Binjoau's 09 WRX MPS long rod-GTX35R Build Thread by binjoau

5 minute(s) of a 278 minute read

Thanks Junior, you will find it amusing because I have an identical twin brother both of us with english accents and when we drink we get hard to undrstand haha.

So the turbo will be fully removed today and ready to ship out to Blouch to see if it can be saved. Luckily I can use the low clearance lift at my employer which makes things a bit easier to remove. Il also snap a load of pics so you guys can see what happened. 

Plus if I am to receive any type of compensation then il obviously need evidence of the damage. I have kept the flex section after it was cut out so you can see how the flex pipe has disintergrated. I have sent initial information to Josh at IIR and he is forwarding it to the manufacturer to see if anything can be done.

Another video of exactly what my tick is like, it states in this video that the car had been checked by Subaru and was to spec, exactly the same as my car. noise is more apparent by the drivers side head and does incease with rpm. Like I said though no driveability issues with the noise and when we pulled it to do the new headgaskets there was no apparent damage to anything. Honestly it sounds more like an electrical ticking. Bizzare............

oh and another picture.........

sorry low res

7-24-2011

Okay guys so a bit of an update:

we got the downpipe off and inspected the turbo, there is no damage to any of the blades. There is a tiny score mark on the hotside but its finger nail catch only. Not a deep scour or anything. 

The cat on the downpipe did catch the metal that had passed through and it was not the weave, it was actually the metal of the flex pipe itself. Perhaps this was a saving grace simply because the flex pipe metal is super thin and soft it lost the fight against the steel hotside blades, if it had been the weave it probably would of locked the shaft and caused a total failure.

As for the vibrating sound that was the pieces of metal flying around in the exhaust before the cat. Once they were removed the sound was gone and the car now drives fine.

We did also run the car with the downpipe off to check for oil coming throught the hotside, there was nothing. It is bone dry but again I still get a bit of smoke under wot and I am still using a bit of oil. This will be the next thing we look at as............

I think we found the TICK!!!!

Il be putting up a video to show you exactly but what we think it is.... stay tuned haha

7-26-2011

The video is uploading now....

So here are some pictures of where the flex pipe section failed and the weave was pulled away from the pipe itself.

You can see in the next picture where the metal flex pipe itself had a hole sucked through it due to the thin metal construction, not exactly capable of higher than stock boost applications.

Then the piece that was found to have passed the turbo blades and was being trapped by the cat in the downpipe.

So with this happening and the oil consumption problem I am having the turbo is still going to get rebuilt, Blouch has still not responded to my email and I have tried calling a few times now with no answer.

I am hoping to start working towards troubleshooting my oil consumption issue so hopefully the experienced ones here can help....

What is known..........

1. The car is using oil at quite a quick pace, I have to add about 1/4 - 1/2 quart every 250 miles/

2. Dark Grey smoke under WOT, in 1st gear it can be seen very easily and is a puff out of the rear of the car. (There was a large puff when changing between 2nd - 3rd yesterday). Higher gears is much less noticeable. No smoke at idle or when revved at a standstill.

3. At start up I am having a bit of soot dripping from the exhaust of the car and leaving a mess on the driveway, this appears to wash away with water and doesnt smell of anything really.

4. Compression test results were close to 140 psi accross all cylinders. (Within 1 - 2 psi)

5. I do still have an exhaust leak, this is on the manifold somewhere, possibly the gasket where the flex pipe was removed and a flange put in. (This should be fixed today with a new thicker gasket and supreme copper sealant).

6. AFR at WOT is 11.0, my afr at idle reads a little high but again probably due to the small exhaust leak.

7. The PCV valve has not been changed on the car yet and will be shortly just in case this is a contributing factor.

8.There is no drivability issues at present, idle seems good, power is good, no real hesitation etc.

So ideas, thoughts?

Il check whatever it can be, just need to figure this all out.

Thanks guys, Alex

Oh and a few more random pics because I am a whore haha