2008 Subaru WRX Project

Tuning
Now that we have all the necessary hardware we want on Project WRX, we can finally look at tuning options. Since our project car currently isn't too different than the average bolt-on project, we decided to go with Cobb Tuning's AccessPort package for the WRX. The Cobb AccessPort is a simple plug-and-play solution for anyone looking to extract some power with a reliably conservative tune without the trouble or wear and tear of getting the car to and onto a dyno.

The system is basically a hand-held reader that can both read and write to the car's ECU via the OBD-II port and also communicate via USB with a PC. So you only have to buy the hardware once. After that, new calibrations for different hardware changes on your car can be ordered and downloaded online onto your PC. Each calibration is uploaded to the AccessPort from your PC and is stored as one of several maps in memory on the AccessPort controller.

Cobb offers several different switchable maps for just one particular platform. Each package comes with tuned, valet, economy, anti-theft, and stock maps. Depending on the hardware on the car, a tuned Stage 1 calibration for stock cars and tuned Stage 2 calibration for vehicles with downpipes and exhausts are available. Different Stage 1 and 2 maps are available for 91- (oxygenated or not) or 93-octane gas, and all of these are downloadable at Cobb's site. The AccessPort is also capable of a third custom tuning option, which lets the do-it-yourself tuner or professional tuner go through and generate custom calibrations for any car. The Access Tuner race software has limited access to certain safe tuning parameters while the AccessTuner Pro is for trained tuners and opens up tuning for most maps.

Project WRX was taken to Jon Drenas at HB Speed in Fountain Valley, Calif., for a custom tune. HB Speed tailors to the Subaru and Mitsubishi market and custom tunes cars for the masses, unlike many inaccessible snob tuners. As a licensed Cobb Pro Tuner, Drenas optimized our Stage 2 map for our new hardware and picked up some additional torque through more boost at the bottom end. While horsepower at the top didn't increase notably because the turbo is maxed out, we were able to make more than 300 lb-ft of torque at 2,500 rpm on the stock turbo and crappy California pump gas. That's almost rally car levels with rally car response. Drenas also worked with us to tweak our e-throttle maps just for our taste of fast response, but smooth modulation for balancing the car on track.

Streetcar Suspension
The last bit of our ultimate streetcar Subaru was additional fine-tuning of the TEIN Super Street coilover suspension that was already on the car. Until now, the car still sat at its SEMA Show ride height. While the lead sled look turned heads, the rear suspension was near the bump stops when the car was loaded up. The lack of travel and lowered geometry meant that the front MacPherson struts, which by design have limited camber gain when compressed, didn't increase in camber at all. On the figure eight, Project WRX would lose most of its steering feel once taking a set and completely washing out at corner exit. Our solution was to raise the car by about a 1/2 inch and dial in more static camber. The fronts now sit at minus 2.5 degrees and the rear was set to 2 degrees of negative camber. Toe remains at zero in both front and rear for highway stability.

To let the suspension work better, we also replaced just about every rubber bushing in the front and rear suspension with Super Pro polyurethane bushings. Distributed through TEIN USA, the Australian-made bushings are some of the best we've seen. Key improvements over other products we've seen are the knurled internal abrasion surfaces, which, along with grooved side edges, allow the bushing to hold and retain more bushing lubricant, better castings that have minimal shrinkage, and a user-friendly white silicone bushing lube that turns into a white powder and still lubricates even when dried out.