Project STI - The Daily Race Car
Discussion
Ok so turns out my project has gone a bit further than expected, it was going to be a light modified Impreza which was fun for weekends.
I've now entered a race series for 2015 and depending how the first couple of rounds go, I might be entering another.
This is taken from a thread I have running on an owners forum, so if there's anything I say which doesn't make sense, that's why.
So this is the story.....
When I bought it, it was standard apart from a ridiculously noisy, no-good, exhaust.
First purchase was a set of RB320 Shocks and Springs, the rears are away getting refurbed and should be back pretty soon. As you can see, one of them is leaking. May as well get both done tho. Obviously they'll be a bit cleaner when they go on the car
The Turbo.
It's a KAMAK TD05 20G, with Billet compressor and 9 blade turbine wheel, apparently 30% lighter rotational assembly than a normal billet turbo which allows for quicker spool and better top end. Full boost should be in around 3500-3600 rpm and I've seen several of these on Americano forums producing 430+bhp (370 whp).
It looks a neat piece of kit at least, lets hope it goes how it looks.
Also had an HRC 340 l/hr fuel pump and 3" turbo back sleeved system fitted. There's also a Denso 3 port solenoid fitted at this point.
Race Wheels.
Paint Strip and powder coated White(ish)
Then Metallic Black Base coat with a Liquid Green Top Coat. Turn Green to Purple/Blue
Now the engine bay to take care of.
Fuelab FPR in bottom left hand corner recently fitted, just needs positioned properly.
Had these items fitted too
Rallytech Machined Bolt Kit (well almost two of them actually) with red washers and the Alternator and Radiator Panels.
1000cc Injectors
After a few track days, it was time to change the engine, kinda broke the old one.
Fully close deck the block, 14mm head studs, 100mm pistons, BC Rods and STi crank.
Eventually had some suspension mods carried out at Chevron Motorsport, I really wish I had done this first, I can't even begin to describe the difference it's made, like chalk and cheese compared to how it was.
Then I went and bought some new shoes.
OZ Formula HLT
Followed by another trip back down south to Chevron which was another complete success, though another expensive one it turned out to be, going from the initial, ARB's, Droplinks and Replacement Top Mounts and 3 hours to Fit, turned out to be that plus a whole lot more and 3 guys working on the car from 9.30am until 6.45pm, so that meant me getting home way past 10. But it was well worth the 19 hours on the road and sitting around waiting, the car feels like a different animal once again, the way Simon can transform a car is unbelievable.
Here's a couple of pics of the work.
Rear
Front
Then the engine build, sorry about the high quality pics, if they break your computer, I can't be held responsible.
Grp N Sump
Closed Deck Inserts
Look how fat my rod(s) is/are
14mm head studs and ceramic coated pistons to aid exhaust gasses
All assembled ready to fit. Good news is, my KAMAK turbo has stood up to the abuse it's had over the last year and there is zero play in the shaft. Nice!
Let's see if I can break it with Anti-Lag
This is how the engine bay currently looks
To be continued.........
I've now entered a race series for 2015 and depending how the first couple of rounds go, I might be entering another.
This is taken from a thread I have running on an owners forum, so if there's anything I say which doesn't make sense, that's why.
So this is the story.....
When I bought it, it was standard apart from a ridiculously noisy, no-good, exhaust.
First purchase was a set of RB320 Shocks and Springs, the rears are away getting refurbed and should be back pretty soon. As you can see, one of them is leaking. May as well get both done tho. Obviously they'll be a bit cleaner when they go on the car
The Turbo.
It's a KAMAK TD05 20G, with Billet compressor and 9 blade turbine wheel, apparently 30% lighter rotational assembly than a normal billet turbo which allows for quicker spool and better top end. Full boost should be in around 3500-3600 rpm and I've seen several of these on Americano forums producing 430+bhp (370 whp).
It looks a neat piece of kit at least, lets hope it goes how it looks.
Also had an HRC 340 l/hr fuel pump and 3" turbo back sleeved system fitted. There's also a Denso 3 port solenoid fitted at this point.
Race Wheels.
Paint Strip and powder coated White(ish)
Then Metallic Black Base coat with a Liquid Green Top Coat. Turn Green to Purple/Blue
Now the engine bay to take care of.
Fuelab FPR in bottom left hand corner recently fitted, just needs positioned properly.
Had these items fitted too
Rallytech Machined Bolt Kit (well almost two of them actually) with red washers and the Alternator and Radiator Panels.
1000cc Injectors
After a few track days, it was time to change the engine, kinda broke the old one.
Fully close deck the block, 14mm head studs, 100mm pistons, BC Rods and STi crank.
Eventually had some suspension mods carried out at Chevron Motorsport, I really wish I had done this first, I can't even begin to describe the difference it's made, like chalk and cheese compared to how it was.
Then I went and bought some new shoes.
OZ Formula HLT
Followed by another trip back down south to Chevron which was another complete success, though another expensive one it turned out to be, going from the initial, ARB's, Droplinks and Replacement Top Mounts and 3 hours to Fit, turned out to be that plus a whole lot more and 3 guys working on the car from 9.30am until 6.45pm, so that meant me getting home way past 10. But it was well worth the 19 hours on the road and sitting around waiting, the car feels like a different animal once again, the way Simon can transform a car is unbelievable.
Here's a couple of pics of the work.
Rear
Front
Then the engine build, sorry about the high quality pics, if they break your computer, I can't be held responsible.
Grp N Sump
Closed Deck Inserts
Look how fat my rod(s) is/are
14mm head studs and ceramic coated pistons to aid exhaust gasses
All assembled ready to fit. Good news is, my KAMAK turbo has stood up to the abuse it's had over the last year and there is zero play in the shaft. Nice!
Let's see if I can break it with Anti-Lag
This is how the engine bay currently looks
To be continued.........
Edited by IvanSTi on Monday 16th February 16:24
AWG said:
Awesome thread, subscribed!
Assume the engine work is to cope with the endurance of the race series? STi engines are good for that power once upgraded anyway.
The 2.0 unit can cope, you're right, up to about 450 bhp, however, they're pretty poop when it comes to producing torque and I don't think they would cope with racing too well after a while. I also sprung an oil leak in mine after a few track days so hence the change. Assume the engine work is to cope with the endurance of the race series? STi engines are good for that power once upgraded anyway.
Ideally I should have gone for a 2.35, however, I can feel the bottom of my pockets.
Next best would have been a stroked 2.0 to 2.1/2.2 using a classic CDB, however I was told that the 2.5 would be a good rout to go down with a closed deck insert. Kinda wish I hadn't as there are concerns with the 2.5 engine, but we shall see how it goes and was too far down the line to change my mind.
But yes, the idea was build an engine which was more reliable than what was in the car. I'll be limited to approx 500-550 bhp with similar torque (using the correct turbo) as the cylinder liners are thinner than the 2.0. Should still be pretty nippy, with little to no lag.
The standard 2.5 can't cope with that sort of power or the boost pressure to get there, plus the cylinder liners have a tendency to move and/or oval when abused which also causes the head gasket to fail. Hopefully the insert and 14mm head studs will reduce the chances of that happening. If it goes pop, I'll go back to the drawing board and go 2.1 or 2.35, but would have to build the latter myself as the funds would have been used on the components/machining.
IvanSTi said:
Konan said:
IvanSTi said:
Grp N Sump
Is that based on the regular sump and modified with plates over some of the holes?I've actually got one of the Cosworth style oil control plates sandwiched in. Also added a pressure gauge to it. All done because my local track is Snetterton and enough speed through Coram corner is reportedly enough to run the sump low.
Konan said:
Probably something I should've done when I replaced my sump then! I wrecked my old one by using an additional gasket. Torqued up to 5nm on the bolt and it was enough to pull the thin metal of the flange into the gasket material. Just went back to fitting it with decent gasket maker as per the factory.
I've actually got one of the Cosworth style oil control plates sandwiched in. Also added a pressure gauge to it. All done because my local track is Snetterton and enough speed through Coram corner is reportedly enough to run the sump low.
Well that's one of the tracks (inner circuit) which I'm running in the sprints, so it will give it a good test.I've actually got one of the Cosworth style oil control plates sandwiched in. Also added a pressure gauge to it. All done because my local track is Snetterton and enough speed through Coram corner is reportedly enough to run the sump low.
The Cosworth Baffle plates are supposed to be good too, but the oil has to be under pressure to drain back into the sump apparently?? so could be a potential problem. This just stops the oil from moving round too much and surging. It's not been tested yet though.
IvanSTi said:
Well that's one of the tracks (inner circuit) which I'm running in the sprints, so it will give it a good test.
The Cosworth Baffle plates are supposed to be good too, but the oil has to be under pressure to drain back into the sump apparently?? so could be a potential problem. This just stops the oil from moving round too much and surging. It's not been tested yet though.
The infield circuit (100) doesn't include Coram, so you're safe!The Cosworth Baffle plates are supposed to be good too, but the oil has to be under pressure to drain back into the sump apparently?? so could be a potential problem. This just stops the oil from moving round too much and surging. It's not been tested yet though.
I'm certainly no engine builder/designer but a lot of what I read around the subject feels a little like guess work (it's hard not to be, if you can't keep an eye on what's going on inside). I do know that Cosworth put the plate through a lot of testing (and the RCM version I have looks rather 'inspired' by the Cosworth plate, to put it politely).
The thing I did notice, is that it takes about another half litre of oil to get to the line. I doubt the thickness of the plate alone accounts for this.
My car is only a WRX with a set of prodrive blue springs and slightly sticky tyres, so it's not going to be generating Gs anywhere a good sprint setup will achieve(especially with me driving). However, I've sat as fast as I dare around that long right hand and never seen the pressure budge.
FMIC finally fitted. HDI but the pipework is poor setup so going to rearrange it once I've got the car mapped on Thursday.
I spoke about the plate a bit more today, apparently the oil moves back through the holes in the sump into the block so the pump can start taking in air. The one I have blocks these holes so is a lot harder for the oil to do that. It's a replica of the group n subaru rally car sump.
I spoke about the plate a bit more today, apparently the oil moves back through the holes in the sump into the block so the pump can start taking in air. The one I have blocks these holes so is a lot harder for the oil to do that. It's a replica of the group n subaru rally car sump.
Fonzey said:
Good read, and bits of it look very familiar!
I've had my car to Chevron for work, and also recently fitted and mapped a billeted TD0520G (made 400bhp). Who's done your engine build?
Good luck in the 22b series, I hope to spectate at a few this year so perhaps will see you around.
Yeah I'm hoping to crack the 400 barrier this time with little to no lag hence the cc increase. I've had my car to Chevron for work, and also recently fitted and mapped a billeted TD0520G (made 400bhp). Who's done your engine build?
Good luck in the 22b series, I hope to spectate at a few this year so perhaps will see you around.
A lad in Chester-le-Street built the engine, he's got plenty builds under his belt, just hope it stands up to being thrashed to within an inch of its life.
If you see me at any of the events come and say hello, unless it's blown up I'll be happy to talk/even give a ride if you so desired And you have a lid.
I'm at all events so far with the exception of Snetterton but am going on the cancellation list Shouldn't really have a problem getting a place.
Edited by IvanSTi on Sunday 22 February 20:17
Had the car mapped again today, Alkatec ECU in with ALS and LC. Thing is mental now, spun the wheels up in second, ok that was in the cold and damp, but never done it before.
Need to try and figure out what I'm doing wrong with regards to Launch though as tried it earlier to show my lass and it wasn't working, not sure what's going on??
However, it feels so much better to drive now, a lot quicker and so much more responsive. My little TD05-20G ran out of puff so had to dial max boost back a little, so next on the shopping list is an Owen Developments turbo
Need to try and figure out what I'm doing wrong with regards to Launch though as tried it earlier to show my lass and it wasn't working, not sure what's going on??
However, it feels so much better to drive now, a lot quicker and so much more responsive. My little TD05-20G ran out of puff so had to dial max boost back a little, so next on the shopping list is an Owen Developments turbo
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