club.liberty.asn.au

FARK YESSS!!!!!

they look beautiful!

tough specs too

They look awesome Michael.... can't wait to see them on your car!

What a choice! So looking forward to seeing these installed!

9.5", 255 rubber...oh yeah

Awesome choice of wheel. Should look epic.

Nice rims! Shame they won't be on any time soon.

Very nice!!
Welcome to the Volk club

Big update finally - over a year in the making!

Some history first - rewind to Nov 2014 when this project was started: Due to a leaking head gasket which was slowly getting worse, I decided I may as well get the engine built and upgrade the turbo (with no expense spared).

Some may recall the Wakefield track day in 2013 when my coolant overflowed, which was an obvious sign of the problem (although the track day was not the cause as I had noted some indications of an issue before then, so I'm not sure exactly when/how it started). The leak seemed to be consistent with the heads lifting under boost only and was not a major issue for quite some time. I was still driving with this problem for over a year and attending track days and the drags. Eventually it got worse and became a daily problem though so something had to be done. Good excuse for more power in my opinion.

Unfortunately due to delays from various parties involved, completion has taken much longer than expected. But I'm happy to say I finally have my car back and it was well worth the wait!

So here it is - my daily drive racecar.

Current power figures (dyno graphs in following posts):
- Post run-in P98 tune @ 19psi - 286kw atw (384hp)
- Preliminary E85 tune @ 28psi - 374kw atw (502hp)
(boost yet to be increased >30psi once hoses fastened more securely!)


All credit for the build goes to Garage 88, Deshele Performance, Emtron & Insight Motorsports.

Engine - Deshele Performance closed deck forged EJ25 engine build
- Forged pistons
- Forged rods
- Race bearings
- Linish crankshaft
- Fully closed deck block
- Bore and hone block
- Two stage drill and tap block
- Deshele Performance 14mm headstud kit
- High volume oil pump
- 272 degree camshafts
- Heavy duty valve springs with titanium retainers
- Bronze valve guides
- Stainless inlet and inconel exhaust valves
- Deshele Performance MLS head gaskets
- Gates Racing timing belt

ECU and sensors
- Emtron KV8 standalone ECU
- Custom ECU harness
- Elixir E85 flex fuel sensor
- Air/fuel ratio sensor
- Fuel pressure sensor
- Fuel temp sensor
- Air temp sensor
- MAC boost solenoid

Turbo - BorgWarner EFR 7670 1.05 A/R twin scroll (external WG)
- Ceramic coated exhaust housing
- V-band clamps and adaptors
- Custom braided oil feed line
- Custom pushlock water feed line
- Custom aluminium oil drain/pickup
- Permaseal turbo to manifold MLS gasket
- TiAL MV-R 38mm external wastegates
- Custom screamer pipes

Fuel system
- SARD fuel pressure regulator
- Bosch 1650cc injectors
- Billet fuel rails
- Speedflow teflon lines and fittings
- Walbro 455 LPH E85 compatible in-tank fuel pump
- SARD surge tank

Custom oil cooler setup
- Thermostat block
- Setrab cooler core
- Speedflow braided lines and fittings

Custom air intake setup and catch can
- Plazmaman front mount intercooler core
- Custom intercooler piping
- Blitz Carbon Suction cold air intake duct
- Custom oil catch can

Exhaust and manifold
- Custom twin scroll / twin gated stainless steampipe manifold
- Custom titanium heat wrapped 3" dump pipe
- Custom stainless steel 3" catted front pipe and center pipe

Clutch and transmission/engine mounts
- Xtreme Clutch twin plate ceramic race series clutch
- STI transmission mount
- Customised front engine mount

Power
- Optima D51 Yellow Top battery


As with any major build there are still a few issues to sort out yet though. So, plans for the immediate future are:

- Built gearbox
The original gearbox suffered a small failure (likely a broken selector fork) so taking the opportunity to get it built stronger anyway.

- Plumb screamer pipes back into exhaust
They sound awesome, but are TOO LOUD!

- Increase boost >30psi
Hoses have now been secured better, so next tune should see more boost hopefully.

- Emtron ECU / full CAN bus decoding
Due to the Gen V GT CAN bus not being fully decoded, the Emtron ECU is currently installed in a parallel setup with the stock ECU which is not ideal. Due to this there are a number of ECU features which are not functioning yet (i.e. traction control - sure it's fun spinning all 4 wheels when I put my foot down, but it's not the fastest way to accelerate!). Hopefully will be able to remove the stock ECU completely once this is finished.

- Fit my Volk ZE40 wheels and AD08R tyres
Planning 255/40R18 tyres with my 9.5" rims, so will most likely need to roll the guards for this.

After the engine was run in, the car was tuned for 98 octane fuel only with boost limited to 19psi and driven for a few weeks before E85 to ensure there were no issues.

Post run-in P98 tune @ 19psi - 286kw atw (384hp)

And the E85 tune dyno graph - boost limited to 28psi due to various hoses popping off whenever we went above 30psi.

Should be able to up the boost some more once the hoses are secured better!

Preliminary E85 tune @ 28psi - 374kw atw (502hp)

Finally, here are some build photos from start to finish...


Engine out in preparation to be sent off to Deshele Performance





Deshele Performance closed deck forged EJ25 built engine returned and ready for install (6 month wait!)




Engine back in - process started of where to fit various items, i.e. surge tank positioned in place of the TMIC




BorgWarner EFR 7670 turbo with ceramic coated exhaust housing





Plazmaman FMIC being fitted (core size 600 x 280 x 76mm)





Turbo and custom exhaust manifold finished (with twin screamer pipes)




Turbo setup as seen from top of engine bay




Custom exhaust fitted up to existing Fujitsubo exhaust tips




Custom oil catch can painted black




Oil cooler and surge tank located where the TMIC used to reside




E85 flex fuel sensor




Blitz carbon suction air intake duct to neaten things up (housing existing Blitz pod filter)





Optima Yellow Top battery (slim battery required due to intake piping)




Final engine bay all neatened up with engine cover cut to fit oil cooler/surge tank




And front bar cut to fit with the FMIC




All done!

GOOD LORD - that curve!!!!

Mick that is unbelievable - I am truly gobsmacked by that power curve. Fantastic work mate and well worth the wait.

I'll be honest and say i havent really been a believer in the EFR turbo's. Well and truly a believer now after seeing that graph.

I'm in the area on Friday if you're around to take us for a wrap.

Well done again mate - so glad to see this update.

Thanks Mick - it's pretty insane!

See ya Friday.

Holy FUCKOLY.!!!


I heard this was a monster but WOW.


Cant wait to see/hear this thing go.


Fanbloodytastic work mate.

Thanks Dan - no joy rides for you though mate, you can appreciate it from a distance instead! I know your history with cars, don't want your car curse affecting my ride!

satogixxer wrote:Thanks Dan - no joy rides for you though mate, you can appreciate it from a distance instead! I know your history with cars, don't want your car curse affecting my ride!

You know what..... I understand. Its fucked. LOL