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Old 03-19-2012, 11:22 PM   #1
cnstman
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2004 WRX STi
10.266 @135.62 @ 7,520'DA

Default DSS Carbon Drive Shaft, GD WRX STi 2004-2007 (R180)

I installed a Drive Shaft Shop carbon fiber drive shaft in my 2004 STi this weekend. My STi has 76,xxx miles on it, and I was still running the original drive shaft. I have a sleeved engine, running a rotated GT3582R. The car makes 550+ WHP at 6,200' above sea level. I have almost every upgraded bushing, mount, brace, etc. I am still running stock struts with pink springs, upgraded sway bars, mounts, whiteline race ALK, etc. My car has alot of NHV as you would expect.

Please see this thread for more information directly from DSS on the product itself. http://forums.nasioc.com/forums/show....php?t=2304526

Initial impressions:

This is a top quality part. I could not find any defects in the finish,. The billet ends are just perfect.

I used a brand new digital bathroom scale and got the following weights:

Stock drive shaft weighs 24.4 lbs
DSS carbon shaft weighs 12.2 lbs
The DSS carbon shaft is 12.2 lbs lighter!

The box almost feels empty when you get it. You just can't believe how light and balanced the shaft feels.

Install:

I have an Invidia G200 cat back exhaust on my car. I was able to get the stock shaft out without removing the exhaust. The DSS shaft fits in nicely with no modification needed to the car at all. The only issue I had is that the shaft is slightly to long to clear the pinion nut / shaft. We had to remove 4 horizontal bolts and loosen the 4 larger nuts on the vertical studs that hold the diff in place. Don't take the nuts off, just loosen them to the bottom of the threads. This allows the diff to tilt down slightly, just enough for the shaft to clear the pinion nut and shaft and mate with the pinion flange. tighten the 4 large nuts back up and reinstall the 4 horizontal bolts, the cover and your done.

UPDATE!! there is NO fitment issue with this driveshaft. My output shaft was twisted prior to installing the shaft for the first time. We replaced my output shaft after breaking it and the driveshaft fits perfect. It must have been hitting the twisted part and not allowing it to slide farther to allow clearance to bolt to the rear diff.

My car has Cusco engine and transmission mounts, a Torque Solution dog bone, Kartboy trans cross member bushings, whiteline diff outrigger bushings, upgraded bushings at the top of the rear diff (can't remember brand) and kartboy rear subframe lock bolts. So basically what I am saying is there is very little play in my drive line, and this may have caused the small fitment issue. On a car without all these the drive shaft may have fit without any issue. either way, it was a 5 minute fix, no big deal at all.

Driving Impressions:

The second I let the clutch out, I could tell there was a difference. I am running a ACT Extreme pressure plate with 6 puck solid disc, and it has some chatter on engagement. The chatter seams to have been reduced by 50% or more. It just feels like you can get the car going so much easier. Driving under low boost, lower rpm's the car feels much more responsive. My car does not spool until 4800-5000 rpm (which does not bother me) so this extra response down low is nice. Rev matching is much easier and up / down shifting is much smoother. it seams like you can get all the drive line to sync up much easier.

The drive line noise is much quieter in my car now. I have some good video of the car with the stock shaft on the highway on the way to install the DSS shaft, but the after video I took did not turn out very good. I will do another video of the same road I took the before video on, and post that video as soon as I get it done. Here is the video I have, sorry the after is so short.


I did a couple pulls to 130 ish, and it feels like the car accelerates faster. I am headed to Bandimere on 4-7-12, so we will find out then.

I did a before and after dyno run. I turned the boost down on these runs to try to eliminate wheel spin. There was not a gain in peak HP, but it did gain through the mid range. It did run more boost but it was also richer. there were zero tuning changes on the before and after, so I don't know why it ran more boost. Spool was the same.

HP/TQ


HP/Boost (this is at 6,200' ASL so deduct 3.6 psi to compare to sea-level boost levels)


HP/Air Fuel



I am happy with the purchase. My car at times can be a pain to daily drive, especially in stop and go traffic. This shaft has made that much more enjoyable. The reduction in noise on the interstate is also a positive. The car feels much more responsive, and seams to accelerate faster. Flat foot shifts in all gears up to 5th feel great. Great product backed by a great vendor / manufacturer!
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Last edited by cnstman; 04-18-2012 at 03:02 PM.
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Old 03-19-2012, 11:30 PM   #2
cnstman
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10.266 @135.62 @ 7,520'DA

Default

Here are some pictures of my stock shaft vs the DSS carbon shaft.




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Old 03-19-2012, 11:30 PM   #3
Bishop
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Nice review!
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Old 03-19-2012, 11:40 PM   #4
cnstman
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10.266 @135.62 @ 7,520'DA

Default

Forgot to add, DSS did not give me this shaft for the review. I paid for it, and I feel it was money well spent.

I also got and installed a set of their new 800 hp rear axles. I have broken 2 of the 600 hp axle bars, as well as an inner and outer stock CV. the new 800 hp kit comes with upgraded CV's, along with their new bar material. I will put up a separate review for those after the track day to see how much better they hold up to 16 psi launches on drag radials, and hopefully some more 1.5xx 60' times.

This new complete replacement axle is a great addition to their other offerings. The level 5 kit was just to much $$ for me, so this bar at 999 is an acceptable price point, for what appears to be a great product

http://www.driveshaftshop.com/import...0hp-rear-axles
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Old 03-20-2012, 03:52 AM   #5
thenewrick
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Sounds good. Did you notice any weird vibrations or noises in 6th gear?
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Old 03-20-2012, 09:07 AM   #6
cnstman
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10.266 @135.62 @ 7,520'DA

Default

I have not noticed any vibrations in any gear. I have had the car up to 130 mph, and it feels smoother than before.

I do have a noise that I did not hear before, its kinda like a window is cracked. hard to describe, but it sounds like a wind noise, its a higher pitch noise. I can't say if this noise is new, or if since the drive line noise is less that now I can hear this other noise.

regardless it is quieter in my car than before, which is a nice change for me.
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Old 03-20-2012, 09:45 AM   #7
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Default

very nice, these have really been picking up steam
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Old 03-20-2012, 09:55 AM   #8
todeswalzer
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Great review. The experience sounds just like mine as my suspension and drivetrain is done up like yours, only I have a little over 1/2 the whp you do. Everything feels so much smoother and just a little more quiet
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Old 04-01-2012, 09:37 AM   #9
cnstman
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Had my car up in the air yesterday. Nothing has changed since the initial install. No rubbing. No issues. My only complaint is that now my car has less drivetrain noise I am now hearing other annoying noises that were masked before!
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Old 04-11-2012, 01:44 PM   #10
cnstman
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Default

If your worried about the strength of this drive shaft, don't be. I went drag racing last weekend and broke the output shaft in the transmission. the drive shaft is still perfect (other than part of my output shaft being stuck in the yoke) I am impressed!



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Old 04-11-2012, 02:24 PM   #11
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wow, sucks to hear on the trans, but great for the dss
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Old 04-11-2012, 02:35 PM   #12
cnstman
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Default

Quote:
Originally Posted by IMPORTIMAGE View Post
wow, sucks to hear on the trans, but great for the dss
its actually an easy fix, and much cheaper than I thought it would be. the broken shaft is removed with transmission tail housing. the transfer gear appear to be unaffected, the shaft just sheared off.
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Old 04-18-2012, 03:01 PM   #13
cnstman
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UPDATE!! there is NO fitment issue with this driveshaft. My output shaft was twisted prior to installing the shaft for the first time. We replaced my output shaft after breaking it and the driveshaft fits perfect. It must have been hitting the twisted part and not allowing it to slide farther to allow clearance to bolt to the rear diff.
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Old 11-06-2012, 04:43 PM   #14
cnstman
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Well after many many 1.5x 60's this year, I broke another output shaft. DSS CF drive shaft and 800hp rear axles/cvs are still perfect.
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Old 11-06-2012, 05:14 PM   #15
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geez, that really says something. great work!
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Old 11-06-2012, 05:46 PM   #16
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Ugghhhh, can't wait to get this piece from IIR. This thread has be salivating!!!
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Old 11-25-2012, 12:15 PM   #17
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Quote:
Originally Posted by cnstman View Post
If your worried about the strength of this drive shaft, don't be. I went drag racing last weekend and broke the output shaft in the transmission. the drive shaft is still perfect (other than part of my output shaft being stuck in the yoke) I am impressed!



Thats Bad Ass!
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Old 11-27-2012, 02:24 AM   #18
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Damn!
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Old 11-30-2012, 10:29 PM   #19
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S.H.I.T. Me!! I was tempted to get one of these from RSD last week when they sent me that email special on these things.
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