Re: Project GC8 AKA USDM STi Killer
 

Looks awesome Shawn! Can't wait to see how it looks after it's completed.

Re: Project GC8 AKA USDM STi Killer
 

Another update
http://sphotos.ak.fbcdn.net/hphotos-..._6329408_n.jpg

For the first time in a few months, she's back on the ground and I drove her 2 feet! I'm really hoping my O2 sensor fixes my problems today so I can get an alignment and drive it to Deadmau5!

Re: Project GC8 AKA USDM STi Killer
 

A lot of you might or might not know my Evo died on Friday. I was leaving MAP to pickup a coupler for this project when I went to shift from 3rd to 4th and, what I believe was, my shift fork in my transmission broke. I managed to limp it back to MAP and they confirmed it's most likely toast so now I have no car. Luckily my wonderful GF can loan me her's for a while.

The reason for this intro is my Evo is going to cost me $2300 or so dollars to fix, which unfortunately brings this project to a halt for this year if I can't figure it out today. I will be working on it until 5PM today and then officially calling it quits as my time and money have now officially run out.

So if anyone is bored today and wants to lend a hand for an hour or two let me know.

All of the hard work is done, the car is put together, rolls, starts and works. The only thing left to do is figure out why it doesn't run well or drive well. The best way to describe the way it runs is it acts like an intercooler pipe blew off.

It's hard to start, once it warms up fully it idles, but as soon as you give it ANY gas over 10% throttle it acts like the fuel or spark shuts down, basically it just stutters. If I kind of spike the throttle to get the RPMs up to 4-5k I can slip the clutch and get her to move.

On tap for today is:
1.) boost leak test, have to make a boost leak tester because the turbo is UNDER the intake manifold basically.
2.) data logging to see what exactly my car is doing, this is where I'll need help because I know nothing really about tuning.
3.) looking at my FPR, because here's the weird part I can swap the feed/return fuel lines and it runs the exact same, not right.

If none of those things pan out... not sure where to go next as my Evo is now taking priority.

-Shawn

Re: Project GC8 AKA USDM STi Killer
 

Sorry to hear Shawn, if I was closer I'd be willing to lend a hand. Hopefully you get it figured out.

Re: Project GC8 AKA USDM STi Killer
 

shit man, sorry to hear.

I'll hit you up soon and try to give you a hand.

Re: Project GC8 AKA USDM STi Killer
 

He no longer needs help, the fix is 2 minutes under the hood.

The problem is acquiring the part.

Stemming from sourcing different components from different cars (Legacy GT motor, STi everything else) a fatal design flaw occurred... it ended up without a fuel pressure regulator. The STi unit is on the fuel rail, but the Legacy one is actually on the return line itself at the strut tower. Having looked at pictures of STi engine bays for guidance, we figured that nothing more than the fuel dampeners went on those lines and left them unimpeded. Oops.

Unfortunately it looks like the part is dealer-only, and being that it has hose hookups at both the outlet AND inlet, nothing from any other car I've seen (or that we looked at at O'Reilly) would work. I suggested cutting off part of a fuel rail with the regulator in order to provide an input tube, but that's in no way, shape, or form ideal.

Re: Project GC8 AKA USDM STi Killer
 

Well said, Spaz. I still have a major issue with not being able to read/write to the ECU. But it really seems like this should fix my symptoms I'm having with the engine running like shit.

Another note, I found a major issue with the PS valve cover. The seal had a chunk missing from it. So I took the whole thing off and re-sealed it with some red RTV for the time being until I can get a new seal and it seemed to smoothing some things out, that was a major boost/vacuum leak and it holds boost now.

I'll keep you guys in the loop but I'll be sourcing a FPR as a last move this week.

Re: Project GC8 AKA USDM STi Killer
 

Sucky on the evo!! :(

Its 2300 to replace a fork? Why not just yank the tranny and throw a new fork in and not rebuild anything else?

Hopefully the FPR issue is all whats wrong with the subi!

Re: Project GC8 AKA USDM STi Killer
 

awesome to hear its a simple fix, hopefully not too pricey from satan.

Re: Project GC8 AKA USDM STi Killer
 

iff you need a fuel pressure regulator lmk..sned me a pm and I will fill you in on the details.

Re: Project GC8 AKA USDM STi Killer
 

I already bought an AEM :( Plus your's wouldn't work, I need one that goes inline on the rubber fuel lines which yours bolts to the fuel rail.

This ladies and gentlemen was the missing piece.
http://farm2.static.flickr.com/1091/...e10b5978_z.jpg

I got it installed set the FP to 41PSi for now and drove it on the highway and it works!! I have a few bugs to fix but overall it works.

Re: Project GC8 AKA USDM STi Killer
 

woot!

Re: Project GC8 AKA USDM STi Killer
 

Re: Project GC8 AKA USDM STi Killer
 

I love that the maiden voyage is just a casual thing, LOL. That's awesome man, and a really nice little piece you got! Now you have the base to start building your 1000whp fuel system! :)

Re: Project GC8 AKA USDM STi Killer
 

Glad to see you got it running good enough to drive! Wish I had half the motivation you do to finsih my project.

BTW,

You should yank that tranny and have DB have it rebuilt or maybe just the shift fork replaced if that's all that's broken.

I just had DB have my VIII 5 speed fixed. It got all new synchros, bearings, a new reverse gear and new TOB for around $800. All on basically a one day turn around too.

Re: Project GC8 AKA USDM STi Killer
 

Way to go on your first full swap

Re: Project GC8 AKA USDM STi Killer
 

Awesome dude!

Yeah as for the tranny, I've replaced forks on DSM's before. Not sure if evo's are any harder/easier, but if that's all it is you could probably do it.

Re: Project GC8 AKA USDM STi Killer
 

LMAO, actually I was scared shitless and listening for noises. The car made it though!! I just have to fix a few things like have a coolant reservoir and the like :) Also I need to get an alignment and clean a few things up, but I was really surprised the hood went on without me having any fitment issues or anything. So we're looking good!

Re: Project GC8 AKA USDM STi Killer
 

Thanks a lot man, it was a hell of an expensive and stressful ride.


Yeah I'm just at the end of my line with working on cars for a while. After a solid 2 1/2 months of working on cars and the cold snap about to hit... I think I'm done for a while.

Re: Project GC8 AKA USDM STi Killer
 

dont remind me i still gotta get my clutch in lol!!

Re: Project GC8 AKA USDM STi Killer
 

Kick ass man, just in time to be a new daily while your tranny gets fixed!! haha

Re: Project GC8 AKA USDM STi Killer
 

Awesome!! glad to hear its fixed!

Re: Project GC8 AKA USDM STi Killer
 

I couldn't have been happier to get a phone call at work, answer it and hear "Hey, listen to this..." through the handset. The sound that followed brought one of the biggest smiles of the past few months to my face.

I'm glad this project is coming to a close, so I can enjoy it instead of swear over it!

Re: Project GC8 AKA USDM STi Killer
 

nice work man. gotta give ya an applause man, that is so much work. I was hangin' out with my cousin that has a GC8 with the jdm sti swap this weekend and man, that thing is a beast and from what he has gone through with the wiring, drive train, mods, etc is just insane. props to you man.

Re: Project GC8 AKA USDM STi Killer
 

Thanks a lot guys for the kind words. It's been a very very stressful few months, especially since Friday LOL. But when I got on the onramp and gave it 60% throttle and it built 7PSi of boost... it was totally worth it.

I get fuel cut past that point and again I have a few bugs to fix. But the car is coming together really well. I also called God, I mean Shane @ DB, and scheduled an appointment for Monday and I plan on getting it aligned tomorrow night so hopefully it'll run and drive really well in the next week!

Re: Project GC8 AKA USDM STi Killer
 

So I made the BOV recirc last night and went for a drive and the car drove like a champ, decided to do another loop on the highway (about 2 miles round trip) and got on it a bit on the highway and I hear a POP and the car stopped making power.

Of course I think "first time I give it more than 50% throttle and I blew up the engine... should have waited for the tune moron" but I keep my cool and pull it over. I take the keys out of the ignition, put on my dorky head lamp, go to the trunk, take my hood rod out pop the hood, put the rod in (yeah that's what she said!) and start looking around. Of course it's fucking cold and windy so this made it a bit uncomfortable.

I see the recirculate pipe has popped off, well shit that's my problem! No big deal just put it back in and drive home... except it won't stay in. I start looking around the car for things I can rig it with. Window scraper, nope that won't work, my GF's blanket... that's not going to do anything and I don't want to get yelled at, my electrical manual for the car... nah, a 1' wire... maybe? I start figuring out how to make the two tubes stick together with that... but it's gauge is too thick and I can't tie it enough to make it stay.

I start to look around again and what do I find? My dinner for a few nights that spaz brought over... party size three musketeers. So I sit and think, well I have two of these left... I GOT IT! So I grab them from the back seat and make my way to the engine bay and I look at the recirc tube back to the intake pipe and look at the two musketeer bars and proceed to stuff them in my recirc tube so that they're snug.

I start the car and drive home, life was grand and I'll always have a candy bar on hand now.

The End.

Re: Project GC8 AKA USDM STi Killer
 

hahahahaha need keep more zip ties and duct tape on hand!

Re: Project GC8 AKA USDM STi Killer
 

LOL By far the best fix I have ever heard.

Re: Project GC8 AKA USDM STi Killer
 

Haha, he called me last night about something and between the phone breaking up a bit and his laughter I almost didn't believe what I heard.

I thought, "He used a candy bar to fix his car? Maybe he meant the wrapper." I'll be damned.

Re: Project GC8 AKA USDM STi Killer
 

Total awesomeness

Re: Project GC8 AKA USDM STi Killer
 

I WIN! :rollinglaugh:

Re: Project GC8 AKA USDM STi Killer
 

sick dude! hahah!!! thats awesome.

Re: Project GC8 AKA USDM STi Killer
 

Got the car aligned today by Jeff the alignment guy. Great guy, very helpful and tuned Sarah into a mean handling machine. I need to get the front sway bar brackets still but other than that it looks/operates like a real car now.

I'll be bringing it to the Halloween party tonight so you guys can see the ugly bastard car in person.

Re: Project GC8 AKA USDM STi Killer
 

^nice, I can't wait to see this bitch.

Re: Project GC8 AKA USDM STi Killer
 

"Sarah" was tuned today. Shane was very patient with the car and as always super helpful and nice. The end of the day tune was 257 and I believe the same tune made 263 a few pulls earlier. Not bad since my realistic goal was 250 and my "world is perfect" goal was 270. This puts me in the Fuji power range.

I would have made more power but for some reason my VF39 was tapering to 10PSI no matter what. I think I have a boost leak at 15PSI though because it whistles, so I'm going to take a look at that. The car performed very very well, did about what an STi does at a stage 2 on that dyno.

A recap of what Shane had to deal with and how awesome he is.
11:00 AM: My car goes on the dyno
11:30 AM: Car is showing different speeds on the rear than the front? Shane has to trick his dyno into allowing my car to keep doing pulls.
12:00 AM: Car goes into limp mode because the throttle goes past 100%, fixed that shit with 9 pennies and some duct tape.
12:00 PM or so: We do the first full on pull and the cheap ass mishimoto radiator cap pops off and spews coolant everywhere all over his dyno.
12:30 PM: We start doing pulls again and my PS CV Joint boot clamp comes off and starts spewing axel grease all over my down pipe and Shane's dyno.
1:30 PM: My clamp breaks off again spewing more axel grease everywhere.
3:00 PM: We finish.

Overall it was a stressful day but Shane stuck through it with me and got the job done.

Re: Project GC8 AKA USDM STi Killer
 

sweet man, how heavy is the car?

Re: Project GC8 AKA USDM STi Killer
 

I would say with the stock engine/transmission it would be down to 2500-2600 lbs with everything I've pulled off, but the STi tranny adds weight so I'm going to go with 2800lbs right now.

Re: Project GC8 AKA USDM STi Killer
 

wow thats gonna be a fun car!! lol i bet it puts you in your seat really well!!

Re: Project GC8 AKA USDM STi Killer
 

Awesome to hear man! Sorry I couldn't talk when you called, today was insane hectic at work (still here actually) :(

Re: Project GC8 AKA USDM STi Killer
 

Nice, that things gotta move pretty good.