EugeneUtopia's 2010 FXT Project by EugeneUtopia

6 minute(s) of a 158 minute read

I've neglected to update the mod list....

Up to date, simplified mod list HERE...

6-26-2014

Power-coated the TMIC (visible) tubing and strut brace. Also ceramic-coated the heat shield and down-pipe

Before

After

7-24-2014

Did a quick dyno run today, now that the air leak between the MAF and turbo inlet has been fixed.

The tune(s) need to be adjusted for the newfound oxygen. Until it is, I won't be able to hit 26-27psi again.

Once it is adjusted, 500 whp should be attainable.

8-1-2014

The place where I got them is no longer showing the blacked out option as available, but they still do have the chrome version... 09-11 Subaru Forester CCFL Halo Headlights- 02-AZ-SF09-PCC-RF-A

Alternately, CarID still has both versions, but they are more expensive. Shouldn't be, since they are exactly the same thing from the same manufacturer... CG® 02-AZ-SF09-PBC-RF-A - Subaru Forester 2009-2011 Black CCFL Halo Projector Headlights with LEDs and Amber Reflector

I won't be selling anytime soon because......... ↓↓↓

Drivability and fuel issues resolved!

Problem 1

Ever since I swapped to the 6MT, I'd noticed that starting from a stop was VERY temperamental. I thought it was because the clutch was abused by the previous owner. As I was letting out the clutch the rpm would pulse up or down between 300 and 800 rpm, making it very hard to balance and be smooth.

My clutch gave out within 3000 miles of having it installed (used), so I replaced it with a "built" aftermarket clutch. That didn't last long and another clutch was installed (see note about this in the previous posts in this thread).

The new clutch was having the same issue, and after many attempts to rectify the problem with a new O2 sensor, tune tweaks and a fuel regulator, I simply got used to it.

Problem 2

Recently I noticed that when my fuel tank was full and the car was parked at (any) angle, I could smell gas. Looked at the ground under the car, and sure enough, a large puddle of gas was on the ground. I once filled the car up on purpose, parked it and didn't drive it for 3 days. Result was a loss of slightly less than 1/8th of a tank.

Problem 3

A few weeks ago my car just flat out would not get any gas delivery to the engine. Driving along and car dies as if it ran out (had more than 1/4 tank left). Coasted to the side of the busy road, cursed for a minute, then embarrassingly opened the hood and had a look around. Managed a few troubleshooting steps before a LEO pulled up behind me and asked if I needed any assistance. He and a friend helped push the Forester into a nearby parking lot by pushing it UPHILL about 30-40 yards. He bid me good day and went on his way. Never asked for the typical paperwork and identification before helping me out, which really is a very nice and unexpected thing. I know it's SOP to do that with any field contact. Just went to show how nice he was. Called AAA (did you know you could save hundreds of dollars in towing costs by switching to AAA? J/K)

Solution to problem 3

The car was indeed being starved of any fuel. in the '09+ (SH & SJ) Forester line, there is a fuel pump controller that is independent of the fuel pump itself. It is meant to vary the voltage to the OEM fuel pump, based on load and rpm and injector duty. The previous DW65C pump was fairly close (electronically) to the OEM fuel pump, so this controller never had a problem with it. The Walboro 460LPH is a MUCH larger unit, and over time the OEM fuel controller unit was overtaxed, and failed (thus no fuel delivery at all).

Bill at Drift Office changed the circuit to the controller by bypassing it in the wiring harness which resolved the issue.

Solution to problem 2

Turns out E85 and rubber don't get along. When my fuel pump was upgraded to the 460 liter per hour Walboro, the rubber gasket on the passenger side of the fuel tank access was exposed to the E85. Over the course of the following 2 months, the rubber distorted enough to allow gas to trickle out.

Gasket - Subaru P/N 42025AG000

Subaru recommends replacing this gasket any time the area it covers is opened. Once this was replaced, the wonderful aroma of gas went away, and there were no more leaks.

Solution to problem 1

During some troubleshooting steps, Bill at Drift Office smoke tested for vacuum leaks. He was able to identify what was initially thought to be a vacuum leak between the cold air intake and turbo inlet hose. He was very busy and couldn't get to repairing it for almost 2 weeks (he was kind enough to sneak me in and get the fuel pump controller issue resolved so I could drive it again), so I made an appointment with my primary tuner, PIA. Mike was able to find what turned out to be an air leak, and not a vacuum leak. Once he fixed it (under the manifold, so a b1tch to get to), the off-idle RPM fluctuations went away.