Member Profile - It's a nice day for a white wagon!

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Re: Member Profile - Hardware Bob's White wagon

Postby HardwareBoB » Tue Nov 04, 2014 8:47 pm

GONEWALKABOUT wrote:strange with the absence of marking, def sounds some sort of aftermarket. Any pictures or did you get it out


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Today I spent most of the day moving around things in my garage so I could setup my new workshop equipment from my father in law:
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But this evening while my wife watched sons of anarchy, I found some time to put on my new intercooler:
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Easiest mod on any car ever! Took me under 30 minutes, bolted on with no problems.

No idea how much difference it makes - didn't have time to drive it!

I don't expect much difference typically, but after I do the exhaust and free it up, as well as in hotter conditions, it should be well worth it.
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Re: Member Profile - Hardware Bob's White wagon

Postby GONEWALKABOUT » Tue Nov 04, 2014 9:07 pm

Removal of the heat shield would have made ID for you a bit easier haha.

Nice yeah the bigger intercooler will probably just give you more time until heat soak but its also a supporting mod so you can run more boost later on and bigger turbos!
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Re: Member Profile - Hardware Bob's White wagon

Postby HardwareBoB » Wed Nov 05, 2014 7:46 am

GONEWALKABOUT wrote:Removal of the heat shield would have made ID for you a bit easier haha.

Nice yeah the bigger intercooler will probably just give you more time until heat soak but its also a supporting mod so you can run more boost later on and bigger turbos!

Yeah I really should have removed it, but I was limited for time - needed to get back inside and put out the washing! I will do that at a later date. I think the turbo I have is already pretty big - given it's boosting up to 1.7 bar on cold nights and is very laggy

Bum dyno says a smidge more power in the top end - but the overboosting is even worse! Just waiting on the new exhaust in the post.

Should really open it up, then a nice tune, and I think in the short term the only other thing would be a 3 port EBC solenoid.

Future: lip, behind rear wheel spats in black, tapturn, custom arduino to handle extended accessories time/window up/etc/etc, redo the crappy tint, shockworks (I read the whole thread today, these sounds like the business. I want a useful ride that improves handling), E85 ...

I'm running 215/45/17 (standard) KU39's, and they seem to be enough, but just barely. The car feels under tired for 180+kw, I'm guessing the easy fix is to throw a lot more money at the tyres - which won't happen in a hurry, because they are brand new!
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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Mon Nov 10, 2014 12:46 pm

Running a base Kido tune on wastegate pressure, which seems to be about 1bar.

Just waiting for the bung and the muffler to arrive and should fit that and the wideband this week.

In the meantime, wax on, wax off:
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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Fri Nov 14, 2014 8:47 pm

Posted about the turbo here: viewtopic.php?f=2&t=27753

Did those pics while I was updating the hoseclamp for the intercooler after it came out when I was on my way to hospital with our foster son! (he's fine)

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Also got a dashcam! it's still powered from the lighter port, I'm hope to hack up power from the maplight/sunroof controls.
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Exhaust goes in with the O2 bung on tuesday next week
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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Tue Nov 18, 2014 8:56 pm

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This is how it was meant to be! The exhaust makes a massive difference. It's like the car has been unstrangled.

I didn't end up getting the centre muffler put in, it's not TERRIBLY drony, but it is a bit too loud. I will get it put in tomorrow.

The noise it makes on full throttle is absolutely glorious.
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Re: Member Profile - It's a nice day for a white wagon!

Postby jslayz » Tue Nov 18, 2014 11:55 pm

Nice to hear good news about mod results.
Enjoy!
CURRENT - ATP GTX 3576 - 22psi - 283.7awkw
OLD - Dom 1.5Xtr - Last dyno 254ahkw, previous 238ahkw, first 224awkw.
My journey thread: http://forum.liberty.asn.au/viewtopic.php?f=10&t=15523
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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Mon Dec 01, 2014 9:13 pm

Put a new tune in, still needs some tweaking, but I'm going to fix my exhaust leak first - looks like it's leaking from the V band that attaches the exhaust housing for the CHRA.

I'll fix that when my pitch stop mount arrives, because I need to take the intercooler off for both - I bought the pitch stop mount after finding I couldn't get into third when I'm seriously moving in second. I grabbed a short shifter as well because what the hell. Didnt end up getting new gearbox/engine mounts and 3 port boost controller this time.


Other minor mods, flip key, greatest thing to ever come off ebay for $15. (and then $25 to cut)

and got my plastidip on!
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Just two coats because that's what I had time for, we'll see how it goes.
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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Tue Dec 09, 2014 9:21 pm

New bits arrived from rallysportdirect, so time to spin those spanners.

STi Group N pitch stop mount. My old pitch stop mount had craploads of movement, this is MUCH better.
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Tightened up the V band where it had a small exhaust leak - I think that's fixed it. It's certainly quiter.
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Cobb short shifter - pretty easy to install, but my shifter mount on the bottom was chock full of grease, so I had to hunt around for the holes for the C clip pliers.

1st to 2nd shift:
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The gear shift is so much tighter, and the pitch mount makes a massive difference in terms of the gearbox moving.

Also put a new cosworth filter on, the old one was filthy.
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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Wed Dec 24, 2014 5:17 pm

Soooo.. my BOV was leaking because it didn't have a gasket, so I bought one, and it was the wrong size. I hacked it to fit and it was working fine.
Then I had to go for a drive to drop off some christmas presents, and it was working perfectly, so on the way back I pegged it in first, and it took off awesomely, and something went *pop*.

I assumed it was the BOV gasket I hacked, so I made a pretty one at work today:
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It was still leaking terribly, and I could hear air coming out.

When I got home I got out my one size fits all boost pressure test machine, with a 100% garauntee to maybe work some of the time:
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and shoved it in the intake:
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It wouldn't hold ANY boost for ANY period of time, you could hear all the pressure escaping.

Then I applied the old 'soapy water in the spray bottle' trick, then hit the trigger on the inflator and see if there's bubbles, and lo and behold:
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It's hard to see because it's a shit pic, but the short version is the throttle body hose is exploded, which is relatively common.

I jumped on the internets to Jackson from Kobe motorsport who sorted me out with a throttle body hose, MAF hose and adapter from the MAF to intake hose (which I already have). With very little notice he had it down to the post office to express post to me at 5:55PM on the 24th of December (it closes at 6), So a huge thank you there.

for the next 5 days or so, I'm stuck to driving miss daisy, because any real boost just leaks out the intake, and it all goes wrong. It's not terrible off boost though, thankfully.
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Re: Member Profile - It's a nice day for a white wagon!

Postby jslayz » Thu Dec 25, 2014 9:35 am

Enjoy the experience of putting it all on :wink:
CURRENT - ATP GTX 3576 - 22psi - 283.7awkw
OLD - Dom 1.5Xtr - Last dyno 254ahkw, previous 238ahkw, first 224awkw.
My journey thread: http://forum.liberty.asn.au/viewtopic.php?f=10&t=15523
My Lib Pics here: http://forum.liberty.asn.au/viewtopic.php?f=10&t=15523&start=570#p370656
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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Tue Dec 30, 2014 11:04 am

jslayz wrote:Enjoy the experience of putting it all on :wink:

Oh, it has been just DANDY.

First: Assemble the hoses you are going to install:
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Second: get all the hoses and stuff out of the car:
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Throttle body:
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Third: compare the hose to the stock one and think it's a little long, because your'e following the AVO instructions, and you have a cold so you're not thinking clearly. Align the BOV holes and notice the difference and cut off the excess..




Wait. shit. don't cut the hose. oh bugger. crap.


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Image is before the cut, you can hopefully see why I was so stupid.




Fourth: Get onto Jackson and order a new intake hose (but one that has the right amount of plugs - the PSR hose is menat for the 2.5)

Fifth: leave car as is because I'm not putting it all back together then pulling it apart again, drive to work in your spare car (you have one of those right?)

Owen suggested putting on a catch can at the same time, which I conveniently had lying around the garage (as you do). In thinking about this more, I think the intake hoses shouldn't even bother TRYING to connect to the factory ccv, and should only have a BOV port, boost control nipple, and a nipple/blocker for CCV plumbing, and include an X piece and some more hose, and an optional catch can (because it's 5 minutes work at this point). It might add some (but not a lot) cost, but it would make the installation a shitload easier and people wouldn't bitch so much.

Basically, if anyone is considering a silicon intake, get some 12.5mm hose and a catch can, and some T/X pieces, and something to block off the extra hole(s) in the intake, because it's a LOT less fucking around, and you should have a catch can anyway.


The good news is that I have positively identified my turbo:
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It's a VF36 from an STI Spec C RA, and looking at the exhaust housing, I likely have the STI headers as well, because the exhaust housing is not the TD04HLA, the bolt pattern is different. This should be good for about 220kw atw or so, with heaps of low end. It also explains why the car made so much more power when it was "stock" (as far as Kirby, the previous owner knew).


Here's the failed throttle body gasket from the intercooler to throttle body hose, both by itself and in context with the hose so that people know how it goes (because I didn't prior to this):
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Re: Member Profile - It's a nice day for a white wagon!

Postby bigBADbenny » Tue Dec 30, 2014 11:18 am

Nice troubleshooting and... trouble!
Where did you buy the multi fit boost leak tester? We need one of those in Melbourne :)
When using it, what did you plug and leave unplugged? (iirc wrong setup/too much test pressure can blow out eg cam seals)
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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Tue Dec 30, 2014 11:29 am

bigBADbenny wrote:Nice troubleshooting and... trouble!
Where did you buy the multi fit boost leak tester? We need one of those in Melbourne :)
When using it, what did you plug and leave unplugged? (iirc wrong setup/too much test pressure can blow out eg cam seals)


I didn't buy it, I made it from a multi fit hose thing from masters, with an end cap to suit. I bought a tyre valve off ebay and drilled a hole in the end cap and put the valve in. The gun tyre inflator attached to a pressure regulator (or just a shit small hose in my case) won't give it much flow, and as long as you don't over do it, you're going to have to try pretty hard to blow anything up. In any case, once you get to about 14 psi IIRC (it never got to ANY pressure in my test this time) the PVC ballons out ridiculously and it leakes from the valve hole.

I stick it into the intake just after the MAF, and you basically pressurise everything - It's possibly not ideal, but you're not running a lot of pressure and not for a long time - This also means you can detect leaks in the CCV system and the intake as well.

If you have a decent leak, the air will just all come out anyway, and you can just spray soapy water with one hand and use the trigger with the other, little bit of setup but it makes finding leaks childs play.
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Re: Member Profile - It's a nice day for a white wagon!

Postby HardwareBoB » Sat Jan 03, 2015 7:47 pm

Finally. All sorted.

Installed the catch can, Kobe motorsports turbo inlet, MAF pipe and Throttle body hose.

I had to trim the throttle body hose because the Hyperflow intercooler isn't quit the same as the stock one (nothing ever is!)

Parts needed:

3M of 12.5mm oil hose (3M is JUST enough)
Plug for the large inlet in the intake, either to cover the elbow or to insert (only bursons was open when I did this, so I had to get a cover)
Catch can (mine is a D1spec cheapo ebay jobby - you will also need a divider (I used some gasket paper - it'll die eventually, but eh) and some metal scouring pads.
Kobe motorsports inlet, maf pipe and throttle body.
2x 12.5mm T pieces
1x 12.5mm elbow
4x large hoseclamps (best to replace them all at this point)
1x T bolt clamp to suit turbo inlet.
about 4 hours, to be sure and ideally a freind to help.

No specialist tools required, except maybe the patience of a saint.


Step 1: get all your shit together, preferably on a childrens table:
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If you need to, prepare the catch can with the metal scouring pads, and bit of a divider between the two halves (to make the air go through the scouring pads so it catches the oil)

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Prepare a short section of hose with the elbow:
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Remove the intercooler.

Remove the intake, this is pretty straight forward, just remove the after maf pipe, hex head bolt on the bracket, and get in behind with some needle nose pliers to get the clamp on the BOV off. Then until the hose clamp on the turbo and pull.
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Remove the bolt on the middle of the back of the intake - This holds the BOV line on, which you will have to move out the way. (Sorry no pic)

Note that the BOV line on the new silicon intake is a bit further back than on the stock line - it's supposed to be like that.
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Remove the head vent hoses on both sides:
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Undo the bolts on both sides holding in the hard pipe going across and into the intake.
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Remove this hose, you don't need it.
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Remove the engine cover bracket from the alternator IF YOU DO NOT DO THIS YOU WILL DAMAGE THE INTAKE.

Now is the best time to install the new intake, because it's as clear as it can be. Block the line in the middle of the intake - this used to go to the hard line we've removed. You may find it's easier to install the intake if you coat it in WD40 first. Before you put the intake in, you should use a hoseclamp on the BOV line on the intake, and place the T bolt clamp on the turbo intake (it's not really feasible to have it on when pushing it down.
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Throw away the spring loaded clamp from the bov line and a hoseclamp on it, then put it on the BOV line on the intake, this is a bit of a fiddly bastard.
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Tighten the T bolt hose clamp. Attach the boost controller to the intake nipple.

Put the length of hose on the drivers side vent.
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Run it through where the hard line used to go:
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Cut it above the vent on the other side and put in a T piece and a section of hose to connect the vent
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Remove the hose off the front of the T(ish) piece in front of the turbo - this is the PCV Valve. Put the bit of hose with the elbow on it, and run the main length of house out of that.
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Run that line below the intercooler and around, and cut it a bit further along, and T in the other line as shown, then connect it to your catch can which you have cable tied to the battery holder in FULL DRIFT SPEC.
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Note: If you bought the same shitty catch can I did, you will either need some 10mm line and some adapters, or a shitload of teflon tape. I used a shitload of teflon tape.

catch can:
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Run the catch can outlet around the back of the alternator into the intake.
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While you have easy access, remove the two 12mm bolts holding the airbox in, and remove it. You can then remove the resonator if you still have it - mine was removed, so I taped up the hole.
Resonator attaches here:
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Resonator lived in here:
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Put it back in.

Push the post MAF hose into the inlet, and hoseclamp them together, then attach the hose to the airbox.
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Reattach the hex head bolt for the bracket. Note that the boost controller won't fit back on, so just cable tie it back as best you can.

When you replace the throttle body hose, if it's a Kobe hose, you put the writing facing DOWN, and in my case, I had to trim the hose to fit my aftermarket intercooler (it probably worked on on a stock IC). Put it on the throttle body first, and make sure it's fully on and the hoseclamp is TIGHT. You will have to access the hoseclamp throught the gap in the inlet manifold.
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If you can't manage to fit your intercooler on the hose and make the bolts line up for the mount, then you have to trim the hose, a pair of scissors will do it.
Mine is nice and squishy now:
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Also, as above, remove the spring loaded clamp from the BOV and put a proper hose clamp on.

Your engine bay might look more or less like this:
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