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Old 05-04-2013, 05:44 PM   #76
akfmx
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Old 05-05-2013, 01:54 PM   #77
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Well, finished the downpipe. My brother and I are still trying to dial in the settings/technique so the welds aren't very pretty, but it will definitely hold up. And I may eventually coat the pipes with VHT, and if so I will probably grind down and make the welds look pretty.

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Old 05-05-2013, 03:42 PM   #78
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lookin good dude!
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Old 05-24-2013, 02:00 AM   #79
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Got my car back from Seth today. They installed the wrx injectors and tuned the eManage. Feels awesome! Definitely stock wrx quick, if not quicker.

Gotta figure out why it doesn't want to hit waste gate pressure...Seth said they couldn't get more than a few psi and waste gate should be anywhere from 5-8 psi. Said they did a boost leak test and didn't find anything. I'm hoping its not the turbo on its last leg. Waste gate isn't stuck open and tightening it doesn't help. Unless there's a massive pre-turbo exhaust leak or a huge boost leak....
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Old 05-24-2013, 02:17 AM   #80
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regardless, that Fozzy is awesome!
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Old 05-24-2013, 12:30 PM   #81
Alaskan EJ20
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No boost leak, then start with exhaust leak, is there any cats between turbo and engine, then look at the turbo if those checkout.
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Old 05-24-2013, 02:09 PM   #82
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No cats on the car. I'll check for exhaust leaks but you'd think a leak large enough to prevent boost from even reaching wastegate pressure would be pretty obvious, no?

I don't know the history of the turbo but it looked fine when I put it on. No obvious bent/damaged fins, no oil leaks or smoke, wastegate looked good and functioned correctly. Of course I'll will check it out again if I can't find anything else.
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Old 05-24-2013, 09:10 PM   #83
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Well, hooked up my leak tester in place of the air filter and could hear the air rushing out almost as fast as I could put it in. Traced it to the intercooler...it's leaking terribly from the weld on the inlet as well as the block off plates on the back. Think I found the problem
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Old 05-24-2013, 09:47 PM   #84
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Glad you found it. How did they miss it? And how were they able to tune it with it leaking so badly?
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Old 05-24-2013, 10:23 PM   #85
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Cuz they apparently will tune anything. Only person they turned away was quasi.

Lil rant lol
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Old 05-24-2013, 11:10 PM   #86
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Haha lets not start throwing around bad words on this thread. I don't know how they didn't notice it leaking there, as it wouldn't hold any pressure at all with my tester.

But I also should have done a leak test before bringing it to them. It somehow slipped my mind.
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Old 05-25-2013, 10:55 PM   #87
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So while I wait for the next business day to hopefully get my intercooler welded, I decided to stiffen up some things...







Using 3M Windo-Weld urethane. Ghetto? Maybe, but others have reported having great success and a definite improvement. Not quite as stiff as Group N, but for $30 I figured it is worth a shot before spending +$200 for the Group N stuff.

I figure the tranny mount will be the most successful as it had the most voids and felt the weakest. The motor mounts didn't have many voids to fill. And I used a whole tube of the stuff FYI. It was just barely enough to do all 3 and I actually could've used a little more. I'm not looking for a huge increase..just looking to reduce some of the drive line slop and anything is better than stock.

Also had a wrx pitch stop delivered to me courtesy of Rascal_Rex! Not sure if this is really an upgrade now that I think about it. My stock one is steel and the wrx one is plastic Oh well, it looks better and significantly lighter.

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Old 05-26-2013, 01:44 AM   #88
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Looks like the 2 pitch stops are differwnt lengths as well?

I did all solid motor mounts and love it. Stiffn up my rear axle cross member to. I need a solid tranny mount soon.

Last edited by cosseywrx; 05-26-2013 at 01:49 AM.
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Old 05-26-2013, 01:48 AM   #89
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Good job with the window weld stuff. I've read about that mod too. Never heard of it for the motor mounts, but always for the trans mount. Some people have had problems with it curing. Hopefully you don't have that issue. Ghetto, maybe, but DIY on the cheap is always awesome. Please report back on how they feel when you reinstall them.
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Old 05-26-2013, 07:51 PM   #90
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Quote:
Originally Posted by cosseywrx View Post
Looks like the 2 pitch stops are differwnt lengths as well?

I did all solid motor mounts and love it. Stiffn up my rear axle cross member to. I need a solid tranny mount soon.
I don't think they are but I never really checked. Just assuming its the same and will work haha.

Quote:
Originally Posted by Dominator View Post
Good job with the window weld stuff. I've read about that mod too. Never heard of it for the motor mounts, but always for the trans mount. Some people have had problems with it curing. Hopefully you don't have that issue. Ghetto, maybe, but DIY on the cheap is always awesome. Please report back on how they feel when you reinstall them.
Thanks Dom. Yea I saw a couple threads on various forums of people doing the motor mounts and seeing an improvement. I will definitely update once I test them out. I have them curing in the furnace room right. Will probably keep them there a few more days. I've heard the tranny mount can sometimes take a week to fully harden due to the amount of urethane it uses.
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Old 05-27-2013, 04:48 PM   #91
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I (Seth) boost leak checked the car personally as part of the diagnostics to try to isolate the issue....kinda basic stuff here guys.

We were able to get it to hold about 10psi then I stopped pressurizing it. There was zero indication of what was described here. I suspect the crack around the inter cooler may have opened up afterwards.

Since all of the work we do has a warranty the customer has been informed and will be welcome to come back to have the tune rechecked. I will throw in a free dyno print out for your trouble as well.

Anyway glad to see this project going well now. We think you have done some really nice work and have a good eye for detail.
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Old 05-27-2013, 05:59 PM   #92
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Thanks Seth. Didn't mean to open a can of worms. I appreciate all your help and communication. I realize my car and modifications aren't what you normally see in your shop

To everyone else, Seth called me after I sent him a pm regarding the tune. I'm not pointing any fingers and I really appreciate him reaching out and offering to help dial in the tune after the leaks are fixed! Good customer service and relations.
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Old 06-04-2013, 03:10 PM   #93
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Welp, some not so great news...

So I got my intercooler rewelded after taking it apart and pulling off the endtank. It comes apart really easy, just bend all the tabs back and pull it off. Its sealed with a rubber gasket that looks like a large rectangular o-ring. However, I don't know if my gasket was warped or what, but it was too big to fit back in the place where it is supposed to fit. As soon as you got one end laying flat, the other end was doing some crazy curve action and/or not laying flat. So I ended up ditching the gasket and using "Right Stuff" RTV which worked really well.



Put it back on the car and leak tested once more....Everything is sealed up BUT now I see there is a leak where the injectors go into the manifold. Atleast on the passenger side. Didn't bother checking the other side. Doesn't really surprise me, since they are wrx injectors going into a manifold that was made for a totally different injector (air assisted injectors).

I figured I would take it for a test to see if the car was building boost any better now that the major leaks were fixed, considering I'm only trying to get 6 psi. Nope. Car only hit like 1.5, maybe 2 psi. Which is worse than before. Part of this is because Seth was able to get the car to hold more pressure with an MBC, which I have taken off, because if the system is working like it should with little to no leaks, it doesn't need an MBC. It is supposed to use the wastegate as the boost regulator.

I am now convinced my turbo (which I got for free) is shot Atleast that will be the next thing I test...finding another TD-04.
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Old 06-04-2013, 03:20 PM   #94
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Sounds like the exact same results we were seeing prior to the IC leak. I have some turbos kicking around I can give you one to try..

How much pressure are you putting into the system? If the injector seals pushed out I have more we can try. I never really pushed it past 10psi knowing that you wouldn't be running that much.

Keep in mind as well you may have some sort of exhaust restriction. You may want to try just running the down pipe with out the rest of the system to rule out any thing else along that line. Also I'm not sure on your up pipe but I have seen catted up pipes do this as well.
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Old 06-04-2013, 03:49 PM   #95
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Thanks Seth. This project is turning into a huge headache haha. The uppipe has no cats, it's custom 2" pipe that I made.

The tire inflator I'm using has a built in gauge. Unfortunately the lowest it goes is 10psi and I couldn't get the system to go over that. Like you, I didn't think much of it since I'm not trying to run that much.

I guess I will try running just the DP, although there is no cats left in the system. Only the stock resonator and the muffler.
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Old 06-06-2013, 01:18 AM   #96
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I can now rule out exhaust restriction as being the culprit. Just took the car for a ride, open downpipe and still only getting a little less than .02 MPa

My brother should be picking up another turbo for me, so I might get to try that this weekend. I am almost 100% positive that is the problem. I took the intake off and looked at the compressor wheel...again. It doesn't look TOO bad compared to other pictures I have seen but the blades do have little knicks and there is some scarring on the housing. And this time I did notice shaft play, side to side. Picture for reference:



Oh and the DIY tranny and motor mounts seem to be working great! The car shakes less upon startup/shut down and the clutch shudder I was getting from the ACT HD upon getting the car moving in 1st gear has improved significantly. It's still there, but not near as bad and isn't as embarrasing in the grocery store parking lot Clunking and/or driveline slop when letting off the throttle quickly has also improved.

The urethane hardens up a LOT. While I was under the car I was feeling the tranny mount and I would have to say the urethane I injected into the voids feels just as hard as the OEM rubber.
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Old 06-06-2013, 01:35 AM   #97
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That's awesome to hear about the urethane. I will have to try that out on my project car this summer. Where did you find that stuff, at Napa or O'Reilly's?
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Old 06-06-2013, 01:38 AM   #98
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I didn't see any at O'Reillys. Got mine at AutoZone. I had them curing for about 4 days before I installed them. The tranny mount still felt soft at that point, but I didn't drive the car for another week after that...so just take that into account. When you have a large volume of the stuff it takes a while to fully cure.
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Old 06-06-2013, 01:43 AM   #99
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I did the urethane trick on all my friends rides back in the late 90's... Works wonders when you're a broke college student.
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Old 06-10-2013, 12:20 AM   #100
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While I wait for my brother to get back from anchorage with the new turbo, I decided to brighten up some things using Zep-a-lume. No before shots but they brightened up nicely really quick.

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