Today I finished the final WOT tuning on the car. Cleaned it up, took some pictures and am getting ready to try and relax and just enjoy it now. For a quick reminder to some who maybe weren't following this already. I bought a 2003 EVO that was a project car that was taken apart brand new and never finished. The car had 232 actual miles on it. No engine, trans, transfer case and some other small things missing. Here is what we did to the car and the approximate costs:

BR 2.3 liter Stage 3 shortblock ($3,550)
-JE pistons
-Manley Turbo Tuff rods
-Stock 2.4 liter crank, balanced and polished
-BR balance shaft eliminator kit

BR Stage 3 cylinder head ($1625+$60 for inconel upgrade)
-Manley Springs/retainers
-Supertech +.5 mm intake valves
-Supertech +.5mm inconel exhaust valves
-O-ringed deck

Front cover, oil pump, gasket kits, oil, filter, antifreeze, new oil cooler, head studs, timing belt, timing belt tensioner, water pump etc. All the things we prefer to replace when doing a full build. ($1250)

Used Jun 272 cams with stock cam gears ($500'ish used value on cams)

Forced Performance Red, ported and coated turbine housing, ($1795+$195 porting/coating)
BR SS 02 housing ($195)
BR ported and coated exhaust manifold ($195)
BR 3" turboback with SD muffler and Magnaflow ($995)
BR polished SS manifold heat shield ($95)

BR race FMIC ($799)
BR lower upper and lower i/c pipes, powder coated wrinkle black ($560)
BR MAF pipe, powder coated wrinkle black ($210)
BR lightweight battery kit ($280)
Stock ignition system
Stock ECU
BR double pumper ($500)
E85 fuel
PTE 1,200 cc injectors ($345)
Exedy triple HD metalic, push style clutch ($3400)
BR ported stock intake manifold ($145)
BR 65 mm throttle body ($300)
Bushwacker Stage 1 with 4.11 gear set ($1500)
Bushwacker rebuilt transfer case with RS differential ($350 for Stage 1, includes big bolt kit and shims)

Eclipse double DIN head unit with DVD, Nav, AM/FM CD
Volk TE37 white wheels, 18"x8.5"

Apexi S1 coil over suspension ($1400)
Suspension Techniques rear sway bar ($199)

For some of you that have followed along you will notice I have changed a few things that were done in the build from the original list.

I am very happy to say that today I made more power than I have ever personally made on a reflashed stock ECU with this car. It is hot here today, in the the 80's I'd guess. Not ideal for dyno numbers.

The car is being dyno'd on what I am assuming is E85, Ohio uses E70 in the winter so I can't be sure it is or isn't E85. Whatever it is, it is working well.

The car was tuned at 30 psi of peak boost. The Peak power was 469 whp and the peak torque was 435 ft lbs. Peak torque comes in at about 3800 rpm and the peak power is out where I stopped the pull around 7500 rpm. You will note that from 5800 to 7000 rpm the graph doesn't look so hot. I honestly have no idea why. The highest knock count on the run was 3 at that was at 7800 rpm after the pull was actually over. The rest is 0. Car feels great, you cannot feel or hear anything in that area. It is rich there, I was hotter than hell and happy with what I was seeing so I called it a day. This pull was done in 4th gear.

Here is the dyno sheet:



For the ECU guru's around here I am using ROM 94170008. I am using all stock sensors. I have a wide band in the car but it is not run into the ECU, yet.

I do not have modified knock tables, so I am running the car with the stock knock limits. I have found that rescaling the MAF has made the car run much better, at idle and at WOT high load it actually has it so I can nearly input the AFR values into the fuel maps and get them to match at WOT on the wide band.

At 30 psi of boost with this combination I am seeing up to 402 on the 2 byte load, so it seems to be moving some air.

There are some things I want to do with the stock ECU yet. Run the wide band in, 3 bar map sensor so I can monitor boost, I would love to be able to live tune the car and last I'm going to put the dual mapping switch in. I just have to get all the information.

Thanks to all the guys who have worked so hard on the stock ECU in the last few years to get it where it is now. You guys have made my life much easier.

Some other thanks that are needed.

Thanks Chad at CBRD for a great radiator. Car runs cool, radiator fits and looks great.

Thanks to Trip Manley for the rods I don't have to worry about breaking and valve train that does it's job.

Thanks to Robert at Forced Performance for building the highest horsepower producing stock appearing turbos available.

Thanks to Apexi for the new S1 suspension. This part is one that I am just flat out impressed with. The ride quality on this suspension is by far the best I have seen in an EVO for any price, that is no sales pitch. If it works on the race track 3/4 as good as it does for daily driving the car, it's going to be amazing. The ride is truly OUTSTANDING. Maybe better than stock.

My "secret" tuner/helper who has been putting up with all my stupid ECU questions. Thank you very much!

Thanks to my brother Dan for putting the engine/trans in the car for me and getting the project done as quickly as possible.

Here are some pictures of the finished car. I may still put a carbon fiber lip on it, I like the look of it. I'll probably also end up tinting the windows. Other than that I am really happy with the outcome.

Mama

Dammit that car super clean.. I would drive 2x a month if that.. Nice work as usual!!

Mike

Car looks amazing...needs to swap out those ugly tail lights though...haha...I really like the wrinkle black intercooler piping and intake...Car is making some pretty nice power on a pretty minor build...when u guys taking it to the track??

clean, thats a beefy power band, must be fun on the streets.!

....oh....oh...ohhhhhhhhhhh yah. Hot damn! Since the car is white, you wont see any of the added white stains I just left. Couldn't help myself, a centerfold profile like that. Awsome build, and sick sexy car. Maybe Betty will be there soon...

IX diverter valve without issue at that boost? I can't seem to get mine to hold more than 26 psi

awesome david! another thoroughbred worthy of the buschur racing stables!!!

Lets see the interior too!

Is that a catch can behind the FPR?

Looks great.
i think the oem ecu believers will be happy
will it go to the track once? and WHEN

Thanks guys, really, I appreciate the comments.

The wrinkle black finish is FOR SURE available, no problem.

Yes, stock EVO9 DV, they work excellent, other than the Tial with speed density it is what I recommend. I was going to smash the top of it and forgot! It will hold even more boost with the smash mod

No interior shots yet. It's a mess to be honest. Floor mats need vaccumed and I have the AEM wide band stuck in the ashtray, flashing cables flung over the center counsole. I will post pics but I want to get the gauges mounted in the glove box and clean it up.

The car is a blast to drive. It's nice driving a smaller turbo'd EVO with the stroker, no downshifting needed. This car will accelerate from 1500 rpm in 5th.

looks super clean nice job!

very very nice

That looks really really good. The white valve cover with the black pipes is a great combo.