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Old 10-25-2010, 09:45 AM   #301
wtdash
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Quote:
Originally Posted by morrocco88 View Post
Thanks Todd! I'm going to be doing a full paint job on JRach's STI swapped forester this winter. It's going to be a ton of work, but should be really nice when it's done.
FSTi FTW! What year Foz?

Quote:
Dom.....found a spark plug
Super secret? Willing to share the brand/part #?

TD
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Old 10-25-2010, 09:53 AM   #302
morrocco88
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Rotated BW S256 6speed

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I'm pretty sure it's a 99'. He's also going to swap a newer style rear hatch and tail lights before we do it.


I don't know what spark plugs they are, he didn't say. He's going to ship some to me so I will know what they are soon.
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Old 10-25-2010, 07:18 PM   #303
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Super clean man! Very impressive, keep this baby going!
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Old 11-10-2010, 05:02 PM   #304
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I just went through all of this. What a build. You have some real talent.

Updates since the new plugs?
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Old 11-11-2010, 10:30 PM   #305
morrocco88
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Hey thanks!

No updates yet. I have the plugs and a new Agency Power unequal length header on the way. Once I get the header I will weld in an EGT bung on #4 and then ceramic coat it. Hopefully once work slows down and the weather clears up, I can get over the mountains to get it back on the dyno.
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Old 11-16-2010, 02:27 AM   #306
morrocco88
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Just got the plugs and header today, and thought I would share some pics and info.

The plugs are "Brisk Racing" part # DR12S. They are supposed to be 1-1/2 steps colder than the BKR6's that are stock for the wrx. The main thing is the center porcelin is recessed which keeps it out of the flame front and helps keep it cooler.

Crappy Pics:











The header is Agency Power and is made from 321 stainless instead of 304 stainless like most headers. 321 is supposed to be far more durable in high heat and is why it's used for aircraft headers. It seems to be a really nice piece. Dom installed one on his car and was expecting to lose some spool in trade for more top end power, but was really surprised to see better spool in addition to more power. How cool is that?

Pics:






It has a really nice collector which makes the flow nice and smooth into the up pipe.





There is one little booger from a weld on the inside of the collector, but no biggie. I will just buzz it down with a carbide burr and smooth it out with a flap wheel. I will also weld in an EGT bung and then ceramic coat it before install.
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Old 11-16-2010, 12:05 PM   #307
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Definitely buzz that bad boy down - you don't need any FOD after after all of you hard work.

321 is my favorite stainless alloy for turbo headers. It can be thinner and therefore lighter than 304 and keep sin heat better to boot. Don't be surprised by one thing about 321, though: After you run the car for the first time, that will be the last time you see your headers in shiny silver. 321 gets a bronze-ish color from heat. It is totally cosmetic, but if look are important to you, get a high heat Chromex header coating before you install.

If money were no object, though, I'd go Inconel on headers. At 3 times the cost, it isn't a common choice.
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Old 11-16-2010, 05:02 PM   #308
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I also got my spark plugs in yesterda. My new code scanner that can read freeze frame data also came in. Once i figure out what was causing my misfire problem in #3 I will put those sparkplugs in at 11 bux a pop they aren't so cheap, so i want to make sure nothing is wrong mechanically.
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Old 11-17-2010, 12:18 AM   #309
morrocco88
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^^^please let me know how the tuning goes and the difference they make when you get a chance. I'm curious and it will be a while before I get back to the dyno.
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Old 11-17-2010, 01:17 AM   #310
NITROS
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Quote:
Originally Posted by morrocco88 View Post
^^^please let me know how the tuning goes and the difference they make when you get a chance. I'm curious and it will be a while before I get back to the dyno.
The code scanner i got gave me some incite as to whats going on with my current misfire. it happens at idle 949 rpm. sounds like it may be a vac leak or injector problem as only happens in cylinder 3.

Absolutely awesome deal on this scanner i got and it definately works with my 2004 wrx ecu, read freeze frame data which is what i needed.

http://www.amazon.com/gp/product/B001LHW9YG/ref=oss_product
I'm going to do another compression check and leak down this saturday. If all goes well i will have the spark plugs that day and do some tuning as well.

I will definately let you know the results.
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Old 11-19-2010, 04:11 PM   #311
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Crazy BD build man! This thread is making me want to build the Eg33 in my 99 LGT! I really like the attention to detail and the sweet oven baking setup. I hear you on your expectation on a house. All I need is a place to ****, shower, shave and sleep and a huge garage for a Trans Am build and to build my LGT!
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Old 12-26-2010, 08:22 PM   #312
morrocco88
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Little Update:


Ive been working on installing the header, re-doing my exhaust and a few other little odds and ends before going back to the dyno.

The rear section of the old exhaust ended up being a little lower than I thought and had a little accident. I drove over the oil change pit at work, which has a 3'' steel lip sticking up and the flange of the exhaust at the mid pipe/axle back caught this and brought the car to an immediate stop . That ended up yanking the whole exhaust sytem which caused some damage and it probably would've been worse if I didn't have the flex sections. It ended up bending and cracking the down pipe, and busting the check valve off my draft tube. So I figured I would have to re-do that rear section to get more clearance, fix my down pipe and then I got a little out of control and re-did everything.


I started by buying this ebay knock-off of a Cobb catback, which looks like the GMS catback too. I figured I couldn't buy the pipe, u-bends, and muffler for this price, so I bought it with the intention of modifying it to fit the BD. Overall I was impressed with the quality of the welds. It has a true straight through muffler and can't be beat for the price. I'm a little worried it might be a bit loud because there are no resonators and this muffler is straight through glass pack baby.
http://cgi.ebay.com/ebaymotors/ws/eB...STRK:MEWAX:VRI

Then I decided to just buy a new DP and ended up going with an Invidia. I did this because it has the one piece cast bell mouth which makes the smoothest transition into the 3'' pipe. My old down pipe had a formed bell which was welded to the pipe, and this is where it cracked during the accident. I also decided to cut off the flanges and go with V-Band connections.

I did a test fit and it was pretty close, but definately needed some modifications to make it fit the BD chassis. I had to cut off and relocate one of the muffler hangers along with lengthening one and shortening the other to line up with the chasis hangers. Once I got the axle back right where I wanted it and had the down pipe on, I just had to get the mid pipe to match up. The BD chassis is a little longer than the impreza, so I had to add in some length. I just added in some Vibrant flex sections and the v-bands and it worked out perfect. Also with the v-bands tacked on, it made it really easy to rotate it around and adjust things during mock up.

The header also fit perfect right out of the box! I was really impressed, because I had counted on having to tweak and adjust. Usually nothing fits like it should, but it slid right on the head studs and matched up perfectly with the up-pipe!

A few pics:


V-band flages are where it's at!




Here is the cast bell mouth of the Invidia DP




V-band on the DP




This fits much better than the old setup. It is just a 1/2'' below the green metal part of the rear axle and perfectly centered from it's surroundings. I will have to keep an eye on the diff seal.




This is tucked up as tight as I can get it, and is better than stock in how far it hangs down past the diff.






Exhaust tip is right where I want it




Flex section and v-band welded on. Man I love this little mig welder!






I just have to weld on a new draft tube, weld the EGT bung on the #4 pipe of the header, and then blast everything and ceramic coat it all.

I'm also using a GM IAT sensor instead of the IAT sensor as part of the MAF. This will be installed at the outlet of the intercooler to get a more accurate reading of the air after it has been compressed and cooled. This is also safer because it will account for intercooler heat soak. This was at the recommendation of Dom, as he does it on a lot of cars. It was being discussed on this thread about Hybrids
http://forums.nasioc.com/forums/show...0#post32795640

I'm also going to try switching to the stock shifter that came with the V8 JDM sti tranny, because I think I might prefer the taller height and less effort in trade for a little longer throw. After driving Dom's RS with the stock 6 speed shifter, I think I like it better. I will still have the heavier knob and all the bushing upgrades, so it should be good.

There is also some other little upgrades I'm making, but I will spare you the details because this post is getting too long!

Thanks for looking!
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Old 12-26-2010, 09:11 PM   #313
kenikh
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Great Christmas project!
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Old 01-07-2011, 05:01 PM   #314
NITROS
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Moar pictures!
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Old 01-08-2011, 12:40 AM   #315
morrocco88
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Rotated BW S256 6speed

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^^^ I will try to get some more pics up soon.

I finished up the exhaust tonight. Welded on the draft tube, welded the EGT bung on the #4 pipe a couple inches down from the head flange. Spent all night last night blasting all the parts, and then cleaned and ceramic coated everything tonight. It's ceramic coated from the header, up-pipe, turbine housing, and full exhaust to the tip! I just have to let it dry overnight and then I can bolt it on and hear it for the first time!
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Old 01-08-2011, 09:23 AM   #316
FuJi K
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why dont you ALL help buy him a digi camera??? lol
or someone who lives closer get a vid clip of it.
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Old 01-08-2011, 02:02 PM   #317
morrocco88
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Rotated BW S256 6speed

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Alright all you peer pressuring SOB's

I just bought a GoPro HD Hero 960 on Ebay. It should be here next week sometime, and then I will take some vids for you guys. It should be pretty sweet once I figure out how to use it!
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Old 01-09-2011, 12:52 AM   #318
stimanmark
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what catback is that?
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Old 01-09-2011, 03:45 PM   #319
morrocco88
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Quote:
Originally Posted by morrocco88 View Post

I started by buying this ebay knock-off of a Cobb catback, which looks like the GMS catback too. I figured I couldn't buy the pipe, u-bends, and muffler for this price, so I bought it with the intention of modifying it to fit the BD. Overall I was impressed with the quality of the welds. It has a true straight through muffler and can't be beat for the price. I'm a little worried it might be a bit loud because there are no resonators and this muffler is straight through glass pack baby.
http://cgi.ebay.com/ebaymotors/ws/eB...STRK:MEWAX:VRI
It's an ebay knockoff, I had a link to it in my post ^^^
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Old 01-09-2011, 04:00 PM   #320
stimanmark
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oh sorry didnt see it. doesnt look bad! You might loose a lil packing down the road....but not bad for the price
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Old 01-11-2011, 01:29 AM   #321
morrocco88
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Update:

Exhaust is finished, on the car and fired it up for the first time tonight!

I was worried it would be too loud, but it's actually quieter than before! It's more throaty but the bumbles are less harsh and the volume is lower. I really like the sound the header gave the car. It's a deeper, throaty sound. I'm just really pumped at how good everything turned out from the fitment, v-band connections, it's tucked up as tight as it can get for the most ground clearance, and then the cherry on top was how good it sounds!

a few pics:


The header all coated and looking sharp!




EGT bung welded on - not my prettiest bead, because I had some issues seeing where I was at through the helmet for some reason and I was using stainless wire.




Axle back. Was going to coat everything, but left the tip polished stainless






looks really good on the car




Here you can see the gold check valve on the draft tube, right after the wide-band and before the v-band flange of the down pipe.




It's hard to take good pics under the car, but hopefully it does it justice






I also tested the draft tube while it was running, and had good suction. More updates to come after I get my video camera (Sound clip)!

Last edited by morrocco88; 01-11-2011 at 01:36 AM.
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Old 01-17-2011, 01:16 AM   #322
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subscribed and inspired
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Old 01-26-2011, 08:02 PM   #323
morrocco88
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^^^ Thanks!

small update:

Thanks to Nitros for sending me a magical link to a guy looking to trade his turbo for a smaller one. He was looking for a Dom2.5 for a little better AutoX action, and I now have a Blouch Dom3 in route to my house . Thanks again Nitros, I would've never seen that thread. I figure I had to go back for a re-tune anyway, and an extra 50 hp for shipping one way wasn't a bad deal at all!

I also decided to go full stand alone and just purchased a Link G4 extreme. I wanted speed density and full control over everything and the G4 is probably the best on the market. Link is the manufacturer who makes Vipec also, and I hear the software is really similar.

It has closed loop knock control with a tune-able knock signal to filter out noise and also has headphones to listen while you tune, Gear dependent boost control, Launch control, Flat foot shifting, anti-lag, 4D and 5D fuel control and the list goes on and on!

My plan is to work on all the time consuming driveability stuff, cold start, hot start, cruise ect. and get it all dialed in. Then I will take it over to Dom for the full power tuning. I have done some tuning in the past and this will allow me to tune my own car and get it as perfect as I want. I can spend a ton of time getting everything just how I like it, and then just use a little of Dom's time and expertise to get the full power stuff done on the dyno.

So the new stuff for this (final) round will be:

Agency Power UEL header
New turbo back exhaust
Brisk Racing plugs
Blouch Dom 3 Turbo (52lbs per min = 520chp max)
Link G4 extreme stand alone ECU

Should have it done early spring and be able to enjoy it this summer!

Now I'm back out to the shop to work on the paint job I've started on JRach's sti swapped Forester. I throw up a couple pics of that as well.
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Old 01-26-2011, 08:10 PM   #324
kenikh
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SWEET.

I think the Wolf v400 is a Link based ECU, as well.
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Old 01-28-2011, 10:34 AM   #325
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Nice! I'm glad the dom3 trade worked out for you
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