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Old 07-29-2012, 11:50 PM   #1
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AVO turbo kit for BRZ - initial build thread

AVO Stage 1 Turbocharger Kit for the 2013 Subaru BRZ and Scion FR-S 2.0!





AVO's front-mounted Stage 1 turbocharger kit for the Subaru BRZ and Scion FR-S is now available! The kit is designed to work with both RHD and LHD models in all countries, and extensive testing has been done on both the Japanese Subaru BRZ and the US Market Scion FR-S and BRZ, both in automatic and manual. The Japanese BRZ has been extensively track tested from day 1 (back in early 2012), and our US Market FR-S spent it's initial 4 days and 1400 miles testing and tuning in varying conditions, in the mountains at 6000 feet and 0 degree temperatures, to sea level and below in the desert in 100 degree heat! This was done to ensure our kit will hold up as a daily driver where ever you go, whatever the conditions. All testing in the American market has been conducted on 91 and 92 octane pump gas to ensure this is going to handle daily driving as well as the track. Our FR-S in America has had over 20,000+ miles on the turbo kit!

The turbocharger kit is designed from top to bottom specifically to the FR-S and BRZ, and consists of the all the parts necessary to bolt the kit up to the car. We utilize an AVO18/49 turbocharger that mounts up under the front of the engine via our ceramic-coated, stainless steel unequal length exhaust manifold, and then it bolts up to the stock exhaust with our ceramic-coated stainless steel turbo discharge pipe. Cooling the pressurized air is an aluminum bar and plate front mount intercooler which uses black piping throughout, mechanical oil scavenging pump, oil reservoir tank, and all necessary water and oil hoses and fittings. Tuning is by AVO Turboworld via EcuTek reflash tools, and we will provide an Ecutek-based AVO Stage 1 base map free of charge with the Stage 1 kit.

Why underneath? Subaru themselves decided on this layout for their new Forester, WRX, and Legacy turbo models, utilizing it on the FA20DIT (direct injection turbo) motors. It is simply the best setup for response and power. The closer the turbocharger is to the exhaust ports, the better the spool response. Not only that, but mounting the turbo in that location helps keep that low center of gravity that's such an important part of the BRZ and FR-S experience. And finally, it helps immensely with the cooling. The way the car was designed from the factory, the air flows through the front and then underneath the engine. With the turbo situated there, it has a good flow of air over it that is immediately vented to the rear, keeping our setup cool. Since our turbo kit literally just replaces the exhaust manifold, that area that it is fitted to was already treated to for heat, so there are no issues with overheating the parts around it. Overall, we aimed at giving FR-S and BRZ owners what they really wanted - a car that felt like it was boosted from the factory. And in that we succeeded.

This turbokit has been designed to bolt up to the stock air intake box and to the stock exhaust system, but we do recommend upgrading the exhaust for the best performance. We have spent a lot of time ensuring it will work with the standard fueling system for a complete bolt on and go setup. The beauty of the system is that it looks very stock from above! The FMIC has been specifically designed to fit with the standard bumper without trimming as well, and on FR-S models would be be difficult to see unless you are looking for it.


So what can you expect from this kit?
From our testing, you will see anywhere from 220 to 250whp at the base 6psi on 91~92 octane pump gas. Even though the stock motor is 12.5:1 compression, incredibly high for a n/a motor. This makes gas quality even more important than ever! If it wasn't for the fact that this FA20 motor is a completely different and modern design with an incredibly well made combustion chamber, we wouldn't even attempt to turbocharge these cars. But while many people associate it with the old EJ20 series motors from Subaru, there is absolutely no comparison besides the fact they are both boxer 4's made by Subaru. The entire design of the engine is different, especially the combustion chamber, which has been improved tremendously from anything previously made by Subaru.

Not only is the engine a major step up, the ECU on this car is also a great design, reacting incredibly fast to knock and adjusting parameters to compensate. This helps increase the reliability of the turbocharged motor. As is well known by now, this is also a direct injection motor, helping both power and gas mileage. We've seen mpg figures as good as stock on the freeway, probably better than stock as we were not exactly sitting on cruise control during our testing!

As you can see from the dyno chart, we saw 230whp (276 crank hp) and 197 ft/lbs of torque at 5-6 psi on 92 octane gas literally from a nearby Chevron gas station. This was with the stock airbox with an AVO high-flow panel filter installed, and a stock secondary cat in place. All these figures were reached on the stock fueling system as well!




The stage 1, base map dyno chart has been updated to reflect the latest version of the turbokit with the upgraded actuator and exhaust manifold design. This is on a totally stock car with just the turbo kit and Stage 1 base map.




Additional charts from other members and tuners:


Drift Office FR-S at 10.7psi

http://www.ft86club.com/forums/showthread.php?t=41463


Automatic BRZ fitted with stage 1 kit

http://www.ft86club.com/forums/showthread.php?t=27957


8psi with a 3" Tomei exhaust



12psi on Race Gas



Turbo Specifications:
AVO18/49 Turbocharger with 5-7psi actuator - Exhaust wheel size 49.1/56 | Compressor wheel size 50.2/67.9
This specially designed AVO18/49 turbocharger comes with a 5-7 psi actuator for precise boost control at lower psi levels, ensuring engine longevity. The turbocharger is rated for 380hp of flow, so there is certainly headroom available with it from the base stage 1 kit, which is doing 276hp on 92 octane.


Mechanical Oil Pump Specifications:
We are unique in utilizing a mechanical oil pump that we locate at the back of the engine, which runs off the back of the RH camshaft. There is also a oil reservoir tank right off the turbocharger itself. This is the most reliable way to pull oil through the turbo to the engine, as it keeps the flow rate tied to the rpm speed of the motor, ensuring that it's properly scavenged at low rpms and idling, and has enough at high rpms.






Front Mount Intercooler Specifications:
Bar & Plate Aluminum Intercooler with cast endtanks. Length = 19" Height = 8" Width = 3"
The intercooler kit utilizes black wire-reinforced silicone piping and two black powdercoated steel piping. The intake piping has ports to mount up a variety of blow-off valves, even OEM ones for a full stealth look.


Pricing:
MSRP on the kit will be $4400.00, and will include the EcuTek base tune. An EcuTek License and OBD-II cable are optional. High Temperature ceramic coating of the exhaust manifold, Turbocharger, and Turbo Discharge Pipe is now standard, and included in that base price.


Optional Parts:
AVO 2.5" stainless steel turbo-back exhaust
coming soon: AVO 3" turbo back setup
AVO high-flow panel filter for the BRZ and FR-S (MSRP $55.00)
AVO Blow-off Valve Kit (MSRP $220.00)
AVO 8psi, 10psi, and 12psi actuator upgrades
3-bar MAP sensor
EcuTek License
EcuTek OBD-II Cable



Edit: I'll start updating this initial post for people new to the thread/forum.

It's no secret we were going to be making a turbo kit, it's a natural fit since we've been making turbo kits for naturally aspirated Subaru's since 2001, and n/a turbo kits for other vehicles for over 3 decades.

This is just an initial information release, to keep the information up to date, and to give a basic run-down of what it will look like.

Turbocharger placement

Name:  avoturbo.jpg
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Size:  100.9 KB

Updated pictures of the final kit:








Frequently Asked Questions:
Borrowed from @Sportsguy83 and expanded upon slightly:

Kit price?

$4400 USD for the Stage 1 turbo kit

How many psi will the kit run?

The turbo is designed with an internal wastegate fitted with a 6 psi adjustable actuator. It has been run up to 16psi on e85.

Will it fit AT cars?

Yes, it fits AT cars and has been installed on several.

How has this kit been tested?

The kit is actively tested in the track on the AVO Japan BRZ for the last 14 months, and has participated in several official time attack and lap events. Also, the kit has being tested in the USA in a variety of scenarios, from sea level elevation to 6000 feet elevation and temperatures from the hottest conditions to the coldest. A 2400 mile roundtrip to SEMA from Seattle, WA helped cover a lot of this varying conditions and was used to fine tune the ECUTek tune. It has been running in that car for the last 20,000+ miles dating from November 2012.

Will my local tuner be able to tune your awesome base map?

AVO approved tuners will have have access to unlocked base maps. They will be able to tweak it to your specific car.

With the Turbo location, can I keep the bottom skid plate or will I need to remove it?

The turbo sits about 2 inches above the undertray/skidplate. It reinstalls in the car. The turbo does not get in the way.

What is included i this kit?

FMIC and all necessary piping.
Unequal Length Exhaust Manifold
Oil and water-cooled Turbocharger
Turbocharger to Secondary cat engine pipe
Mechanical Oil Pump
Oil reservoir tank
Stainless Steel Oil Line and oil fittings
All assorted hoses, clamps, and other fittings necessary

And finally, a base map for running the car with the turbokit. This will be an Ecutek base map, and does require that you have a Ecutek license and cable for your car. If you have those already, we will send you a base map ROM. If you don't, you can purchase the license and cable with the kit, or from any Ecutek vendor.

What type of Turbo is used?

TD05 18g variant; AVO 18/49 turbocharger. Compressor wheel size 49.2/56 | Exhaust wheel size 50.5/68

Dyno numbers?

On 91 octane, Dyno numbers are: 230 WHP and 197 WTQ. Max Boost is achieved before 4K RPM.

Tune for other octane ratings (e.g. 93 octane) will come later on.

Will it hurt my car to use 93 octane while having a 91 octane map?

No, it will not hurt your car. If anything you will make a bit more HP than what the 91 Dyno plot says.

The Kit Moulded, reinforced black rubber piping look weak and cheap, I prefer Stainless Steel piping can I order it?


Moulded, reinforced black rubber piping was not chosen because it was cheap. It was chosen because it is best for this application. The hoses are wire-reinforced, and are so sturdy you can stand on top of them and they will not bend. They are good to 50 psi, no need to worry about them. There is no option for SS piping.

Why is the kit so cheap? Where are you cutting corners?

People may assume we are skimping on the parts. That's not the case at all, we can do the kits at that pricing because of the commitment we make towards them. We will be putting parts for the kits into our factory production line, and making a fairly significant investment towards tooling. We may not even break even on the kits in the first year. The idea we will be making the money back eventually. The kit will be RHD and LHD compatible as well, as we have operations in Japan, Australia, Thailand, and America.

We've been making turbocharger kits for cars for 30+ years, and are in this for the long haul. Our lineup of kits stretch from Toyota Landcruisers to the Mazda Miata, with a lot of other models in between.

Where is the kit being built?

The main factory operation is in Thailand. We moved our head staff and equipment there a while ago due to some large scale projects in that location. It keeps our pricing from going completely off the board - USD has lost about 35% or more of it's value vs. the Yen over the last few years.

What is the HP rating for the Intercooler?

The IC is rated up to 360 WHP

Will this kit include a BOV? Can I use any BOV on this kit?

BOV will be an optional part, with an AVO 100% recirculate (or 50/50) available, as well as other aftermarket or even OEM. The flange for the BOV will be the same as the EVO 7/8/9, for customers that want a full "OEM" look to it.

Does the kit include a BOV or exhaust components coating?

Both items are offered as an option and at additional cost.

Does this kit remove both Cats?

This kit removes the Cat from the OEM exhaust Manifold. Your choice of exhaust will dictate if you keep the secondary Cat, located in the frontpipe.

Do other exhaust systems bolt on to this Turbo Kit?

Any header back exhaust that bolts on to the stock location of the OEM header will bolt on to this kit.

Where is the Dyno plot, where can I see videos, I want MOAAAARRRR!

Dyno plot is in the first page, Look up Avoturboworld on Facebook to see the cool videos showing off the kit.

This post has the Youtube videos all in one spot:
http://www.ft86club.com/forums/showp...postcount=2015


Steve Sutcliffe tests Fensport's Toyota GT86 Turbo, then drives the firm's bare-knuckle turbocharged race car. And pits it against a McLaren 12C to see how fast a GT86 can really go.

http://www.autocar.co.uk/car-video/v...claren-mp4-12c

Fensport is the authorized AVO distributor in the UK. They sell, install, and tune the AVO turbocharger kit for the FR-S and BRZ, and has been having great success with it on their Toyota Sprint Series GT86R. You can visit their website here: http://fensport.co.uk/

Youtube vidya:
[ame="http://www.youtube.com/watch?v=Ut55yR2Yu8M"]New Toyota GT86 TURBO vs McLaren MP4-12C - YouTube[/ame]



Stage 3 testing on the AVO Turboworld Japan BRZ

We've been hard at work here at AVO on a variety of projects, with possibly the biggest one right now being the Stage 3 upgrades for the AVO BRZ/FR-S turbocharger kit. Our Stage 1 turbocharger kit has been incredibly popular worldwide, and has made a lot of people very happy by bumping the power up dramatically, from 165whp to 260+whp. Yet some people want more, much more, and we've listened to their requests.

It would have been easy enough to just up the boost and get a few glory runs on a dyno, but we are far more committed to our customers long-term enjoyment than that. We wanted Stage 3 to be as reliable as possible, with all the high-quality engineering and attention to detail that has been a trademark of AVO for the last 40+ years.

To this end, we spent a considerable amount of time and testing on our fuel pump upgrade, as the car was already starting to reach the limits of the pump at 300whp, and we were planning to go much further than that. After much time and effort, we have now got a full bolt in, no fitment compromise fuel pump that does not require any re-wiring or dremelling. It clips right in to the assembly, and doesn't require you to have the fuel filter mashed up against the bottom of the pump housing. The standard wiring harness will clip right into it as well, and it doesn't require additional O-rings to seal up.



Matched up with that is our upgraded Port Injectors. These were also designed to fit to the BRZ/FR-S, with the longer "neck" on it so that they reach down into the intake system and spray properly, unlike some other "short" designs that merely let the gas puddle down. Put these together with the fuel pump, and we now had the fueling to push the engine further.

But why so much extra fuel? Because we upgraded the turbocharger as well! The Stage 3 turbocharger utilizes a new billet compressor wheel with a more efficient design. While the overall size of the turbocharger hasn't changed, the flow has improved dramatically enabling us to push it harder at higher boost levels. This allows up to bump up the peak horsepower available while keeping the impeccable low-end torque that makes this turbo kit such a pleasure to drive.



The final piece of the power puzzle is the complete 3" exhaust system that will come with this kit. We don't mean just from the cat-back, no, this exhaust is 3" from the turbo charger exhaust housing back. The turbo discharge pipe and crossover pipe have been re-designed to provide maximum flow from the turbo all the way back.



As part of the testing we recently put the Stage 3 kit through it's paces at the RevSpeed Super Battle Time Attack at Tsukuba Circuit. It went very well, with the car going roughly 1.5 seconds faster around the circuit on the exact same tires as earlier in the year. Power through the corners was very well controlled, and it was a rocketship exiting the corners and on the straights.



Immediately after the event we put the car on the dyno to see how it was doing at the race settings. Power was quite impressive, with 373whp on tap at 6400rpm, and a peak of 318ft/lbs of torque at 4800rpm. Even more exciting is how it was doing 290ft/lbs of torque from 3300rpm. This is a quick-responding turbo!

We are still undergoing testing, but expect to see this available soon from AVO!

Last edited by AVOturboworld; 01-20-2014 at 01:26 PM.
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Old 07-29-2012, 11:53 PM   #2
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sounds super exciting!
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Old 07-29-2012, 11:55 PM   #3
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Awesome! Thanks for keeping us updated, cant wait!
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Old 07-29-2012, 11:57 PM   #4
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OMG! and the turbo race is on. (i feel sorry for anyone who bought an extended warranty)
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Old 07-30-2012, 12:01 AM   #5
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AVO kits are quality. Weren't you one of the first (if not the first) to have new-style WRX placement turbos available?
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Old 07-30-2012, 12:10 AM   #6
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Yes, we were the first on the new WRX's (and actually, the Legacy), and the first and only to make regular production turbo kits for the 1999-2004 Impreza RS, 2005-2012 Impreza 2.5i, and the 2005-2009 Legacy and Outback 2.5i. We keep busy!
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Old 07-30-2012, 12:20 AM   #7
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I understand it's extremely early at this point, but do you have any goals you are aiming for with this build? WHP, price, etc.
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Old 07-30-2012, 12:25 AM   #8
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according to the installation placement, i just guess it will have a higher boost response than the Accelerated Performance. Waiting for the dyno
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Old 07-30-2012, 12:25 AM   #9
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droooool... Can not wait to hear that UEL boxer rumble emit from a BRZ/FR-S!
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Old 07-30-2012, 12:35 AM   #10
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Quote:
Originally Posted by Gen View Post
I understand it's extremely early at this point, but do you have any goals you are aiming for with this build? WHP, price, etc.
We do, actually. We have been planning this kit out for a while now, and using our experience from other cars as a base. However, we'll announce pricing when we are closer to delivering, whp when we've clocked some significant mileage on the kit, and other details as we go.
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Old 07-30-2012, 12:36 AM   #11
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Quote:
Originally Posted by AVOturboworld View Post
We do, actually. We have been planning this kit out for a while now, and using our experience from other cars as a base. However, we'll announce pricing when we are closer to delivering, whp when we've clocked some significant mileage on the kit, and other details as we go.
To newbies: AVO kits cost $$$. It's all about the quality of the parts.

IIRC, weren't you also the first to offer ball-bearing stock placement Legacy style turbos?
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Old 07-30-2012, 12:46 AM   #12
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Quote:
Originally Posted by OrbitalEllipses View Post
To newbies: AVO kits cost $$$. It's all about the quality of the parts.

IIRC, weren't you also the first to offer ball-bearing stock placement Legacy style turbos?
If true, lots of $$$ then that leaves me out. Correct me if I"m wrong, but if a turbo is much over $5k, doesn't that put you in the Nissan 370Z category that comes with 332hp stock?
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Old 07-30-2012, 12:48 AM   #13
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Actually, our base turbo kits for the 2008+ Impreza 2.5i are $3200. Just something to keep in mind...
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Old 07-30-2012, 12:51 AM   #14
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Quote:
Originally Posted by AVOturboworld View Post
Actually, our base turbo kits for the 2008+ Impreza 2.5i are $3200. Just something to keep in mind...
I fear I was misunderstood. The kits do not cost an exorbitant amount, in my opinion. I always found them a TAD bit more expensive, but I knew whenever I bought AVO...I bought quality. You can always buy China garbage: "Hey my turbo kit cost $2000!"

Speaking of, any plans for urethane bushings?
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