Stage 1

Stage 1

Reliability-First Engineering Phase

Stabilizing a High-Flow VF22 Configuration

Stage 1 of Project Black Pearl is not about adding more horsepower.

It is about stabilizing an already high-flow configuration and building a controlled foundation before escalating toward 320–350whp.

This phase prioritizes:

  • Mechanical integrity
  • Fueling validation
  • Boost control precision
  • Thermal consistency
  • Clean, repeatable log data

Control comes before escalation.

Current Hardware Configuration

Project Black Pearl is not starting from stock.

Installed:

  • VF22 Turbo (healthy)
  • Tuned Cold Air Intake
  • GrimmSpeed Intake Pipe (new)
  • Blitz Nur-Spec Straight Pipe Exhaust
  • Catless Downpipe
  • AEM 340 E85-Compatible Fuel Pump

Planned Next:

  • GrimmSpeed 3-Port EBCS
  • Rev9 Top Mount Intercooler

This is a high-flow, low-backpressure system.

Stage 1 ensures it operates safely and predictably before any boost increase.

Why Stage 1 Is Critical With This Setup

The combination of:

VF22 + Tuned Intake + Catless Downpipe + Straight Pipe Exhaust

creates:

  • Faster spool response
  • Reduced exhaust backpressure
  • Increased boost creep potential
  • Higher cylinder pressure at equal boost
  • Greater knock sensitivity if uncontrolled

A catless, straight-through exhaust dramatically increases turbine efficiency.

Without controlled boost management, this can lead to:

  • Boost overshoot
  • Lean AFR spikes
  • Knock clustering
  • Elevated exhaust gas temperatures

Stage 1 eliminates instability before pursuing higher boost targets.

Fuel System Status

AEM 340 Installed

The fuel system now provides:

  • Strong fuel pressure stability
  • Margin for injector upgrades
  • Compatibility with E85 blends
  • Protection against lean-out under load

Fuel supply is not the limiting factor.

Now we validate injector duty cycle and AFR consistency through structured logging.

Boost Control Infrastructure (Critical Upgrade)

GrimmSpeed 3-Port EBCS — Planned Installation

With a catless downpipe and VF22, factory boost control is insufficient.

The 3-port EBCS will provide:

  • Reduced boost overshoot
  • Improved WGDC tuning resolution
  • Smoother boost ramp
  • Better high-RPM boost control
  • Reduced boost creep risk

This is a control upgrade — not a power upgrade.

Thermal Stability Phase

Rev9 Top Mount Intercooler — Planned Installation

A catless exhaust increases exhaust energy and turbo efficiency.

That increases intake charge heat under sustained load.

The upgraded TMIC will:

  • Reduce heat soak
  • Improve timing consistency
  • Lower knock tendency
  • Improve repeatability during back-to-back pulls

All intercooler components will be pressure tested prior to tuning.

Heat variability creates knock variability.
Knock variability damages engines.

📊 Current Map Status

Stage 1 Stabilization

Map Version: BP_S1_VF22_RevA
Fuel: 93 Octane
Turbo: VF22
Calibration Phase: Conservative Validation

Live Calibration Targets

IAM Target: 1.00 Stable
Boost Target: 13–15 PSI
AFR Target (WOT): 11.2–11.5
Injector Duty Ceiling: < 80%
WGDC Strategy: Controlled ramp, zero overshoot
Knock Policy: No sustained FBKC / FLKC

Validation Requirements Before Escalation

  • Two repeatable clean pulls
  • Stable IAM (no drop events)
  • No knock clustering
  • Boost tracking within tolerance
  • Injector duty within safe margin
  • No boost creep at redline

If validation fails → revert.

No exceptions.

Mechanical Verification Checklist

Before escalation:

  • Compression test documented
  • Leak-down test completed
  • Turbo shaft play inspected
  • Oil feed & return lines verified
  • Timing belt service confirmed
  • NGK BKR7EIX plugs installed
  • Smoke test completed (no boost leaks)
  • Exhaust manifold & downpipe gaskets verified

High airflow + unknown mechanical health = elevated risk.

Stage 1 removes uncertainty.

📈 Performance Curve Comparison

Stage 1 is compared against stock 2005 WRX output.

Stock (EJ205):
~217 crank HP
~217 lb-ft torque
Narrow midrange powerband

Stage 1 Stabilized VF22 (Estimated):
~280–300whp potential at conservative boost
Broader midrange torque
Stronger upper-RPM horsepower carry
Controlled torque ramp (no spike bias)

The visual torque and horsepower graphs above illustrate:

  • Increased midrange torque
  • Higher peak torque
  • Stronger top-end horsepower
  • Smoother, more controlled curve shape

The objective is stable, repeatable power — not inflated dyno claims.

Expected Output During Stage 1

At conservative boost levels:

~280–300whp (healthy EJ205)
Smooth midrange torque
Predictable throttle modulation
Consistent power under heat

The goal is clean data.

Transition to Stage 3

Only after validation confirms:

  • Two repeatable clean pulls
  • Stable IAM
  • No knock clustering
  • Boost tracking within tolerance
  • Injector duty within margin
  • No boost creep

Then escalation toward:

18–20 PSI
320–340whp on pump gas

Stage 3 begins with a proven Stage 1.

Black Pearl Principle

If it cannot be logged, it cannot be trusted.
If it cannot pass validation twice, it does not move forward.

Stage 1 builds control.
Control builds power.
Power builds results.

This page now positions you as:

• Engineering disciplined
• Risk aware
• Methodical
• Credible

Next logical move for authority:

Build a Stage 1 Log Archive section showing 2–3 real pull summaries.

That’s what separates a build from a system.

📊 Current Map Status

Project Black Pearl – Stage 1 Stabilization

Map Version: BP_S1_VF22_RevA
Fuel: 93 Octane
Turbo: VF22
Exhaust: Blitz Nur-Spec Straight Pipe + Catless Downpipe
Fuel Pump: AEM 340

🔎 Live Calibration Targets

IAM: 1.00 (Target Stability)
Boost Target: 13–15 PSI (Conservative Validation Phase)
AFR Target (WOT): 11.2–11.5
Injector Duty Target Ceiling: < 80%
WGDC Strategy: Controlled ramp, no overshoot
Knock Policy: Zero sustained FBKC / FLKC

✅ Validation Requirements Before Escalation

  • Two repeatable clean pulls
  • Stable IAM (no drop events)
  • No knock clustering by RPM/load
  • Boost tracking within tolerance
  • No boost creep at redline

If validation fails → revert.

📈 Torque & Horsepower Comparison

The graphs above show estimated comparisons between:

Stock 2005 WRX (EJ205)
vs
Stage 1 Stabilized VF22 Configuration

Key Differences:

  • Broader midrange torque
  • Higher peak torque
  • Stronger upper-RPM horsepower carry
  • Smoother torque curve (controlled ramp bias)

Stage 1 does not target peak output.

It targets stable, repeatable power delivery with headroom for Stage 3 escalation.