Forged Performance: 2011 STi Sedan MONSTER Build **check back often**

[chaseamundo]

you guys love those te-37's huh

[Tray@Forged]

you guys love those te-37's huh

Yeah, These are the new hotness. They are lighter in weight then the standard ones.

[NCPhotog]

need pics of it at road atlanta?

[Tray@Forged]

need pics of it at road atlanta?

Let's set something up for the next one. We will be out at Sebring this weekend.

[NCPhotog]

sounds good. wish i could be at sebring for the le mans testing and the race

[Tray@Forged]

Ok, we just wrapped up our prototype 3inch exhaust. We are still making some changes to the system, but I want to share a quick teaser dyno. On the first pull, I realize just how much trq, spool, and power we were missing and the results are nothing short of spectacular. Boost level is the same on both runs, and I think we're one of the only shops to post boost curves. All in the interest of sharing as much as possible with the community.


The only change is we switched from the stock exhaust to our 3 inch exhaust. I did not adjust timing, but I did have to ADD additional fuel because the new exhaust naturally resulting in less backpressure and more efficiency from the engine.


400rpm earlier spool which shifted the power curve 400rpm to the left
50ft/lbs peak trq improvement and 21whp peak improvement.
But even more telling, is the 100lb/ft trq improvement in the midrange


That said, the car as it sits now is actually decent in the midrange and a lot of fun to drive around town. Certainly not a road racing turbo by any means but much more tolerable than I would have expected with this big PTE 6765. I've got a bit more tuning to do on pump, but so far these are the highest numbers I've produced from 20psi on a 100% stock engine STi on our dyno. It would be nice to hit the magic 400whp on pump. Good stuff.


Shortly after that, we'll do some before/after testing of the one-of-a-kind AMS Prototype Intake Manifold.

[Tray@Forged]

Posting for Sharif:

So I got bored on Sunday and converted over to E85. Just did some quick adjustments of fueling to get me going, but OMG it's much more responsive on E85. I will be on the dyno this week with it again for the big stock block numbers. I really want to see 450-500whp on our Dyno Dynamics. I will definately have the video camera rolling for those pulls.

Also just heard from JRZ today that the suspension bits are back from the anodized which means assembly and shipping is just around the corner.

[Tray@Forged]

Sorry for the lack of updates. We have been completely consumed with customer projects that the STi has been neglected. Here is a picture of our new FP Dual 3inch exhaust. This baby sounds killer!



Thanks for looking!

Tray

[Bacon]

In for sound clip. I loves this car.

[Tray@Forged]

Just wanted to chime in and say the car had some tuning last night performed. Sharif is going to chime in a bit later with the results, and dynograph with video. We apologize for the lack of updates. Our customer cars take #1 priority over our Project STi. We are currently working on over 50 customer project vehicles.

A little peak of what is to come!
- Dynograph with Video
- Group N Mounts
- CSF Radiator Installation & review
- Whiteline Suspension review
- AMS Prototype Manifold Install and test (Before & After)
- Viper Smart Start kit and Escort 9500ci Radar & Laser Shifter Kit
- Pioneer unit with HKS Camp 2 review
- OS Giken Clutch & Install review
- Forged Performance Stroker Kit - Manley & Tomei Components
- Tomei Timing Belt, Timing Belt Guide, Engine Baffle Stiffener & Spec'd 270 Degree Camshafts
- Break In tune & write up
- Race gas tune & write up
- OS Giken (Front & Rear) Differential Install & Testing
- Track Testing
- JRZ RS1 Suspension Installation
- Track testing
- Lip kit, Side skirts, and rear diffuser.
- Hopefully some more goodies along the way!

[Tray@Forged]

Hi everyone, it's been hectic to say the least. I wanted to thank all of you your interest and support of this project. The 11 of us that work at Forged are all hard core enthusiasts that live, breath and eat this stuff just like all of you. As such, I can get pretty addicted to working, tuning, and trying to do the best possible job for everyone. So bear with us as we're burning the midnight oil.

As Tray mentioned, I spent a couple hours last night finally getting a chance to tune the car on E85 at higher boost. The objective was to push to 30psi on the stock block, knowing our single pump DW pump would not make it that far. But I was pleasantly surprised at just how far it did make it and far exceeded what can be done with the traditional Walbro 255.

At the end of the tuning session with E85 fuel, I acheived 471whp@26psi peak boost pressure on our Dyno Dyanamics AWD Dyno (no BS inflation added) before running out of fuel. For reference, our project car did a 197whp baseline. The turbo absolutely JUMPED to life after about 24psi, and I can tell it's begging for much much more. Full boost at 4750rpm isn't too shabby either for a big PTE 6765 turbocharger. Before our stroker engine goes in, I'll do one more tuning session with our big flow fuel system before yanking out this engine.

Enjoy the pics from last night, and the videos are being edited as we speak.

[chaseamundo]

*mouth dropped*

[msanch24]

rockstar? movie star? Pro athlete? no. I wish i was Tray lol

[chaseamundo]

Ha i chuckled ^

[Tray@Forged]

rockstar? movie star? Pro athlete? no. I wish i was Tray lol

LOL. No you don't you wish you were Sharif. haha

[msanch24]

LOL. No you don't you wish you were Sharif. haha

True, but id be satisfied anywhere near Forged.

[Tray@Forged]

Here is the sought after AMS Intake Manifold. Let me remind you this is their Prototype. This is not a final product. The final product will be made from cast and will look much different. Forged Performance is honored to be given the opportunity to test the manifold. We will be performing a back to back dyno session. We will let everyone know the performance, and feedback of the AMS prototype.





Install and Testing coming soon!

Thanks for looking!

Tray

[Tray@Forged]

Got a few more items in the mail today that I'd like to share. Tomei sent us a few goodies that are going to be perfect for our Engine Build. We ordered the Tomei Timing belt, Belt guide, Baffle stiffner, and 270/270 Camshafts. The quality of each of the Tomei parts are second to none. We look forward to installing these items, and putting the camshafts to test.




The Tomei Kevlar Timing belt, and Belt guide. The timing belt is super tough and is claimed to be 4x the strength of OEM without sacrificing durability. We paired the timing belt with Tomei's belt guide. The Belt guide is a straight cut of aluminum with an extended length to securely apply more tension to the timing belt. This product comes in handy when immediate changes in torque are experienced by the engine, eliminating belt whip.



Tomei's highly experienced engineers developed an engine baffle stiffener to help prevent bearing failure, and help regulate the oil supply. During the R&D Tomei found one of the main causes of engine problems on the EJ20/25 are the bearings. The majority of the cases were caused by lack of motor oil in the oil pan (sump) and passages. They also found that the lack of rigidity in the crank case is also another problem facing this engine design. Under extensive research, Tomei created the baffle stiffener which helps strengthen the left and right side of the crankcase to help provide the added support with its dual structural design. The rubber baffle design greatly aids the regulation of the oil supply. This gives added control to reduce blowby for EJ20/25 owners who use their cars for high performance driving.




The most exciting parts that arrived were the Tomei PROCAMS. We decided to go with Tomei's PROCAM 270 Intake, & 270 Exhaust. We felt this was the best bet for our large turbo application. The specs on the camshafts are quite impressive. The Intake side has 11.0mm lift, and the exhaust side has a lift of 10.8mm. With that lift we know it will make an significant improvement to our 2011 STi build. Not only do we hope to achieve more power with the camshafts but improve the powerband. We look forward to performing a dyno test in the weeks to come.

Thanks for looking!

Tray

[msanch24]

it just keeps getting better.

[EG_Ryder]

Wow, AMAZING build guys! But its been a whole week and still no videos

[Blitanicle99]

Nom Nom.

[Genji-Sama]

Dayum, that's just sick, and with the stroker engine in there it gonna be scary

[uho]

sweet build on this thing, there should of been a dyno vid in this thread

[merfwin]

sick build!

[carton30643]

Great Great progress! Awesome power too!

[justin30107]

Crazy sick car mane

[Tray@Forged]

Hello everyone. No major mods for today's update. But I did want to share some pictures after our most recent auto detail. Mike from Mirror Detailing spent the afternoon performing a 2 stage paint correction. We had a lot of swirls on the car straight from the dealership. Have a look at the work!


Before Paint Correction:




After 2 Step Paint Correction:







Outside shots:

[Got Milk?]

If i dropped off my wrx, would you guys play with it..


Very nice build. From what I've seen so far, no short cuts have been taken. top notch(and i dont mean top notch as in that gay ass car group with shitty cars).

[Blitanicle99]

Hey guys and girls, just a little teaser update on whats next for the Forged Performance STi!








What your looking at is a Manley stoker kit, including crank, rods, pistons, valves and springs with ACL bearings.

Next up, the first and only set available right now...




That's right, we have the first and only set available of JRZ RS1 which are a new design.

And thats how its done.

[msanch24]

And thats how its done.

[OG-Skinny]

And thats how its done.

And that's how it's done.

[G.C]

And that's how it's done.

And that's how it's done.

[Tray@Forged]

Ok, the moment you've all been waiting for. Before reviewing the dynos I would like to review my testing methodology so that everyone is on the same page with respect to the gains achieved.

At Forged Performance, we take delta testing very seriously. I personally handle all aspects of the process to ensure a true and accurate comparison. Results can easily, yet often, become unintentionally skewed in either direction. But our objective is to give you all a true no-BS assessment of any part that we test.

That said, here is our testing methodology.

1) E85 Fuel and Stock Engine (Baseline was 196whp on our dyno)
2) Boost pressure reduced to 23psi to insure a very stable AF ratio while not overwhelming our single fuel pump.
3) Same day test 6 hours apart and vehicle was not unstrapped or moved from the dyno. We had to do quite a bit of modification to make this prototype fit, but of course production versions will be bolt on like all AMS products.
4) Ambient temp was within 3 degrees F variation in our shop, through the dyno testing process.
5) Ramp rate (load on the rollers) was reduced to 140 in order to reduce the effects of heat soak, which can mislead the results.
4) Dyno Fan running for all runs.
5) 2 second "dwell" or hold time before releasing the dyno. For reference, the dwell time can alter the boost ramp up as it pre-heats the turbo.
6) The lowest and highest dyno numbers are rejected for both plenums as well as any unusually high or low numbers.
7) AF and boost was equalized within .2 psi and .2 AF ratio points for a true apples to apples comparison of the gains. Boost curve is posted for reference so there is no dispute on boost levels run.

That said, the results were outstanding at such low boost pressure. We achieved a peak of 20whp and 28lb/ft trq. More impressively, there was virtually no loss of power or trq anywhere on the curve, and many areas showed gains of 30whp and 40lb/ft! So in addition to a notable peak power improvement, we saw a tremendous improvement in area under the curve throughout the power band.

So far, we are very pleased with the AMS Protoype STi plenum. We feel the gains will be even more impressive as we raise the boost further after our FP S2 stroker race engine goes in. We will be working with AMS closely on some additional changes and modifications to make this plenum the best out there.

And the best part......we have a video coming soon!

[MazdaStrider]

Not a fan of 2011 Subraru with that huge spoiler, I think if you add the front lip it will complete the whole even look.. if you look at the side of the car in the first picture, the front looks a little "off"....

[msanch24]

Not a fan of 2011 Subraru with that huge spoiler, I think if you add the front lip it will complete the whole even look.. if you look at the side of the car in the first picture, the front looks a little "off"....

Its a purpose built track car...

Ipso facto, function trumps form every time.

[CHADbee]

This past weekend, we decided to bring the Forged Performance 2011 STi to the annual gathering of Nissan's called ZDAYZ. This four day event began with the 4th Annual Top Dawg Airstrip Shootout that we sponsor each year at the Hendersonville Airport. Running E85 and 23psi of boost (we bought 200 gallons to feed our STi and GT-R), we made dozens of 40-140mph passes down the airstrip. The STi never missed a beat and performed flawless and still on the stock block.

After Thursday's event, we headed to Deals Gap and enjoyed the next three days hurting many a sport bike owner's feelings. With near infinite amounts of grip, phenomenal brakes, and terrific power the STi was a dream to drive through the twisty stuff.

[patrick4588]

im in love.

[slostang]

Simply beautiful build.

But i cant decide if im more jealous of the car or that you guys get to work on new cars without all the rusted ass seized hardware and dry rotted vacuum / evap / coolant hoses...

[Deke]

But i cant decide if im more jealous of the car or that you guys get to work on new cars without all the rusted ass seized hardware and dry rotted vacuum / evap / coolant hoses...

I feel your pain (note: not about the car in my sig)

[Sol-Badguy]

I would have loved to see it run at the Dragon. Ahhh, I'm jealous.