Forged Performance: 2011 STi Sedan MONSTER Build check back often

Tray@Forged · 02-07-2011, 11:19 AM

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.

esfourteen · 02-07-2011, 01:38 PM

factory exhaust was really holding that turbo back, awesome gains!

Tray@Forged · 02-16-2011, 08:14 AM

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.

Kastley85891 · 02-16-2011, 08:24 AM

E85 on that motor is great, so much more smoother with all that extra timing.... my STi loved the stuff, up top on a 20G with 30-33 degs of timing lol

Sure yours will be an animal.

Tray@Forged · 02-18-2011, 11:24 AM

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

TypeOne · 02-18-2011, 11:40 AM

I would probably give my first born for this car...

I want. I want. I wannnnttttt!

Tray@Forged · 02-23-2011, 04:58 PM

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 · 02-24-2011, 07:32 AM

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.

Tray@Forged · 03-03-2011, 11:40 AM

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

christian370z · 03-03-2011, 11:51 AM

The manifold looks great, that Sti is a beast!

Tray@Forged · 03-03-2011, 02:05 PM

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

Kastley85891 · 03-03-2011, 02:31 PM

Awesome

Tray@Forged · 03-07-2011, 04:47 PM

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:

Kastley85891 · 03-07-2011, 05:41 PM

Very nice, makes me miss my STi's bad.

Interested to see your current and post cam shaft install AVCS settings

Jose Aliling · 03-08-2011, 07:59 AM

makes me want one!!

02-07-2011, 01:38 PM	#62 (permalink)
esfourteen A True Z Fanatic Join Date: Mar 2010 Location: LI, NY Posts: 1,375 Drives: 40th TT Rep Power: 18	factory exhaust was really holding that turbo back, awesome gains! __________________ Build Thread \| GTM TT Install Thread \| Engine Build Thread

02-16-2011, 08:24 AM	#64 (permalink)
Kastley85891 A True Z Fanatic Join Date: Nov 2009 Location: ATX 370 - Sold Posts: 1,149 Drives: 2003 Wagon Rep Power: 17	E85 on that motor is great, so much more smoother with all that extra timing.... my STi loved the stuff, up top on a 20G with 30-33 degs of timing lol Sure yours will be an animal. __________________ Boosted V8 hunter 2850 lbs and 375WHP

03-03-2011, 11:51 AM	#70 (permalink)
christian370z A True Z Fanatic Join Date: Jul 2010 Location: Newport Beach Posts: 3,900 Drives: 2010 370Z/Saab 900se Rep Power: 431	The manifold looks great, that Sti is a beast! __________________ -320whp / 259wftlbs- SP Rays -- RE-11s -- SpecialtyZ Tune -- Swift Springs -- Stillen 25R Oil Cooler -- Stillen G3 Intakes -- Berk HFCs -- F.I. 12" CBE -- Stillen Sway Bars -- Es14 Spring -- INGS+1 lip -- CF Spoiler -- GTR Start Button -- VLED Parking Lights -- PWJDM V2 shift knob

03-03-2011, 02:31 PM	#72 (permalink)
Kastley85891 A True Z Fanatic Join Date: Nov 2009 Location: ATX 370 - Sold Posts: 1,149 Drives: 2003 Wagon Rep Power: 17	Awesome __________________ Boosted V8 hunter 2850 lbs and 375WHP

03-07-2011, 05:41 PM	#74 (permalink)
Kastley85891 A True Z Fanatic Join Date: Nov 2009 Location: ATX 370 - Sold Posts: 1,149 Drives: 2003 Wagon Rep Power: 17	Very nice, makes me miss my STi's bad. Interested to see your current and post cam shaft install AVCS settings __________________ Boosted V8 hunter 2850 lbs and 375WHP Last edited by Kastley85891; 03-08-2011 at 08:09 AM.

02-07-2011, 11:19 AM	#61 (permalink)
Tray@Forged The370Z.com Sponsor Join Date: Jan 2010 Location: Johns Creek, GA Posts: 540 Drives: 05 Infiniti FX35, Rep Power: 0	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.

02-16-2011, 08:14 AM	#63 (permalink)
Tray@Forged The370Z.com Sponsor Join Date: Jan 2010 Location: Johns Creek, GA Posts: 540 Drives: 05 Infiniti FX35, Rep Power: 0	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.

02-18-2011, 11:24 AM	#65 (permalink)
Tray@Forged The370Z.com Sponsor Join Date: Jan 2010 Location: Johns Creek, GA Posts: 540 Drives: 05 Infiniti FX35, Rep Power: 0	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

02-18-2011, 11:40 AM	#66 (permalink)
TypeOne A True Z Fanatic Join Date: Jul 2010 Location: Baton Rouge, LA Posts: 2,682 Drives: BSM 370 Rep Power: 1850	I would probably give my first born for this car... I want. I want. I wannnnttttt!

02-23-2011, 04:58 PM	#67 (permalink)
Tray@Forged The370Z.com Sponsor Join Date: Jan 2010 Location: Johns Creek, GA Posts: 540 Drives: 05 Infiniti FX35, Rep Power: 0	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!

02-24-2011, 07:32 AM	#68 (permalink)
Tray@Forged The370Z.com Sponsor Join Date: Jan 2010 Location: Johns Creek, GA Posts: 540 Drives: 05 Infiniti FX35, Rep Power: 0	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.

03-03-2011, 11:40 AM	#69 (permalink)
Tray@Forged The370Z.com Sponsor Join Date: Jan 2010 Location: Johns Creek, GA Posts: 540 Drives: 05 Infiniti FX35, Rep Power: 0	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

03-03-2011, 02:05 PM	#71 (permalink)
Tray@Forged The370Z.com Sponsor Join Date: Jan 2010 Location: Johns Creek, GA Posts: 540 Drives: 05 Infiniti FX35, Rep Power: 0	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

03-07-2011, 04:47 PM	#73 (permalink)
Tray@Forged The370Z.com Sponsor Join Date: Jan 2010 Location: Johns Creek, GA Posts: 540 Drives: 05 Infiniti FX35, Rep Power: 0	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:

03-08-2011, 07:59 AM	#75 (permalink)
Jose Aliling Enthusiast Member Join Date: Aug 2010 Location: Manila Posts: 298 Drives: tricycle Rep Power: 14	makes me want one!! __________________ http://www.farmofminds.com/2012/10/r...hp-garage.html

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

Forged Performance: 2011 STi Sedan MONSTER Build check back often