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Old 03-16-2005, 04:01 PM   #1
Pursuit
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Default Bosal downpipe on Baja T

Installed the Bosal divorced downpipe on the BT, thought I'd pass along a few hard earned tips...

1. You MUST use PB Blaster to get those nuts off, or you will regret it.
2. Take the cat pipe off with the OEM downpipe, it will save you major grief in the long run (the Bosal doesn't replace the 2nd cat).
3. When re-installing, loosely seat ALL the bolts and then gradually tighten everything up from the turbo back. The WRX downpipes are a tad on the short side and make it tough to get everything to hook up with the exhaust. Leave the cat pipe hanger bracket off until everything else is tight.

This was by far the biggest PITA downpipe install I've done. Mainly because I didn't follow the above steps, and the Bosal isn't quite as factory fit as I hoped it would be. I don't know whether this applies to all 'shorty' WRX downpipes fitted to a Baja or not but I have a feeling it does.

That said, I really like this downpipe. Absolutely wicked sound, definitely growlier than the stock. Turbo lag is gone, boost comes on almost instantly. The money saved in clutch replacement should pay for this mod !!

Flange fit at the turbo and at the cat pipe are good, I reused the original gaskets with no problems.

If you're looking for a divorced downpipe, don't want to lose the 2nd cat, and don't mine some minor noise increase under the hood... look no further.
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Old 03-16-2005, 09:08 PM   #2
cliffhanger
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Quote:
Originally Posted by Texas S
Installed the Bosal divorced downpipe on the BT, thought I'd pass along a few hard earned tips...

1. You MUST use PB Blaster to get those nuts off, or you will regret it.
haha, i know what you mean, unfortunately i didnt think of it either and just used curse words and bloody knuckles
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Old 03-16-2005, 09:29 PM   #3
02_Forester
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congrats -- any picts?
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Old 03-17-2005, 09:20 AM   #4
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Quote:
Originally Posted by cliffhanger
haha, i know what you mean, unfortunately i didnt think of it either and just used curse words and bloody knuckles
Tell me about it, my dog doesn't understand why I can't rough-house with her... my hands are too cut up and sore!!!

Two of the bolts I had to cut off with a torch, as the threads gave before the seized material did!!

I didn't take any install pics but I'll get some of it in there and post them up.
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Old 03-18-2005, 06:37 PM   #5
Chris N
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Quote:
Originally Posted by Texas S
This was by far the biggest PITA downpipe install I've done. Mainly because I didn't follow the above steps, and the Bosal isn't quite as factory fit as I hoped it would be. I don't know whether this applies to all 'shorty' WRX downpipes fitted to a Baja or not but I have a feeling it does.

I've done 2 DPs so far. One on the WRX, it was an MRT, it sucked big time. The other was a Cobb on an STi, that one went SOooooo smooth, I couldn't believe it. I guess some are bigtime PITA, some are sweet.


So, any codes yet? Any HP noticed by the butt dyno? Got a link to whom you purchased the Bosal from? Thanks.
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Old 03-20-2005, 09:59 AM   #6
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Quote:
Originally Posted by Chris N

I've done 2 DPs so far. One on the WRX, it was an MRT, it sucked big time. The other was a Cobb on an STi, that one went SOooooo smooth, I couldn't believe it. I guess some are bigtime PITA, some are sweet.


So, any codes yet? Any HP noticed by the butt dyno? Got a link to whom you purchased the Bosal from? Thanks.
One thing I forgot to mention that really made it tough to fit the Bosal is that the wastegate tube actually hits the engine bay brace. That's what I meant about all divorced WRX DP's will probably give fits on the Baja.

If you look down in the passenger corner closest to the firewall, there's a black brace that diagonals the corner. So it's really tough to connect everything up as you have to fight all the exhaust hangers to get the whole assembly to scooch forward, 'cause the DP's going nowhere! I'm putting in an up pipe this week and will take off the DP to dimple it so it doesn't contact there.

Yeah I threw a CEL about 200 miles down the road, I'll be putting in mechanical fixes when I put in the up pipe.

The butt dyno says definite gains, more so than I noticed on the 2.0 Scoobies. Did you notice the same difference between the WRX and the STi 2.5?

I've been taking back roads just so I can drive like a freaking maniac. I think the stock up pipe is still hindering the turbo, but the DP is a winner for sure. You hear a TON of turbo noise, which is fun but the wastegate flutter is kind of annoying around 2500 rpms.

One unexpected result of this mod was the jerky on-off throttle (you know the one that embarasses you in stop and go traffic) seems to be gone!

I got mine used from a guy here on NASIOC.
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Old 03-20-2005, 10:52 AM   #7
Chris N
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Do you think a bellmouth would fit better? Or will most DPs have to be dimpled for the Bajas?
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Old 03-20-2005, 11:09 AM   #8
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Yeah I'm guessing a bellmouth would likely fit, you could ask one of the guys with the xcceleration turboback to measure their width at that crossbar just to make sure.
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