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Old 09-19-2013, 11:59 AM   #1
Motion Lab Tuning
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Join Date: Nov 2009
Chapter/Region: South East
Location: AEM Infinity Trained
Default Motion Lab Built 09 WRX - Cosworth/ETS 6466/Manley Performance- The Quest for 800

Though some view the 2008-2010 as the ugly duckling of the various WRX generations, we had one customer who doesn’t think so at all. He had big aspirations for his 2009 WRX and we were happy to help him out. The car came to us sporting some bolt-on mods like a turbo back exhaust and Turbo XS FMIC kit, but for some reason was being controlled by an old TurboXS Delta Utec piggyback. We sat down and began to put together a game plan for his goals with this project. He essentially wanted to keep it as comfortable and compliant as possible, but with a big surprise for those suspecting a slightly more stock WRX. He has one target in particular which is one of his friends that recently picked up a GT-R, haha. He explained his goals and we set out a budget. Over the next few days we exchanged ideas and discussed what was going to need to be done to make his dream a reality. We settled on the ETS 6466 rotated turbo kit in light of their recent results and stellar quality, and then focused on everything needed to make this set-up really put some power down.

We started out with a focus on building a shortblock capable of withstanding the abuse, but also with the ability to allow for higher RPM redline to provide a more suitable powerband with the large PTE6466 turbocharger going in place. We sent out the original case to our friends at LA Sleeve for their ProCross ProCool “Closed Deck” sleeves. These sleeves are similar to the old AEBS product, but with superior cooling and durability. Then we turned to the guys at Manley Performance, as we do with almost every build, for the high quality internals that are required for the type of power the 6466 has the potential of making. For this build we are utilizing their amazing 79mm billet lightweight crankshaft, their “TurboTuff” I-Beam connecting rods, and their Platinum series lightweight 99.5mm pistons. We used ACL Race bearings as we do in all of our engines, they have the sizes we need to keep the bearing clearances perfect and consistent throughout the motor. We were confident in this combination and moved on to discussing the cylinder head work to allow the power to climb steadily until redline.

First step for the cylinder heads, weld them up and get them ported! We have gone a step further than most and truly dissected the EJ castings. We sacrificed a bad casting to chop into small pieces and examine the coolant passages and material thickness throughout the ports. Just like our short blocks, we don't accept the norm we reengineer for better results. Everything from the ports to the combustion chambers were worked, enlarged, blended, and enhanced to allow the best flow possible. Parts started trickling in from Manley Performance and Kelford camshafts. We are using +1mm oversized RaceFlo stainless steel valves, 92lb seat pressure spring set, titanium retainers, and the Kelford 282/278 grind. The Kelford 272 and 282 grinds require you to notch the head castings to allow for the appropriate clearance with the aggressive lift they offer. They returned from our machinist fully ported, lashed, cleaned, and ready to run.

While the engine work was being completed we accomplished another important task in this build, the necessary drivetrain upgrades. The customer opted to perform a full STi drivetrain swap to move to the 5x114.3 hubs and get the stouter 6speed and R180 installed. The gear ratios might not be ideal for the absolute fastest passes down the 1/4mi, but we are more concerned with the feel of the car on the street as that’s where it will be driven most. We ordered in a new 6speed transmission, R180 rear diff, axles, STi black Brembos, Exedy multi-disc clutch, Stoptech slotted rotors, Stoptech stainless steel brake lines, Stoptech street performance pads, Driveshaft Shop CF Driveshaft, STi Short throw shifter assembly, and everything else needed to get it rolling with the new drivetrain. Not to mention the beautiful WORK CR KAI ULTIMATE wheels in 18x9.5 +38 with the Matte Bronze finish. Wrapped in Michelin 265 Pilot Super Sport tires this combo not only looks good, but should limit how much wheel spin we see.


Came with a few basic bolt-on upgrades and will be leaving with quite the mod list. We will do our best to list everything utilized on this build below.

Turbo and fuel systems:
ETS Rotated Turbo Kit - Precision Turbo 6466
ETS 4inch FMIC KIt ETS
Exhaust Manifold
Tial Q BOV
Tial 44mm Wastegate
Cosworth Intake Manifold
Cosworth TGV Deletes
Omni Power 4Bar Map Sensor
AEM air intake temp sensor
Aeromotive Top Feed Fuel rail kit
Full Blown Motorsports Dual Fuel Pump InTank Hanger
Twin DeatschWerks 320lph Fuel Pumps
XRP -8 Braided Fuel Line(feed) XRP -6 Braided Fuel Line(return)

Engine Components:
Motion Lab ML1200 spec engine
LA Sleeve Pro Cross Pro Cool Sleeves
Manley Performance 2618 Forged Pistons
Manley Turbo Tuff I-Beam Rods
Manley Billet 79mm stroke Crank
ACL Race Bearings
Manley 33mm Race Flo Valves
Manley 37mm Race Flo Valves
Manley 92lb valve Springs Kelford 282 Cams
Motion Lab “Big Port” cylinder head porting including welding and reshaping of exhaust ports
Cosworth Head Gaskets
ARP Custom AGE625+ HeadStud Kit
ACL High Performance Oil Pump
Killer B Oil Pickup tube
Gates Racing timing component kit

Drivetrain upgrades:
Full STI Driveline swap
New STI 6-Speed
STi R180
OEM Axles
5x144.3 STi Hubs
Driveshaft Shop carbon fiber drive shaft
STi Short throw shifter assembly
STi GrpN Transmission mount
STi GrpN Motor mounts

Brake and suspension upgrades:
STi Black Brembos
KW V3 Coilovers
StopTech Slotted Rotors
StopTech Stainless steel brake lines
StopTech Street performance pads

Interior/Electronics:
ATI Gauge Pod
SMY Cluster Maker
AEM Digital Wideband
DEFI 52mm Boost Gauge
DEFI 52mm Fuel Pressure Gauge
DEFI 52mm Oil Temp Gauge
DEFI 52mm Oil Pressure Gauge
STi S204 Limited edition leather shift knob

Wheels and tires:
Work Wheels CR KAI Ultimate 18x9.5 +38
Michelin Pilot Super Sport 265/40r18
Project Kics R40


















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Old 09-19-2013, 12:18 PM   #2
mr.twichey
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blue

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What did that cost lol
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Old 09-19-2013, 12:20 PM   #3
juanmedina
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Vehicle:
07 FPgreen [email protected]
WRX VF39+E85 12.0, 121mph

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very nice!

Quote:
Originally Posted by mr.twichey View Post
What did that cost lol
more than you can afford pal
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Old 09-19-2013, 12:36 PM   #4
subezero
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Chapter/Region: South East
Location: Charlotte, NC
Vehicle:
2008 WRX Hatch VF52d
SSM

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Good god..may have to swing by the shop and check this out. Will you guys be tuning it? Would love to watch this thing spin the rollers. Probably costs $texas.
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Old 09-19-2013, 01:14 PM   #5
Jive Turkey
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why not twin scroll?
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Old 09-19-2013, 01:50 PM   #6
kizzer505
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Join Date: Jan 2008
Chapter/Region: MWSOC
Location: Lakewood, OH
Vehicle:
2016 WRX
DGM

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This will be one bad narrow body. I also have an 09 wrx and am happy to subscribe for future inspirations. I'll be maxing the stock vf52 and setting up for an aftermarket turbo too. Keep posting. I'm excited to see this roll forward

Last edited by kizzer505; 09-19-2013 at 03:48 PM.
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Old 09-19-2013, 04:32 PM   #7
Motion Lab Tuning
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Default

Quote:
Originally Posted by mr.twichey View Post
What did that cost lol
This is definitely up there with some of our other big projects. The last motor we went full out with like this was for one of our clients in Hong Kong. It was a destroked model, however that was the motor we learned that the OEM water pumps have cavitation over 9000RPM

Quote:
Originally Posted by juanmedina View Post
very nice!

more than you can afford pal


Quote:
Originally Posted by subezero View Post
Good god..may have to swing by the shop and check this out. Will you guys be tuning it? Would love to watch this thing spin the rollers. Probably costs $texas.
We will absolutely be tuning it. We are going to put the first 150 miles on the motor and then release the car to the customer towards the end of next week to allow him to finish loading the break-in miles. Then we will be tuning on 93OCT, 110OCT, and VP Import race fuel. Probably be on the dyno within 3 weeks at this point.

Quote:
Originally Posted by Jive Turkey View Post
why not twin scroll?
No need IMO. Targeting superior top end performance and power. Also we chose to go with the v-band housing so twin scroll wasn't an option.

Quote:
Originally Posted by kizzer505 View Post
This will be one bad narrow body. I also have an 09 wrx and am happy to subscribe for future inspirations. I'll be maxing the stock vf52 and setting up for an aftermarket turbo too. Keep posting. I'm excited to see this roll forward
Glad we can inspire! Thanks for checking it out, we will do our best to share all the pics we have of the transformation. You can also check us out on Instagram @MotionLabTuning, we have been posting some progress pics along the way there as well as our facebook page.


Thanks for all the comments so far guys!

Thanks,
Alex Goodwin
[email protected]

Last edited by Motion Lab Tuning; 09-19-2013 at 04:47 PM.
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Old 09-19-2013, 07:55 PM   #9
bluemax189
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Location: Baltimore
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2011 WRX 6spd
GTX3076r

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amazing!
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Old 09-19-2013, 10:15 PM   #10
YZ86
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GD Widebody STI
Lexus Pearl White

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Great stuff, will be follow for sure!
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Old 09-20-2013, 10:35 AM   #11
xluben
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2002 WRX - 750WHP
9.5s @ 150mph

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Quote:
Originally Posted by Motion Lab Tuning View Post
First step for the cylinder heads, weld them up and get them ported! We have gone a step further than most and truly dissected the EJ castings. We sacrificed a bad casting to chop into small pieces and examine the coolant passages and material thickness throughout the ports. Just like our short blocks, we don't accept the norm we reengineer for better results. Everything from the ports to the combustion chambers were worked, enlarged, blended, and enhanced to allow the best flow possible.
Copying Fuji K!
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Old 09-20-2013, 11:43 AM   #12
Motion Lab Tuning
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Default

Quote:
Originally Posted by xluben View Post
Copying Fuji K!
Well I actually have a good shot to show a comparison between our port work versus a set of heads for our customer Jason R. who had purchased some castings off Fuji and had them ported before getting shipped out. Ours are on the left in these pics. The most significant difference is on the exhaust side. I am not knocking anybodies work, simply posting these to show a comparison in response to this comment.




I also understand that these are not the absolute highest quality pictures. I think you can still see the differences in the size of the ports just visually from the outside looking in, not to mention the dimensional differences all the way throughout the ports that you cant see in these pictures. You can see some close up shots of the ports themselves in the first post.

Thanks,
Alex Goodwin
[email protected]
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Old 09-20-2013, 12:01 PM   #13
xluben
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9.5s @ 150mph

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^Too big!

I was just referring to the chopped up heads.
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Old 09-20-2013, 03:49 PM   #14
wuuusaa
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2015 Wrx

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This is going to be epic, just added you guys on IG. Follow me back haha.
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Old 09-20-2013, 05:15 PM   #15
Mr.Chow
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Join Date: Aug 2010
Chapter/Region: MWSOC
Location: Manitowoc, WI
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2004 Baja Turbo
Dark Blue

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just curious, how much rotational mass does a cf free up? Any data on how much more power it helps put down?
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Old 09-21-2013, 02:50 AM   #16
fyjdyjycghwen
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why not twin scroll?
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Old 09-21-2013, 11:03 AM   #17
Motion Lab Tuning
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Default

Quote:
Originally Posted by xluben View Post
^Too big!

I was just referring to the chopped up heads.
Haha thanks man, I appreciate you checking out our build.

Quote:
Originally Posted by wuuusaa View Post
This is going to be epic, just added you guys on IG. Follow me back haha.
Haha thanks for following! Whats your username we usually get several likes everyday at least .

Quote:
Originally Posted by Mr.Chow View Post
just curious, how much rotational mass does a cf free up? Any data on how much more power it helps put down?
I dont have any specific data yet, it is about ~12lb lighter than stock. I can tell you from personal experience on my 2006STi, the combination of the Exedy multi plate lightweight flywheel and the carbon driveshaft make a DRASTIC difference on the way the car feels and drives. The car is much easier to get moving off the line and you can row through the gears like a maniac. I would recommend it even for a stage2 car! Haha.

Thanks,
Alex Goodwin
[email protected]
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Old 09-22-2013, 03:22 AM   #18
wuuusaa
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2015 Wrx

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Old 09-22-2013, 03:45 AM   #19
winksozwm
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This will be one bad narrow body.




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Old 09-23-2013, 11:47 AM   #20
Motion Lab Tuning
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Default

Working on the fuel system today. Running a XRP -8AN braided stainless fuel lines from the tank which is utilizing a full blown dual hanger with 2x Deatschwerks 320 LPH fuel pumps with a -6AN return. We decided to use an inline XRP fuel filter in the feed. Should be finishing up the fuel lines to the rails today.

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Old 09-23-2013, 12:15 PM   #21
Supa LA
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2015 Mustang 5.0
Guard Metallic

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So, why didnt the guy just buy a Sti? Hell, prob coulda bought a first gen gtr for that kind of money.

Looks great tho dude. Im ready to see the power numbers.
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Old 09-23-2013, 01:25 PM   #22
Motion Lab Tuning
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Quote:
Originally Posted by Supa LA View Post
So, why didnt the guy just buy a Sti? Hell, prob coulda bought a first gen gtr for that kind of money.

Looks great tho dude. Im ready to see the power numbers.
Honestly I'm not 100% sure why he didn't. I did suggest the idea of getting a STI to begin with but he didn't seem interested with that and before I knew it he wanted to get started with the build.

Thanks for the interest. Hopefully we will have some numbers in the next couple weeks.

Thanks,
Andrew
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Old 09-23-2013, 02:46 PM   #23
nddavis2
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Satin White Pearl

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A lotof work done to this thing since I saw it at the open house. Didnt even have all the brakes on if I remember correctly. Looking forward to seeing how. this ends up
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Old 09-23-2013, 05:15 PM   #24
Motion Lab Tuning
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Quote:
Originally Posted by nddavis2 View Post
A lotof work done to this thing since I saw it at the open house. Didnt even have all the brakes on if I remember correctly. Looking forward to seeing how. this ends up
Yeah once parts started showing up we were able to get the swap done in just a few days outside of some various hardware components that we ended up needing to track down.

Customer pick-up is scheduled for this Friday right now so once break-in is done we will be ready to lay some power down!

Thanks,
Alex Goodwin
[email protected]
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Old 09-23-2013, 05:41 PM   #25
j2nicee
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2006 STI
BBC

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This build is going to be epic Alex!!


PS Thanks again for the spacers!
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