrive alternator pulley
Greddy Oil catch can
Cusco ZeroR2 E Coil Over's with Econ Controller
Cusco Strut tower Brace
Cusco Triangle Rear Strut Brace
Cusco 33mm Front and Rear Sway Bars
Cusco Chassis Brace
Cusco Brake Booster Brace
Agency Power Stainless Brake Lines
Agency Power Short Shifter
Volk GT 7's 18x8 42 offset wrapped in Toyo Proxy 4's
Rays LUG Nuts


----INSIDE----
Defi Amber BF Gauges with Defi Controller and gauge pods
(A Pillar and Center POD) Boost, EGT, Fuel Pressure, Oil Pressure, Oil Temp
AEM UEGO O2 Gauge
Apexi AVCR Boost Controller
Sparco Harness Bar
Team Tech 4 point Harnesses with Cam Lock
















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Last edited by AZ04STI; 04-21-2007 at 09:24 PM. Reason: CAUSE I RAN 10's!!!!
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Old 11-21-2006, 01:57 PM   #2
FATgc8
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id like to say bye bye aps tsr70 hello FAT GT40R TWINSCROLL...

Last edited by FATgc8; 11-21-2006 at 02:09 PM.
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Old 11-21-2006, 02:29 PM   #3
PolarisSnT
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Sweet looking setup.

I dont like how the EWG is plumbed back into the exhaust though. Just not a fan of it but still that setup looks amazing. Great fabrication skills.
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Old 11-21-2006, 02:46 PM   #4
AZ04STI
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Quote:
Originally Posted by PolarisSnT View Post
Sweet looking setup.

I dont like how the EWG is plumbed back into the exhaust though. Just not a fan of it but still that setup looks amazing. Great fabrication skills.
Hey I wanted it to be a sleeper....


OK OK I know that's a bad joke... but it made me laugh...
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Old 11-21-2006, 02:49 PM   #5
richy_21
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good god! That looks nasttyyy
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Old 11-21-2006, 02:50 PM   #6
SloRice
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When did Garrett come out with a .62ar for the GT40R? I thought the smallest ar was .85?

Interesting setup for the twin scroll. According to "everyone" the wrong cylinders are paired to make the twin scroll header. But according to Clark (azscoobie), the way you paired the cylinders works. It will be interesting to see what happens with your setup.

Why did he neck the downpipe back down to 3 inches by the trans?

Why the big oil pan??

Not quite sure how into the wastegate setup I am, but still a sick looking setup. Whens it going on the dyno?
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Old 11-21-2006, 03:11 PM   #7
compton
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That is the cleanest fab job I have seen for such a large turbo on a subie. What is the displacement and the compression ratio on this beast? Do you have a HP number you are shooting for?
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Old 11-21-2006, 03:15 PM   #8
AZ04STI
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Quote:
Originally Posted by SloRice View Post
When did Garrett come out with a .62ar for the GT40R? I thought the smallest ar was .85?

Interesting setup for the twin scroll. According to "everyone" the wrong cylinders are paired to make the twin scroll header. But according to Clark (azscoobie), the way you paired the cylinders works. It will be interesting to see what happens with your setup.

Why did he neck the downpipe back down to 3 inches by the trans?

Why the big oil pan??

Not quite sure how into the wastegate setup I am, but still a sick looking setup. Whens it going on the dyno?
The .62 was a Typo the actual AR is a .72 I fixed the typo.

The down pipe necks to 3.5" nches not 3" and to be 100% honest I am not completly sure why, I would assume to build some back pressure

The larger oil pan is to hold more oil than stock... JK With the amount of boost and heat I don't think you can go wrong with extra fluid to cool and lube your internals.. Do you?

WasteGate I have heard a few people say they didn't like it which is cool, everyone has there opinion, I personaly love it!

Dyno.. hmmm good question, I would hope to see it there next week, one thing I am not doing is perstering my builder, I have waited a year and a half few more days ain't going to kill me.
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Old 11-21-2006, 03:26 PM   #9
STi_Guy04
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Yea man Killer set-up... I might have to Head over to FAT... Looks Like Top Quality Work!!!!

Good luck with the project!!
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Old 11-21-2006, 03:29 PM   #10
pickinicholas
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I believe that the displacement is still 2.5L and the compression ratio should still be 8.5:1 as well. Watching the whole buildup was awesome! There is so much time and fabrication that went into this setup. We will be building another soon for my track car. Possibly with another power adder too...
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Old 11-21-2006, 03:32 PM   #11
ShaggyGT
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FAT never ceases to amaze me. WOW.....
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Old 11-21-2006, 03:34 PM   #12
AZ04STI
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Quote:
Originally Posted by STi_Guy04 View Post
Yea man Killer set-up... I might have to Head over to FAT... Looks Like Top Quality Work!!!!

Good luck with the project!!
I honestly can not say enough good things about FAT!!!!
Both Robert and Chris are the shizznit!!!
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Old 11-21-2006, 03:37 PM   #13
AZ04STI
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Quote:
Originally Posted by pickinicholas View Post
I believe that the displacement is still 2.5L and the compression ratio should still be 8.5:1 as well. Watching the whole buildup was awesome! There is so much time and fabrication that went into this setup. We will be building another soon for my track car. Possibly with another power adder too...

Nick you are Correct, still 2.5L and 8.5:1 Ratio...
Thanks for the added Support, and not stealing my motor

As for the added power maker... hope I don't beat you to it
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Old 11-21-2006, 03:39 PM   #14
prophet413
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insane
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Old 11-21-2006, 04:24 PM   #15
AZ04STI
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Quote:
Originally Posted by prophet413 View Post
insane

you took the words right out of my mouth...
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Old 11-21-2006, 04:50 PM   #16
dmross
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Get rid of the exhaust and put a 90deg elbow facing straight up through your hood like a bigrig!
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Old 11-21-2006, 04:50 PM   #17
STREETFAME16
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wow!!!!!!!!!!!!!!

I am complaining because I haven't driven my car in 3weeks (spun bearing) and I'm dying. I couldnt imagine going 1 1/2 yr with out my car. Maybe I need to stop being a pain, I could be in a worse situation.
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Old 11-21-2006, 04:59 PM   #18
dream
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Very very nice! wow
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Old 11-21-2006, 06:02 PM   #19
fobiawrx
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nice to see more gt40rs out there! looking good!
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Old 11-21-2006, 07:34 PM   #20
bcblues
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That looks like quality fabrication. You definitely found a "good draw" when you hooked up with FAT. Be sure to post some pics of the finished install so that we can see how well the custom fab work fits into the engine bay and chasis.
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Old 11-21-2006, 07:42 PM   #21
VSB XT
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This car has the goods to put down some good power reliably! Can't wait to see it in action one day!
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Old 11-21-2006, 07:46 PM   #22
Capt Crunch
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ummm.... aren't you supposed to pair the cylinders differently? Like this:



That said amazing fab work. I would get a good tuner, because if I recall whoever runs FAT claimed they made some obscene hp on the twinscharged sti with only sti pink injectors.

EDIT: I guess someone already pointed out the pairing of the cylinders. Please post your results, because I think everyone is interested in seeing how/if it works.
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Old 11-21-2006, 07:53 PM   #23
kcook
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now thats what im talkin about
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Old 11-21-2006, 08:48 PM   #24
mxturboracer86
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Quote:
Originally Posted by Capt Crunch View Post
That said amazing fab work. I would get a good tuner, because if I recall whoever runs FAT claimed they made some obscene hp on the twinscharged sti with only sti pink injectors.

EDIT: I guess someone already pointed out the pairing of the cylinders. Please post your results, because I think everyone is interested in seeing how/if it works.
going to the single pipe from the dual helps to increase the velocity, there is a point where having 2 pipes all the way actually loses heat and velocity which also causes a loss in efficiency, actually most dynos have shown the stock style headers spool sooner, and between porting and remaking something similar design to stock that flows better the benefits should show when he dynos it
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Old 11-21-2006, 09:11 PM   #25
kb2spn
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Awsome
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