IT RUNS!!! - My 500whp build - Element motor and Moore Performance Twin Scroll Kit! by dexterous

10 minute(s) of a 312 minute read

All,

Its about time for an update. As usual, I have been extremely busy with work, house and family stuff so the car has taken a back seat in my life. Fortunately, when I have driven it, it has performed perfectly.

In other news, for the past five or six years, I have gone on a work related road trip in early July and this year is no different. The work site is around two hours away from my house and while I am there, I stay about ten miles (all city driving) from the work site. I have taken my STI on this trip and daily driven it every year with the only notable exception being last year. This years trip starts tomorrow and has been shortened by the July 4th holiday so I will only be putting about 350 miles on the car. I have found that daily driving the car for a week gives me a pretty good idea of anything that needs attention and I am assuming that this week will be no different.

My car is packed, the fuel is topped off and everything is ready to go for a 7:45AM departure tomorrow. Wish me luck!

7-4-2013

I made it back form my work trip just fine and the car is doing great. I am now at the 550 mile mark on the motor and it feels good to be over the half way point. Many of those miles have been highway miles but I try pretty hard to keep the speed varied and work in a bit of light boost / engine braking. The car is well tuned to about 10psi / 5000RPM but its really hard to keep it below those marks as it REALLY wants to go! I am VERY VERY excited with how the car feels in terms of its responsiveness and "perkiness" when I get on it. I would say that its pretty much exactly how I had hoped it would be when I sat down with Ryan and Dale from Moore Performance in late 2010 to go over my turbo kit design.

In other news, I have never really been into car shows but since I cant race the car right now, I have decided to give them a shot. I went to the first show on Monday night during my work trip, the second one was our local monthly Pittsburgh "QSL" meet and the third was a July 4th community days event at neighboring town. Outside of the Subaru tuner community, most people are just shocked to see whats under the hood...

9-3-2013

Since its been six weeks since my last post I figured I owe the world a quick update. Things are great with the car but my job totally sucks as I have been working six million hours. At least I have good job security! Any way, I had a chance to drive the car to a local car cruse this past weekend, here's a quick pict of the car and Abby:

(note her T-Shirt)

9-16-2013

I just figured that I would pass along the news that I have a tune scheduled for Friday the 27th of this month. I wont be getting the "full" tune that I really want but I will finally be able to go WOT and run the car to 8k on pump gas. If all goes well and the car gets fully tuned on 93, we will be creating a base map for E85 and starting on the driveability stuff. Once I am confident that everything works as desired, I will return either later this year or in the early spring for a full E85 dyno tune.

I had a chance to go to another car show this past weekend and it was pretty cool.

9-21-2013

Thanks! Its not been all the cars (motors) fault though. The car has been working pretty well for about 18 months. The closed deck block went in this past winter and since then, I have been extremely busy with zero time to drive the car. Its my hope that next year will be a bit better for me.

In other news, I finally hit 1000 miles on my new motor on Thursday:

9-28-2013

Success!

As I mentioned a few days back, I went down to Element Tuning yesterday for a street tune. The tune went really well and I am very very happy. Our plan was to start by finish up my 93oct pump gas map by doing some drivability tuning. We drove around the urban neighborhood surrounding Phil's shop for about 20 minutes and then headed out to the highway to do some highway driving for maximized fuel economy. The highway stuff is pretty important to me because I live way out in the country and it takes over to get to Pittsburgh on the high way. Once we were both convinced that the car drove as well as a stock car, we moved on to power tuning on pump gas. After about a half dozen pulls to 8200RPM, we had the car tuned up to 20psi and it started felling very fast.

Once Phil finished up my pump gas map, we drained the last few gallons of fuel in the tank and went to a local Sunoco gas station for a full tank of E85. This was was my fist ever experience with E85 and all I can say is HOLY CRAP! The car REALLY spools quickly and the power is just nuts! After about a half dozen E85 pulls, the car got to the point where it would break all four of my 245 width starspecs free at 50MPH when I shifted into 3rd gear! Even under 93oct, my turbo kit is impressive but with E85, this thing is just Fing nuts!!! When we started getting rolling wheel spin during the pulls, Phil and I immediately agreed that additional street tuning would be poor judgment for safety reasons so he verified that the map was safe and we bagged it for the day. The car runs really well, its safe and its FAST!

There's a lot left on the table and I really want to get this thing on the dyno so thats my next step. As of today, my plan is to keep the car exactly as-is until spring, at which time I will return to Element for a final dyno tune. I was originally thinking that 30psi was in my future but with the crazy power that we are seeing at only 20psi, I am thinking that I may limit it to 25psi and call it a day.

My first E85 fill-up:

10-26-2013

I have been super busy lately so I haven't had a chance to post anything up here but I am unfortunately trying to work through yet another frustrating issue. For maximum exposure, I have started a new thread in the built motor section here:

http://forums.nasioc.com/forums/show...8#post40840798

I welcome any theories or comments guys, thanks!

3-16-2014

Its very possible that I have mental issues...

Its actually a Borg EFR 7064 with the 1.05AR T4 hot side.

Compressor Specifications

Compressor Type: Forged-Milled Wheel (FMW) Extended Tip, EFR 7064 compwheel
Compressor Wheel OD (exducer): 70mm
Compressor Wheel Inducer: 52.2mm
Max Flow Rate: 56 lb/min
Compressor Housing: 3.5" Ported shroud inlet, 2.0" hose coupler outlet
Built-in BOV: All EFR compressor housings incorporate an integrated BOV.
Connections:
Inlet: 3.5" Hose Coupler
Outlet: 2.0" Hose Coupler

Turbine Specifications

Turbine type: Low Inertia Gamma-Ti Turbine Wheel
Turbine Wheel OD: 64mm
Stainless Steel Investment cast Housing
Housing: 1.05 A/R T4 Twin Scroll (External WG
Turbine outlet: GT-Vband (aka small 3" vband) ~92mm OD for all EFR turbos











I decided to significantly reduce the potential power output of the car. I also wanted a tried and true turbo that has been used many times before as I am EXTREMELY tired of being an alpha tester for automotive parts. The EFR 7076 is nearly a 100% direct bolt on swap with any Garret GT or COMP brand turbo, only the air inlet and outlet will require different couplers for me to install it. Even though this turbo is smaller, I think it will still be able to pull off 500whp with my setup as there are many graphs in the high 400s on pump and stock motors. I am running the Element Pro Comp motor custom built for E85 which should net me a touch more power over a stocker on 93. The COMP CT4 turbo that I have been running was rated at something nuts like 750CHP which was really never my goal (note the name of the thread).

As for EMS, I didn't have good luck with they Hydra 2.7 for whatever reason so yes, I am moving back to the Access Port and having it tuned by Mike at Innovative Tuning in Buffalo, New York. I am completely confident that Phil would have been able to iron out the issues with the Hydra but I am just not willing to spend the money it takes to get the Hydra working. My F250 burns over $300 of fuel during the 11 hour round trip to Element which is pretty expensive. In addition, Phil upped his rates to $300/hr and when it takes four to five hours minimum to get the Hydra tuned, its extremely hard to justify. If you have the coin, Phi is the man when it comes to big power projects, racing, etc but I am just not in the game as much as I used to be. Innovative has a fantastic reputation with Access Ports and its only 2.5 hours away on FLAT land verses going through the mountains to get to the DC area. That being said, Phil will ALWAYS have my motor business, I feel its worth every penny.