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Old 04-02-2013, 02:41 PM   #51
Zefy
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Quote:
Originally Posted by rs420 View Post
That looks awesome Greg. Another successful swap

Gonna keep it around 5psi? Or bump it up after break in?
well I think my goal is going to be 10-15psi. I'm really not sure what this is capable of. I hear that this setup is good for about 14psi on a td04. This turbo is bigger than that though so I have no idea.

Also, no break in period! Used block and clutch means fun right away.

Only running this low boost because I want to have someone knowledgeable check it out first.
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Old 08-01-2013, 05:20 AM   #52
Zefy
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well I've been driving around for 4 months just playing around with different settings and trying to get it all dialled in. I've been a little terrified of upping the boost so I've been building slowly towards it. I'm also worried that I will get bored of it rather quickly so I've been holding back on everything.

I hit 12psi the other day (sort of on purpose almost...) and holy poop it's quick. Plus it sounds really cool...

So things I've done since the update...

Well first off I swapped out the headlights... I got these puppies... Excessive, yes...



Oh and I have one of these on my table right now getting set up...





Ohhhh hello cusco RS front diff!

And hey look... Type R gearset...? with DCCD...? and DCCDPro!?



And mechanical LSD R180 diff with 4.44FD



yay and 4/2 pot brakes to match the r180 rear!



But for things that I've done so far, I've made quite a few improvement and dealt with the steep learning curve of the emanage ultimate and the hoops you have to jump through to get it to work properly. For instance, it has no way to tune partial throttle boost... It's full throttle or nothing. So I added a system that I stole from an RS25 thread that uses the vtech controller to fix it. Pretty sneaky! And it works!

I also had to deal with my wideband sensor kinda failing... It just gave wrong readings...

Another project I've been working on ever so slowly is my AOS. I didn't want to buy one and the cheapo ones I am sceptical about... So I opted to make my own. It's elaborate and time consuming and so far it's only a box but it's fun to do little machining projects like this.

It started off like this:



And then after some time on the mill it turned into this



And then I made some lids like so



And now it will fill the home of the air conditioning pump after I get fittings and internals sorted out. Been fun so far!

Lots of other little projects that I've been working on and will have to document them a little bit better. Either way, it's an update...
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Old 08-01-2013, 11:07 AM   #53
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Thanks for the update Greg. I'll have to come up there one of these days and say hi. It's been too long. I've also been busy working on the 92' Subaru Loyale. You plan to come down to WCSS15? I'll be there with both the EA81 and EA82. Hope your summer is treating you well.
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Old 08-01-2013, 09:32 PM   #54
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Looks good Greg, some beefy parts for sure. Nice work
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Old 09-07-2013, 04:11 AM   #55
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great build any updates? which center diff are you using?
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Old 09-07-2013, 12:40 PM   #56
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great build any updates? which center diff are you using?
DCCD yo!
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Old 09-07-2013, 06:34 PM   #57
Solar
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ahhh reading skills fail
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Old 09-10-2013, 04:21 AM   #58
Zefy
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ya it's got a DCCD and I'm using the dccdpro universal controller. Works great! Anybody running a dccd diff without a controller is an idiot and doesn't know what they're missing.

Beyond that though, not a whole lot to report. Just buttoning up little things here and there to get it working the way I want. Just drove it 850km's over the weekend for WCSS! Worked flawlessly and because I drove down with a bunch of super old GL wagons that could barely do the speed limit, I actually got good fuel economy too! About 650km's to a tank! Not as good as the n/a with USDM gears but much better than I expected.

I've got a few things in the works which I will post about within the next few days I think. I have my first track day coming up and I have a few things I want to finish first.
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Old 09-11-2013, 02:52 AM   #59
Subaruman5
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It wasn't our faults we slowed you down ;D Nice riding up with you. Was a hoot. Will be watching the progress of your "new car".
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Old 09-12-2013, 12:19 AM   #60
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Been watching your build, good work and has gave me motivation to do work on my project.

First track day is like the first time you have sex! It's great and you will never forget it, but it gets better each time you do it!
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Old 12-09-2013, 06:48 AM   #61
Zefy
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so many things since I swapped the transmission. Hopefully going to get a few things installed in the next few months to prep for the most reliable frankenswap ever...

first up is finishing the AOS/CC thingy I made...



The center was stuffed with filtering goodness..



Huge swagelok fittings put on...



Then a shot of wrinkle black...



And I installed those 4/2 pot brakes months ago with goodridge lines and HP+ pads!







And then after I got them thoroughly covered in brake dust making them no longer red, I made a set of OEM 15" wheels fit...



Questionable...? possibly. No problems yet though.
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Old 12-09-2013, 10:08 AM   #62
Subaruman5
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You always run with only 2 lug nuts on each wheel?
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Old 12-09-2013, 03:21 PM   #63
Zefy
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Originally Posted by Subaruman5 View Post
You always run with only 2 lug nuts on each wheel?
weight reduction BRO.

I also like to keep em loose... that way they can move smoother so less rolling resistance = +1000000000001hp.
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Old 12-09-2013, 03:32 PM   #64
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did you put any steel wool or anything inside the aos?
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Old 12-09-2013, 03:40 PM   #65
Subaruman5
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weight reduction BRO.

I also like to keep em loose... that way they can move smoother so less rolling resistance = +1000000000001hp.
You're truly a genius!
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Old 12-09-2013, 03:42 PM   #66
Zefy
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did you put any steel wool or anything inside the aos?


yes it has this stuff in it...

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Old 12-09-2013, 05:23 PM   #67
pope_face
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I just made myself a ghetto AOS the other day too, using the same curly steel wool stuff... I found a fuel oil filter (basically a metal canister with a replaceable insert), cleaned it out, and added some barb fittings. I think it cost me under $6.50 in total, including some extra hose. It's nowhere near as nice as the one you made though... I've gotta stop looking at build threads where people have nicer tools than mine.

BTW: OEM 15" wheels with 4-pots? Wow, I'm jealous... How did you do it? Or are you planning on offering said fitment services for other people that want to run 15" wheels as well?
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Old 12-10-2013, 02:52 AM   #68
Zefy
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Originally Posted by pope_face View Post

BTW: OEM 15" wheels with 4-pots? Wow, I'm jealous... How did you do it? Or are you planning on offering said fitment services for other people that want to run 15" wheels as well?
15mm wheel spacer and a bit of grinding on the caliper. I bet with a 20mm you wouldn't have done it with no grinding but I don't have any 20mm.

also this amount fits 15" VW bbs wheels with no spacers.
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Old 12-13-2013, 04:40 AM   #69
Zefy
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have collected a few things mostly to improve reliability and a couple of fun things. Lots of cooling mods to be done to improve the reliability of the swap. So far I've been running no oil cooler (even OEM... n/a motors don't come with them) and stock n/a rad. This has been fine for most of what i do with the car but at the end of a 20min track session everything was pretty toasty.

So before I do my next track day I will be installing these things!



Up at the top there is a nice big koyo racing rad. Looks pretty good! still need to get some new fans for it as it is substantially thicker than the stocker. Also debating mounting the fans on the front as I have no a/c core so there is lots of room in front of it.



Also picked up a mocal 19 row oil cooler with the thermostatic sandwich plate so it won't be "overcooled"



And to go along with that, I also picked up a smaller 10mm oil pump (instead of the stock 2011 sti 11mm pump) as it is to big and bypass to much as shown by my UOA. Note the low (still within spec) viscosity of the oil. And this is with oil added and only 5600km.



Also picked up some fun stuff... I got some ball joint adaptor bosses so I can run my sti control arms and get some added caster goodness!

And also a group n clutch plate kit for the stock rear diff. Hoping to better pair it with my cusco front and from what I gather, this plate kit with the group n ramp kit will make a really stout LSD. And only a fraction of the price compared to buying an aftermarket diff!



So I will work through these things probably during the spring mostly. Still work outside for the most part...
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Old 12-13-2013, 10:35 PM   #70
REED FLEMMMMING
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Hey man what cusco did u get, I've been looking at the RS trying to get myself to pull the trigger
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Old 12-13-2013, 11:13 PM   #71
Zefy
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Hey man what cusco did u get, I've been looking at the RS trying to get myself to pull the trigger
it's an older cusco RS. But I only have the front. Hence why I'm building the group N rear. Building up the stock diff with groupN bits I'm hoping will make it comparable to the cusco but a fair bit cheaper. Clutch plate kit new from rallispec and other rally shops is $440 and the ramp kit is $400. Compared to the cusco (~1400 bucks) it is a lot cheaper. However the r160 diffs are cheaper from cusco and the group n r160 bits are way more...

Apparently the cusco modulates a lot better than the group N due to the springs they use in the diff. They're actually coil springs instead of bevel springs like in the picture above.

However currently the cusco front i have reacts WAY faster than the stock 2way rear sti diff. Really noticeable at autoX when I'm powering out of a corner. The front diff locks up and starts pulling you through the corner while the inside rear tire is slipping. Suddenly the rear diff will lock up and shoot me into oversteer. While fun, this is actually really awkward to drive. I would much rather have oversteer first then be able to roll onto the power as the front diff grabs.

Either way... diffs are awesome. cusco, kaaz, carbonetics, whatever... They're all pretty awesome. However if I were to buy a front diff right now, it would probably be a helical/torsen diff like a quaife, modena, ppg, or cheaper like mfactory... But probably not OBX... they sketch me out.

The issue with clutch type front diffs is you have to run a balance between diff performance and syncro performance. If you make your syncros happy by having no friction modifiers then the diff will clunk around low speed corners as the clutches are grabbing and slipping. If you add friction modifiers then you will have a quiet diff but a crappy shifting trans. Helical/torsen diffs do not have this problem as it is entirely gear driven. There are downsides to these to but I think for 99% of people this would suit them better.

Currently I'm running no modifiers and just straight hypoid C. I need to change it out though for some fresh stuff.

Rear diffs... clutch type all the way! Cusco RS would be a solid choice for an r160.
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Old 12-14-2013, 03:03 AM   #72
REED FLEMMMMING
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Ya been looking into them quite a bit. I'm tempted on the obx cause of the price, but I know I'll soil my pants braking hard into a snowy corner.
That Modena on the other hand looks pretty good. It doesn't actually say 1way in the description. Think I'm gonna call up a supplier for a chat.
For the rear end....I took care of it. It's called a REDNEK. The discs and clutch material are made by a French company called air liquide
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Old 12-14-2013, 04:11 AM   #73
Zefy
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Quote:
Originally Posted by REED FLEMMMMING View Post
Ya been looking into them quite a bit. I'm tempted on the obx cause of the price, but I know I'll soil my pants braking hard into a snowy corner.
That Modena on the other hand looks pretty good. It doesn't actually say 1way in the description. Think I'm gonna call up a supplier for a chat.
For the rear end....I took care of it. It's called a REDNEK. The discs and clutch material are made by a French company called air liquide
ah yes the ol' lincoln locker. nice.

modena is not a clutch type LSD and therefore does not have a 1,1.5,or 2 way description. it is torque biasing or "torsen" diff... these work differently and actually a diff very similar to these is available in most of the 6speed transmissions (mostly ap suretrac in ~06 and prior and torsen in everything newer).

just having a look around though, it turns out modena actually makes a clutch type lsd for the 6speeds. it's not cheap... and according to the description, completely undriveable without r-comps.

http://www.flatironstuning.com/p-212...rear-diff.aspx

What I was thinking of was this...

http://www.flatironstuning.com/p-197...02-07-wrx.aspx

so unlike a clutch type diff, this won't lock up. It acts kind of like a 1-way diff in that under decel it is open but under load it's really quite different from a clutch type diff.

much cheaper than modena in the same style is mfactory. When I was unsure of what diff was actually in my transmission i was going to replace it with either the stock sti ap suretrac or the mfactory. These are available locally from imageinmotion (maple ridge) for about 750... pretty good compared to other options available and according to honda folk, these mfactory guys are really good.

http://www.imageinmotion.com/MFACTOR...-TRS-05WRX.htm
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Old 05-01-2014, 05:51 AM   #74
Zefy
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So I haven't updated this in a while. A bunch of stuff has gone into the car that I haven't really taken photos of but I got a bit of stuff to show. I got the oil cooler mounted and the rad installed. I cheaped out on the fans and it's kind of biting me in the butt. It doesn't overheat but I'm worried about summer time, sitting on the hot tarmac at autox between runs. Really wish I could run stock fans but that koyo is just to damn big!



Being that my main goal was increasing reliability, I added a killerb oil pickup and windage tray along with an sti oil pan. You can see I've added the taps already for the oil return line and oil temp sensor to the pan.



I also got a couple new gauges to replace my oil innovate oil and boost pressure gauges. I got a couple PLX DM-6 gauges. I really like these units and they allow me to have only two gauges but monitor 4 sensors. So I now have boost, oil pressure, oil temp, and EGT(not yet installed) all being routed through two gauges! Less clutter with more data!

Will have to grab some better pics of these, but I picked up a set of enkei ES-tarmac wheels with AD07's. The tires are a little big at 255/40/17 but I was somehow able to stuff them on with only minimal rubbing... And only in the front...



Fronts look pretty good as far as fitment goes. I need to roll the fenders a little more than I have already.





The rears though... I had to run the spacers on the rear to fit with the coilovers. I have around 1mm of clearance between strut and tire on all 4 corners. Stupidly lucky that these fit on the inboard side. The outboard side... Not so much...





I'm kind of at a turning point with this car. It's super fun as it is but I'm deciding if I want more. I've got a dozen things that would like to do but I'm not sure I am able to justify the expenditures. The only thing I really have going for me is that it's still cheaper than a new car... Not saying much...
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Old 05-01-2014, 12:11 PM   #75
Bruere
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Very cool thread, lots of work! You're basically building my V-limited with the dccd, front LSD, etc.
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