Been busy in my garage........
09 July 2011, 11:20 PM
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Been busy in my garage........
I have owned my 2004 wrx from new.
For the first 5 years of its life the car stayed pretty much standard, apart from WR sport backbox and a few minor bits. I then started using it for trackdays and got bitten by the modding bug!
In May 2010 the car was fitted with a H+S sports cat downpipe, De-resonated centre section, walbro fuel pump and prodrive intercooler pipe. It was then mapped by JGM at 276bhp.
After a year and a few trackdays I wanted a bit more power so I decided to get my spanners out!
Here she is in action at Cadwell on June 13th 2011 before the work started:
For the first 5 years of its life the car stayed pretty much standard, apart from WR sport backbox and a few minor bits. I then started using it for trackdays and got bitten by the modding bug!
In May 2010 the car was fitted with a H+S sports cat downpipe, De-resonated centre section, walbro fuel pump and prodrive intercooler pipe. It was then mapped by JGM at 276bhp.
After a year and a few trackdays I wanted a bit more power so I decided to get my spanners out!
Here she is in action at Cadwell on June 13th 2011 before the work started:
Last edited by C8 DHC 04WRX; 10 July 2011 at 12:10 AM.
09 July 2011, 11:27 PM
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I have been after a Hyperflow top mount for a while and one came up in Doncaster (not too far away) so I went to pick it up.
I also wanted a bigger turbo. I decided that a VF35 would be my best option so the search began. A few came up but I wanted a low mileage turbo at the right price. Then out of the blue I received a text from the chap I bought the Hyperflow from saying he was having a bit of a clearout and was I after anything else? Just happens he has a VF35 that had done just 15k miles! I got a good deal on turbo and some pink injectors too.
I also wanted a bigger turbo. I decided that a VF35 would be my best option so the search began. A few came up but I wanted a low mileage turbo at the right price. Then out of the blue I received a text from the chap I bought the Hyperflow from saying he was having a bit of a clearout and was I after anything else? Just happens he has a VF35 that had done just 15k miles! I got a good deal on turbo and some pink injectors too.
sorry..
09 July 2011, 11:45 PM
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The only thing with the Hyperflow was it was missing the silicone hoses so I popped down to a local manufacturer - Roose Motorsport. They took some measurements for the elbow and coupler and I popped back nextday to collect.
Here they are fitted:
I also had to adapt the undertray to fit the Hyperflow. I first made templates out of an old cornflake box (blue peter style!) then cut them out of some thin plate. I then spot welded it all together and sealed all of the joints with a flexable sealant:
Then gave it an undercoat:
This is my engine bay with old top mount removed, nothing very exciting but itt's a start!:
Here they are fitted:
I also had to adapt the undertray to fit the Hyperflow. I first made templates out of an old cornflake box (blue peter style!) then cut them out of some thin plate. I then spot welded it all together and sealed all of the joints with a flexable sealant:
Then gave it an undercoat:
This is my engine bay with old top mount removed, nothing very exciting but itt's a start!:
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09 July 2011, 11:48 PM
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Not got ported headers and unsure on what spark plugs are fitted but I know they where done on the service at Carnetix about a year ago?
09 July 2011, 11:54 PM
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When at Roose Motorsport I got talking to the boss who likes his old Fords and has a Sierra Cosworth with a gold plated engine! He doesn't currently do hoses for my car but asked if he could borrow my hoses to replicate them in return for a set of silicone hoses at a reduced price.
First of all I marked up all of the hoses so that the 'Roose Motorsport' badges could be added in the right places.
The turbo inlet pipe runs under the inlet manifold and as I also need to change the injectors and turbo I thought it would be easier to take it out and give me some space to work.
Looks a bit grubby and could do with a clean and paint (watch this space!)
First of all I marked up all of the hoses so that the 'Roose Motorsport' badges could be added in the right places.
The turbo inlet pipe runs under the inlet manifold and as I also need to change the injectors and turbo I thought it would be easier to take it out and give me some space to work.
Looks a bit grubby and could do with a clean and paint (watch this space!)
10 July 2011, 12:01 AM
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One TD04 turbo in place:
And removed, alongside the VF35:
When on trackdays I have been getting a bit of a crunch into 4th when the car gets very hot. It doesn't do it on normal/heavy road driving so my thinking was it could be the gear oil not being able to cope with the high temperatures, and hopefully I can do something about it before the syncro gets damaged. I contacted Opie oils for some advice and they recommended some 'Motul Gear 300' which is fully synthetic:
And removed, alongside the VF35:
When on trackdays I have been getting a bit of a crunch into 4th when the car gets very hot. It doesn't do it on normal/heavy road driving so my thinking was it could be the gear oil not being able to cope with the high temperatures, and hopefully I can do something about it before the syncro gets damaged. I contacted Opie oils for some advice and they recommended some 'Motul Gear 300' which is fully synthetic:
10 July 2011, 12:27 AM
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Inlet manifold in many pieces:
Masked up and ready for painting:
A splash of yellow:
And some black crinkle paint:
Then put it all back together:
Masked up and ready for painting:
A splash of yellow:
And some black crinkle paint:
Then put it all back together:
10 July 2011, 12:35 AM
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It's the bits I didn't realise I'd need and the waiting for parts to arrive thats holding me up.
I work at a steady pace and enjoy learning about the car as I go along. Tonight is the 1st night I have had free to post up my progress over the last couple of weeks as I have now pretty much run out of bits to fit/modify/clean/paint/etc! (now where's that postman!) I like to read about what others have done so now it is my turn to give some bedtime reading!
10 July 2011, 07:37 PM
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Got myself a perrin 3 port boost solenoid.
http://cgi.ebay.co.uk/PERRIN-3-PORT-...item3f06b0e5c9
This unit looks very good quality and comes with all pipework and fittings. I removed the old 2 port and the new perrin unit fits nicely in the same spot:
I then trial fitted the turbo and cut the boost solenoid pipes to length:
Next up was a CDF racing short shifter. I have had this for a while, just never got around to fitting it. I have read up about the fitting in the group buy thread as you need to modify the metal surround, something that is not mentioned in the instructions. A quick bit of angle grinder action and job done:
Then I refitted the gear surround. I decided to keep my momo gear **** over the CDF supplied one as I prefer it:
http://cgi.ebay.co.uk/PERRIN-3-PORT-...item3f06b0e5c9
This unit looks very good quality and comes with all pipework and fittings. I removed the old 2 port and the new perrin unit fits nicely in the same spot:
I then trial fitted the turbo and cut the boost solenoid pipes to length:
Next up was a CDF racing short shifter. I have had this for a while, just never got around to fitting it. I have read up about the fitting in the group buy thread as you need to modify the metal surround, something that is not mentioned in the instructions. A quick bit of angle grinder action and job done:
Then I refitted the gear surround. I decided to keep my momo gear **** over the CDF supplied one as I prefer it:
11 July 2011, 06:01 PM
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Nice work dan have I inspired you then !
Let me know who did your crinckle painting I'm up for some of that mate looking good so far what other plans you got ?
Let me know who did your crinckle painting I'm up for some of that mate looking good so far what other plans you got ?
11 July 2011, 10:10 PM
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http://cgi.ebay.co.uk/ws/eBayISAPI.d...=STRK:MEWNX:IT
It is quite difficult to get it right as you have to put it on in 3 thick layers to make it crinkle - too little paint and it doesn't go, too much paint and it sags a bit. I bought 2 cans as I am doing a few other bits with it but if you are just doing an inlet manifold then you could possibly do it with 1 can?
Things to do:
Oil cooler (arrived today but with some bits missing!)
Oil pressure/temp/boost gauges (due tomorrow)
Carl Davey inlet manifold gaskets (due this week)
Silicone hoses (still being designed and made - hopefully all finished by weekend?)
PUT IT ALL BACK TOGETHER!!!
JGM remap (due friday 22nd)
11 July 2011, 10:35 PM
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The HEL oil cooler arrived today. Unfortunatly some of the bits were missing from the kit but that should hopefully be sorted asap!
I firstly wrapped the new oil cooler in cardboard to stop it getting damaged during installation. After experimenting with a few locations I decided to put it in front of the A/C rad on the drivers side (did a search on here and it seems to be the favourite spot)
To save draining off all of the oil I just slackened off the oil fiter and put a can and funnel underneath. Fuel cans come in very handy but don't worry - this one is labelled up for oil so I don't get them mixed up!
The kit comes with a thermostatic sandwich plate and some fancy black fittings! You get a hose colour option with the kit - I went for black hoses (they are stainless braided with a black fabric braid over the top). I am also having black silicone hoses so it will all match.
I offered up the sandwich plate but it was fouling the exhaust heat shield bolt. I removed the bolt and bent the bracket up a bit - it is secure enough without the bolt so Il leave it out.
I firstly wrapped the new oil cooler in cardboard to stop it getting damaged during installation. After experimenting with a few locations I decided to put it in front of the A/C rad on the drivers side (did a search on here and it seems to be the favourite spot)
To save draining off all of the oil I just slackened off the oil fiter and put a can and funnel underneath. Fuel cans come in very handy but don't worry - this one is labelled up for oil so I don't get them mixed up!
The kit comes with a thermostatic sandwich plate and some fancy black fittings! You get a hose colour option with the kit - I went for black hoses (they are stainless braided with a black fabric braid over the top). I am also having black silicone hoses so it will all match.
I offered up the sandwich plate but it was fouling the exhaust heat shield bolt. I removed the bolt and bent the bracket up a bit - it is secure enough without the bolt so Il leave it out.
11 July 2011, 10:47 PM
#26
That will be a cracking "humble" WRX when complete.
I went down similar route some years ago. 5 years on and I'm still content. I stopped at the VF35, STI pinks, decatted up pipe, K&N panel filter with Turbo back 3" Milltek system. Made 312.1 bhp after a Zen remap. I may go for and STI intercooler for a touch more in the future. Plenty fast enough and really driveable on the road as it is IMHO. Brakes and suspension modded before the bhp. Best of luck with the rest of your work. Bob
I went down similar route some years ago. 5 years on and I'm still content. I stopped at the VF35, STI pinks, decatted up pipe, K&N panel filter with Turbo back 3" Milltek system. Made 312.1 bhp after a Zen remap. I may go for and STI intercooler for a touch more in the future. Plenty fast enough and really driveable on the road as it is IMHO. Brakes and suspension modded before the bhp. Best of luck with the rest of your work. Bob
11 July 2011, 10:53 PM
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I know what you mean. I don't think I will really need any more power after this batch of mods and anything more on a wrx and things start breaking! I may just tweek a few bits here and there as funds permit. I just want reliable power that I can handle on track.
11 July 2011, 10:58 PM
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As the oil cooler is going to be restricting the flow to the other rads slightly I thought I would re-locate the horns to give a bit better air flow. I fitted some different horns not long after buying the car as the originals are so camp! There is loads of space behind the passenger side fog light so an ideal location for them. I have earthed them onto the mounting brackets so filed a bit of paint off to get a good earth
Then bolted the horns in place and re-routed the wires/relay
Then bolted the horns in place and re-routed the wires/relay
12 July 2011, 09:58 PM
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Gauges arrived today!
I managed to get hold of a brand new genuine Subaru Lamco gauge set off ebay for a sensible price (bet is was mega £££'s from dealer!)
The great thing about this kit is it plugs in-line with the stereo wiring connector so I don't have to mess about tracing wires. There are still quite a few connectors though!
I have positioned them in the stereo slot and have put the old pocket from my wifes forester underneath.
I may get a single din stereo to go in there in the future but who needs a radio when you have a flat 4 burble!
Also been cleaning up and painting a few rusty brackets with some of the left over crinkle paint:
I managed to get hold of a brand new genuine Subaru Lamco gauge set off ebay for a sensible price (bet is was mega £££'s from dealer!)
The great thing about this kit is it plugs in-line with the stereo wiring connector so I don't have to mess about tracing wires. There are still quite a few connectors though!
I have positioned them in the stereo slot and have put the old pocket from my wifes forester underneath.
I may get a single din stereo to go in there in the future but who needs a radio when you have a flat 4 burble!
Also been cleaning up and painting a few rusty brackets with some of the left over crinkle paint:
