The AVC-R is an excellent boost controller, the 99/00 OE boost control is not quite up to that standard.
As boost control is a major part of the Tek 3 mapping procedure, I would not charge any more in this case to set up an AVC-R with 2 boost maps at the same time.

Andy

 

Had all the bits fitted to the car today. Arrived at Robs' (tweenierob) house in the morning and it was all finished by around 4/5pm. He fitted everything on the spec list all apart from the CAK & STI8 i/c. Also fitted a new cambelt.

Top bloke and really knows his stuff. I think I amused/entertained him by volunteering to re-fit the airbox......I must have set a new world record for taking the longest time to re-fit it .

We had a test drive to ensure all was running well and AFRs were good and no knock activity. Boost set to 0.8bar max for saftey until csr gets mapped.

Intial thoughts were that there was no noticeable increase in lag and the turbo just pulls and pulls through to the redline where the TD04 runs out of puff. Had a 4.2kg flywheel fitted and initial thoughts were that it made the car 'feel' lighter and more responsive. Idle was not great though, but I had been made aware if this prior to choosing it.

On my way home on the motorway and hear this big BANG from the engine bay and felt as if something had come off the car and hit the road. Pulled over to the hard shoulder and the car was sounding like a clattery diesel . My heart sank as I was convinced that the engine had blown . Sat in the car and rang Rob who made his way down. I started thinking of the rebuild costs that I couldnt afford and kicked myself for not leaving the car as it was etc. Was a real downer. Started the engine a couple of times whilst waiting for Rob and found that there was blowing coming from the up-pipe. Felt some hope that the engine wasnt cooked. Rob arrives and finds that a bolt which was bunging one of the unused sensor holes had blown out, which explains the bang and the sound of something falling onto the road.

RELIEF is not the word. I was over the moon.

Phew.

Weather pending, I will be fitting the intercooler tomorrow and plugging the hole in the up-pipe. Might even get around to sorting a 'hoselock special' intercooler waterspray. Just need a scoop and undertray which I will hopefully do on the weekend

Its invaluble to know someone who is so knowledgelable and effecient on working on the car, especially when you're like me and the most used tool in the garage is a hammer. Many thanks again to Rob

The project is another step closer

Bob

 

No worries Bob, Everything just seemed to fall into place yesterday (not literally!)

Was a pleasure to work on the car!

Rob

 

looks like we're all getting there had the bung blowing out before, quiet alarming to say the least!

 

yup, had the o2 boss plug in the up pipe blow on mine as well.
that'll teach me to dot eh egt sensor up with spanners and leave the 02 sensor plug finger tight.
diesel tractor and no pull!

 

nice to know I'm not the only one

Went to local hardware shop and brought a bolt for 75p which solved the problem.

Today was intercooler fitting day...really thought it would be easier than it was.

Problem 1....getting the ba$tard i/c in place and the samcos in place...what a pain. Not much room to work the pipes on but got there eventually by putting some oil on the inlet and turbo and sliding them on.

Problem 2....I thought I was well prepared and well stocked for the install. I had a OE STi8 d/v and a HKS SSQV mounted on a STi8 flange. Plan was to fit the HKS but it wont clear the bonnet. Plan B was to fit the OE one. Good contigincy plan but the blasted samco re-circ pipe wouldnt fit. Had to cut away some of the insides of the samco and literally force it onto the d/v and then clamped it into place with a jubilee clip. Still not ideal as the samco is angled wrong and there is a kink in it as I've had to twist it. Have more cuts on my hands than fingers.

Didnt bother with any brackets as I'm not strong enough to bend them into shape with my bear hands.

Remaining couple of hours daylight were spent trying to blow the newly installed bolt on the up-pipe out. Raised the boost on the Dawes to 1bar and all is good. No KL activity and AFRs all good. Feels like absolutely no holes in the map as the off boost it pulls well. Boost comes in early, smooth and strong. Really does charge to the redline. I should add that I'm using a JB tek'd TD05 map from a car with virtually the same spec as mine.

Feels like a well sorted car already. I thought it would be a bore to drive before the re-map.

Next step is bonnet scoop, undertray and waterspray....then the re-map.

Its all coming together very nicely.


Bob

 

Good stuff Bob. I tried some initial fitting of my STi8 TMIC and came across some problems straight away. The clutch res was in the way - I knew this would be a problem but thought I could work around it, but not it'll have to be shifted first. The next was my catch can on the near side that had to be moved too The offside STi8 bracket seems about right but much head scratching will be needed for the nearside bracket The undertray will be a challenge but hopefully the STi7 Scoop will go straight on

Keep up the good work.
F

 

I left my clutch res where it was and just cut down the cylinder. Easy job.

I may try and source a STi8 offside bracket in that case as I currently dont have any.

I was thinking of buying a undertray from somewhere like ETS. Should just be bolt on.

Still keeping your spec under wraps?

Bob

 

yeah come on Floyd, spill the beans

 

anybody know if an OE STi7/8 i/c undertray will be a direct or relatively straight forward fit onto MY99 bonnet?

Can get the scoop from ets/drmotorsport

Bob

 

F: what year is your car? Just wondering if a STi7 scoop will be a direct fitment on mine.

Bob

 

MY00, but the STi7 scoop came from drm IIRC. It is a copy as the OEM STi7 scoop doesn't fit (or I've not seen anyoone who has mde it fit yet).

I've just received a STi7/8 clutch master cylinder and res, so this is a better solution for me. Trouble is that the new one has got 2 connections and a bleed nipple where the original MY00 one has only 1 connection. Anyone know how to connect it? I have an idea but would like to confirm.

No secret about my spec but it may have some tweeks that have not been combined at this level before. They are relatively easy for anyone to do as well. I just haven't had the time to post the project yet!

F

 

The one for £120 supplied painted? Whats the quality of the scoop like and the paint finish?

No idea about the clutch res I I just removed the cyl and cut it (very crudely).

Look forward to hearing the full details of your project.

Bob

 

The scoop is acceptable quality and paint match is fairly good, not tried it on the car so can't really comment yet. I'll probably need to tweek it as there are no supports in the middle as there are on the std one - just wondering how it will cope at 150mph as it is higher and unsupported presently. You may see some matting close up but it sorta looks cool and carbon fibre - ish.

F

 

that doesnt sound quite right?

Should be able to seal it with silicon sealant?

Bob

 

Right the DRM/ETS "higher Scoop" is good quality, Can't comment on the paint match though. The fit was quite close. I did have to rub down some of the corners to get a getter fit though.

I've had mine upto 130MPH and it's still there It does cause the bonnet to lift in the airflow and I have the UK steel bonnet
The scoop is very strong and doesn't need supports, though it could do with some smoothing on the inside and rear mounting points. (there is a lip at the back where it meets the bonnet).

For the undertray I just cut the std tray hole bigger. I took about 1" off all the way round and it suits the MY02 WRX IC I have quite well
I did have a MY02 WRX undertray but all the mounting holes are different and the tray is a different shape to the classic one

 

Thanks mate. Sounds ok. Just need to find a undertray or maybe a DIY job is on the cards. Have taken the undertray off for the time being.

 

Andy is mapping the car this Sunday so I need to get moving with the finishing touches. Undertray is top priority. Need to find out if a sti7 undertray can be made to fit or if one is available off the shelf. Will do some phoning around.

Was driving the car last night and it holds a steady 1bar in all gears. It is already very quick. 1st and 2nd gear are very short lived. First time I experienced some wheelspin round a corner in second gear. With the old TD04 you dont need to worry about things like that.

Cant imagine what its going to be like when its been mapped

 

if the scoop lifts a steel bonnet what's it going to do to a flimsy carbon one like mine?

 

I guess you'll need some bonnet pins!

I'll have to put some thought into the reinforcing of the scoop. The pressure will be very high at 150mph and the last thing I want is it to break or detatch itself and hit the windscreen

I've already experienced the gearbox undertray doing the same self removal routine and it scared the **** out of me

F

 

I remember when you told me to remove the gearbox undertray and I didnt bother. Shat myself when it did remove itself

I'm currently trying to figure out the best option for a scoop undertray. What are you planning for your undertray or have you already done it

 

If I have the time I'll just get a sheet of 2mm ali and make a new one. It should be easy to create a flange for a rubber seal and get it in the right place with the scoop removed. It'll need a bit more thought to smooth the flow inside the scoop - it's not bad to start with but I'm not happy until I've had a go at everything If there isn't time then I'll do the 1 inch removal from the original tray and make one at a later date.

F

 

I do have plans to make a new undertray to suit the WRX IC, just got to get motivated and measure it out

 

Keep us posted. Am going to have a look at it today as I've got some time to work on the car. At worst I can put some rubber sealant on like Graham has:

http://tinypic.com/2bp760

Going to phone DRMotorsport about the scoop....I hope they have a quick turnaround.

BTW whats a non-return valve look like and where does one purchase it from (for I/C waterspray).

Bob

 

Halfords, about £1.79.
looks like a pack with NRV written on it
its in the washer/wiper spares section.

 

ah....I see...my stupidity is quite transparent once again

I hate going to Halfrauds....chav magnet.....luckily I park around the corner (although admittedly not out of choice though....damn those anti chav speed humps )

Cheers mate.

Bob

 

No scoops in stock until next week

AndyF: Need to start thinking about what qty of NF to use so that I can ensure that its there for the mapping. Say if we go for an adjustable boost controller and lets say we get 1.3bar (for arguments sake) max boost and 1.1/1.2 for daily drive. Now if the map is optimised for the max boost and ign timing using NF would it be possible to not run any or as much NF when on lower boost setting? Or is the boost/ign relationship not such?

Bob

 

I have PM'd you

 

Fitted the APS CAK last night (well finished fitting it at around 2am this morning). Was a real pain. Its so tight in the wing with no flex. Thought it would be a 20minute job.

Andy is due over in a couple of hours to do the mapping.

Just need to go run some miles in with NF on the tank.


Bob

 

Good luck! Lol, no such thing as a 20 min job. Those times are given to her in doors "only a 5 min job dear, won't be long"

Pictures?

F