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Old 09-16-2013, 11:39 AM   #1
RexFTW
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Default 2003 WRX with S400SX 67mm FMW 2.6L, Updated/shakedown results

Hi all,

I have finally got this car running after a looooooong time, and it is better than I had hoped it would be. Granted, I had to stop at 28 psi as any more than that was having fuel pressure starting to fall from the single walbro 400 so there is a long ways to go after I change the fuel system and go to e98/ignite red instead of e85.

I didn't have time to get the fuel upgrades 100% completed before the event on Saturday so this is where the car is going to sit for a bit while we get the fuel system put together.

Event: Dyno Pull
Location: Aspec tuning (renting their dyno)
Ambient Temp: ~75* on the dyno
Elevation: ~600 ft
Weather: Partly cloudy

Car: 2003 WRX
Tuner: Me
Dyno Info: Dynojet
Transmission: 07 STi 6 speed with Exedy triple plate
Engine Management: Carberry ROM on v7 ecu - will be going to a Vipec for the spring
Gear: 3rd
Peak HP at RPM: 631 @ 7800
Peak Torque at RPM: 525 lb/ft at 5600 rpm uncorrected
Baseline hp/tq for a stock on same dyno: 04 STi ~220-230 whp uncorrected
Target Boost: 28 psi
Target AFR: 11.6-11.7
Fuel: E85

Engine:
Maxwell Power 2.6L - Cosworth 79mm crank, JE 102.33 pistons, 1200 hp +2 rods, sleeved, o-ringed, ACL bearings (I believe), arp case studs
The heads are v7 ej207 heads worked over by Maxwell Power, cnc'd, ported, polished, Kelford 280 cams, +1mm valves, springs, retainers
Head studs are ARP 625+ on the outside 4 and 13mm headstuds on the center two

Intake/turbo:
S400SX 67mm FMW 1.25 AR T4
Custom Bell core intercooler with 3" charge pipe (Fabricated by Six Star Motorsports)
Boomba billet throttle body
Stock intake manifold opened up for the throttle body (going to do a NA 2.5 short runner manifold over the winter, ran out of time)
Phenolic spacers

Exhaust:
Fobiawrx fog light mounted T4 larger runner manifold with twin 44mm Tial wastegates
4" dump right next to the turbo

Fueling:
APS twin injector TGVs with ID2000 and ID1000 for when the car finally gets pushed on e98/ignite red on a Vipec V88.
Single hard wired walbro 400
Fuel pressure regulator @ 3 bar

A whole crap ton of other stuff as well but those are the main things.

I also took this car to the track on Saturday but was getting shift lock out in every gear. The one time I connected a 3rd-4th, by fully lifting at 7500 rpm, I went 90.x in the 1/8 and 130.x in the 1/4 so the power is there, I just need to be able to shift and get a clean pass to know what it is actually capable of at this power level. I should be able to go give it a shot in a couple of weeks.



This is also without AVCS as yet (I think one of the sensors or wiring is going bad but didn't have time to get a new one by Saturday). I also need to work on trying to smooth it out a bit. She pulls extremely smooth and is very brutal right from 4500-5500 rpm on the street though.

20 psi by 4800 rpm (28 by 5200), without AVCS, is far better than I was expecting for spool.

Thanks again to Six Star Motorsports for helping me put this project together!

Ignore the dust on the car - it has been in the shop forever, lol.


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Last edited by RexFTW; 09-27-2014 at 10:55 PM.
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Old 09-16-2013, 01:04 PM   #2
Zee Biker
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In before the holy cow train that IS coming.
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Old 09-16-2013, 01:35 PM   #3
everdying55
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fap fap fap fap fap fap fap
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Old 09-16-2013, 01:48 PM   #4
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Looking good! Cant wait to see the power once all the issues are fixed. Im glad the turbo kit is working well for the big turbo. Twinscroll foglight kits rule all!
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Old 09-16-2013, 02:10 PM   #5
rexworx
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Oh my!!!
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Old 09-16-2013, 03:08 PM   #6
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God damn look at that 300whp by like 4300 and a **** load more power all the way to 8800


I think I want to copy you slightly. But with a s300sx fmw. Same motor setup. 2.6L long rod is ****ing boss.

That's funny I've wanted to run a vipec v88 too.


We better see some rally style antilag hahahaha 20psi at idle but really though. Wiring in rotational idle etc would be a really nice feature for cool down. I think it's more of a pita on a cable throttle car though.
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Old 09-16-2013, 03:11 PM   #7
RexFTW
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Quote:
Originally Posted by WhatTurboLag? View Post
God damn look at that 300whp by like 4300 and a **** load more power all the way to 8800


I think I want to copy you slightly. But with a s300sx fmw. Same motor setup. 2.6L long rod is ****ing boss.
Boost recovery is surprisingly good as well.

Just wait until AVCS is running - it should gain several hundred rpm of spool.
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Old 09-16-2013, 03:32 PM   #8
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Quote:
Originally Posted by RexFTW View Post

Boost recovery is surprisingly good as well.

Just wait until AVCS is running - it should gain several hundred rpm of spool.
At least 600 would be my guess.
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Old 09-16-2013, 03:46 PM   #9
RexFTW
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Quote:
Originally Posted by Maxwell Power View Post
At least 600 would be my guess.
That would be insane. 20 psi by 4200 on a turbo this size?!

It spools a smidge faster on the street as well from air being rammed into the turbo.
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Old 09-16-2013, 03:58 PM   #10
Mishal Jackson
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Why torque so much lower? Can't just be because of those cams can it?
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Old 09-16-2013, 04:02 PM   #11
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Looks great! I love the fog light mount on the Bugeye!
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Old 09-16-2013, 04:08 PM   #12
RexFTW
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Quote:
Originally Posted by Mishal Jackson View Post
Why torque so much lower? Can't just be because of those cams can it?
The whole setup is geared for mostly top end and AVCS is not functioning yet.

With AVCS working, the spool + VE from it will bump up torque quite a bit.

What would you expect the car to make in terms of torque at 28 psi?
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Old 09-16-2013, 09:53 PM   #13
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I think people are used to seeing the whole tiny turbo/big motor power and torque numbers and just expect everything to have more torque than horse power. When you do as much to improve airflow as you have, I just don't see picking up a ton of PEAK torque. Broadening the curve? Absolutely!!! This thing is soooooo sweet. Except the intercooler looks crooked . But seriously though, this bugeye is a freakin BOSS!!!! Love it. The power just hangs on forever!! Ok, I'm done.
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Old 09-17-2013, 09:36 AM   #14
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Quote:
Originally Posted by xluben View Post
Looks great! I love the fog light mount on the Bugeye!
I see what you did here.
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Old 09-17-2013, 09:56 AM   #15
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I don't know, I don't think that compressor cover is big enough JK I do like the Fobia foglight front mount, pretty direct into the IC!

The spool should be amazing if like Dom says you pick up 600 rpm's with the AVCS, damn you'll make 300wtq by around 4k and be able to rev it out to 8500! That's crazy for this big of a turbo and the 280 cams. That will drive pretty well on the street! Good job here!

You do need to straighten out that inter-cooler though
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Old 09-17-2013, 10:28 AM   #16
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Whoa.
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Old 09-17-2013, 11:04 AM   #17
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I think the issue with the knock has to do with the Carrberry rom. Having a similar problem in a friends car that I tune with the Carrberry rom.
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Old 09-17-2013, 11:09 AM   #18
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^^What knock are you referring to?
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Old 09-17-2013, 12:11 PM   #19
RexFTW
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Quote:
Originally Posted by manitou View Post
I don't know, I don't think that compressor cover is big enough JK I do like the Fobia foglight front mount, pretty direct into the IC!

The spool should be amazing if like Dom says you pick up 600 rpm's with the AVCS, damn you'll make 300wtq by around 4k and be able to rev it out to 8500! That's crazy for this big of a turbo and the 280 cams. That will drive pretty well on the street! Good job here!

You do need to straighten out that inter-cooler though
The intercooler is "straighter" now, I should take another picture. It wasn't actually the intercooler that was off, it was the bumper as for that picture the car was still in need of some work for the oil cooler and the bumper wasn't sitting right. The oil cooler was canted out a little bit and there wasn't enough cut out of the fog light to let the bumper sit all the way back so it was drooping on that side in back as it didn't make it to the clip.

Quote:
Originally Posted by wil06STI View Post
I think the issue with the knock has to do with the Carrberry rom. Having a similar problem in a friends car that I tune with the Carrberry rom.
I need to look more into why it was so wavy, but it wasn't pulling timing (nor is timing all that aggressive yet), and yes, the RPM settings are covering that area. Could very well be a peculiarity or problem with the ROM though as this is the first car I have pushed this far on it - I have done a few mid 400 to low 500 wheel cars on this ROM that don't show this kind of anomaly and in the logs timing, boost, and fueling are all smooth.

I had myself convinced it was a problem with the dyno, or clutch, or the way the car was strapped down (all that stuff up front doesn't make this very convenient and the car tried to walk around a little bit) as practically every pull showed this sort of waviness (not as abrupt as that 7800 rpm wave is) to it that doesn't show up on other cars I tune. Even running much lower timing (about 5* less than shown here) and/or less boost and/or richer, it was still very wavy and was making substantial power per degree of timing even at this level.

Just to be safe next week when she is running again I'll try and find the best noise cancelling headphones I can locate and listen to her with my det cans and run an airboy/VD to see if it shows up at all there.

Last edited by RexFTW; 09-17-2013 at 12:18 PM.
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Old 09-18-2013, 02:36 PM   #20
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Sick!!!

That thing makes power nice and early and just keeps on going until you let off.

That's exactly why I love these fobiawrx foglight setups. Just wait until you crank the boost and the power looks like your going to go to the moon!
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Old 09-18-2013, 02:52 PM   #21
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Originally Posted by TDagen View Post
Sick!!!

That thing makes power nice and early and just keeps on going until you let off.

That's exactly why I love these fobiawrx foglight setups. Just wait until you crank the boost and the power looks like your going to go to the moon!
I seriously can't wait. I started hashing out the new fuel system with the guys at Six Star last night, and it is going to be pretty sick.
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Old 09-18-2013, 04:18 PM   #22
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Can't wait to see more updates....
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Old 09-18-2013, 07:46 PM   #23
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Seems kinda low for 28 psi on a turbo that size. Don't get me wrong, I'm stoked to see this girl running finally and making power. I'm proud that it's our engine. I just noticed the 28psi mark and thought..."hmm.... that's a big ass turbo. I made 598whp on a similar dyno with a smaller turbo on less boost. Something is up."

Shoot me an email with your timing curve data. Did you try leaning it out any more? Seems to me the wavy top end could be smoothed out with some leaner mixtures. I know your initial tune was very conservative. I'm hoping this one is still very conservative.
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Old 09-18-2013, 08:10 PM   #24
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Quote:
Originally Posted by RexFTW View Post
I seriously can't wait. I started hashing out the new fuel system with the guys at Six Star last night, and it is going to be pretty sick.
Awesome!!

I can't wait for updates after the new fuel system!
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Old 09-18-2013, 08:16 PM   #25
TDagen
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Quote:
Originally Posted by Maxwell Power View Post
Seems kinda low for 28 psi on a turbo that size. Don't get me wrong, I'm stoked to see this girl running finally and making power. I'm proud that it's our engine. I just noticed the 28psi mark and thought..."hmm.... that's a big ass turbo. I made 598whp on a similar dyno with a smaller turbo on less boost. Something is up."

Shoot me an email with your timing curve data. Did you try leaning it out any more? Seems to me the wavy top end could be smoothed out with some leaner mixtures. I know your initial tune was very conservative. I'm hoping this one is still very conservative.
Remember this is a Borg Warner, these turbos shine with high boost. He is probably just getting into the area where this turbo will really start to shine at 28psi.

Plus I'm sure he isn't doing a kill mode tune right away with the awesome brand new motor after having the car down so damn long!
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