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Old 04-29-2020, 10:21 AM   #1
Barge
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Member#: 62941
Join Date: May 2004
Chapter/Region: MWSOC
Location: @brgperformance
Vehicle:
2004 #LesboRacer
#TunedbyBarge

Default LesboRacer - 2004 FXT Track/Summer Build

Finally getting my Forester ready for track season on-time and I have to deal with Covid.

I've been considering doing a build thread for a while and figured now is a good time to start. I'll work through filling out more information.





Engine:
EJ20x Longblock
KillerB Header
Custom Rotated 321SS up-pipe
Custom Rotated downpipe
Custom td06sl2-20g with billet compressor wheel
Custom fabricated inlet and intercooler tubing w/ custom intercooler
Circle track radiator modified for use w/ 12" radiator fan (Fan controlled by Mercedes Benz PWM Fan controller)
Modified coolant crossover for more clearance for turbo outlet to run underneath the manifold
Custom long runner big plenem NA25 intake manifold
- 80mm Hemi DBW Throttle Body
Custom Titanium Exhaust

Electronics
Link PNP ECU
Retrofit 2007 STI ABS module
Retrofit 2005 STI DCCD OEM control module with all required sensors
ECUMaster ADU5 dash cluter
Jaguar high amperage fuel pump controller
relocated lithium battery to the fenderwell
remade/relocated/custom power distribution
Electric power steering pump (volvo)

Most devices connected over CANbus for monitoring and signal exchange.

Transmission:
2013 6MT Swap
Southbend clutch

Suspension and Brakes:
Front Brakes : Z06 calipers with rotors
Rear Brakes: 2 Pot subaru
2015+ STI Brakes

TSS Fab Front Subframe
TSS Fab Rear Subframe
TSS Fab Trans Mount
TSS Fab Diff T Bar
TSS Fab Trailing Links

RCE Tarmac 2 Coilovers (500#/400# Springs)

Aero:
Custom Front Splitter
Nine Lives Racing Wang w/ custom designed and fabricated rear wing mounts
RaceLouvers Hood Vent

Wheels:
Konig Rennform - 18x9

Overview Shots of mostly current setup






End of the EJ255
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Last edited by Barge; 06-10-2020 at 01:42 PM.
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Old 04-29-2020, 10:22 AM   #2
Barge
Scooby Newbie
 
Member#: 62941
Join Date: May 2004
Chapter/Region: MWSOC
Location: @brgperformance
Vehicle:
2004 #LesboRacer
#TunedbyBarge

Default

Wiring Adventures

My wiring board setup for custom wiring harness


In process


A bundle of wires with heatshrink and no connectors... apparently never really took a pic of it finished


This shows what power distribution I still have in the engine bay along with Electric Power Steering


ECUMaster ADU5 Installed


Dual AVCS harness add-on

Last edited by Barge; 04-29-2020 at 09:03 PM.
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Old 04-29-2020, 10:22 AM   #3
Barge
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Member#: 62941
Join Date: May 2004
Chapter/Region: MWSOC
Location: @brgperformance
Vehicle:
2004 #LesboRacer
#TunedbyBarge

Default

Fabrication

Warning: Some welds prettier than others. I'm still a work in progress

Current Turbo and downpipe setup


321SS EWG Up-Pipe


Turbo Compressor Outlet Tubing




Inlet Tubing and Modified Coolant Expansion Tank


Added EMAP (Exhaust Gas Pressure in the Header) sensor to verify turbo sizing and Exhaust:Intake Pressure ratio monitoring


A pic showing more of how the wing is mounted and bracket design


Added some head shielding to the downpipe. Using safety wire works great.

Last edited by Barge; 06-11-2020 at 09:15 AM.
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Old 04-29-2020, 10:23 AM   #4
Barge
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Member#: 62941
Join Date: May 2004
Chapter/Region: MWSOC
Location: @brgperformance
Vehicle:
2004 #LesboRacer
#TunedbyBarge

Default

Fueling System Upgrades

Fuel Lab brushless external pumping out of a custom designed/built surge tank. Surge tank fed by a DW 340lph pump. Venturi transfer removed and I've installed a DWmicro pump as a transfer pump from driver to passenger side.




Leak tested to almost 40PSI. No fuel leaks here.


Sender Mods


Last edited by Barge; 07-31-2020 at 01:50 PM.
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Old 04-29-2020, 10:23 AM   #5
Barge
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Member#: 62941
Join Date: May 2004
Chapter/Region: MWSOC
Location: @brgperformance
Vehicle:
2004 #LesboRacer
#TunedbyBarge

Default

Misc

Power Steering cooler mounted in front of my oil cooler.


Changed from a 10cm housing to an 8cm. Helped spool a bit but increased header pressure a good amount. A better size for the limited boost levels I'm running.


Little tire upgrade after my first rainy track day.

Last edited by Barge; 07-31-2020 at 01:59 PM.
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Old 04-29-2020, 11:39 AM   #6
JeffrWRX
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Member#: 48589
Join Date: Nov 2003
Chapter/Region: SCIC
Location: San Marcos, CA
Vehicle:
2016 WRX 6mt CWP
@thejeffruhl 387hp/350tq

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This thing is sweeet
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Old 04-30-2020, 12:17 AM   #7
AZ-GT
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Member#: 192
Join Date: Aug 1999
Chapter/Region: SWIC
Location: Las Vegas, NV.
Vehicle:
2011 WRB WRX
2000 Impreza 2.5RS

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Ambitious project. Good luck with it.
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Old 04-30-2020, 09:17 AM   #8
96accord
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Member#: 145105
Join Date: Apr 2007
Chapter/Region: MAIC
Location: Middle River, Maryland
Vehicle:
2007 Impreza WRX STi
'15 Accord (Daily)

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Nice Subscribed!
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Old 04-30-2020, 01:08 PM   #9
Gigs90
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Member#: 306719
Join Date: Jan 2012
Chapter/Region: MWSOC
Location: Troy ,Michigan
Vehicle:
2003 Sti Wagon
@jn_garage

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I like pictures and encouraging others financial pain
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Old 04-30-2020, 02:05 PM   #10
BlueSTI4Me
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Member#: 34361
Join Date: Mar 2003
Chapter/Region: MWSOC
Location: MI
Vehicle:
04.7 STI
WRB IG @got2boostit2

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Nice work as always. Keep it up.
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Old 04-30-2020, 03:25 PM   #11
Barge
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Member#: 62941
Join Date: May 2004
Chapter/Region: MWSOC
Location: @brgperformance
Vehicle:
2004 #LesboRacer
#TunedbyBarge

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Quote:
Originally Posted by Gigs90 View Post
I like pictures and encouraging others financial pain
Oh yeah...lots of good bad ideas hah
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Old 06-08-2020, 04:04 PM   #12
Barge
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Member#: 62941
Join Date: May 2004
Chapter/Region: MWSOC
Location: @brgperformance
Vehicle:
2004 #LesboRacer
#TunedbyBarge

Default

Some pics from my first track day of the season... nice rainy day to break in the car.

I was very happy with how everything worked. More days and testing to come.

Cool and rainy day wasn't much of a stress test for the cooling system but coolant and oil were 180-185F all season.





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Old 06-08-2020, 05:03 PM   #13
WhiteZombie
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Member#: 338863
Join Date: Nov 2012
Location: Bethlehem,PA
Vehicle:
PSM 05 WRX WGN 5MT
95 Caprice 6spd Track Rat

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Lookin sweet!

What's your suspension setup? I didn't see anything listed.

How long were you tracking before diving into this build?
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Old 06-09-2020, 08:45 AM   #14
Barge
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Member#: 62941
Join Date: May 2004
Chapter/Region: MWSOC
Location: @brgperformance
Vehicle:
2004 #LesboRacer
#TunedbyBarge

Default

Quote:
Originally Posted by WhiteZombie View Post
Lookin sweet!

What's your suspension setup? I didn't see anything listed.

How long were you tracking before diving into this build?
RaceComp Engineering Tarmac 2's that I ran on my wrx before this for years.
I just changed to the stiffer 500/400# spring setup.

I did some open tracking with my WRX but most of it was a good while ago. The building stuff has always been fun to me so the car is definitely faster than the dude behind the wheel right now.

This car is kind of a culmination of potentially crazy ideas i've had over the years to modify a subaru and never really had the equipment. Finally just decided to dive in head first.

Last edited by Barge; 07-31-2020 at 02:13 PM.
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Old 06-09-2020, 03:47 PM   #15
WhiteZombie
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Join Date: Nov 2012
Location: Bethlehem,PA
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PSM 05 WRX WGN 5MT
95 Caprice 6spd Track Rat

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Quote:
Originally Posted by Barge View Post
RaceComp Engineering Tarmac 2's that I ran on my wrx before this for years.
I just changed to the stiffer 500/400# spring setup.

I did some open tracking with my WRX but most of it was a good while ago. The building stuff has always been fun to me so the car is definitely fast that the dude behind the wheel right now.

This car is kind of a culmination of potentially crazy ideas i've had over the years to modify a subaru and never really had the equipment. Finally just decided to dive in head first.
Yeah man, I'd say it looks pretty wild! Good job and good luck! Maybe I'll see you at the track somewhere/sometime!
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Old 06-09-2020, 11:33 PM   #16
JDMJNKY
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Member#: 253498
Join Date: Jul 2010
Chapter/Region: SCIC
Location: sOuL-CaLiFoRnIa
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02 RSTI
MURK'D

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Dude that thing is sick.
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Old 06-10-2020, 07:46 AM   #17
Barge
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Member#: 62941
Join Date: May 2004
Chapter/Region: MWSOC
Location: @brgperformance
Vehicle:
2004 #LesboRacer
#TunedbyBarge

Default

Quote:
Originally Posted by WhiteZombie View Post
Yeah man, I'd say it looks pretty wild! Good job and good luck! Maybe I'll see you at the track somewhere/sometime!
I'd like to get out to Pittrace if you track there. Hopefully this year.
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Old 06-10-2020, 08:14 AM   #18
Hyper
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Location: MOCKBA
Vehicle:
1999 WRB GM6
2.34 LR destroker

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Quote:
Originally Posted by Barge View Post
This shows what power distribution I still have in the engine bay along with Electric Power Steering

This is very interesting, can you share more details? Any additional things it requires?
Does this module replace the OEM fuse box completely? How is it fused? I am trying to hide or optimize my OEM fuse box somehow and this seems interesting

how much was it?
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Old 06-10-2020, 10:41 AM   #19
WhiteZombie
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Member#: 338863
Join Date: Nov 2012
Location: Bethlehem,PA
Vehicle:
PSM 05 WRX WGN 5MT
95 Caprice 6spd Track Rat

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Quote:
Originally Posted by Barge View Post
I'd like to get out to Pittrace if you track there. Hopefully this year.
Yes! Hit me up when you start making plans.
It's about 5 hours from home, but I've run there a few times now, and it keeps growing on me. Killer elevation change, and an overall top notch facility.

My car is probably nowhere near as quick as yours, but it'd still be fun to rip some laps in our oddballs.

Hot day last summer, forgot my gloves! Rare, but they also let us run in shorts and T shirt. Glad nothing caught fire

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Old 06-10-2020, 11:28 AM   #20
Barge
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Member#: 62941
Join Date: May 2004
Chapter/Region: MWSOC
Location: @brgperformance
Vehicle:
2004 #LesboRacer
#TunedbyBarge

Default

Quote:
Originally Posted by WhiteZombie View Post
Yes! Hit me up when you start making plans.
It's about 5 hours from home, but I've run there a few times now, and it keeps growing on me. Killer elevation change, and an overall top notch facility.
Awesome... I haven't heard a ton about the actual track I'm just trying to get out to more tracks as I think it'll help my driving... finding lines and such.
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Old 06-10-2020, 11:34 AM   #21
Barge
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Member#: 62941
Join Date: May 2004
Chapter/Region: MWSOC
Location: @brgperformance
Vehicle:
2004 #LesboRacer
#TunedbyBarge

Default

Quote:
Originally Posted by Hyper View Post
This is very interesting, can you share more details? Any additional things it requires?
Does this module replace the OEM fuse box completely? How is it fused? I am trying to hide or optimize my OEM fuse box somehow and this seems interesting

how much was it?
I moved the main OEM fuses to a fuseblock that's under the drivers seat. I was able to pull all the stock wires back to that location only extending a few as needed. I feed that with a big feed from my trunk mounted battery.

Matching the stock fuse sizes was a pain because most typical distribution items that you can buy use fuse types that only go up to 30, maybe 40 amps and a bunch of the stock stuff is 50A and some other random bigger sizes. Based on loads I actually see on those fuses I'm not sure it's actually necessary.

Just an FYI the box i mounted under the seat has a cool cover... that doesn't fit if you use the ATO circuit breakers instead of fuses. I may try 3D printing a different cover or switching to fuses... but it's not been an issue to date.

I'll eventually replace it with a PDM.

The box shown there in the engine bay has some fusing and relays for things light headights, AC, and anything else that was actually in/used in the engine bay.

The parts and pieces for exact quantities of what I actually used i'd say were probably $300. I spent a lot more buying minimum quantities and multiples of things just to have extra, backups, etc etc.
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Old 06-10-2020, 12:16 PM   #22
CursezZz
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Obsidian Black Pearl

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info on how you got the Grand Sport calipers mounted up? very interesting
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Old 06-10-2020, 12:35 PM   #23
ARKTiKPENGUiN
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Location: Buffalo, NY
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2002 Impreza WRX
PSM

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Quote:
Originally Posted by CursezZz View Post
info on how you got the Grand Sport calipers mounted up? very interesting
Not OP, but Mike at Innovative made his own kit to fit the Corvette 6 pots up front, and I believe BWC Fabrications also makes a kit for Corvette 6 pots. I'm using their ATS Brembo kit and it fits beautifully.
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Old 06-10-2020, 01:40 PM   #24
Barge
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Member#: 62941
Join Date: May 2004
Chapter/Region: MWSOC
Location: @brgperformance
Vehicle:
2004 #LesboRacer
#TunedbyBarge

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Quote:
Originally Posted by CursezZz View Post
info on how you got the Grand Sport calipers mounted up? very interesting
Quote:
Originally Posted by ARKTiKPENGUiN View Post
Not OP, but Mike at Innovative made his own kit to fit the Corvette 6 pots up front, and I believe BWC Fabrications also makes a kit for Corvette 6 pots. I'm using their ATS Brembo kit and it fits beautifully.
I'm using the BWC Fabrication Brackets. These use stock Z06 rotors redrilled with hubcentric rings.
The innovative kit would probably be a lot easier for someone that doesn't want to fiddle around with different parts and pieces... and they've done their own testing on it as well.

The braking performance seems very solid so far. Once I do some more testing and and satisfied i'll probably have custom top hats made to run z06 2-piece rings with a subaru hub.

The stainless brake lines I already had worked fine on them as well.

Oddly enough the first set of calipers I got from Summit leaked like crazy. I got replacements and have had no issue. I did use the hex style pad bolts instead of the stock allen key style. The calipers don't come with any so be sure to factor that into your cost.

I'm running KNS brakes rotors with powerstop track pads.
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Old 07-31-2020, 01:36 PM   #25
Barge
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Join Date: May 2004
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Vehicle:
2004 #LesboRacer
#TunedbyBarge

Default

I added some pics of my fuel system above.

Here's the overview shot if you don't feel like scrolling up.


Had some serious fuel pressure issues prior to this. Once I pulled the old sender out to do all these mods I realized how bad the stock Forester sender is.
The return just kind of shoots down towards the sock filter from about 6" away. No internal surge tank or anything of any kind.

I used a 2007STI sender as a base here.
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