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Old 07-07-2015, 11:16 AM   #1
Unabomber
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OMGHi2U 2004 WRX Hybrid + Blouch 16G-XT-R

Location: All Aspects Motorsports
City and State: Chesapeake, VA
Ambient Temp: ~83*
Humidity: ~78%
Weather: Sunny
Elevation: 35 FT


Car: 2004 WRX 2.5 liter hybrid + Blouch 16G-XT-R Turbo
Tuner: Kienan at All Aspects Motorsports
Dyno: Dynojet
Peak HP at RPM: 356 HP ~5400 RPM
Peak Torque at RPM: 373 TQ ~4400 RPM
Baseline HP/TQ for a stock on same dyno: 172HP for stock 2004 WRX
Previous 2.0L tune with same turbo on same dyno: 270HP/270TQ
Target Boost: 24 PSI
Fuel: 93 Octane
Engine Management: Cobb AccessPORT V3









Engine Modifications:
2.5L Hybrid using JE FSR Pistons, Eagle rods, ported and polished heads, OEM everything else
Blouch 16G-XT-R Turbo
JDM STi BPV
Grimmspeed Lightweight Pulley
TurboXS downpipe no cat version
TurboXS adapter (makes downpipe normal OEM length)
Borla Hush catback
Killer B equal length header + v-band uppipe
CSS Performance FMIC
Grimmspeed TGV deletes
Grimmspeed FMIC phenolic gaskets
IAG billet cam seals
Turn In Concepts FU cam bolts
Walbro fuel pump
APS turbo inlet
ID 1000 injectors
Cobb AccessPORT ver 3
TurboXS big MAF intake
Grimmspeed BCS

Driveline Modifications:
PPG helical syncro 1-4 gears
South Bend K70350-HD-OFE Stage 3 clutch
Lightweight steel driveshaft
Every Kartboy and Turn in Concepts bushing ever made

Story

So...what had happened was....

About two years ago, my stock motor was inching towards 200k miles and I wanted to upgrade/build my motor. I also wanted to do so on a budget of about $9 and my max goal was 400WHP, so I called about 83 Subaru friends and made a list. I saw a ton of people building motors for like $10,000 with my same goal, so my hope was to save a bunch of money and show people that you don't need a 5 digit build to make power, but that's for a later post in the Built Forum. From this list I scoured eBay, craigslist, dumpsters, amazon, and scammed vendors to get things as cheap as possible.

Ultimately, I ended up with a 2.5L block using JE FSR pistons designed for hybrid builds as the basis. The rest of the engine was going to be 100% OEM. All the engine work was done by Andrewtech Automotive in Gaithersburg, MD. They found some old used Eagle rods they hammered back into shape and put those in for a free upgrade and instead of using an OEM 2.0L rebuilt head, they swapped me into a ported and polished unit.

I went up to their shop a few weeks ago and did the motor swap, then have been driving like a good Christian boy for the last 1000ish miles. On July 3rd, my good local friend Kienan at All Aspect Motorsports became the 4th or 5th tuner of teh wagon. Once the tune was done, my ultimate deciding factor was Kienan's test drive. When he got back, he said that my Subaru was now his favorite Subaru in terms of fun factor, which is all the praise I needed. It also makes more power than even 18G and 20G cars he's tuned, which he attributed to the heads plus supporting mods. The above dyno plot is my main driving map. The car did make a few more horsepower and a tick over 390 TQ, but that's where things started to look sketchy on the plot so we dropped it back down to what you see.

390TQ.....on a 16G....whodathunk it?

Sponsorship thanks:

Andrewtech Automotive
All Aspects Motorsports
JE Pistons
Blouch Turbo
IAG Performance
Turn in Concepts
Grimmspeed
TurboXS
South Bend Clutch
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Last edited by Unabomber; 07-07-2015 at 11:34 AM.
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Old 07-07-2015, 11:33 AM   #2
ride5000
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very nice ron.

anything besides pnp done to the head? how extensive was the porting? any combustion chamber work?

these engines have a NA VE peak between 3.5 and 5.5k. if you size your turbo to come on full boil in that region you can make gobs of torque. like you've done! so i'dda thunk it...
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Old 07-07-2015, 11:39 AM   #3
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Quote:
Originally Posted by ride5000 View Post
very nice ron.

anything besides pnp done to the head? how extensive was the porting? any combustion chamber work?

these engines have a NA VE peak between 3.5 and 5.5k. if you size your turbo to come on full boil in that region you can make gobs of torque. like you've done! so i'dda thunk it...
From what I know, and I'm NOT a head work guy, these heads were ported to remove the lip/step inside the head, tapered near the valve seat, and combustion chambers were polished. No 5 angle job. Only shot I have during install:

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Old 07-07-2015, 12:07 PM   #4
freddy121389
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Simple and reliable. Nice build. What do you have the redline set at, and do you see any really big hp drop off towards redline?
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Old 07-07-2015, 12:19 PM   #5
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Nice power but it does come on pretty late for a 16g no? Do most graphs from that dyno looks shakey like that? Seems to fall off after 6.5k which I'm sure is attributed to the stock WRX cams. I woulda thrown some STI sticks in there while apart but I can understand they weren't in the budget of 9$.

Nice basic cheap setup!!
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Old 07-07-2015, 12:22 PM   #6
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The torque drop is most likely do to the 16g just being a tad too small for a 2.5. But good numbers none the less! Must be a fun street set up.

Quote:
Originally Posted by Paul View Post
Nice power but it does come on pretty late for a 16g no? Do most graphs from that dyno looks shakey like that? Seems to fall off after 6.5k which I'm sure is attributed to the stock WRX cams. I woulda thrown some STI sticks in there while apart but I can understand they weren't in the budget of 9$.

Nice basic cheap setup!!
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Old 07-07-2015, 12:32 PM   #7
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Quote:
Originally Posted by freddy121389 View Post
Simple and reliable. Nice build. What do you have the redline set at, and do you see any really big hp drop off towards redline?
Stock redline. To the butt dyno no, it just keeps ripping up to redline.

Quote:
Originally Posted by Paul View Post
Nice power but it does come on pretty late for a 16g no? Do most graphs from that dyno looks shakey like that? Seems to fall off after 6.5k which I'm sure is attributed to the stock WRX cams. I woulda thrown some STI sticks in there while apart but I can understand they weren't in the budget of 9$.

Nice basic cheap setup!!
While a "16G", she's the biggest one ever at 38lb/min, so perhaps that's the reason for the lateness but it really feels like a V8 under acceleration. Not sure of the shakey....I'm not a plot analysis guy. Concur on STI sticks + perhaps below.

Quote:
Originally Posted by IanMAPerforance View Post
The torque drop is most likely do to the 16g just being a tad too small for a 2.5. But good numbers none the less! Must be a fun street set up.
This and/or a combination of above. One will never know, but I'm super happy regardless.
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Old 07-07-2015, 01:40 PM   #8
NA STI
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Those heads look done perfect for your build. Looks like fairly mild porting and blended the end of the runners to the valve seat which is exactly what you want. A lot of people have gone way overboard and cause more damage to their powerband then good when it comes to headwork especially on mild turbo setups.

You got a nice combination together now you just need an e85 toon to show teh PPB nerds how strong the car really is lol most people that come on here aren't use to looking at basic 93oct numbers, Id say it would do 400whp 450wtq on our local E85. The ID1000s will be enough to support it with a tiny bit of room left even using the stock FPR. You might just need a slightly bigger pump, the new AEM310 would be perfect to fully support ID1000s without pump drop off up top @ stock base fuel pressure after looking at the flow chart and running the basic calculations
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Old 07-07-2015, 07:09 PM   #9
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I did 360/340 on a DynoDynamics at 5k' colorado , 24psi, e85. 2008 wrx with that turbo
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Old 07-07-2015, 07:18 PM   #10
Paul
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Quote:
Originally Posted by Unabomber View Post

While a "16G", she's the biggest one ever at 38lb/min, so perhaps that's the reason for the lateness but it really feels like a V8 under acceleration.
I understand and not hating since I'm sure she rips but you've been around for awhile and I thought you'd have a reason for the lateness. I figured the tuner did it on purpose til I noticed the ppg gears. But what do I know 😣


Is the hot side 10cm?
This is DBB right?
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Old 07-07-2015, 07:22 PM   #11
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8cm hotside and DBB.
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Old 07-07-2015, 11:10 PM   #12
thatsubyguy
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Teach me your budgeting ways oh wise one. Lol
Ordered this turbo the otherday from this shop, excited to see how it goes
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Old 07-08-2015, 07:49 AM   #13
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Quote:
Originally Posted by thatsubyguy View Post
Teach me your budgeting ways oh wise one. Lol
Ordered this turbo the otherday from this shop, excited to see how it goes
I plan on doing a "how to" in the Built Motor forum pretty soon that goes over budgeting as my build took forever and I nickel and dimed the hell out of it in terms of parts rather than looking into the end of a shotgun blast of money all at once like so many others. Another reason I went built was I wanted to encourage/prove/show to others that you can go "built" without spending $10,000. There are people that need to spend that to meet their goals, but for the sub-400WHP goal people, their budget doesn't need to be THAT high.
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Old 07-08-2015, 09:29 AM   #14
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Ill be sure to keep my eyes out for that. Probably eventually do a hybrid myself, someday. How big was your budget for your build?
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Old 07-08-2015, 11:50 AM   #15
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Wow 24 psi on gasoline? Amazing.

What were the timing levels like? My friends 2.5L hybrid with thicker gaskets was a little picky with stock pistons and combustion chambers. We could not run much timing.

Nice build and numbers. Looks like fun.
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Old 07-08-2015, 12:06 PM   #16
ride5000
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Quote:
Originally Posted by Shiftace420 View Post
Wow 24 psi on gasoline? Amazing.
i've got plenty of logs at >30psi...

Quote:
What were the timing levels like? My friends 2.5L hybrid with thicker gaskets was a little picky with stock pistons and combustion chambers. We could not run much timing.
that's pretty much par for that course--quench is wrecked.
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Old 07-08-2015, 01:53 PM   #17
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Looks like an awesome fun setup Ron! I don't think it looks late for a turbo of that size either, old school 18g's flowed the same. Not to mention that the throttle looks like it wasn't put down until close to 3k. Hope you get to enjoy it for a long time!
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Old 07-08-2015, 09:09 PM   #18
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Jermaine at TurboXS said it reacted identical to the OG FP18G that they no longer make and he sadly wishes they still made, so you are right.

No idea on timing as I leave that to the tuner. The above plot isn't super "timey" though as he pulled some out as more torque was made (biggest number was 293 TQ I think) but the plot started to get all dippy and it would have take 900 pulls to make it look good, so we decided to go with what was more conservative. This IS my daily driver and is used for a 50 mile round trip to work and not some trailer queen so my main goal is 100% longevity vice making numbers to make the internet happy.

Budget for the build....like I said, I'll detail that in a post pretty soon and I'll likely link it here. I'd give the final figure, but it does require a story or three and I don't want to give the wrong impression and get people's hopes up.
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Old 07-11-2015, 03:33 PM   #19
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I am glad to see your car up and running Ron and real happy to see the theory that you have to chamber match the heads disproved again.
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Old 07-12-2015, 11:41 PM   #20
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Awesome thread I recently picked up a a 16gxt for my hybrid. I hope to make some good #'s like that I'll have to post when I get it tuned.
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Old 07-15-2015, 12:56 PM   #21
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hey so how loud are you pistons on start up?would it be possible to load a video?
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Old 07-15-2015, 01:37 PM   #22
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I know you had the 16G-XTR on the 2.0L. Did you notice a decent improvement in low end response? That's my biggest complaint right now on my '04, 2.0L with the 16G-XTR, from 4krpm-redlilne it's about perfect for my needs (autox) but it there's a fair bit of lag exiting the tighter corners that are a bit too fast for first gear...though I'm only running 91 not 93.
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Old 07-15-2015, 03:40 PM   #23
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EPIC! Glad it's finally up and running! That sticker on the back made me laugh!
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Old 07-15-2015, 04:35 PM   #24
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Looks Good Ron!

Jermaine
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Old 07-22-2015, 01:06 PM   #25
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Ron... crazy... I have basically the same motor build going (I believe I'm the next in line over there at Andrewtech), almost all the same mods. (Coincidentally the same PSM 04 Wagon)

The differences are:

I'm going to be running the Kelford 268/264 cams with my pnp heads. The heads are also from Andrewtech. I can only assume they had the same guy do the pnp. I'll ask just for the sake of knowing when I'm over there next. The valves were sized just a bit over stock, and everything had been cleaned up, de-burred, and polished up. Just like your description.

I've got one of TurboXS's new line of turbos.. their 18g. (billet compressor wheel w/ journal bearing). I don't know the flow rate on that turbo... I'll have to ask Jermaine when I see him next.

The last and perhaps most significant difference is that I don't know if I've got the same "sponsorship" you've got. LOL

We've got a good comparison going though. Keep up with me. I'm doing the swap (myself) should be in about two weeks, followed by a week or two of break in, then it's off to TXS for my tune.

Brian
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