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Discussion Starter #1 (Edited)
Sponsored by Agile Auto in Fallston, MD

For those that don't know me, my name is Josh and I'm planning on using this thread to document my STU autocross build as well as my progress throughout the season including setups and changes. To start things off, I would like to give a BIG THANKS to Hill McCarty at Agile Auto for his support and help in this build, along with all the help in the past!
Now for a little background. I've been autocrossing now going on 5 years, with all of my previous experience coming from building my 2003 Nissan Sentra SE-R Spec V that I built for STX. Although the car wasn't the prime choice for the class, I was able to win STX for Philly Region in 2006, WDCR Region in 2007/2008, and Autocrosser's Inc. in 2007/2008.
After driving the car for 5 years, I knew it was time to get into a car better suited for it's class. I sold the car in August 2008 and spent the next few months doing some co-drives to figure out what best fit my wants/needs. A special thanks to John W. (ButtDyno) for letting me co-drive the WRX to finish out the WDCR STX season! But after driving Iman's (bdi) STU prepped STi, I knew exactly what car I wanted to buy and what class I wanted to run in. I've enjoyed the ST* class and knew that it was the right fit for me.

Through research gained here and conversations with several great STU drivers (Thanks Colin, James, Iman, JR, John W, and anyone else I left out!) I decided that a 2006 STi was going to be tool of choice. I searched through the classifieds on here, IWSTI, autotrader.com, etc. for about a month before I found what seemed to be the right car. It was a 2006 Aspen White STi with only 17,300 miles, a 3.5" APS exhaust, COBB short ram intake, and Accessport with Stage 2 tune. And to make it even better, the guy only lived 25 minutes away. A couple of weeks of pricing negotiations and the car was mine on November 21st!

The car shortly after purchase



The old autocross ride



Needless to say, the next 4 months were hell. Having this beauty sitting in the garage, doing research, dealing with snow and cold...just painful. Fortunately all that ended last Sunday when I began the autocross modification process.




Through yesterday I had installed the following modifications (it's been a busy week!):

- APS 3.5" turbo back exhaust with MIL.SPEC 100 cell race cat welded into downpipe by Agile Auto







- Hawk HP+ brake pads




- Braille 6lbs race battery



- Re-installed stock intake to replace COBB short ram to reduce intake air temp during summer events



- Corbeau 3 pt. Harness (autocross use only)




- Rolled front part of rear fenders



- Whiteline 24mm adjustable front sway bar with Whiteline spherical endlinks




Midway through the work



- Whiteline 22mm adjustable rear sway bar with Whiteline spherical endlinks




- Racecomp Engineering Tarmac 2 coilovers with 600lbs front springs and 500lbs rear springs topped with Vorshlag camber plates set at Racecomp suggested Track settings (Thanks Myles for the discussion and help!)





After the installs (before alignment and fixing front ride height...at 2am)



Test fitting some borrowed 17x9 et35 RE30's (before alignment and fixing front ride height at 1:30am)



- Ported stock headers by Agile Auto (no pics...forgot the camera)

- STU Protune by Hill at Agile Auto...318whp/318wtq (I know, kind of high...dyno chart to follow) along with a street tune 325whp/350wtq





And a few other things

- Alignment set at -3.2 front camber and -1.9 rear camber with zero toe for both
- Ordered 5Zigen FN01RC's 17x9 et43 in flat black
- Deciding between 245/40/17 Bridestone RE-11's or Kumho XS's
Where the car currently sits as of 3/14/09




First test day is this coming weekend on March 22nd with the Philly Region, followed by the WDCR practice event on March 29th. I'll either be running the borrowed RE30's with Dunlops, or if I make a tire decision tomorrow I should have that setup by the weekend. We'll see what happens. I don't know how everything will work first time out, but it should be interesting. Iman (bdi) will be co-driving with me this coming weekend to help work on the setup a little bit.

My plans for the season are to run a full WDCR schedule, Fed Ex Field events with Autocrosser's Inc, Citzen's Bank Park events with the Philly Region, the DC Pro (and hopefully Toledo, but doubtful), either the Seneca Tour or NE Divisional, and Nationals in Lincoln, NE.
 

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Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

This looks like a lot of fun. Good luck on the autocross and looking forward to more development.
 

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Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

awesome good luck ill be keeping an eye out for you im in md as well so if theres anything local let us kno
 

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Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

Thanks guys! There are a lot of events going on in MD through WDCR SCCA and Autocrosser's Inc., you guys should try and make it out. ;)
 

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Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

looks good looks good. I'm also planning to do autox and track this season. I'll probably shoot you some questions later...goodluck this season
 

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Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

car looks sick. Very impressive numbers and mods. Good luck this season. I cant wait to see how you like the car.
 

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Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

Thanks! The power mods are Protune, APS 3.5" turboback exhaust with MIL.SPEC race cat welded in, and ported stock header. The 3.5" exhaust is what I'm told is the major cause of the power gains. The high flow setup is generating a little bit of overboost which we're using to our advantage. I believe it tops out around 16psi. Not sure how that compares though, still learning this crazy STi stuff. :D
 

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Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

Good...I already got questioned on it once, I'm going on what Hill told me about what was happening with the 3.5" setup because I knew most only get around 300whp. I'll take what I can get though. :D
 

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Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

Josh, for what its worth. Im sure you know how much Torque helps in Autoxing. Im pretty sure a slightly more restrictive exhaust will yield significantly more Torque and only slightly less HP. And the torque is what really helps in when zipping around a tight course in a turbo charged car. I got 365 wtq with a el header, tbe, fuel pump, and spark plugs, tuned at 18 psi. But I sometimes over boost to about 23ish in the colder months. My whp was only 306 but Im not complaining, cuz it feels great!
 

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Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

Josh, for what its worth. Im sure you know how much Torque helps in Autoxing. Im pretty sure a slightly more restrictive exhaust will yield significantly more Torque and only slightly less HP. And the torque is what really helps in when zipping around a tight course in a turbo charged car. I got 365 wtq with a el header, tbe, fuel pump, and spark plugs, tuned at 18 psi. But I sometimes over boost to about 23ish in the colder months. My whp was only 306 but Im not complaining, cuz it feels great!

If you are implying he pick up headers for the car, it won't be STU legal and that is what it looks like he is trying to stay legal in.

But I hear ya, I stopped autoxing and modded outside of the rules and now have 360tq, but no header yet.

To the OP, congrats on the car and glad to see your an avid autoxer. You should write up a small review on the differences in autoxing fwd to awd, if you have time.

-Jordon
 

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Discussion Starter #14
Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

Headers ARE legal in STU, I have the stock ones ported actually.
 

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Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

I forget the wording exactly, but it mentions being able to replace the exhaust system, which in this case would included the headers.
 

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Discussion Starter #17
Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

Just arrived yesterday! These are 5Zigen FN01R-C's in 17x9 et43. In need of some rubber soon, still debating between the RE-11 and XS.


And also, I have dyno graphs. Directly below is the STU graph with the Street tune just below that. I'm looking to get the STU graph plotted against boost, at which point I will post as well.


 

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Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

5 spoke wheels look great on STi's. Nice choice.

Pretty good dyno #'s too.
 

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Discussion Starter #20
Re: piknockout's STU Autocross Build - 2006 STi sponsored by Agile Auto

Fitment should be good, I'll let you know when I finally make a tire choice and get them mounted. ;)
 
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