mdx555 400bhp install 2005 Sti

[John86sti]

Hello. I thought id start a thread about my 2005 Sti

Here it is



Had a bit of a miss-hap



Got a new turbo to fit

[bonner]

thats abit savage!! what happend there?? some times its not so bad after all! good excuse for a new one like the above lol come to the right place there are many on here who know what there talkin about and are happy to help!! enjoy the new turbo!!

[Hongkongfooi]

bloody hell good job the wheel didn't get into the engine

[John86sti]

Not sure what happened really I've got a few theories, just gonna put it down to poor maintenance, little tweaks and the turbo being 80k old.

Think the bearing dropped, the exhaust wheel hit the housing and sheard off

Got it back the last 2miles off boost with oil going in the exhaust.

I've managed to the old turbo, exhaust and intercooler off. Im cleaning/inspecting everything atm in the kitchen. The gf loves it, lol.

[scotty]

Originally Posted by John86sti

Not sure what happened really I've got a few theories, just gonna put it down to poor maintenance, little tweaks and the turbo being 80k old.

Think the bearing dropped, the exhaust wheel hit the housing and sheard off

Got it back the last 2miles off boost with oil going in the exhaust.

I've managed to the old turbo, exhaust and intercooler off. Im cleaning/inspecting everything atm in the kitchen. The gf loves it, lol.

Don't no why but for some weird reason we always strip and clean anything that is dirty in the kitchen and the ladies of course love to clean up the mess we leave lol

[John86sti]

Finally got the turbo sat in place. The hose had split quite a bit, so i trimmed it off, some how from taking 3mm off i have a 15mm gap**Im thinking of getting it as far over the shoulder as possible, then using some self emalgimating tape to secure it in place before doing up the jubilee clip? So like an ok mod/fix till i get the cash for a new intake?*

[John86sti]

Had a fight with an exhaust bolt



I WON!!!!

[John86sti]

Cleaned the intercooler a bit

[John86sti]

The girlfriends kitchen floor

[scotty]

Originally Posted by John86sti

The girlfriends kitchen floor

Looks about right apart from wheres the grease and oil lol

[John86sti]

Art takes time my man. I'll take a picture of the expressionistic art left on the floor when Im done. Lol

[bonner]

lol could be worse! could be doin a full rebuild like a mate done with his pulsar engine in his mothers kitchin lol if you can use someone elses kitchin floor why not!! looks like you got a beast of a turbo there matey!

[SpecB]

I've got a couple of spare OE intakes here if you want one, yours for the cost of postage?

[John86sti]

Soooo ... New problem. Turbo is fouling on the gear box
I've got 2 options. Shall i just grind a little off the gearbox housing? Or shall i wait till Monday and get down to turbo dynamics.




I've used white paint to mark where needs grinding.

[scotty]

That is a tough call . Go for it and shave a little bit off at a time .

[Scott.T]

Most just get physical on the gearbox.

[John86sti]

Umm.. Im just reluctant/annoyed because it was sold to me as bolt on. Went for bolt on because i don't particularly fancy removing bits of my pride and joy. Guess that's modding tho.

[Scott.T]

That's the sacrifice you have to make when going for such a large turbo housing.

[John86sti]

Hi silver surfer. Do you think its alright to shave a little off the gearbox housing then? One of my friends suggested putting a spacer gasket in. I wasn't too keen on that idea. What do you think would be best?

[SpecB]

Most just grind the bell housing.

[C. J.]

Originally Posted by BlueBugEye

Most just grind the bell housing.

Not most everyone it's on the block not the box though
You can wait till Monday but their just say grind it off !
It's normally just the white mark where the bolt goes through from the gearbox to block

[Moley_WRX]

Get the grinder out!

We took most of that lug off when we fitted my turbo

[John86sti]

Grinder it is.

[John86sti]

So, i got the grinder out



Its on there good

[John86sti]

[scotty]

Well done and you saved a bit of money doing it yourself

[C. J.]

Good stuff , when's it being mapped ?

[John86sti]

I've talked to Bob Rawle and he's not available till 7th of May, Japfest is on the 11th, ummm. I need a new fuel pump before i get it mapped. Kinda thinking over my options at the moment. The coolant lines don't connect tho, so that's today's first job. I was also thinking, surely if i set the actuator pressure to the same as the vf35 i should be able to run a standard map to get to work?

[Scott.T]

Originally Posted by John86sti

I've talked to Bob Rawle and he's not available till 7th of May, Japfest is on the 11th, ummm. I need a new fuel pump before i get it mapped. Kinda thinking over my options at the moment. The coolant lines don't connect tho, so that's today's first job. I was also thinking, surely if i set the actuator pressure to the same as the vf35 i should be able to run a standard map to get to work?

Ermmmm, No.
Just because the pressure is the same doesn't mean the airflow will be.
The MD will have a much greater volume of air shifting through it causing the ECU to run in a completley different region of the map, or even off the maps calibration scale and hence uncontrolled.

The easiest solution is to temporarily plumb the turbo direct to the actuator rather then through the BCS, or have it plumbed normally and disconnect the BCS electrical connection, then just drive off-boost.

[John86sti]

Cheers for the heads up silver surfer. Guess i overlooked the fact that pressure and volume are not directly proportional. I'll plumb the actuator straight to the turbo.

[John86sti]

Got sick of turbo dynamics rubbish fitting kit. So I made my own.

[SpecB]

Make sure you use a restrictor on the oil feed if the original kit had one.

[C. J.]

Originally Posted by BlueBugEye

Make sure you use a restrictor on the oil feed if the original kit had one.

they be water lines

[bonner]

lookin good!!

[John86sti]

Cheers for the info and keeping an eye on the project. They were new water lines i made up, one wouldn't fit nice i.e. Had a harsh bend. So I've got a nice braided one at the top and recycle the old top line for the drain line at the bottom. Can't believe the amount of fabricating for a so called bolt on kit! Oh well, my fingers are bleeding but my turbo has oil and coolant now just the intercooler and service tomorrow. The only part i kept of the original fitting kit is the oil feed, it does have a few restrictors on the line. I'll take more pics tomorrow.

[John86sti]

Not quite a mirror finish but not too bad using only elbow grease

[John86sti]

Its on! Time for a test run.

[John86sti]

Roger Clark motorsport fuel pump installed.

[Hongkongfooi]

This been mapped yet?