Tuning A MY98, Is 300bhp A Reality On A Budget?
24 October 2004, 01:19 AM
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Tuning A MY98, Is 300bhp A Reality On A Budget?
A few months ago i decided i'd try the now well trodden route of tuning my MY98 Impreza, or fridge. I devised a modest plan that i hoped (and still do hope) would take me over the magic 300bhp mark - see here.
So this is what i started off with...
A tarty MY98. Only mods of note being the H&S turbo back de-cat system and a Knock and Lambda Link. Time to give it some go to go with the show.
The car made 261bhp at Star in February this year and then made 259 at Wallace Performances Dastek RR at the beginning of October. The Dastek figure will be the baseline as it will be there where the 'after' run takes place.
So before i went looking to fry what was already engine number two i thought it'd be best to stick some gauges in there. Cue my 'bargain' Defi setup. I spent ages scouring the For Sale section on here for the individual gauges, control unit and pod. In the end i bought the final gauge brand new and saved next to bugger all on the price initially quoted by Simon Lau (bar the pod). Let that be a lesson to anyone that tries to be a stingy ******.
Anyway, they look awesome and i've already found them invaluable in the few weeks since they've been fitted.
However, whilst i was collecting the Defis i was also scouring the For Sale section for other parts and found a FETD05 not too far away from me, cheers Davie.
And then i started collecting injectors for a frickin' hobbie.
Initially i only wanted some Phase 1 440's but then a bargain set of Phase 2 400's came up as did a set of 550's... A picture of each for reference.
I wasn't planning on buying the Apexi until later on in the year but then one came up on here (cheers Rob
) for a price i couldn't refuse. The only problem was it came with the Commander as well which i really wasn't interested in (extra cost!!) but i took never the less and have now been convinced to keep thanks to Steve and Gerry on here.
Then came a K&N filter, also from For Sale - cheers Ray.
I'd been planning on fabbing up some injector collars so i could fit the Phase 2 440's or Denso 550's so made some spacers to tilt the intercooler for practice.
Next came what has been the cause of my biggest boob in the project to date. My STi V5/6 TMIC. I got it off eBay and it really is a credit to the seller, being in excellent condition until my clumsy fingers flattened a good few fins when i lifted it out of the box! Nothing a toothpick won't fix though!
You can see in the picture the MY00 dump valve. This i bought seperately off eBay thinking it would cure the issue with fitting the unit to the <99 cars. I even bought MY00 STi Samcos thinking i'd covered every base - then i offered it up today... PMSL An adaptor is required methinks!
I've also got a Walbro and FSE lying here ready to fit - shock horror i don't have a picture of something!
Anyway, that takes us to the present day, which basically involved some tinkering. I never managed to get the coolant topped up correctly since fitting the water temp sender in the top rad hose and the car had been playing up since. A little fiddling with the coolant to get it topped up properly and replacing the two hose clamps i'd previously removed and reused and touch wood all appears to be well after a 80 mile run this evening.
I also made a wee bracket to hold the Defi boost modulator and fitted my intercooler spacers so we're all ready for the STi TMIC.
So the total cost so far in my 'budget' build is as follows, assuming i use the Phase 2 440's and move the Samcos etc on.
£376.50 - Defis (Boost, Oil Pressure, Water Temp, Control Unit, JW Racing Pod + hose adaptor for water temp sender)
£250 - FETD05
£70 - Phase 2 440's
£50 - K&N
£168 - STi V5/6 TMIC
£185 - Walbro 255l/hr + FSE Reg
£500 - Apexi PFC + Commander
Total cost at the moment = £1609.50 plus mapping and whatever else i need to get the car up to spec before the 3rd November.
So this is what i started off with...
A tarty MY98. Only mods of note being the H&S turbo back de-cat system and a Knock and Lambda Link. Time to give it some go to go with the show.
The car made 261bhp at Star in February this year and then made 259 at Wallace Performances Dastek RR at the beginning of October. The Dastek figure will be the baseline as it will be there where the 'after' run takes place.So before i went looking to fry what was already engine number two i thought it'd be best to stick some gauges in there. Cue my 'bargain' Defi setup. I spent ages scouring the For Sale section on here for the individual gauges, control unit and pod. In the end i bought the final gauge brand new and saved next to bugger all on the price initially quoted by Simon Lau (bar the pod). Let that be a lesson to anyone that tries to be a stingy ******.
Anyway, they look awesome and i've already found them invaluable in the few weeks since they've been fitted.However, whilst i was collecting the Defis i was also scouring the For Sale section for other parts and found a FETD05 not too far away from me, cheers Davie.
And then i started collecting injectors for a frickin' hobbie.
Initially i only wanted some Phase 1 440's but then a bargain set of Phase 2 400's came up as did a set of 550's... A picture of each for reference.I wasn't planning on buying the Apexi until later on in the year but then one came up on here (cheers Rob
) for a price i couldn't refuse. The only problem was it came with the Commander as well which i really wasn't interested in (extra cost!!) but i took never the less and have now been convinced to keep thanks to Steve and Gerry on here.Then came a K&N filter, also from For Sale - cheers Ray.
I'd been planning on fabbing up some injector collars so i could fit the Phase 2 440's or Denso 550's so made some spacers to tilt the intercooler for practice.
Next came what has been the cause of my biggest boob in the project to date. My STi V5/6 TMIC. I got it off eBay and it really is a credit to the seller, being in excellent condition until my clumsy fingers flattened a good few fins when i lifted it out of the box!
Nothing a toothpick won't fix though!You can see in the picture the MY00 dump valve. This i bought seperately off eBay thinking it would cure the issue with fitting the unit to the <99 cars. I even bought MY00 STi Samcos thinking i'd covered every base - then i offered it up today... PMSL
An adaptor is required methinks!I've also got a Walbro and FSE lying here ready to fit - shock horror i don't have a picture of something!
Anyway, that takes us to the present day, which basically involved some tinkering. I never managed to get the coolant topped up correctly since fitting the water temp sender in the top rad hose and the car had been playing up since. A little fiddling with the coolant to get it topped up properly and replacing the two hose clamps i'd previously removed and reused and touch wood all appears to be well after a 80 mile run this evening.
I also made a wee bracket to hold the Defi boost modulator and fitted my intercooler spacers so we're all ready for the STi TMIC.
So the total cost so far in my 'budget' build is as follows, assuming i use the Phase 2 440's and move the Samcos etc on.
£376.50 - Defis (Boost, Oil Pressure, Water Temp, Control Unit, JW Racing Pod + hose adaptor for water temp sender)
£250 - FETD05
£70 - Phase 2 440's
£50 - K&N
£168 - STi V5/6 TMIC
£185 - Walbro 255l/hr + FSE Reg
£500 - Apexi PFC + Commander
Total cost at the moment = £1609.50 plus mapping and whatever else i need to get the car up to spec before the 3rd November.
24 October 2004, 10:53 AM
#3
the phase 1 440s should be enough for 300hp, I would sell the other injectors if you are going to be happy with 300 at dastek.
If you want adaptors for the 550s, I might have some more soon, but shhhhhhhh!
Paul
If you want adaptors for the 550s, I might have some more soon, but shhhhhhhh!
Paul
24 October 2004, 02:23 PM
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No probs Carl.
If you don't an i have the standard dv off ya and i'll sell you either of me Forge ones? They are either atmospheric or recirculating! Go on.....what's a wee bit more dough?!?!?!? 
.If you don't an i have the standard dv off ya and i'll sell you either of me Forge ones? They are either atmospheric or recirculating!
Go on.....what's a wee bit more dough?!?!?!?
25 October 2004, 01:43 PM
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Well it's been pissing rain again today so couldn't get much done other than the K&N. Not 100% sure that i'm going to stick with it tbh, will at least have to look into getting some ducting sorted out and shall be keeping a close eye on the Knocklink as well.
It was a bit of a pig to fit and needed the odd bit of pipework re-routing but i got there in the end. I also had to rotate the MAF round by about 45 degrees so the male connector wasn't stretched to it's limit reaching the female. I had to chuckle when i took it for a test run though. It's louder than i'd expected and i can hear the (standard!!) dump valve chuffing away through it - almost thought i was in an RS Turbo for a second.
I also got a picture showing the intercooler spacers fitted and by how much they've tilted it.
Paul, i'm glad you reckon i'll be ok on the 440's. AndyF thinks the same so i'm happy to run with them for the time being. But why make things easy by using the Phase 1's lol?
Knocked that one up a while ago and now the reamer and boring tool have arrived i've just to pull my finger out and make 4 good ones!
The parents do actually have a double garage but as my project isn't the number 1 project in the Davey household it doesn't get any garage space.
Anyway, next stop is Subaru to order all the gaskets, nuts and bolts i'm going to need - place your bets now as to how many bits i'll forget to order.
It was a bit of a pig to fit and needed the odd bit of pipework re-routing but i got there in the end. I also had to rotate the MAF round by about 45 degrees so the male connector wasn't stretched to it's limit reaching the female. I had to chuckle when i took it for a test run though. It's louder than i'd expected and i can hear the (standard!!) dump valve chuffing away through it - almost thought i was in an RS Turbo for a second.
I also got a picture showing the intercooler spacers fitted and by how much they've tilted it.
Paul, i'm glad you reckon i'll be ok on the 440's. AndyF thinks the same so i'm happy to run with them for the time being. But why make things easy by using the Phase 1's lol?
Knocked that one up a while ago and now the reamer and boring tool have arrived i've just to pull my finger out and make 4 good ones!
The parents do actually have a double garage but as my project isn't the number 1 project in the Davey household it doesn't get any garage space.
Anyway, next stop is Subaru to order all the gaskets, nuts and bolts i'm going to need - place your bets now as to how many bits i'll forget to order.
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31 October 2004, 09:11 AM
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Saturday
The final parts, 3-port, adaptor for STi TMIC, gaskets and various other screws i've broken in the past.
Filter and IC off.
Heatshield off.
Water pipes + oil feed off.
Guess which is the TD04?
As i left it last night.
Filter and IC off.
Heatshield off.
Water pipes + oil feed off.
Guess which is the TD04?
As i left it last night.
31 October 2004, 06:41 PM
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Sunday
OEM FPR bypass in, nice and easy without the turbo there.
380cc grey ready to be plucked.
Phase 2 440cc yellow in.
FSE FPR cleverly located to almost completely obscure the gauge...
STi top mount and adaptor.
Modified gasket.
380cc grey ready to be plucked.
Phase 2 440cc yellow in.
FSE FPR cleverly located to almost completely obscure the gauge...
STi top mount and adaptor.
Modified gasket.
01 November 2004, 10:42 PM
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Monday
FETD05 on.
3-port solenoid partially fitted (didn't realise the fittings on the TD05 were larger bore than '04 so didn't have enough hose).
Modified TMIC, cheers Dad.
And with a bit of manipulation of the N/S mounting bracket it's finally on.
Running!
But then fuel started literally gushing from the OEM FPR adaptor... Half an hour of fiddling (girly fingers) saw the adaptor out and the o-ring i fecked when i fitted it replaced with a new one - so much for it being easier with the turbo off...
Fuel pressure set to 3bar for the time being.
Although it looks ready for the map i've somehow still got a list of things as long as my arm to do tomorrow. Includes some investigation into a possible exhaust leak @ turbo (praying this is nothing), buy/fit final 3-port hose, air filter cold air ducting, tidying FPR bracket, checking turbo oil return hose has made a good fit, refit turbo heatshield, yadda yadda....
3-port solenoid partially fitted (didn't realise the fittings on the TD05 were larger bore than '04 so didn't have enough hose).
Modified TMIC, cheers Dad.
And with a bit of manipulation of the N/S mounting bracket it's finally on.
Running!
But then fuel started literally gushing from the OEM FPR adaptor...
Half an hour of fiddling (girly fingers) saw the adaptor out and the o-ring i fecked when i fitted it replaced with a new one - so much for it being easier with the turbo off...Fuel pressure set to 3bar for the time being.
Although it looks ready for the map i've somehow still got a list of things as long as my arm to do tomorrow. Includes some investigation into a possible exhaust leak @ turbo (praying this is nothing), buy/fit final 3-port hose, air filter cold air ducting, tidying FPR bracket, checking turbo oil return hose has made a good fit, refit turbo heatshield, yadda yadda....
02 November 2004, 10:53 AM
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any idea when it will be getting mapped then?
u got a mechanical back ground apart from working offshore? as u seem to know what your talking about!
what do u work as offshore mate?
u got a mechanical back ground apart from working offshore? as u seem to know what your talking about!
what do u work as offshore mate?
02 November 2004, 11:08 AM
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Just in from tightening the bolts on the up pipe a little (gasket must have shrunk
) and the leak is a little better now. Also sealed the connections on the FPR with some PTFE now i have finalised the location.Cheers WW.
Ciaran, it gets mapped tomorrow.
I don't have much of a mechanical background apart from tinkering with cars in my spare time and allegedly being "good with my hands". TBH i've hardly touched the Scooby since i bought it (scared) and usually get other folks to do the work for me. However, my buddy Russ is offshore atm so it's up to me to do everything! Dad is a helicopter engineer so he's more than handy to have around and generally helps me out when i get stuck. He's also handy with a lathe and has been teaching me how to use the metal one. I'm a mongo proddy offshore btw.
Last edited by Carl Davey; 02 November 2004 at 11:11 AM.
02 November 2004, 12:26 PM
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Aye, i know a few peeps who've gone through their apprenticeship with them. Best thing is to hope you land on a decent platform next March. Start crying if they say you're going to Miller.
We have an apprentice tiffy out with us at the moment, he did his training through another crowd whose title escapes me atm. They're based in Edinburgh though.
Proddy = Production Technician.
We have an apprentice tiffy out with us at the moment, he did his training through another crowd whose title escapes me atm. They're based in Edinburgh though.
Proddy = Production Technician.
02 November 2004, 05:07 PM
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Tuesday
Final day of tinkering, let's hope i've done it all right.
As above, day begun with me getting my fingers burnt finding the leak on the up-pipe. Tightened a couple of bolts, went for a drive, tightened them some more and i'm 90% sure it has sealed now. Really regretting not using a dab of fire putty either side of the up-pipe gasket like i did on the d/p one.
Anyway, some crude ducting was the main focus of tinkering today after the up-pipe and FPR.
A quick wash so my car isn't shown up completely tomorrow by Davids mint WRX and i think i'm ready for the map...
As above, day begun with me getting my fingers burnt finding the leak on the up-pipe. Tightened a couple of bolts, went for a drive, tightened them some more and i'm 90% sure it has sealed now. Really regretting not using a dab of fire putty either side of the up-pipe gasket like i did on the d/p one.
Anyway, some crude ducting was the main focus of tinkering today after the up-pipe and FPR.
A quick wash so my car isn't shown up completely tomorrow by Davids mint WRX and i think i'm ready for the map...
02 November 2004, 05:49 PM
#22
Keep the update comming.! All great stuff and every credit to you. Thinking about similar spec myself, but already have the advantage of TD05 EUTEK, walbro etc. Just looking at uprated intercooler and injectors.
Very interested to see the outcome of map and performance and your opinion of driveability.
Keep up the good work
Very interested to see the outcome of map and performance and your opinion of driveability.
Keep up the good work
02 November 2004, 10:34 PM
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Thanks guys.
Gerry, i didn't know that, but then i have virtually no idea of the capabilities of the Commander.
To be completely honest i don't even know what language the manual is in... yet. I'm glad it can monitor water temperature though as i rather fancied investigating whether or not i could use my Defi Water Temp gauge/sender to monitor inlet charge temps (email to Defi coming up, i know the gauge parameters aren't *ideal* ).
Gerry, i didn't know that, but then i have virtually no idea of the capabilities of the Commander.
To be completely honest i don't even know what language the manual is in... yet. I'm glad it can monitor water temperature though as i rather fancied investigating whether or not i could use my Defi Water Temp gauge/sender to monitor inlet charge temps (email to Defi coming up, i know the gauge parameters aren't *ideal* ).
02 November 2004, 10:55 PM
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Originally Posted by Carl Davey
Final day of tinkering, let's hope i've done it all right.
As above, day begun with me getting my fingers burnt finding the leak on the up-pipe. Tightened a couple of bolts, went for a drive, tightened them some more and i'm 90% sure it has sealed now. Really regretting not using a dab of fire putty either side of the up-pipe gasket like i did on the d/p one.
Anyway, some crude ducting was the main focus of tinkering today after the up-pipe and FPR.
A quick wash so my car isn't shown up completely tomorrow by Davids mint WRX and i think i'm ready for the map...
As above, day begun with me getting my fingers burnt finding the leak on the up-pipe. Tightened a couple of bolts, went for a drive, tightened them some more and i'm 90% sure it has sealed now. Really regretting not using a dab of fire putty either side of the up-pipe gasket like i did on the d/p one.
Anyway, some crude ducting was the main focus of tinkering today after the up-pipe and FPR.
A quick wash so my car isn't shown up completely tomorrow by Davids mint WRX and i think i'm ready for the map...
I like it when my car is discribed as mint
cheers david
02 November 2004, 11:15 PM
#29
Originally Posted by Carl Davey
Thanks guys.
Gerry, i didn't know that, but then i have virtually no idea of the capabilities of the Commander. To be completely honest i don't even know what language the manual is in... yet. I'm glad it can monitor water temperature though as i rather fancied investigating whether or not i could use my Defi Water Temp gauge/sender to monitor inlet charge temps (email to Defi coming up, i know the gauge parameters aren't *ideal* ).
Gerry, i didn't know that, but then i have virtually no idea of the capabilities of the Commander.
To be completely honest i don't even know what language the manual is in... yet. I'm glad it can monitor water temperature though as i rather fancied investigating whether or not i could use my Defi Water Temp gauge/sender to monitor inlet charge temps (email to Defi coming up, i know the gauge parameters aren't *ideal* ).Made arrangements tonight for him to map mine on Thursday too
Enjoy!!!
02 November 2004, 11:39 PM
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Russ, i will whip it off (ooer) in the morning before i leave, cheers.
I just can't wait Gerry, David was telling me you can set it to only rev to 3000rpm for 'valet' mode pmsl.
Anyway, had best get some sleep...
I just can't wait Gerry, David was telling me you can set it to only rev to 3000rpm for 'valet' mode pmsl.
Anyway, had best get some sleep...