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Old 07-06-2016, 07:13 PM   #1
thenewrick
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Default Need help with Baja Turbo Build-up!

So the time has come. I want to start doing more mods to my 05 Baja Turbo. I am on a budget so I can't go full custom everything. Shooting for mostly used parts if I can help it.

I have to replace the exhaust because it is leaking and rusty. I've read the stickies and searched but haven't gotten a whole lot of useful info. I've read that most downpipes will work with modification to Baja firewall bracing?

Haven't seen any info on catback systems though. I talked to xcceleration and they no longer carry the exhaust for the Baja.

So I'm thinking I need to get an STi downpipe that requires the least amount of modifications, and some type of catback exhaust that wont need extensive modifications.

I noticed the rubber hose around the intercooler is severely cracked and warped. I imagine I need to completely replace all those hoses and stuff. I'm guessing WRX/STi parts will work in this situation? Are there complete silicon kits for this type of job?

I'm also planning on going with an STi fitment topmount intercooler and turbo. I reckon I also need an up pipe, electronic boost controller, and a tune. Anything else I'm missing?

I was going to try and get a used STi turbo and intercooler but I'm open to ideas on that as well.

I'm shooting for STi power levels so about 300hp at the crank would be plenty for me. My engine has 155k miles on it so I don't want to push it too hard.

Thanks for the read and I hope this starts up some discussion and interest. I know this is a very small community. Maybe some STi guys will come in here and help me with the build as well. I imagine it's not a whole lot different.
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Old 07-10-2016, 12:58 AM   #2
forcijo
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This is actually my first post on this forum but long time lurker so Hello! We have a 05 Baja sport NA as a family utility/hauler. I recently had to replace the axle back and ran into a similar issue of not being able to obtain any premade parts. I'd recommend taking the old catback assembly to a local exhaust shop. Might get tricky if you want to upgrade to a larger OD but For me they bent up a new pipe on the spot!
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Old 07-11-2016, 07:50 PM   #3
thenewrick
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I think I'm going to end up doing the same thing. I'll probably buy an STi downpipe and have it modified to fit a custom cat-back. It'll be pricey but should do the trick.

The hardest part about modding the Baja is the tune. I still haven't found a tuner that's worked on Baja's, let alone any near me.
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Old 07-11-2016, 08:59 PM   #4
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Quote:
Originally Posted by thenewrick View Post
I think I'm going to end up doing the same thing. I'll probably buy an STi downpipe and have it modified to fit a custom cat-back. It'll be pricey but should do the trick.

The hardest part about modding the Baja is the tune. I still haven't found a tuner that's worked on Baja's, let alone any near me.
I have the Xcceleration exhaust on my Baja, a previous owner had it installed. FWIW, it's beautiful exhaust and built incredibly well so I definitely understand the cost for it. Compared to some of the exhausts available for other turbo or H6 Subarus it was nowhere near what I would call mega$$$.

If you switch to an STI ECU you can use a Cobb AP. There has got to be some maps for Bajas on romraider too. I'd like to get mine retuned eventually, probably back off on the power a bit.
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Old 07-13-2016, 07:36 PM   #5
thenewrick
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As I mentioned in the OP, Xcceleration no longer sells the Baja exhaust.

I'm sure it's possible to tune the factory ECU. It's just a matter of finding someone to do it really. Especially in North Florida it's very difficult to find car enthusiast anything.
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Old 07-13-2016, 11:19 PM   #6
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Quote:
Originally Posted by thenewrick View Post
As I mentioned in the OP, Xcceleration no longer sells the Baja exhaust.

I'm sure it's possible to tune the factory ECU. It's just a matter of finding someone to do it really. Especially in North Florida it's very difficult to find car enthusiast anything.
A Subaru is a Subaru as far as tuning goes. If you can get someone to open source tune it it shouldn't be too hard. I have a vf39,sti top mount. Catless up and down pipes and a custom exhaust. Open source tuned myself and it's been running 100,000 miles like that on 18.5 psi of boost. Your goals are pretty conservative and can be done pretty easily and affordably.
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Old 07-17-2016, 06:18 PM   #7
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So my exhaust literally fell off today. Broke apart near muffler. I'm working on removing the catback. =/
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Old 07-18-2016, 08:32 PM   #8
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Quote:
Originally Posted by thenewrick View Post
As I mentioned in the OP, Xcceleration no longer sells the Baja exhaust.

I'm sure it's possible to tune the factory ECU. It's just a matter of finding someone to do it really. Especially in North Florida it's very difficult to find car enthusiast anything.
I wasn't disputing the availability, just thought I'd offer my input on the exhaust because I have it.
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Old 07-24-2016, 03:43 PM   #9
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Aside from the up pipe cat, and the turbo oil line banjo bolt, are there any other important things I should fix/swap out on the car when considering tuning?

I'm thinking about going cheap, just an exhaust and a tune. If I get a turbo and supporting parts it would be an extra $2k or so.

Anyone here had much luck with Baja tuning and results? Longevity?
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Old 08-07-2016, 12:22 AM   #10
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So I'm ordering a bunch of stuff:

uppipe
downpipe
turbo inlet
intercooler
electronic boost control solenoid
custom catback

Sticking with the TD04 unless it's toast when pulled out of the car. It's old and rusty so I wouldn't be surprised if it's on its last legs. If it is, I'll probably replace with a used STi turbo or maybe just get a Blouch 16g. I really don't want high power levels. Just a safe, reliable, usable tune.

I imagine the car is around 190whp/210wtq as it sits now. I'd like to be around 220whp/240wtq. I figure that'll be in the safe zone for not blowing the engine or transmission.

Super excited!
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Old 08-07-2016, 04:54 PM   #11
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I'm selling my old Baja Alloy Wheels. They're in about 8/10 condition and come with good all-season tires but not a lot of tread left.
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Old 08-08-2016, 04:51 PM   #12
Flowmastered87GL
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I have low profile tires on my Turbo wheels (hey they came free with the wheels) so those look so massive compared to mine. They should be a pretty easy sale as they look to be in nice shape.
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Old 08-09-2016, 09:03 PM   #13
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These are stock spec tires 225/60. They're cushy and bouncy and trucky.

The wheels are in great shape, it's a great deal!
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Old 08-11-2016, 09:38 PM   #14
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Parts are coming in. I'm excited!

I'm doing a downpipe, up pipe, STi TMIC, EBCS, and a tune.

I will try to get dyno numbers before and after so we can get an idea of what a stock Baja and a stage 2 Baja puts down.

My guess is 170whp/190wtq to start and 200whp/225wtq after tuning.
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Old 08-13-2016, 12:21 PM   #15
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Just for comparison, way back when I dynoed mine, it was 218whp/247wtq on a conservative mustang dyno.

VF39, up and downpipe. catless 2.5" to a modified stock muffler and a USDM 2004 sti intercooler and my own open source tune.

It should be pretty easy to hit your goals.

[IMG][/IMG]

Looking forward to seeing your results!
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Old 08-13-2016, 10:27 PM   #16
thenewrick
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Thank you for the info.

I'm actually surprised you didn't make more power with the VF39. My STi made 230/240 stock tune on a AWD Mustang dyno. I suppose the internals of the STi motor allow it to make more power but your increased boost gave it more torque.

I ended up making 267whp/306wtq when I was stage 2.

I found a shop and a tuner though. It'll happen soon! Hopefully within a month.

*Just noticed how old your dyno run was, wow! I'd love to see some stock Baja dynos, although I know that's a little pointless. I'm going to try my best to get a true before and after. Hopefully drive up, dyno, have the parts put on and tuned, dyno again for an in/out comparison.

I'm so excited!

Last edited by thenewrick; 08-13-2016 at 10:33 PM.
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Old 08-14-2016, 12:08 AM   #17
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Yeah it was a long time ago! I have been running it like that ever since. Alittle more boost and alittle less timing than an STI. It was a few HP less and a few Ft Lbs more than a Cobb tuned VF39 FXT that ran right before me on the same dyno, except My Baja had about 1,000 more Useable RPM in the power band. The goal was stock STI power levels for daily driving duties. It has over 100,000 miles in that configuration. The early EJ257 and EJ255 pretty much were the same inside. Part numbers are the same for the individual components.

I could never get my TD04 to perform. It never achieved advertised max boost stock. Only after a tune could I get the desired boost with the factory boost control solenoid. The vf39 solved that. When I pulled the TD04 it had a surprising amount of play in the shaft. I think I just got unlucky and got a sloppy one from the factory. I would imagine with your boost control solenoid upgrade you won't have any problems.

Stock was a mid 15 sec. 1/4 mile. I only made one single pass after the turbo swap in all of these years and it was a 13.9.

Really glad to see people still modding the Bajas as they get older. I'de love to see your before and after dyno graphs when you get it all together and tuned.
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Old 08-14-2016, 01:05 PM   #18
thenewrick
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My engine and turbo have 155k hard miles on them. Lots of rust as well. It wouldn't surprise me at all if when we replace the exhaust we find the turbo is pretty much dead. If that is the case I'll likely get an STi turbo.

I'm shooting for reliable daily driver as well. Top power no biggie for me.

I'm just avoiding the STi turbo because I don't want to do fuel pump, injectors and push the old motor/trans too hard.
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Old 08-15-2016, 12:33 AM   #19
Hawk296
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Quote:
Originally Posted by thenewrick View Post
My engine and turbo have 155k hard miles on them. Lots of rust as well. It wouldn't surprise me at all if when we replace the exhaust we find the turbo is pretty much dead. If that is the case I'll likely get an STi turbo.

I'm shooting for reliable daily driver as well. Top power no biggie for me.

I'm just avoiding the STi turbo because I don't want to do fuel pump, injectors and push the old motor/trans too hard.
What year Baja? The 04/05 turbos already have the STI yellow top injectors, so if you are not pushing it that far you have plenty of safety margin.

That's the limiting factor on mine, the stock Injectors are as far as I'm comfortable taking them.
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Old 08-15-2016, 06:58 AM   #20
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Another alternative to think about is to swap in an 04 STi ecu, a vf39 along with the STi intercooler. This set-up can save you $$ on a tune.
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Old 08-22-2016, 09:47 PM   #21
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That sounds super expensive. I'm shooting for a mild-drivable tune, not huge power.
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Old 08-23-2016, 02:04 PM   #22
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Thenewrick,

I'm also a new baja owner. I'm very interested in your progress as I'm considering the same path myself in the next year or so.
My exhaust only has surface rust, so I have plenty of time to plan.

What up and down pipes did you choose? It seems that many of the down pipes listed as fitting with no modification in the sticky thread are no longer available.

Also, do you have a quote on the custom exhaust? I'm wondering how much I need to budget.
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Old 08-25-2016, 05:32 PM   #23
thenewrick
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Most downpipes should fit with minor modification, grinding some firewall bracing or something.

I think it's about $400 for a custom catback without mufflers.
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Old 11-19-2016, 07:18 PM   #24
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Planning on getting some mods done and a pro tune the weekend after Thanksgiving.

I'll get a dyno sheet for before any mods, stock car and then after.

Mods include:
catless downpipe
turbo inlet tube
STi intercooler
electronic boost control solenoid
catless uppipe


My guess is it'll make 180whp/195wtq before tune and 200whp/225wtq after the tune.

Super excited and it'll be nice to get some info out there for other Baja Turbo folks.

Last edited by thenewrick; 11-20-2016 at 02:43 PM.
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Old 11-20-2016, 01:58 PM   #25
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Quote:
Originally Posted by thenewrick View Post
Planning on getting some mods done and a pro tune the weekend after Thanksgiving.

I'll get a dyno sheet for before any mods, stock car and then after.

Mods include:
catless downpipe
turbo inlet tube
STi intercooler
electronic boost control solenoid


My guess is it'll make 180whp/195wtq before tune and 200whp/225wtq after the tune.

Super excited and it'll be nice to get some info out there for other Baja Turbo folks.
Unless your uppipe is already gutted, I'd try and add in a cat less up pipe to your list. 06+ subies (other than baja) had stock catless uppipes. I have seen them laying around junk yards before and I'm sure could be had for very cheap. I just did the same upgrades you are doing as well as full catless 3" system. I ended up at like 216hp and 265tq to the wheels on a mustang
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