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Old 10-01-2013, 04:17 PM   #1
Element Tuning
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Member#: 54918
Join Date: Feb 2004
Chapter/Region: MAIC
Location: Gaithersburg, MD
Vehicle:
673 WHP Element
Tuning Pro Comp Engine

Default 473 WHP OMG Pump Gas ;) Element Tuning Hydra EMS 2005 STi Hydramist BV Heads 272 cams

I know I havenít posted in awhile as Iím just so busy and my customers just donít really care to post but I had a rare free moment to put this together.
I was making a joke about pump gas because it seems like people only post E85 dyno plots these days but let's not forget there are still alternatives to that extra power if you don't have access to E85. In this case this customer came to us to add to his existing build from another shop, a Hydramist water/meth system, and tune his Hydra EMS. It's been a very long road for this customer and when it came to us we need to straighten things out under hood and correct some problems along with a few upgrades. We installed a Grimspeed intake manifold and TGV deletes, painted IC pipes to match, made a straight 4" intake, installed the Element Tuning Competition Catch Can, Hydramist water mething injection system, Turbosmart E-Boost, Defi oil pressure, a Pod, Accessory cover, and just corrected the mess that was made of the vacuum lines. Something as simple as poor installation of the vacuum lines could take out a motor so I need this to be correct and well done before tuning.

Numbers
Dyno: Dynajet, Infinite Speed and Performance
Tuner: Phil Grabow Element Tuning
Wheel HP: 473 whp SAE
Wheel TQ: 398 ft-lbs SAE
Target Boost: 22 Psi
Target AFR: 11s
Fuel: 93 pump gas, Hydramist -32F Washer Fluid (80% water 20% meth)
Ambient Temp: 85F
Elevation: 0


As we went in to upgrade to Whiteline sway bars we noticed problems under the car and the uppipe had been leaking melting the axle boot and all the grease was gone. The original uppipe was huge and was really slowing down the turbo spool so we decided to replace the uppipe with a smaller diameter piece to help improve performance. At the same time in went a new axle.
With things sorted under the hood it was time for some tuning.


With a spy hunter smoke screen behind the car I knew someone was no bueno. I looked over the Hydra data logs and nothing really looked that bad, no knock, fueling not excessively rich, and boost was moderate. Did a couple more pulls to see if this could have been residual but no such luck. At this point I really didnít want to give this customer anymore bad news as thatís all he got over the a couple years the build took. My first thought was the turbocharger so we had that inspected and I made sure the oil restrictor was correct.

Onto the motor we ran a compression and leak down test. Compression was good across the board but leak down was marginal for a low mileage motor at 8%. Not like the 2.5%-4% we see with our motors but itís not the end of the world however we could see oil on plugs 1 and 3. Given the basics were acceptable it was probably the valve seals. At this point I informed the customer we could most certainly tear it down and fix what might be wrong but he would get a pretty big bill and I suggested he contact the engine builder and see what they would be willing to do for him. I would support him and them with the data and our findings.

Sure enough when the engine was torn down the valve seals were nicked from the valve stem trimming (not deburred properly) which is what resulted in the oil burning. This was kind of a strange situation since the old shop went out of business along with the owner/builder but the new shop owners who took over much of the operation repaired the motor.

With the engine fixed and our schedules syncing up the car came back to me for dyno tuning. Overall things progressed slowly but with a big gap in time between our installs and with another shopís hands into things I had to go back over stuff. I reconfigured the boost lines after it overboosted and I had to purge the air and set the low and high faults for the Hydramist before we could get busy.


From that point on smooth sailing tuning wise but the fuel system just wasnít built for the potential this car has. A walboro 255 and 1000cc injectors just arenít enough for a built motor, head work, cams, Precision 65 lbs, Hydra EMS, and Hydramist so we had to stop due to the injectors running at over 90% and the fuel pressure dropping. I also had to cut RPM short because it was just barely adequate for this power level (only held 70 psi) to 7200 rpm. You can tell by the power curve that it could continue with useable power higher in the RPM range.

This is a strong number for this dyno as it reads on the lower side with my FRS baselined at 150 whp but more importantly we stopped at safe limit for the fuel system with enough headroom that he can get through the winter at this power level without leaning out. 22 psi I pretty laughable for this setup but well have to do something about his fuel system and oil pressure before we got for that extra boost and 100 whp.


The car was originally road tuned elsewhere and only put down 280 whp so he's really happy with this power for now


Thanks,
Phil Grabow
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Last edited by Element Tuning; 10-02-2013 at 02:43 PM. Reason: edited turbocharger details
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Old 10-01-2013, 06:59 PM   #2
Paul
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Join Date: Feb 2004
Chapter/Region: Tri-State
Location: south nj
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00 RSTI Coupe
Twin Scroll 2.5XTR EJ207

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does the car have AVCS?

You say it has a 35r on it put the pic shows a precision turbo?
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Old 10-01-2013, 08:00 PM   #3
Half Crazed
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Join Date: May 2012
Chapter/Region: NESIC
Location: Manchester, NH
Vehicle:
2008 STi
Blue

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You're looking at it with 0 smoothing.. does that matter? I thought people usually use 3-4.
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Old 10-01-2013, 10:22 PM   #4
Th3Franz
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Join Date: May 2003
Chapter/Region: MWSOC
Location: Wisconsin
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2005 Legacy GT
Stage tree fitty

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What RPM did you achieve stable idle with those cams?
more pics of your AOS/catch can?
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Old 10-01-2013, 11:48 PM   #5
Element Tuning
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Member#: 54918
Join Date: Feb 2004
Chapter/Region: MAIC
Location: Gaithersburg, MD
Vehicle:
673 WHP Element
Tuning Pro Comp Engine

Default

Quote:
Originally Posted by Paul View Post
does the car have AVCS?

You say it has a 35r on it put the pic shows a precision turbo?
Yes the car has AVCS.

Yeah it's Precision's equivalent to a 35R don't remember the exact number (6365? .82 exhaust) as we didn't sell it to him.

Quote:
Originally Posted by Half Crazed View Post
You're looking at it with 0 smoothing.. does that matter? I thought people usually use 3-4.
I tend to just leave it a zero for smoothing. It's just a preference and since Dynajets rarely deliver a smooth curve on turbo cars (picks up the wastegate blips) I don't bother smoothing it.

Quote:
Originally Posted by Th3Franz View Post
What RPM did you achieve stable idle with those cams?
more pics of your AOS/catch can?
850-900 RPM but we can get a smooth idle with the Hydra because we can target AFRs a little richer at idle. On this car idle AFR was set to 14.0.

It's a little hard to see the catch can on our STi setup since it's tucked in the corner but here's a better look on our turbo FRS/BRZ



Thanks,
Phil Grabow
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Old 10-02-2013, 01:42 AM   #6
Phatron
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Join Date: Apr 2003
Chapter/Region: SCIC
Location: Tuning Lab
Vehicle:
CEO PhatBottiTuning
2006 STi GTX3582 + Meth

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Quote:
Originally Posted by Element Tuning View Post
850-900 RPM but we can get a smooth idle with the Hydra because we can target AFRs a little richer at idle. On this car idle AFR was set to 14.0.
you can also do this with OS and AP's via the Closed Loop Fueling Comp table.
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Old 10-02-2013, 12:40 PM   #7
wrxsubiemod
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Location: name where you like it
Vehicle:
E85 SoCalPorting
Phatron tuned

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Wow what a story
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Old 10-02-2013, 02:41 PM   #8
Element Tuning
NASIOC Vendor
 
Member#: 54918
Join Date: Feb 2004
Chapter/Region: MAIC
Location: Gaithersburg, MD
Vehicle:
673 WHP Element
Tuning Pro Comp Engine

Default

Quote:
Originally Posted by wrxsubiemod View Post
Wow what a story
Yeah he's a really nice guy and military and I see this way too often. When you get shipped off it's really hard to keep tabs on your project. So far things are looking pretty good for him as he just needs a beefier fuel system to get power up.

Unfortunately no easy fix for the lower than optimal oil pressure other than to increase oil viscosity, limit RPM, and keep an eye on it. As long as it doesn't dip into the 60s under full load it should be ok. At 60 psi this is where in our engine testing program we started to see bearing skimming (at 500 whp).
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