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Building the FR-S FA20 with Stay Crushing: Installing the Engine and Making Big Power!

  • Mike Kojima

,

The Radium Engineering crankcase catch can is a nice and clean installation in a crowded engine compartment thanks to the plug and play no drill bracket!

Next, the PCV system catch can is installed on the passenger side near the battery. The well-engineered bracket makes this a piece of cake as well.

Radium engineering now makes a self-draining larger capacity catch can/filter much like what we used on Project STI that installs in this location as well. This system removes moisture from the blow-by oil and returns it to the crankcase.

 

With our engine neatly in place, it was time to do some dyno tuning. Since we wanted to run E85, we used a flex fuel kit from Delicious Tuning. We figured that would be the easiest and safest way to run E-85 in daily operation.

The Delicious Tuning flex fuel system will allow any percentage of E-85 to gas, so it is a seamless, very convenient, and safe way to run E-85. The kit is very simple to install, requiring a flex fuel sensor be added to the fuel feed line and the ECU reflashed using the Ecu-Tek tuning suite.

With all the cool parts in place, it was time to fire her up and do some tuning!  Ronnie Diaz at R&D tuning used Ecu-Tek software to tune the engine on a mixture of 50% pump gas and 50% ethanol. For conservative tuning on a street engine, most of the gains in detonation reduction seen by ethanol are found with a total ethanol content of 50-60%. When the car is running 100% E-85, it will be a very safe tune indeed.

 

Our motor blasted out 321 whp and 235 lb/ft of torque at 14 PSI of boost on the stingy MotoIQ Superflow chassis dyno. This would be around 360-370 whp on a dynojet and is about 100 more hp than it did before on pump gas with the smaller blower on the stock engine. This is the most powerful FA20 we have ever dynoed here.

The linear rising powerband and torque curve are characteristics of the centrifugal Vortech supercharger and are a good thing because the stock transmission becomes iffy at around these power levels and the gradual rise in power and torque are a lot easier on the drivetrain.

With our new engine, the Stay Crushing FR-S is no longer a show car poser but seriously fast. The power delivery of the engine gives a feeling that the power just wants to build and build, rocketing to the fuel cut. If we were not being conservative with the rev limit, the power would continue to climb to 8000 rpm.

Well, now Robert wants more and is talking about turning the screws on his blower up even more as the Vortech V-2 has a lot of headspace to go before it runs out of breath.  We told him he needs to do something to the transmission first before that and maybe he just needs to go out and have fun with the car first!

 

Read Part one of our FA20 Engine Build!

Check out Part two of our build here!

Part 3 of our build is here!

Sources

ACT

Verus Motorsports

Perrin Performance

Raceseng

Vortech Superchargers

DC Sports

Jackson Racing

HPS

ARK Design

Radium Engineering

Deatschwerks

Delicious Tuning

RD Engineering

Portflow Design

Brian Crower

JE Pistons

Supertech

ARP

King Bearings

Moroso

Related

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Related Topics
  • Perrin Performance
  • Delicious Tuning
  • FA20 engine
  • Throwout bearing fork
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  • ACT
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  • Vortec Superchargers
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  • Radium Engineering
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  • Moroso
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Project E46 M3, Part 19: Powerflex Bushings and Maintenance

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KW – Adaptive DDC Plug & Play Coilovers for the Ford Focus RS

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