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Old 01-16-2010, 11:44 PM   #1
Cobb Tuning
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Default COBB Tuning Surgeline: 2004 WRX Wagon 2.5L GT35R E85 Employee Car Build

4/20/2010 -- Update at post #16

Location: COBB Tuning Surgeline
Ambient Temp: 43.5 F (daily mean)
Elevation: Approx. Sea Level
Weather: Indoors

Car: 2004 Subaru Impreza WRX Wagon
Tuner: Lance Lucas
Dyno Info: Mustang AWD-500
Peak HP at RPM: 405whp @ 5740 rpm (uncorrected)
Peak Torque at RPM: 388wtq @ 5160 rpm (uncorrected)
Baseline hp/tq for a stock vehicle on same dyno: Most recent stock vehicle reference -- 2010 STi: 239 wtq, 228 whp
Target Boost: ~22-19psi
Target AFR: .75 lambda
Fuel: E85

Engine/Power Modifications:
- EJ257 STi Longblock
- Perrin Performance/COBB Tuning GT35R Rotated Turbocharger Kit
- CP 100mm Forged Pistons
- Cosworth Rod and Main Bearings
- Cosworth Headgaskets
- Brian Crower 272/272 STi Cams
- Brian Crower Valve Springs and Spring Retainers
- Shotpeened Subaru STi Rods
- JDM Subaru 12mm Oil Pump
- ARP Head Stud Kit
- Perrin Performance/COBB Tuning Front-Mount Intercooler Kit
- Perrin Performance/COBB Tuning Topfeed Fuel Rails
- Ported and Polished TGV Deletes
- DeatschWerks 1000cc Injectors
- Walbro 255LPH High-Flow Fuel Pump
- Crawford Performance Air/Oil Separator
- COBB Tuning MAP Sensor Adapter
- COBB Tuning Lightweight Crank Pulley
- COBB Tuning Battery Tiedown
- COBB Tuning Oil Filler Cap
- AEM Standalone Programmable EMS
- AEM 3.5 Bar MAP Sensor
- GrimmSpeed Boost Control Solenoid
- Cosworth Cam Angle Sensor Bracket
- GrimmSpeed Ported and Polished Exhaust Manifolds
- DEI Exhaust Wraped Uppipe and Downpipe
- Greddy EVO2 Catback Exhaust
- COBB Tuning Hardened Exhaust Hangers
- OEM Subaru Engine Block Heater Kit
- Amsoil 20w-50

Driveline Modifications:
- STi 6 Speed Transmission (2006)
- STi Driveshaft
- South Bend Stage 3 Clutch Kit
- Redline Lightweight Shockproof Trans and Rear Diff Gear Oil





I recently finished this rebuild on my personal car, a 2004 WRX Wagon I've owned for about 3.5 years. The last setup was a 2.5L hybrid with an 18G and EWG on E85 that I used, abused and eventually destroyed at the dragstrip I refused to let a broken OEM piston slow me down and immediately began the rebuild. We made the active decision to build the car using commonly available, proven products as a good example of what can be acheived with a "budget" build by Surgeline, without our normal touches -- no AN fittings, no V-Band flanges, no Tial exhaust housings, no rotated manifold, etc. Everything has turned out wonderfully and my car is a great example of the potential available using the good-ole K.I.S.S. principle. Stay tuned for another employee's recent build that is absolutely blinged-out bananas with commensurate dyno results

These are the priliminary dyno tuning results, at both wastegate (16psi) and a couple days later at 22psi tapering to 19psi or so. At a very rich .75 lambda I am out of injector at ~21psi, so I kept boost low on top for the time being. Timing curve is extremely soft as well. My long-term plan is to add a second Walbro in-tank and raise base fuel pressure slightly, then tune to 450whp on E85 for daily driving and hopefully an easy 500whp on C16 for drag strip fun!






Virtually all work was done on my car after work or on Sundays over a 3 month span as I'm currently juggling graduate school and work. I couldn't have finished without a LOT of help! Special thanks to COBB Tuning, Dustin Harris, Tim Bailey, Brandon Lumpkins, Nick Blake, Chris Fogg, Audio Integrations, my parents, and a lot of other people I am forgetting.

Thanks for looking,
Lance Lucas
COBB Tuning Surgeline
16580 SW 72nd Ave
Portland, OR 97224
(503) 670-9500
http://surgeline.cobbtuning.com
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Last edited by Cobb Tuning; 04-20-2010 at 05:11 PM.
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Old 01-16-2010, 11:56 PM   #2
juanmedina
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great numbers for such a low boost and conservative tune, just get ID2000s and raise the boost...

Its been proven on EVOM that there is not really a good reason to run C16 if E85 is available; there is almost no power difference. Fastest street evo is E85 powered and Buschur is switching Bad Bish to E85 full time...no more race gas

Another car with BC cams, how do you guys like them?
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Old 01-16-2010, 11:57 PM   #3
Gray Ghost
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Very nice ride!
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Old 01-17-2010, 12:27 AM   #4
jmlaser
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Nicely done I like your approach

How do you like the South Bend Clutch?
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Old 01-17-2010, 04:05 AM   #5
project_skyline
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It ceases to amaze me like someone from COBB would decide to run c16 and e85... e85 > c16 all day long. Why waste the money???

Car looks good though.
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Old 01-17-2010, 08:39 AM   #6
dmross
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Looking good! Was the slower spoolup on the higher power run was due to boost control issues or did you get on the throttle earlier or use a lower gear? Are you using the AEM for boost control? After years of fiddling with my AVCR and dealing with temperature changes, spool up issues and overboost, I switched to a Hallman Pro MBC (very K.I.S.S.) and I couldn't be happier.

Good luck and nice car.
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Old 01-17-2010, 11:44 AM   #7
Cobb Tuning
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Default

Quote:
Originally Posted by juanmedina View Post
great numbers for such a low boost and conservative tune, just get ID2000s and raise the boost...

Its been proven on EVOM that there is not really a good reason to run C16 if E85 is available; there is almost no power difference. Fastest street evo is E85 powered and Buschur is switching Bad Bish to E85 full time...no more race gas

Another car with BC cams, how do you guys like them?
Quote:
Originally Posted by project_skyline View Post
It ceases to amaze me like someone from COBB would decide to run c16 and e85... e85 > c16 all day long. Why waste the money???

Car looks good though.
BC cams seem to deliver some very nice bang for the buck. Another customer recently chose them with a Dom3.0 and both cars have a nice fat power band from 4k-7k.

E85 is great stuff, no doubt! Tihis car has been on E85 100% full-time since August 2008. Corn booze baby

There is one good reason for me to run C16 over E85 at the track -- I can't afford to build a fuel system that is big enough to support over 500whp on E85 Achieving 500whp on E85 the sustainable way means at least a surge tank and external 044 with -8 feed and -6 return. In a nutshell, using gas (C16) means I get ~30% more capability out of my current fuel system setup. I'll put a fuel system in the car next winter and then get bonkers on E85.

Quote:
Originally Posted by jmlaser View Post
Nicely done I like your approach

How do you like the South Bend Clutch?
It's awesome for the price! Very smooth as well. I doubt it will hold too much more power though.

Quote:
Originally Posted by dmross View Post
Looking good! Was the slower spoolup on the higher power run was due to boost control issues or did you get on the throttle earlier or use a lower gear? Are you using the AEM for boost control? After years of fiddling with my AVCR and dealing with temperature changes, spool up issues and overboost, I switched to a Hallman Pro MBC (very K.I.S.S.) and I couldn't be happier.

Good luck and nice car.
Different day and got on the throttle at a different point, etc. The car spools better after a few consecutive pulls, I think the higher power run was done after quite a bit of idling.

I am using the AEM for boost control, so far I've had decent luck with the controller. It's more or less just a duty cycle controller with some simple feedback corrections for me right now. May stick with it, may go Hallman Pro. We shall see what happens when the winter finally breaks.

Thank you to all for the questions and the kind words!

Regards,
Lance
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Old 01-17-2010, 12:38 PM   #8
The Dome
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Good #'s. I like the Honda battery!
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Old 01-17-2010, 03:29 PM   #9
1_STi_2NV
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Great numbers tho
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Old 01-17-2010, 03:46 PM   #10
fourmicah
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Nice work Lance!

So what does the Cobb/Perrin combo mean on the turbo and intercooler kits, I'm assuming they are modified in some way, what is that?
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Old 01-17-2010, 04:14 PM   #11
twigg107
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Wow.... your car changed so much after the last time I seen it Lance! Did you tune it or tim and did you use a AP2 or are you still tuning it with open source?

Congrats on the awsome power..... Can't wait until I can reach 450ish on my car.
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Old 01-18-2010, 04:15 AM   #12
wrxridah
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Yea whats the deal with the Honda battery? I saw it on Brandon's car as well. What size is that and how much?
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Old 01-18-2010, 05:31 PM   #13
Cobb Tuning
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Quote:
Originally Posted by fourmicah View Post
Nice work Lance!

So what does the Cobb/Perrin combo mean on the turbo and intercooler kits, I'm assuming they are modified in some way, what is that?
We modify them a bit to suit each car's needs -- we disassemble and re-align the turbo kit, make up new coolant lines, fabricate a new intake, etc.

Quote:
Originally Posted by twigg107 View Post
Wow.... your car changed so much after the last time I seen it Lance! Did you tune it or tim and did you use a AP2 or are you still tuning it with open source?

Congrats on the awsome power..... Can't wait until I can reach 450ish on my car.
I tuned it with some helpful pointers from Tim using an AEM Standalone. He can't help himself and ends up hopping in the backseat whenever he hears us goofing around on the dyno The 02-05 ECU has enough limitations that using a standalone made the most sense to get all of the features I'm looking for.

Quote:
Originally Posted by wrxridah View Post
Yea whats the deal with the Honda battery? I saw it on Brandon's car as well. What size is that and how much?
They are Honda 51R batteries. That group size is a bit smaller than OEM and gives some much-needed space up in that corner of the engine bay. Plus it's Honda so it's worth like +15 whp

Thanks for positive feedback guys!

Regards,
Lance
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Old 01-18-2010, 10:10 PM   #14
modaddict
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sold to a good bud
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Hmmm, guess I didn't realize you worked for Surgeline Lance.

Good job! post up your results once the C16 is done! In the mean time, Enjoy your car!
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Old 01-21-2010, 08:01 AM   #15
ShugSTi
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I like the fact that its a wagon and a weekend (meh when I find the time)

Cobb FTW

NIce build!
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Old 04-20-2010, 05:11 PM   #16
Cobb Tuning
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Update!

Location: COBB Tuning Surgeline
Ambient Temp: ~60 F
Elevation: Approx. Sea Level
Weather: Indoors

Car: 2004 Subaru Impreza WRX Wagon
Tuner: Lance Lucas
Dyno Info: Mustang AWD-500
Peak HP at RPM: 454whp (uncorrected)
Peak Torque at RPM: 437wtq (uncorrected)
Baseline hp/tq for a stock vehicle on same dyno: Most recent stock vehicle reference -- 2010 STi: 239 wtq, 228 whp
Target Boost: ~23-22psi
Target AFR: .75 lambda
Fuel: E85


The car has undergone some minor mechanical changes over the past few months:

- Dual Walbro Fuel Pumps In-Tank
- Injector Dynamics ID2000 Injectors
- Perrin Equal-Length Header
- COBB Tuning XLE Blowoff Valve
- C&L v2 3" Speed Density Intake
- Koyo Aluminum Radiator
- Amsoil 15w-50 Fully Synthetic Oil


The results have been great! Here are the new power numbers (wastegate vs. 23-22psi):



Excuse the wavy boost lines, the dyno sensor seems to have gotten a bit shaky. The boost curves are nice and smooth in reality (as seen by the torque curves).


Comparing wastegate vs. wastegate before an after shows a nice incremental power increase from the Perrin EL Header:



Thanks for looking

Regards,
Lance
COBB Tuning Surgeline
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Old 04-21-2010, 05:13 AM   #17
jason miller
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Nice results. Sorry to sidetrack, but do you have anything from the 18g for comparison?
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Old 04-22-2010, 01:13 AM   #18
jibber
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Looks like fun Lance, nice work!!!
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Old 04-22-2010, 11:54 AM   #19
modaddict
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Lance, have you run across the perrin header blowing apart?
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Old 04-23-2010, 12:36 AM   #20
reddevil
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Get it to the track this weekend!!!!!
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Old 07-11-2010, 08:39 PM   #21
Cobb Tuning
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Update time!

Carnage Final score for this engine: 500 whp = 1, stock connecting rod = 0.

Fastener failure on #1 connecting rod. All is trashed!

It happened during the 2nd pass of qualifying at our Race Against Cancer event on July 4th. First pass was 12.4 @ 120.75











Will be starting the new engine build this week!

Regards,
Lance
COBB Tuning
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Old 07-11-2010, 08:57 PM   #22
juanmedina
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ouch.... weird it wasn't making a lot power and the motor was not pushed at all, did the shotpeening on the rod had anything to do with the failure?

again ouch
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Old 07-11-2010, 09:48 PM   #23
boost4life
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man that is so painful to look at...But i'm sure you guys will build it up better then ever.
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Old 07-11-2010, 09:52 PM   #24
project_skyline
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Holy smokes. That is not a pretty looking failure, it looks like it fell from the sky lol.

I'd say 437wtq on a MD is quite a bit of torque for stock rod.

Sucks to hear about the failure.
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Old 07-12-2010, 12:14 AM   #25
subydude02
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carnage it's like your proud of it!! i'm suprised too it failed with not really pushing it that hard! think it had to do with what juan mentioned?? ^^
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