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2004 WRX STI Family Car Progress
2004 WRX STI Family Car Progress
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Old 12-20-14, 12:17 PM   #11
TimM
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Default Re: 2004 WRX STI Family Car Progress

Cosworth Pistons (99.5 / 8.2 to 1):





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153 MPH STI
Autobahn!
Stage II: 262 WHP / 270 WTQ / 12.84 @ 105.3 MPH
Stage III: 327 WHP / 12.73 @ 106 MPH
Stage IV: 412 WHP / 367 WTQ / 12.28 @ 112 MPH
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Old 12-20-14, 12:24 PM   #12
TimM
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Default Re: 2004 WRX STI Family Car Progress

Previous Chassis Updates:

Carbon Fiber Driveshaft @ 141,116 miles (The Driveshaft Shop):



High HP Rear Axle Shafts (new OEM front as well) @ 160,000 miles (The Driveshaft Shop / 800HP):

__________________
153 MPH STI
Autobahn!
Stage II: 262 WHP / 270 WTQ / 12.84 @ 105.3 MPH
Stage III: 327 WHP / 12.73 @ 106 MPH
Stage IV: 412 WHP / 367 WTQ / 12.28 @ 112 MPH

Last edited by TimM; 01-11-15 at 08:46 AM.
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Old 01-03-15, 07:12 AM   #13
TimM
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Default Re: 2004 WRX STI Family Car Progress

Placed an order for a Blouch 1.5 XTR turbo with 3 inch inlet and 10 CM outlet.

I'd love to make some decent power, but the street manners and autocross response kept me from going any larger. Although this is my first foray into modifying a turbocharged car. We will see if I'm too conservative or will be disappointed removing the original VF39 turbo (it does have a slight crack in the waste-gate area, but sure runs very well).

Plan to chassis dyno the car as it sits-wish it was completely stock, but it is not.
Current:
Cobb AP Stage II
K+N Typhoon
Perrin 2.4 Turbo Inlet
Cobb TBE

169,000 miles and 22.5 mpg average on a tank

Next, same chassis dyno shop tune with (23 psi? / 93 octane):
Blouch 1.5 XTR 3 inch inlet/10 cm outlet
Perrin 3 inch Turbo Inlet
Process West TMIC
850 cc Injectors (Top Feed Conversion)
Grimmspeed Electronic Boost Control Solenoid
TVG Deletes
Walbro Fuel Pump

Finally, same chassis dyno shop tune with (23 psi? / 93 octane):
New Long Block with Cosworth Cylinder Heads
Cobb Up Pipe
Ported Exhaust Manifolds

Any comments? Thanks.
__________________
153 MPH STI
Autobahn!
Stage II: 262 WHP / 270 WTQ / 12.84 @ 105.3 MPH
Stage III: 327 WHP / 12.73 @ 106 MPH
Stage IV: 412 WHP / 367 WTQ / 12.28 @ 112 MPH

Last edited by TimM; 01-03-15 at 09:43 AM.
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Old 01-04-15, 11:31 AM   #14
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Default Re: 2004 WRX STI Family Car Progress

I built my 05' for road course use primarily. It had an FP Red turbo when I acquired it. I changed it to a Blouch 18g XTR. Some thought it would be too small. If you check out my dyno sheet Although have 14 HP MAX less, I gained 22 HP average. From my perspective I moved 20 HP from over 6K rpm into the power curve under 6K rpm where I have more opportunity to use it. I love the responsiveness, its much better coming out of slow corners.

I LOVE your history with the car! Good luck with the new engine!
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Old 01-05-15, 04:31 PM   #15
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Default Re: 2004 WRX STI Family Car Progress

bossdog: Thanks. Honestly, figured I would keep the car for quite a bit as it fits my requirements so kept a bit of a log as I went. It has been thru 12 countries as well-used to have a flag of each on the side window (small decals) as we checked off each one.

I hear you on the turbo response. Autocross it is even more evident, but likely can be minimized with a good driver, I suppose.

This video alone shows me shifting 8 times...not counting the initial accel:

https://www.youtube.com/watch?v=3eVP_0d597k

I was surprised, but the gearing is relatively short. I recall a course that had a 'pin' turn...I took FTD by over a second on entire field, all because the car would come out in second and once the boost hit (very early) it accelerated far better than any other car. The organizers haven't used a pin turn since... :-)

I've reviewed your journal...lots of useful info-thanks.
__________________
153 MPH STI
Autobahn!
Stage II: 262 WHP / 270 WTQ / 12.84 @ 105.3 MPH
Stage III: 327 WHP / 12.73 @ 106 MPH
Stage IV: 412 WHP / 367 WTQ / 12.28 @ 112 MPH
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Old 01-07-15, 07:43 PM   #16
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Default Re: 2004 WRX STI Family Car Progress

Finally moving to the next stage...prepare the new shortblock for disassembly!

It really is a box motor...:



Even fits on my previously Chevy only stand:



Amazing I just picked the little powerhouse up and stuck it on the stand...so much easier than a 150 pound block of iron-I like these little engines. Amazing it supports 300 + HP stock.

Hate to take it apart, but new rods seem like an easy deal for ~$400 update along with the Cosworth Pistons.
__________________
153 MPH STI
Autobahn!
Stage II: 262 WHP / 270 WTQ / 12.84 @ 105.3 MPH
Stage III: 327 WHP / 12.73 @ 106 MPH
Stage IV: 412 WHP / 367 WTQ / 12.28 @ 112 MPH
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Old 01-07-15, 07:50 PM   #17
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Default Re: 2004 WRX STI Family Car Progress

Yep, they're not heavy at all. I think the bare block on my SHO weight much as an STi long block. The SHO crank was also something like 50lbs (long block with intake and exhaust manifolds was nearly 500lbs).

Building motors can be fun!

Been meaning to ask you... Where in Omaha/Bellevue did you live?
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Old 01-08-15, 04:18 AM   #18
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Default Re: 2004 WRX STI Family Car Progress

I resided in La Vista off of 96th Street.

Your suggestion on the rods makes sense...I would like a few more RPMs out of the engine.

I will say the cylinder heads are fairly substantial in weight and size compared to the shortblock.
__________________
153 MPH STI
Autobahn!
Stage II: 262 WHP / 270 WTQ / 12.84 @ 105.3 MPH
Stage III: 327 WHP / 12.73 @ 106 MPH
Stage IV: 412 WHP / 367 WTQ / 12.28 @ 112 MPH

Last edited by yamahaSHO; 01-13-15 at 05:09 PM.
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Old 01-10-15, 06:46 AM   #19
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Default Re: 2004 WRX STI Family Car Progress

Motor unwrapped:



'Famed' 704 casting!



BBBB Subaru pistons:

__________________
153 MPH STI
Autobahn!
Stage II: 262 WHP / 270 WTQ / 12.84 @ 105.3 MPH
Stage III: 327 WHP / 12.73 @ 106 MPH
Stage IV: 412 WHP / 367 WTQ / 12.28 @ 112 MPH
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Old 01-10-15, 06:49 AM   #20
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Default Re: 2004 WRX STI Family Car Progress

Turbo arrived...Blouch 1.5 XTR with 3 inch inlet and 10 CM outlet (coated hot section):



Billet compressor wheel close up:



Turbine:



Exhaust Inlet:



Hope it all works!

__________________
153 MPH STI
Autobahn!
Stage II: 262 WHP / 270 WTQ / 12.84 @ 105.3 MPH
Stage III: 327 WHP / 12.73 @ 106 MPH
Stage IV: 412 WHP / 367 WTQ / 12.28 @ 112 MPH
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