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Old 04-22-2015, 03:43 AM   #1
aeromech
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Default Cavalli Stage 2 E85 370hp/375tq

So after a few hardware kinks were ironed out I got my E85 tune done tonight. Car is a 2005 STI with all the bolt ons and a stock motor. Turbo was the Cavalli Stage 2 @ 20 PSI. Car made 370 awhp/ 375 tq. My 91 octane tune was completed a couple weeks prior to this and it made 315 awhp/ 295 tq and turbo was @ 14 psi. I gave my opinions, good and bad, on the Cavalli in the thread started here on Nasioc by RallySportDirect if anyone is interested in seeing more info.

Shop---Soulless Performance in Mesa, AZ
Elevation-- 1000ft
Temp---- 85 degrees F
Dyno----- Dyno Dynamics

Parts on this car include the following... Cobb V3, ID 1000cc injectors, AEM fuel pressure regulator, Walbro 450, GrimmSpeed Downpipe, Invidia catless uppipe, Tomei expreme unequal length header, Fujitsubo power getter 3" exhaust, TGV deletes, Cobb SF intake w/ Cobb post MAF hose and heat shield, Perrin turbo inlet, Grimmspeed TMIC, GrimmSpeed 3 port boost cont solenoid, and Cavalli Stage 2 turbo.
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Last edited by aeromech; 04-23-2015 at 09:03 PM. Reason: Edited temperature, location, and added mods.
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Old 04-22-2015, 04:07 AM   #2
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hows this turbo compared to blouch 1.5xtr
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Old 04-22-2015, 04:59 PM   #3
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I think its more a td05 18 size.
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Old 04-22-2015, 09:48 PM   #4
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Originally Posted by Slamfan4life View Post
hows this turbo compared to blouch 1.5xtr
For a stock location turbo, it is similar in supported horsepower and output. Rallysport says it's very similar to the Blouch 1.5 and the owner of Cavalli says it's even on par with the Dom 2.5 XTR. The Cavalli is a triple ceramic ball bearing turbo though, and all components are designed in house besides the bearings themselves, which are made in Germany. Im trying to figure out how to post my dyno graph for 91 and E85, so i'll get that up soon.
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Old 04-22-2015, 09:49 PM   #5
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Originally Posted by nate_fisher View Post
I think its more a td05 18 size.
It flows 54lb/min, but I'm not sure how the actual dimensions compared to the 18 or 20.

Last edited by aeromech; 04-22-2015 at 10:03 PM.
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Old 04-25-2015, 03:53 AM   #6
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Quote:
Originally Posted by nate_fisher View Post
I think its more a td05 18 size.
I think its much bigger he's only running 14lbs and getting close to 18 numbers at a 18g at 19 psi
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Old 04-28-2015, 02:55 AM   #7
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I think its much bigger he's only running 14lbs and getting close to 18 numbers at a 18g at 19 psi
It flows more than an 18g but looks very similar from the outside. One thing I have noticed with this turbo on both tunes is that the torque drops off pretty hard past 5000 rpm. On my E85 tune i hit max torque at 5000rpm and at 375 ft/lbs. By redline my torque is right around 260 ft/lbs. That's a pretty steep drop when i would really like to see the power pull hard. Not to mention that full boost isn't acquired until around 5000 rpm. So max torque and max boost both hit at 5k, but the power tapers off really fast. It's nice and punchy and all, but I think I'm going with a GT3076 instead for a stock location turbo. I'll give the Cavalli some more throttle time before I make the final decision. And before anyone says it must be the tune, my tuner is pretty damn experienced with these cars. He's the only Cobb ProTuner in damn near all of Arizona, and he learned from some of the best minds in the Subaru world.
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Old 04-28-2015, 03:13 AM   #8
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The 54lb/min is a lot more than a 18gxt that's like close to a 3071 or so
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Old 04-28-2015, 04:16 AM   #9
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The 54lb/min is a lot more than a 18gxt that's like close to a 3071 or so
The jury is still out on whether or not it's really capable of that output though. A 54lb turbo should be able to push over 500 hp easy. I have yet to see any, including RallySport's 15 STI (which is a stage 3, not stage 2) get anywhere close to that. The specs look promising, but the end result has alot of people (including tuners) scratching their heads. I think the design needs to be refined. Its a great concept with the ceramic ball bearings and all, but the in house designed stuff needs some work. Garret got it right and it has been proven time and time again in both the GT3076 and GT3576. If it aint broke, don't fix it. And trust me I aint hating on their turbo, i'm running it for christ sake. That said, I expected much more considering the overall investment in my build.
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Old 04-28-2015, 04:20 PM   #10
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Yeah I know with not only thing turbo but all these turbos that claim big lb/min numbers most just don't seem to add up
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Old 04-28-2015, 05:19 PM   #11
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Keep in mind, low octane and that high ambient IAT are keeping timing low. I think on 93 and anywhere a bit more temperate, and you'd see some big gains. I also assume you have Turner doing the tune, and he is not one to sacrifice longevity for a bit more power, from what I've seen.
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Old 04-28-2015, 06:09 PM   #12
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Quote:
Originally Posted by aeromech View Post
A 54lb turbo should be able to push over 500 hp easy.
I disagree with that statement. On some dynos you'd never hit that number.
Fully maxed out on built motor/cams and on a dynojet you might see 500-540whp

Quote:
Originally Posted by eg33GC View Post
Keep in mind, low octane and that high ambient IAT are keeping timing low. I think on 93 and anywhere a bit more temperate, and you'd see some big gains. I also assume you have Turner doing the tune, and he is not one to sacrifice longevity for a bit more power, from what I've seen.
There was a 91 AND E85 tune. Power does seem low for the mods but I'd be more upset with the boost threshold. 20psi around 4900rpm is really poor for that power and no mechaincal issues
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Old 04-28-2015, 08:16 PM   #13
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I just saw a stage 1 cavalli put down 390WHP on E85 and it spooled much sooner even at 5000'. There must be a problem somewhere.
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Old 04-28-2015, 09:52 PM   #14
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Originally Posted by Shiftace420 View Post
I just saw a stage 1 cavalli put down 390WHP on E85 and it spooled much sooner even at 5000'. There must be a problem somewhere.
I agree, I have a stage 2 cavali on my car and I make 22psi at 4k on 93 and E. Check for boost leaks
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Old 04-28-2015, 11:24 PM   #15
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And that stage one was on a dyno dynamics. (And that peticular one doesn't spool turbos well)


Last edited by point78; 04-28-2015 at 11:32 PM.
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Old 04-30-2015, 06:54 PM   #16
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idk why but thats not much power at all.. i just made 365AWHP and 445tq on E85 with my VF39. i thought this turbo on E85 would be mid 400 hp and tq
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Old 05-01-2015, 12:28 PM   #17
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My tuner and Cavalli are in the process of troubleshooting for my setup. That's all I'm gonna say. I will mention that I am on a stock motor and that I told my tuner above all else to keep the tune safe and reliable. Alot of tuners out there pushing the most they can on E85 to make their customer happy. Until i build my motor, I want longevity. Im sure he could have extracted another 50 whp and tq if he had gone beyond 20 psi and upped timing. Also, I wasn't tuned for pure E85 summer blend, but to accommodate for both high quality and low quality E85. My dyno sheet shows E74 as the actual fuel type tuned for.

Last edited by aeromech; 05-02-2015 at 05:31 PM.
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Old 05-04-2015, 03:21 AM   #18
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Quote:
Originally Posted by Paul View Post
I disagree with that statement. On some dynos you'd never hit that number.
Fully maxed out on built motor/cams and on a dynojet you might see 500-540whp



There was a 91 AND E85 tune. Power does seem low for the mods but I'd be more upset with the boost threshold. 20psi around 4900rpm is really poor for that power and no mechaincal issues
I was under the impression that turbocharger manufacturers rate their supported horsepower by crank horsepower not wheel horsepower. So a 540 hp capable turbo would really equate to a high 400 horsepower at the wheels. I could be wrong on this though, as I have never asked any of the turbo manufacturers directly. As far as my lack of power compared to many other E85 tuned STIs, I think its a mix of a conservative tune, a conservative dyno, and possibly a turbo that needs some tlc. That's what I'm hoping at least.
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Old 05-04-2015, 03:32 AM   #19
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I just saw a stage 1 cavalli put down 390WHP on E85 and it spooled much sooner even at 5000'. There must be a problem somewhere.
Generally speaking the smaller the turbo the quicker the spool, so that's not all that alarming. What dyno was that car tuned on and what was target boost and timing? I've seen alot of cars throw down well over 400 hp and torque, but then again they were over 20 psi and most had built motors; a few were on stock motors as well. Im on a stock motor, so one of the things my tuner and I agreed on was keeping it under 400 at the wheels. He wouldn't have gone over 400 if I begged him to, not until I build my motor at least. One thing you guys need to understand is that i am nowhere near maxed out on my current setup. This car was tuned for reliability, not bragging rights.
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Old 05-04-2015, 06:36 AM   #20
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That video I posted above is the Cavalli stage 1, e85, at 5000'.

It's on a dyno dynamics, and this particular one always spools turbos a little slow due to its ramp rate, or something? (I think stock on this one is usually about 215, and a stage 2 91pump is about 275hp, for reference)

He said they kept the tune mild due to the stock engine & not wanting to push it(from experience with him, that's usually under 400hp and 20psi on corn.)-but if you look at the plot at the end, it looks really nice.

Hell, the stage 1 out spooled my 38lb 16g on this same dyno, and held torque pretty well.

How does your plot look compared to the one in the video?

Seems like something is definately going on with yours?
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Old 05-04-2015, 09:18 AM   #21
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Harvey is a good tuner and I doubt he is pushing the engine hard especially with the stock internals . In all my experience with working with him he is not into going to push an engine too hard, erring towards safety.
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Old 05-04-2015, 11:52 AM   #22
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Quote:
Originally Posted by point78 View Post
That video I posted above is the Cavalli stage 1, e85, at 5000'.

It's on a dyno dynamics, and this particular one always spools turbos a little slow due to its ramp rate, or something? (I think stock on this one is usually about 215, and a stage 2 91pump is about 275hp, for reference)

He said they kept the tune mild due to the stock engine & not wanting to push it(from experience with him, that's usually under 400hp and 20psi on corn.)-but if you look at the plot at the end, it looks really nice.

Hell, the stage 1 out spooled my 38lb 16g on this same dyno, and held torque pretty well.

How does your plot look compared to the one in the video?

Seems like something is definately going on with yours?
There is something. Im not going to state it over and over in numerous threads though. The Rallysport thread has more info on my tune. One thing I will mention is that based on the proven power bragging E85 tunes that have been posted, my HP isn't too shabby. Its actually higher than many other tunes at higher boost. But because my torque isn't in the 400s, people seem to think my car has a bad ring land or something. That FXT made awesome power considering the elevation and boost (if it was at 20 psi). But I would consider that car an exception not the rule.

Last edited by aeromech; 05-04-2015 at 12:15 PM.
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