The Project Car Thread

[Just4fuN]

Well, I figure it's about time I post up some of the work I've done on my WRX. After owning the car for almost two years, a few months back I finally decided it was time to start throwing some money at it.

I started out by instally an HKS Hi-Power CBE, removing the dealership badging from the trunklid, and disabling my DRLs. Shortly after, I put on a set of bigger (17x7.5 vs. the 16x6.5 stock) wheels on for the summer. I wrapped them in Bridgestone Potenza RE-070s. I will still be using the stock wheels with Goodyear Eagle F1 A/S for the winters.

After this, I installed a K&N Typhoon Short Ram intake.

I also began to notice that there was a problem with one of the exhaust hanger arms chattering against the rear sway bar at certain RPMs and over rough road. I installed 4 Kartboy Hangman hangers (much stiffer than stock) to resolve this issue.

It wasn't long after that I was ready for more power, so I installed a Cobb Bellmouth DP and reflashed (open source) the ECU to raise target boost from 13.61psi to 16.05psi. After logging the ECU a few times after the reflash, we noticed that the wastegate was pinning itself shut and staying that way in order to hit target boost. We determined that the wastegate wasn't actually shutting, so we shortened the wastegate actuator arm and logged the car again. No more problems after that.

As part of the reflash, we also put a LC program on the ECU. If the car is moving less than 9mph, the rev limiter drops to 4000rpm.

Shortly after the reflash, I installed an Autometer vacuum/boost guage on the A-pillar as a stop-gap until I can get a more expensive, and more tastefully mounted boost guage setup.

The next things on the list are springs and sways. The springs will serve as a stop-gap (literally) until I'm ready for coilovers. I will also need new brakes soon (62K miles on the current ones... starting to warp). The LC jerks the engine block around pretty good, so stronger motor mounts are also a priority.

The car is my daily driver, so I can't go too overboard with it.

I'm going to attempt to add some pictures later tonight hopefully, but I don't own a camera, so I only have pictures that others have taken and sent me. For now though, I've gotta run to look at a house.

[VR6 Man]

Originally Posted by Just4fuN

Well, I figure it's about time I post up some of the work I've done on my WRX. After owning the car for almost two years, a few months back I finally decided it was time to start throwing some money at it.

I started out by instally an HKS Hi-Power CBE, removing the dealership badging from the trunklid, and disabling my DRLs. Shortly after, I put on a set of bigger (17x7.5 vs. the 16x6.5 stock) wheels on for the summer. I wrapped them in Bridgestone Potenza RE-070s. I will still be using the stock wheels with Goodyear Eagle F1 A/S for the winters.

After this, I installed a K&N Typhoon Short Ram intake.

I also began to notice that there was a problem with one of the exhaust hanger arms chattering against the rear sway bar at certain RPMs and over rough road. I installed 4 Kartboy Hangman hangers (much stiffer than stock) to resolve this issue.

It wasn't long after that I was ready for more power, so I installed a Cobb Bellmouth DP and reflashed (open source) the ECU to raise target boost from 13.61psi to 16.05psi. After logging the ECU a few times after the reflash, we noticed that the wastegate was pinning itself shut and staying that way in order to hit target boost. We determined that the wastegate wasn't actually shutting, so we shortened the wastegate actuator arm and logged the car again. No more problems after that.

As part of the reflash, we also put a LC program on the ECU. If the car is moving less than 9mph, the rev limiter drops to 4000rpm.

Shortly after the reflash, I installed an Autometer vacuum/boost guage on the A-pillar as a stop-gap until I can get a more expensive, and more tastefully mounted boost guage setup.

The next things on the list are springs and sways. The springs will serve as a stop-gap (literally) until I'm ready for coilovers. I will also need new brakes soon (62K miles on the current ones... starting to warp). The LC jerks the engine block around pretty good, so stronger motor mounts are also a priority.

The car is my daily driver, so I can't go too overboard with it.

I'm going to attempt to add some pictures later tonight hopefully, but I don't own a camera, so I only have pictures that others have taken and sent me. For now though, I've gotta run to look at a house.

Nice dude, sounds like you have really dug into your car. I'd love to see pictures.

How do you like the launch control? I will have the ability to add this as well on my car. Does it just let you rev to 4000rpm, or is it a drag race style that retards timing and lets you build boost as well?

[Just4fuN]

Originally Posted by VR6 Man

Nice dude, sounds like you have really dug into your car. I'd love to see pictures.

How do you like the launch control? I will have the ability to add this as well on my car. Does it just let you rev to 4000rpm, or is it a drag race style that retards timing and lets you build boost as well?

It revs to 4000rpm, then bounces off, just like the regular rev limiter. By keeping my foot in it, it'll keep bouncing between 3700-4000, which is where I hit my peak torque output. Also, by doing this, it puts the engine under load and I can build up to around 8-9psi after 3-4 bounces off the artificial rev limiter.

Once I've built this boost, I can just drop the clutch, chirp all four tires, and jump forward. The trouble is that I could do with some more low-end torque because the car still tends to bog after lunging forward. For best results, I can slip the clutch just a little, rather than dumping it.

The summer after I bought the car, still all stock:



The CBE exhaust install (still stock DP in the pic). The spring bolts were seized and one broke while trying to remove. Put these together using various parts from the local Westlake Hardware:


After we finished the CBE install and removed the dealership "ADAMS" badging from the trunklid:



Side-by-side with a fellow WRX:


With some buddies outside the movie theatre (mine's the blue '05 w/ black wheels on the end):




At a big car meet Memorial Day weekend '09 (first car on the end):


Like I said, unfortunately I don't own a camera, so I can only post more pics as other folks take 'em and send them to me.

Sorry for the poor quality on some (camera phone).

[VR6 Man]

Nice dude. I hadnt realized you edited your post with pictures. Car looks good man.


Update for my Cabby:

Well its been a few days since my last update, but I've been doing at least a little each day.

I finally mounted the battery, which had just been sitting in the trunk with no tray or anything. Now its bolted down.

I did some wire tucking and wrapped some sensor wires with hockey stick tape (it looks just like the stock tape VW wraps all their wires with).

As far as being ready to start, the motor is totally assembled, all pipework back on the car, and it is mechanically ready.

I have oil pressure. ~35-38psi while cranking over.

I got little stuff like my center gauges all wired up, they work correctly and light up when I turn on the headlights.

I got all ground straps replaced with new ones.

All lights and sensors seem to be working.

[Driftster]

well poop!

My coil just crapped out..

lol lame..

like litterally..died....Time to barter

BTW i'm in talks with a guy out in chandler, whos daughter recently wrecked her 325i...

hopefully i can get his m50 from him for a 300-400 dollar price tag.

[Heretic]

Originally Posted by Driftster

well poop!

My coil just crapped out..

lol lame..

like litterally..died....Time to barter

BTW i'm in talks with a guy out in chandler, whos daughter recently wrecked her 325i...

hopefully i can get his m50 from him for a 300-400 dollar price tag.

that is a project i would like to see

[Driftster]

I'd actually like to find a non-vanos M50...simply because of their sturdier guts, and better head design ...and well..

Less electrical doo dads... (if it aint VTEC..i don't need/want it)
plus there's no fun in replacing those vanos boxes left and right...

I just havent taken the time to go scout out older 5/3 series cars at the wreckin yards or BMW graveyards...

however i'm not going to argue with a newer m50/m52 if the price is right.

Chances are the engine wouldn't go into the car until next summer..give me a good year to enjoy the lack of power and spirited driving.

[VR6 Man]

Why not man up and go for the S50/S52 engine?

Kidding, I assume they are almost non-existent, excpet for like 30 seconds on bf.com when one goes up for sale.

[Driftster]

actually its easier to find s50 and s52's than it is m50's and m52's,,,,


s50s go for 6-7 grand for longblocks..... but 750 bucks for a m50 is almost "pricey"

an making an m50 outclass the s50 aint crazy, especially the nonvanos which has larger bore spacing allowing for 86.5mm cyls.....

[VR6 Man]

Originally Posted by Driftster

actually its easier to find s50 and s52's than it is m50's and m52's,,,,


s50s go for 6-7 grand for longblocks..... but 750 bucks for a m50 is almost "pricey"

an making an m50 outclass the s50 aint crazy, especially the nonvanos which has larger bore spacing allowing for 86.5mm cyls.....

Yeah I guess that would be the case. All the E30 guys would gladly take the cheaper M50 I'm sure.

Nonvanos would be nice. I always felt a little scared that the vanos would go out on my E36 M3 and I'd have to replace the unit.

[VR6 Man]

Well, I have some really good news. Not the best possible news, but good news.

Today I finally got to turn the ignition to the "ON" position and have the ECU start up. Before I did this I connected my old-as-crap laptop that has Windows ME on it, through a communication cable that is wired into the ECU harness. Basically as soon as the key turned on, the laptop was connected to the ECU and the gauges on the program read correct readings.

Here it is. I am using a modified version of MegaTune which is usually used for MegaSquirt SEM. But Lugtronic who made my ECU has been able to use MegaTune with the VEMS ECU that they use. This is awesome if you have ever used MegaTune because it is so simple to work with.



That was a very exciting part of my day.

But the downer is, I have to wait until the 3rd of June for my 10.4mm spark plug wires to get here. So until then, I cant start the car. And I am not about to go buy a cheap set to tide me over, since they are $120 for a cheap set (yes, expensive. You'd have to see them to understand why).

Here's the ECU all hooked up. Once I have the car running I will make a bracket for it up under the dash.



Still no seats and wires everywhere.



I finally found a filter that would fit into the very small space I had to put one. I dont even want to admit where I bought it, but it was the only one I have ever seen that was both the correct length, and had a 4" opening to fit the turbo... Advanced Auto Parts. . We will see how well it does.



There is a shot of the harness where it connects to the injectors. Notice I have the main part of the harness running below the fuel rail. I had to cut the harness open and extend a few wires that werent long enough to a couple sensors. So you can see the hockey stick grip tape on that part of the harness.



Full engine bay shot. Its a lot cleaner than it used to be. I have hidden some of the wires and cut a few out. There are still a group of wires that will be removed, but I am waiting until the car is running and all sensors work before I cut anything out.



A shot of the Throttle position sensor plug and wire. I just wanted to show some of the quality of the harness. All the wires are twisted before being wrapped in shrink wrap stuff. Very nice.



Here is a shot of the main group of wires coming from the fuse block. I put all the smaller harnesses together and wrapped them in grip tape. You can also see the 30A circuit breaker on the strut tower that I added when I installed the rad fan relay today.



Here is the rad fan relay. It's from Jegs and seems to be pretty decent quality. It came with really really long wires, which was nice and it came with the 30A circuit breaker as well. Its right above the MBC and attached to the underside of the rain tray using the the old coil bracket bolts.



Just a general shot of the engine bay from the driver's side.



And passenger's side.



A little better shot of my "high quality" air filter. It was hard to get on since it hit the back of the valve cover a little. Since it was only $22 I didnt mind messing it up a little getting it in there.



Here is the battery mounted in the trunk. I finally bought a tray and hold downs for it. I drilled through the rear floor pan and attached the tray with M10 bolts. I drilled through the carpet too so I could keep the carpet in there. The only thing I was disappointed about was that I had to move the battery from the middle of the compartment to the driver's side because I would have been on top of the spare tire. For some reason the spare is off set to the passenger side a little and there is a flat spot on the drivers side, so that's where I bolted her down.



Another shot of injectors and their plugs. Again, nice quality work.



Just a random engine bay shot. A nice view of the Tial BOV. I can't wait to hear that sucker release for the first time.



My nice BBM short runner.



She's almost ready!



These next two shots are of the fenders that I haven't completed yet. I need about one more coat of filler on either side, then a good final sanding.





My boost gauge and oil pressure gauge light up. But my middle volt gauge doesn't. It never has, and I even switched the bulb and assembly with one of my old gauges.



Finally, one last shot. I thought it would look cooler. Plus my arm got in there a little, as I had to hold the camera against the wall to keep the camera still. Oh well.



Enjoy!

Look here on June 3rd because that's when my plug wires are supposed to be in, and I plan on starting it that day.

[clutch]

I also recommend a short video of that moment.


I love the entire build, I hope she starts up on her first attempt. Great work man.

[VR6 Man]

Originally Posted by clutch

I also recommend a short video of that moment.


I love the entire build, I hope she starts up on her first attempt. Great work man.

Thanks dude. I will definitely have a video up of me starting it and it running and some revving so we can hear that BOV and some turbo spool.

I probably wont record the first attempt to start it, because I am starting to wonder if I used the ignition timing mark on the flywheel to time the cams on accident . I cant remember, so either I will check that out before I try starting it, or when I do, it will be a rough runner and I'll have to shut her down to correct timing. So we will see.

But definitely a video for you guys.

[hyphon12]

Well I'm short of a car at the moment was fitting a MLS head gasket yesterday and did my timing belt, but to do the belt I have to remove the engine mount on the belt side, well someone had been at it before and cross threaded the mount and I tried my best to get it back in but just made it worse so now I need a new engine mount nothings simple on cars, especially when bosh mechanics have been at it.

[C.A.R.]

Ha, Hyphon that last comment is so true. Here's my weekend's acheivements-

Right, first off, here's my disaster from this weekend -

Firstly, removed 1.8 Inlet manifold - (that's a PTFE gasket btw)


Then, look at this. This will never do.


Bend it. Like this.


So it clears the manifold. Like this.


Look at this. 2nd Hand Engine Loom for spares.


Extend this, MAP sensor.


Phase differences FTW


See this? It's a MAP sensor.


Fits here.


Cut this off.


Look at that. That's where the difference lies in this conversion.


Rediculously tight bolt angle. (cue lots of swearing)


All fitted.


After this stage I connected up all the remaining hoses and fitted a K&N filter.

Then I started it up.

Brum splatter splatter vrooooooooom...mmmmm.mmmm

4Krpm :badair:

Fiddle with TB. Nothing wrong. It's shut.

Block the ICV. Hang on. Engine is still running.

Air leak is somewhere. I could get it to idle at 1.5Krpm, still not good, and it was lumpier than a fat birds tits.

So no pictures of it complete as such. Lots of swearing proceeded the above and I'm now back to running a standard 1.8 manifold again. FML.

Anyway, more fantastic weekend events were to be had underneath the car.

A trip to Top Gear Performance in St Albans saw a nice bald bloke tapping my cat.

"not good news mate"

"what's the damage?" (I actually said that, a failed attempt to out-cool myself).

"Cat's blown, contents have taken out the centerbox"

"FARK" (I said that too, only in my head)

Basically it was £250 for him to fit an FIA-approved sports cat, £250 I didn't have too.

"What can you do for £60?"

This -


Straight thru sucka's.
Then Today,

I was absolutely shattered. Sunday saw me spend 7 hours on the car and achieve nothing.

This afternoon I decided that dirty wheels and tatty calipers just wouldn't do. And I was bored. And the girlfriend went to work. Obvious really,

I learned to paint at playschool. Never saw any reason to try harder.



This is a spacer. A good mechanic told me that you should coat the faces with copper grease to protect against seizures. Like it says on the packet. If only John Travolta knew the power of copper grease. Maybe his son would still be around. Funny coincidental link there too - Travolta/grease. I'll stop now.



Waxed my wheels. Did the inside too, but that's not all that exciting to look at.



Sexy sexy





Notice how my tinted rear lights have faded? They look better now I reckon!



And look at the state of my paintwork. That's next weekends' mission -




More swirls than a Hippies favourite T-shirt.