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FLI 06 STI built GT30 Legacy reverse intake manifold and more...
A few months ago we had a customer come to upgrade from his FP green to a garrett GT30. With the customer already having the APS 3.5in turbo back and the APS Header and not wanting to get rid of them we set out to modify his existing up-pipe and down-pipe to accommodate the GT30. Along the way the project snowballed a little into what your have before you today.
FLI Stage 3 closed deck block.
FLI stage 3 ported heads
Cosworth 264 cams
Cosworth timing belt guide.
JDM 12mm oil pump
APS header modified by FLI
APS 3.5 in turbo back modified by FLI
APS Fuel rails
APS FMIC BOV
Power Enterprise 850cc injectors
Legacy reverse intake manifold
Perrin FMIC core
Intercooler piping custom done by FLI
Greddy Oil cooler
APS rotated mount intake
Tial 44mm waste gate
Garrett GT30 .82
Tein FLEX coilovers
Cobb front and rear swaybars
Cobb SS lines
Motul RBF600 fluid
Seibon carbon fiber hood
APR side mirrors
This is the car right when is came into the shop to us before all the work started.
First step take engine out of the car.
Next step assembling the FLI stage 3 closed deck block.
Fully assembled long block with the FLI stage 3 cylinder heads. These heads use 1mm oversize intake and exhaust valves and a good amount of port work. If anyone is interested I have flow bench number of these vs COBB heads and version 7 STI
Next up was modifying the APS up-pipe for the 4 bolt Garrett flange needed for the GT30. This was a pretty simple process that involved welding a section of pipe with the proper flange onto the existing up-pipe then fabbing a new support bracket for the GT30
Here are a few more pictures with the Legacy intake manifold on it. This was a pretty straightforward mod it just required the Legacy throttle body as well as the manifold.
Next up on our list was fabbing up the down-pipe this was not to hard just took a little time.
And the finished product down-pipe
Next up was test fitment of the intercooler pipes up-pipe and down-pipe before they went out for thermal coating and powder coating.
Next up on our list is finishing the waste gate dump-tube and how the waste gate mounts to the up-pipe. After that its pretty much all down hill and the car will be ready for final assembly and the brake in tune. Ill post back with more pictures as the project wraps up. If anyone has any questions or comments they are always welcome.
A small update on this project. The intercooler pipes came back from being powder coated and the down-pipe and up-pipe had the final welding done and were wrapped. This is the final mock up of all the piping before we move it into the STI for the final time. Hopefully some time next week we will be braking the car in and getting ready for the dyno.
This was a long project but well worth the wait. We went with a GT35R turbo because the GT30R ran out of air , which I guess is a good thing right? The car will be back in a month or so for the race fuel tune and the Hydra 2.6 upgrade (now he is running the Hydra 2.5). The customer wanted to re unite with his baby before a massive power increase. This STI actually broke our 91 Octane record by 37 hp to the wheels. Max boost is set at 22 psi tapering to 21 psi.
Also, take note of the difference between the FLI reverse Legacy plastic intake manifold set up (which did not get hotter then 80 degrees) and the standard mount GT35R front mount intercooler set up that held the previous 91 Octane record on FLI's Mustang dyno. This car made 300 ft. of torque at the wheels at 3450 rpm vs. 3850 rpm.
Notes from dyno graph: Temp in room is 63 degrees with 42% humidity, IAT is 60 degrees and max boost of 22 psi.
Without loosing the AC its the only way to do a revers intake manifold. Another up side are the lower intake manifold temps. Usually the metal intake manifold after running on the dyno for a while are in the 140 deg temp range.