RM1Sepex Build Thread

[Hindsight]

Wow 1868.... not bad! I'm sure you'll be in under 2,000.

[RM1SepEx]

Aligned it yesterday, was a hoot to work through all the adjustments, rear to front, using the Subaru dealer's equipment while they were closed. So many links to adjust and each rotation of a link effects more than one setting! Now to work on my exhaust exit from the body, more exterior panel finalization and continued massaging of the surface of the panels. I wish that they would look good with a simple buffing but that's far from the case.

I did boot it across the parking lot, damn this thing needs smooth pavement or it grinds on the nose. I don't even have the splitter, diffuser and side extensions on yet!

I've cleared all my codes using the advanced parameters table yet that damn Po183 fuel temp sensor high keeps popping up! I don't understand why after it's been cleared/eliminated...

[Frank818]

1868, that's light!

[RM1SepEx]

My finished goal with interior is 2000, I'm pretty sure I can get there

[RM1SepEx]

My friend couldn't find his 4 inch hole saw for the exhaust so I ordered a large set on Amazon Prime...

Working on my air intake ducting for the cone filter and the IC, they share the side vent. I'll also be bringing air to the intake through what was the intercooler duct.

I need to borrow a couple profile gauges from a friend in the AM

Here is the roughed in aluminum box to isolate the intake from the intercooler and direct the IC fan airflow

P1120736.JPG

Similar to what Tamra and Andrew did for their intake

[RM1SepEx]

Dyno update:

Several issues: lean condition bank one CEL flashed on very low load before starting pull, occurred twice

I only data logged two pulls of 4, OOPS!

Max boost observed 9 PSI UGH time to debug

220 hp 200 torque on Dynocom 150,000 dyno, very conservative compared to other at the wheel dynos. So finding my boost problems and some slight mixture problems and I should be in great shape. I'll be uploading my data logs later

[Bob_n_Cincy]

Dyno update:

Several issues: lean condition bank one CEL flashed on very low load before starting pull, occurred twice

I only data logged two pulls of 4, OOPS!

Max boost observed 9 PSI UGH time to debug

220 hp 200 torque on Dynocom 150,000 dyno, very conservative compared to other at the wheel dynos. So finding my boost problems and some slight mixture problems and I should be in great shape. I'll be uploading my data logs later

Dan the 2005 WRX is rated at 227 HP at the crank. (unless you have other goodies)
your 220 at the wheels sounds great. What were you expecting?

[Mechie3]

Low boost: Double check that your wastegate is closing all the way. With the clocking bracket it's possible that the arm is too long and needs to be adjusted. The details are in my turbo clocking writeup.

[Tamra]

Did the tuner have any ideas on how to solve the problems?

Sounds like progress! 220whp is still probably a lot of fun

[RM1SepEx]

Just waded through the data log max boost was 10 PSI, Bob, I expected a bit higher boost, more HP (240 ish). Craig, yup that was my first thought, re-adjusting the contact of that waste gate disc vs the turbo was a bit tricky, I did have to shorten it, I might be bleeding some boost.

My Subaru friend expected more boost 12-13 PSI

The good news, 4 pulls, with my 1250 CFM 10 inch fan pulling through the side mount IC with a fan on it, went from 66 to 70 degrees. I think that with a modest 3-4 inch deep/wide scoop on the side it should work fine. It did take 6-7 pieces of aluminum to duct off the IC and intake air flows

I'm thinking my lean condition may be due to running an almost non-existent intake tube and the header, to 3 inch bellmouth, cat, 90 bend muffler, exit setup. My intake and exhaust flow restrictions are very low compared to a WRX. Cobb did feel that it would be safe and the lean is only below 2000 rpm in 3rd while spinning up the rollers to start the pulls.

I may need to bite the bullet and go to a custom tune. However It goes like a raped ape... I can leave double patches of rubber as long as you desire or can afford. I can not imagine much more HP on the street, just can't use it.

Edit: found a boost table for 2.0 WRX on Nasoic Stock is around 13.5 PSI

stockboost 05 wrx 2.0L.jpg

[RM1SepEx]

Did the tuner have any ideas on how to solve the problems?

Sounds like progress! 220whp is still probably a lot of fun

not using a "tuner" yet. Cobb and AJW thought a straight up Cobb stage 2 tune would be a safe setup with my system as described. My friend with the dyno works with Megasquirt systems as do many in our autocross community.

I'm sure with some simple tweaking I can get a bit more boost from the stock setup, I have my goal set at an old school 10 lbs per loaded HP at the wheels. 2000 lb car with 400 lbs in payload needs 240 WHP.

Edit: Bob you and your son need a slightly higher target... ;-)

[RM1SepEx]

Stupid Subaru sedan belts locked up again. Ordered FFR harness bar and Schroth Rallye Cross belts today. http://www.rockymtnautosports.com/schroth-rallye-cross/ Now I'll have a DOT harness and won't be stranded with a belt that stops working!

[Tamra]

Nice! We are very happy with our Schroth harnesses. We went with the Profi II ASM FE with the sub strap to make it a 5 point, but the Rallye ones look nice too. It's great that they are safe as a 4 point. Our DMV inspector wanted to see the tag that stated they were FMVSS 209 approved, so just be prepared.

The attachment points on the frame for the FFR harness bar were a little off for us, so we moved the tabs a little to get the right angle.

[RM1SepEx]

Belts arriving today... I need to call FFR no shipping confirmation yet.

Last autocross of the year Sunday, I got FTD in Frankenstein again, it's good to finish the year with consecutive FTDs!

[RM1SepEx]

Project on hold, 92 yr old mother in law's in the hospital... she fractured her spine, c3- c4 area, prognosis isn't good she's tiny at 70 lbs or so

[Hindsight]

Ouch, sorry to hear it Dan. Will send good thoughts your way.

[RM1SepEx]

Thanks, we all realize how frail and helpless we are as babies, at 92 it's not much different except you are on the tail end of life. Makes for a ton of stress in life... she's a wonderful person and I despise seeing her in so much pain. I told my wife that if/when I'm at that point we have a goodbye party for friends and I slip away on a morphine induced permanent sleep!

[AZPete]

My thoughts are with you, Dan, and I hope she recovers quickly. Reaching 92 is an accomplishment so she must be tough.

[RM1SepEx]

Thanks Pete, she escaped China and Chairman Mao when she was a young woman from a wealthy family marked for elimination. My in laws are/were very humble and meek but tough as nails and very strong willed. He was a doctor, she was a nurse, nothing but rice for years during their schooling, he did medical school in China and in Canada to move to the west. We all need to realize how lucky we are to be citizens of the US.

[Frank818]

Oh god, sorry Dan. My GM was 92 and about 70lbs as well when passed away. She's done her life, but hopefully your MiL still got a few miles in left.

[RM1SepEx]

I think I found my low boost problem soln today... when I clocked the turbo I had to modify the vacuum lines for the boost controller. I no longer have a restriction pill! I'll have a replacement next week, fingers crossed!

[RM1SepEx]

I found a use for all those Chinese takeout chopsticks! I used white vinyl edging on the body cutout, softened with a heat gun. Used clear silicone to glue the RAL 2008 orange powder coated grill in the rear opening

P1120783.JPG

[TrickyPete]

How did the restrictor pill work out? Did it solve your boost issue?

[RM1SepEx]

Haven't brought it back to my friend's dyno Pete. I thought you were going to stop by last weekend...

I did snake through the wires for my AAIC intake temp sensors. I had to order a couple bungs, they will be in this week. The old seat belts have been removed and I'm ready to start laying out the interior and gauges, switches etc... I think I'm going to do custom door pulls vs the WRX units since I'm not using the aluminum door inserts.

[Mechie3]

I just boxed up those prototype arms I don't need anymore. They'll be heading your way tomorrow.

[ssssly]

The missing restrictor pill is likely the reason for both the lean low RPM issues and the lack of boost up top.

Without it the system will act like there is no BCS installed. There is no wastegate control other than the WG spring. So the turbo will not bleed any air until it hits spring pressure. So it will spool a bit faster than stock giving you your down low lean condition.

It however will also not keep the wastegate closed past spring pressure, giving you your lack of top end boost.

Should be good to go.

[TrickyPete]

Haven't brought it back to my friend's dyno Pete. I thought you were going to stop by last weekend...

I did snake through the wires for my AAIC intake temp sensors. I had to order a couple bungs, they will be in this week. The old seat belts have been removed and I'm ready to start laying out the interior and gauges, switches etc... I think I'm going to do custom door pulls vs the WRX units since I'm not using the aluminum door inserts.

I learned a valuable lesson in communicating with the wife. She had the whole weekend planed out with hair appointments, cheering stuff and a birthday party so I was tied up at home. I'll send you a text later today.

[RM1SepEx]

I learned a valuable lesson in communicating with the wife. She had the whole weekend planed out with hair appointments, cheering stuff and a birthday party so I was tied up at home. I'll send you a text later today.

My my my, that never happens to me! Last day of muzzle loader season, I'm going to be occupied until after dark

[RM1SepEx]

Looks better w/o the chopsticks!

P1120784.JPG

[wallace18]

Looks better w/o the chopsticks!

P1120784.JPG

Sure does! LOL.

[RM1SepEx]

Anything to get rid of those aluminum "trim" pieces and exposed screws Tom! Anyone have a nice solution to get the blinkers and a reflector cleanly on the side of the rear clip? I need them for a sticker in Maine. Hoping for something flush mount

[RM1SepEx]

Slow going with so much going on!

Shifter is finalized with Craig's aluminum shifter plate. It holds the MR2 ball tighter and tightens up the shift action. Shifting throw is very short and positive, great feel, even with a pair of cables.

P1120786.JPG

My intake tubes are getting their bungs welded in for the AAIC temp sensors. Not sure when I'll get it to Chris' new AWD Dynocom dual 150,000 dyno with all options. He's the lead software developer for their latest offerings to run the dyno from a single laptop in the car!

http://www.corvetteonline.com/featur...and-afr-system

I've also decided to screw down the engine cover and use a small door to access the oil fill and dip stick. I should be finishing up this area upholstered in black vinyl and will use a small switched LED light to illuminate the area.

P1120785.JPG

I'd like to go with a std heater system but I'm not looking forward to running the water feed and return to the heater hose loop. Any ideas how this can best be done with a nice appearance before I settle for DC powered defroster vents and the seat heaters that I already have?

I'm also looking for ideas for the ODBII port and the two green plugs and the white one... I need easy access for the Cobb Accessport

[RM1SepEx]

I wanted the gauge pod to hold tighter to the dash molding so I added that thin black vinyl edging over the fiberglass, (use a heat gun to get the glue that is in the middle to activate) and a thin strap up and over the gauge pod. I used those 1/4- 20 studs and fiberglass bonded them in. During one of my in and out installs I broke one of the gauge pod brackets... I had to bond it back on with epoxy

P1120787.JPG P1120788.JPG

[mikeb75]

You can leave the white ECU connector closed with the loop plug you received with your AP; makes no difference to ECU operation.

You can connect the 2 green (test) plugs with a simple open/closed toggle switch hidden somewhere under the dash that is accessible. It's only needed for reflashing the ECU. I put mine high in the passenger footwell on the center console aluminum; just the perfect place for the passenger to kick it when taking a corner very fast

[idf]

You can leave the white ECU connector closed with the loop plug you received with your AP; makes no difference to ECU operation.

You can connect the 2 green (test) plugs with a simple open/closed toggle switch hidden somewhere under the dash that is accessible. It's only needed for reflashing the ECU. I put mine high in the passenger footwell on the center console aluminum; just the perfect place for the passenger to kick it when taking a corner very fast

I took a similar approach, but used a keyed switch.

[RM1SepEx]

I got tired of getting the screw into the frame using the angled tab of the rear fender so I just riveted on a 1 inch piece of 1/8 thick aluminum.

P1120789.JPG

[RM1SepEx]

Busy day, finally got off my butt after over thinking my center console. The majority of it will be covered with the high grade medical vinyl I bought. The section going up to the dash is an odd shape as it goes from the center between the sheets up to the dash. I hand cut and filed to fit holes for the seat heater, IC fan, foglights, interior light switches, Inlet and outlet IC temp gauge, USB and 12V power ports and my Kenwood stereo. I will be laminating thin 1/4 sawn oak veneer on it to match the dash and door panel inserts. I have to go borrow a 1 1/8 inch hole punch to finish the power ports. I also got to take a spin around the driveway on a nice sunny day! Note the cement filled kart tires that allows for gravity to continue to work on the body contours

P1120812.JPG P1120813.JPG P1120818.JPG

[Hindsight]

Lookin good Dan! Do you find the console intrudes on your leg area at all? I've been thinking about making something similar but was worried about that.

[RM1SepEx]

Plenty of leg room on both sides. I have to borrow a friends leather beating bag to put a bump on the passenger side, the stereo has a bit of conflict. I pulled the WRX console apart. I'm trying to use the dual fold out cup holder off the passenger side of the console. I'm using the upper storage compartment as the top of the console/armrest.

The dash and door inserts are just about done. The dash is not a very regular shape and is damn wavy. It was difficult to bond the veneer on with contact cement to get it flat. It's stained and has multiple coats of spar varnish, yellows it a bit but puts on a nice finish that will stand up to the weather in an open car.

I bought some custom turned aluminum knobs to use as door pulls. I need to get the old oven out and powder coat them orange to match the door pulls and steering wheel center. I also made a cute door to access the oil fill and dipstick w/o pulling up the engine cover. It includes a small switch and a LED light.

[Hindsight]

Nice, looking forward to seeing the finished product.