Project 1, from scootarida1, My 2005 Subaru Forester XT Turbo Project

Here is some work I am currently doing on my Subaru. It is a 2005 Forester and I'm making a custom twin scroll setup for it. Here are some pictures:

This is before anything and was just used to find a good location for the turbo.
http://i1093.photobucket.com/albums/...otarida1/1.jpg

Here is what the flange locator looks like so I can run the tubes to the flange
http://i1093.photobucket.com/albums/...arida1/7-1.jpg

I took a header that looked like this:
http://i1093.photobucket.com/albums/...0121111810.jpg

And turned it into this:
http://i1093.photobucket.com/albums/...308111613a.jpg

I will post up more pictures as I do the build.

By the way the model of the turbo is a Borg Warner S200SX-56 1.05 A/R

Here is some more pictures of the progress I made:

http://i1093.photobucket.com/albums/...0519111638.jpg

http://i1093.photobucket.com/albums/...519111638a.jpg

http://i1093.photobucket.com/albums/...0521111715.jpg

http://i1093.photobucket.com/albums/...0521111716.jpg

http://i1093.photobucket.com/albums/...521111716a.jpg

http://i1093.photobucket.com/albums/...521111716b.jpg

http://i1093.photobucket.com/albums/...0522111958.jpg

http://i1093.photobucket.com/albums/...522111958a.jpg

Here is the intake I plan on running. It is an electrical pvc 45 degree bend that I cut to fit with an AEM dry flow filter. I wraped it wit dei gold heat tape.

http://i1093.photobucket.com/albums/...1/100_0112.jpg

I dont have any pictures of it installed yet but I should this weekend.

Here is what the setup looks like on the car.
http://i1093.photobucket.com/albums/...0528111103.jpg

It still needs a turbo blanket which should be this weekend

Here shows somewhat of the clearence of the downpipe and frame. The down pipe needs another bung for a wideband which I also plan on doing this weekend
http://i1093.photobucket.com/albums/...0527111702.jpg

Here is a picture of the bypass valve I will be using that i modified to work for my car. Basically there is a silicone coupler between it and it will use two t-bolt clamps to hold it in place:

http://i1093.photobucket.com/albums/...0715111647.jpg

I got some more work done on the car and it runs now but still needs to be tuned which is going to happen on the 31st. I got the wideband bung welded in and the heat shield for the oil return in and the turbo blanket installed. I also fitted the re circulation tube for the bypass valve.

Here is how the turbo blanket sits:
http://i1093.photobucket.com/albums/...0723111808.jpg

Intercooler is installed and some views of the intake:
http://i1093.photobucket.com/albums/...724111329a.jpg

http://i1093.photobucket.com/albums/...0724111328.jpg

http://i1093.photobucket.com/albums/...0724111330.jpg

Here is how the recirc valve is setup:
http://i1093.photobucket.com/albums/...724111329b.jpg

Here are the gauges i installed. Still havent made the mount yet but thats another project I have in store:
http://i1093.photobucket.com/albums/...0724111331.jpg

Full engine bay:
http://i1093.photobucket.com/albums/...0724111329.jpg

Exhaust Back End:
http://i1093.photobucket.com/albums/...724111330a.jpg

Heres a link to what the car sounds like:

http://www.youtube.com/watch?v=-HF7sTxZCIo

Good project Brandon. Looks like a lot of work. What did you paint it with make it look like aluminum. Does not look like much room to work in there. What size turbo is on it and are you going to take it to a strip and run it or dyno it.

yeah it was a pain but hopefully its worth it in the end. I ended up using VHT Fireproof and followed the instructions they give for cure time to a T. If you take your time for fitment things come out well but it does take much time. Also it is a 76mm exducer i believe with a 1.00 a/r. I currently have a tuning appt this sunday so it should be interesting to see what will happen. Im shooting for 400awhp

Here is a video of a pull after my tune:
http://www.youtube.com/watch?v=zLT6WCcbwA4

Made 340awhp 330awtq at 18.9psi. In a couple of weeks we will be doing more logging and maybe push it to 360-370awhp. Pulls really hard and it was hot as hell outside. It drives very smooth and one problem with the bypass valve we believe that it is stalling after a rev from the valve opening. I will be trying to find some sort of shims to keep the valve closed during idle. Also I couldnt really see the gauges so I was deffinately short shifting.

Here is a better pull from 2nd-4th but not all the way through 4th. It was filmed on a rolly road. Tuner said he had it at 370awhp but detuned it to make it safer.

http://www.youtube.com/watch?v=CGXLoxB6FQM

Well I decided to build a new intake because were thinking that that is the culprit for the bad idle. Here are some picutres, I will add more after I weld on the barb and the maf flange.

http://i1093.photobucket.com/albums/...818112025a.jpg

http://i1093.photobucket.com/albums/...0818112026.jpg

http://i1093.photobucket.com/albums/...0818112202.jpg