Boosted's WRX build. Audi 6 speed, 20g, forged engine and more
 

Ok, after several people asking for a project thread here it is.
Little bit of background for those who have missed out, I have a blue blob WRX (the inferior model) wasn't a dear car, I've been tidying it up over the past year, bit of paintwork and the likes.
Shortly after buying the car I decided more power was required, putting on a TD05 16g, converted to front entry and remapping the car myself through an AEM piggyback.
The big ends went on a 100,000 mile old engine, no massive suprise but a pain none the less.
So a re built it quickly and cheaply using the best bits from a few engines and that's the way the engine has been for around 6500 miles now.
Looking to take my favourite past time of drag racing back up I went about converting the gearbox to audi quattro O1E 6 speed, audi diff and gear linkage all swapped over.
Having just completed the gearbox conversion and a
Few small driveshaft problems just as the drag season comes to a close, I have not yet dragged the car, roll on feb 2015!
For next year I may run the car in it's current tune to lay down a time somewhere in the 13's.
Time for more power!
I'll start by saying anyone can spend money to go fast, thats the easiest thing in the world to do, but not a lot of people can go fast on a very tight budget. And that's what I have a very tight budget.
This is also to remain my road car, a daily driver with a baby seat.
A few pics to help tell the story so far:

http://i959.photobucket.com/albums/a...psfyo8csif.jpg
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http://i959.photobucket.com/albums/a...psqld03oru.jpg

Subscribed! again!

Hopefully most of you are upto speed so far, quick spec update as the car stands.
2.0 std WRX engine
16g
440's
1.5 bar peak, 1.1 at redline
Four puk cerametalic clutch
Audi O1E gearbox, custom flywheel, shafts and diff mount. Audi prop and rear diff.
3" downpipe, 2 1/2" system.
Thinking about 300 hp and a mid 13 second run the way it is.
Hoping for some 12's later next year!
So first things first we need some fuel! I am building an engine just now (more on that later) to do so I bought a spare engine, came with all ancillaries.
So be rude not to decap the injectors, 840cc injectors for free. Thanks.
http://i959.photobucket.com/albums/a...ps8pnxvzgq.jpg
http://i959.photobucket.com/albums/a...psayvu3vzi.jpg
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The engine I'm building will be a WRX block, crank and heads, new bearings etc, forged H section rods, forged STI pistons.
Oh and I bought a bargain basement TD05 20g turbo too;
http://i959.photobucket.com/albums/a...psl4xcd7nt.png

Looks good, did you do the painting yourself also ?

Yeah man

Looking forward to this one :D.

Should be interesting.
I've had problems with my welded rear shafts breaking on launching hard, so have bought solid ones and re-machined the splines in the ends to suit subaru cv's. Fit them tomorrow, then see if I can break them.
http://i959.photobucket.com/albums/a...psh2agjrut.jpg
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http://i959.photobucket.com/albums/a...ps3cz3mpis.jpg
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excellent , it looks to be a pretty tidy job, its on my DIY todo list

I spent about £600 on mine, end result being a 12.4s. :D

Good luck with the project, I'm sure it'll be a good read. :thumb:

Be careful uncapping the blues matey. Theres a chance they wont be as matched (spray pattern will be much more sloppy) with the directed nozzles removed. I thought about doing it but for the sake of the 550s being a hundred quid decided that tried and tested was better and still good for up to 400 horsies.

I've done it before in my golf, used mazda RX8 yellows decapped. Worked well.
Who said I'm not flow checking them!? Ha

Good luck on the 12's, 300/300 should see a 12.9 on a 5 speed wrx, have you compared the ratios of the Audi box to the stock 5 speed?

Thanks, the ratios are almost identical 1st-5th as UK WRX 5 speed. Within .1 anyway.

Bought these today;
http://i959.photobucket.com/albums/a...psigjhchlv.png

I thought this was budget perfomance?

Add in pistons, head studs, rod bolts and you'll have spent more than me. :p :D

I'm excluding your gearbox, as a lot of DIY effort has went into that. :thumb:

I've got V5 Sti pistons in stock, head studs??! Are they required for sub 400hp?
Been told I need forged rods and pistons, so had to buy some rods!

What did you spend £600 on to do a 12.4 with your WRX?

My stock STi 5 EJ207 and TY754 5-sp. has been running 384/349 (on a 20g) for 4 years to the month now. :D

But I guess I've just got lucky (although, I never do standing starts and don't do trackdays). Plus, my 'on-boost' forays are few and far between, anyway.

But it IS my daily commuter/driver.

Boost controller, induction kit and an FMIC. :thumb:

Standard TD04 turbo? No remap? Or you remap it yourself?

Good stuff, bearing in mind that a 2.5 will make the same power but with less boost on the same turbo as a 2.0, you will probably find it's a lot less stressed.
On the 2.0/2.5 subject, I want to keep the engine size sub 2.0 to remain in the upto 2.0 turbo class.

Has the 20G arrived yet?

Negative, thinking mid week next week. It will be fine!

Standard TD05 16g, no remap. Add £450 for the Nur Spec R, so just over a grand.

Ah, it's a classic. That explains 12's with low 300's hp.
I'm going to need a bit more poke with the blob, plus a drivetrain that will cope with said poke.
For te sake of £200 I be as well use the forged rods when I build this engine

Yeah it's a classic. :)

I'd use proper forged pistons too, if it was me doing it. Do it right, do it once.

Don't have the money. I've sold my water injection kit to fund the turbo and rods.
Got a wife and baby, mortgage to pay and I'm in the process of gutting my house! I'm not some young lad living at home with mum And dad, or I would be buying forged everything brand new! A budget is a budget. I'll not be using new oil pump either as that's far too much money.