Early March 2007, FLI decided to sponsor the All Wheels Driven GC8 Open Class Rally car. All Wheels Driven is a high performance Subaru shop located in Bend Oregon, which specializes in prepping rally cars in all levels.

This Rally car is shop owned and has gone through the ultimate reconstruction. The car started out as a 1996 1.8 liter AWD dark green Brighton Coupe and now is a graphite grey 2.2 liter Sti Open Class Rally car. The entire car has been swapped, or built leaving very few parts from the original shell.

The owner/driver of this beast is Barrett Dash and the co-driver is Jonathan Schiller.

FLI’s role in this project is mainly tuning and supporting the engine management system. FLI installed and tuned a Link 44S plug in stand alone ECU. The custom dyno tuned and road tuned maps include using 91 and 103 Octane fuel. The biggest challenge is obtaining the most torque and horsepower through the 34mm sized Open Class turbo restrictor. The goal is to have maximum torque in 2nd-4th gears and a stable horsepower band in 5th gear. This must be done with the engine achieving volumetric efficiency while keeping the turbo in its efficiency range. Normally this would not be a challenge but due to the turbo restrictor, it was hard for the car not to fall on her face above 4500 rpm. After multiply road tuning days on wet, dry, icy, rocky volcanic dirt, she was dialed in. All road tuning was done in Oregon, where weather condition changes daily from hot and dry to snow/wet humid air.

Open Class Regulations

The Open class regulations for Non Stock Turbo 4WD are: No limit on the power plant (block) as long it is offered from Subaru. The block can be built to whatever specification you want. No limit on turbo size as long as you run the 34mm restrictor. You must maintain stock appearance, but can change factory panels to either carbon fiber or aluminum material. The car cannot weigh less then 2600lbs.

In Action

Performance

Mechanicals

• Complete engine/wiring swap w/ Hybrid EJ22T w/ massaged EJ20 DOHC heads
• WRX intake manifold
• Link Standalone ECU Tuned by Miles Hechtman of FLI
• VF39 turbo w/ 34mm Open Class restrictor
• PE 800cc injectors
• Worx Tuning TMIC, Worx Tuning Lightened pulley
• Samco and Perrin Silicone hoses
• Koyo Racing Radiator w/ Flexalite racing fan
• PDE uppipe, PDE rally spec gravel downpipe
• 3″ custom cat back exhaust by Scott Exhaust
• Ver 4 STi Type R transmission w/ DCCD
• Exedy Hyper Single clutch/flywheel
• STi Short Shifter w/ Kartboy hardened bushings
• STi transmission mount, STi motor mounts
• R180 rear diff. w/ LSD, STi rear axles
• Subaru Group N 4 pot front brakes, 2 pot rears w/ Axxis pads
• Slotted Brembo rotors front, vented rotors rear
• Stainless brake lines w/ Superblue synthetic brake fluid
• Custom Bilstein/H&R gravel coilovers built by All Wheels Driven
• Subaru Group N Strut Tophats
• STi Strut brace
• STi trailing arms, STi lateral links

Cosmetics/Underbody

• Ver 5/6 front bumper, modified
• Ver 5/6 grille, modified
• Carbon Fiber Ver 5/6 hood w/ 22b vents
• 22b Rear spoiler
• Roof vent
• Custom Light bar w/ Hella 3000 Rally Lights
• Custom tubular subframe w/ aluminum skid plate
• Aluminum rear diff. guard
• Urethene mud flaps
• Complete HDPE (high density polyethelene plastic) underbody armor
• 15″x6″ or 7″ Team Dynamics Pro Rally 1 Gravel wheels
• Silverstone gravel rally tires

Interior

• Custom roll cage built to Rally America Specs, built by Judd Weld
• FIA roll cage padding
• Cobra Imola 2 GT Kevlar Seats
• Schroth and Gforce 5 point FIA Harnesses
• Momo steering wheel
• Ver 5 STi shift knob
• Ver 5 STi aluminum pedals
• Terratrip 303+ rally computer
• Terratrip map light
• Two extra 12v power outlets
• 2 fire extinguishers
• Spill kit
• First aid kit
• 20′ tow strap
• 3 safety triangles
• Spare gravel wheel/tire
• Random knobs, switches, and gauges

Weight of vehicle without driver and navigator is 2800 lbs.