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will300

Will300's Subaru BRZ Build

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The parcel shelf got some attention, I cut up a Silent Coat tile and applied it over various parts of the shelf:

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I added some of the insulation material to the lid

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Next was to start one of the doors - Door cover removed:

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Silent Coat tiles applied

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Knowing that I was going to sound proof the doors, I thought it best whilst on Amazon to pick up a set of Focal IS165TOY speakers. I installed these at the same time.

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All ready for the door card to go back on

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The guide on FT86forum suggested to add some MLV to the door cards, so I cut some to shape

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However it turned out this was a waste of time as I couldn't get the door card to fit back on, after around 45minutes of felting and re-cutting the MLV, I gave up. It was late in the day and I need the car back together for work the following day.

 

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During the following week I read about EB2429 install, on the owners club (http://www.gt86ownersclub.co.uk/forum/focal-speakers-and-sound-deadening_topic15043.html), he suggested using Silent Coat absorber foam for the door cards.

So I binned the MLV idea of and went on Amazon and bought some absorber foam. This was much easier to cut to shape and it has a sticky back so was alot less fiddly to apply. 

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Applied to door card

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Here are a couple of pictures of the Focal speakers (and a couple with the stock units)

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Side by side comparison - Stock on the left, Focal on the right.

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The focal tweeter come with a plug and play adapter that pushes on the end of the tweeter cable

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The focal tweeters don't click into place like the stock units as they are slightly taller, however the fit is tight so they won't go anywhere.

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Stock tweeter

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Fitting the Focal tweeters and sound deadening the boot was my task for today. I'll see how the car sounds over the next week for road noise, and test out the newly installed Focal speakers. 

The next big job on the list is to deaden the floor and under the rear seats, however that'll have to wait until I have a free weekend. 

Quick notes on the Focal speakers: I ran one of the Focal speaker for two weeks, as I started the drivers door late on sunday and due to the MLV not fitting on the door card I gave up doing anything else. There is a decent jump in quality that quite distinguishable between the stock units and Focals. The quality of the speakers makes them worth the £££ alone. However I'll see how I get on over the next week and report back.

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Wow you really want full on!! Good work! I skipped the MLV on mine as it's quite heavy.

For people interested there are a few types of sound deadening, though each one does a bit of everything the main divisions go like this:

1) mass loaders, such as silent coat and dynamat. These add mass to lower the resonant frequency of the surface they are loading. The panels in our cars ring like buggery so very useful.

2) sound disspersers. This is the egg foam stuff or something like 3M thinsulate. It helps stop standing waves but only over cirtain bands depending on its design. Generally the lower frequency you want it to break up the deeper it has to be. In recording studios you often see up to 1meter deep triangluar foam on the wall.

3) sound barriers. A very dense material that reflects sound. Mass loaded vinyl is popular in cars.

4) closed cell foam that attenuates sound as it passes through but main purpose is to stop vibrations. Used on the back of doors on top of mass loaded vinyl.


For home the environment decoupled surfaces are also very useful. They basically stop vibration travelling via contact by decoupling walls of plasterboard with foam. In cars MLV often comes with a layer of foam in an attempt to decouple it but when it's squished between doors cards its not going to be very well decoupled.



Sent from my SM-G935F using Tapatalk

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Well worth it though. I didn't go this far as I left out the mass loaded vinyl but it still.made a massive difference to road noise. I'd estimate one third quieter on my noisy AD08Rs.

Sent from my SM-G935F using Tapatalk

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Well worth it though. I didn't go this far as I left out the mass loaded vinyl but it still.made a massive difference to road noise. I'd estimate one third quieter on my noisy AD08Rs.

Sent from my SM-G935F using Tapatalk


I'd better add it to "the list" then

Sent from my ONEPLUS A5000 using Tapatalk

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thanks for posting pics and an installation guide! will be adding 'some' deadening when i get the focal speakers :)

i see you refit the stock waterproof skin on the door card? how did you manage to remove and reapply? 

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4 hours ago, br0wny said:

thanks for posting pics and an installation guide! will be adding 'some' deadening when i get the focal speakers :)

i see you refit the stock waterproof skin on the door card? how did you manage to remove and reapply? 

I gently pulled it, and used a sharp knife to cut the adhesive. The first door picture shows how far down I pulled it down, you don't need to remove it.

Once I finished the sound deadening I simply pushed it back into place, rubbing the adhesive with my finger. The current temperature helps as it means the adhesive is really soft and stretchy.

 

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Update: 08/09/18 - End of year track prep 

Twelve months ago myself and a few others did a couple of track days in August, of which two of those days were at Bedford Autodrome. Unfortunately the 2nd time at Bedford got cut short due to my car being black flagged for noise, at the time my exhaust consisted of ACE Manifold & AVO Non-Res Catback (More about this can be read here: http://www.gt86.org.uk/forums/topic/4097-will300s-subaru-brz-build/?page=3&tab=comments#comment-88143

Anyway earlier this year I decided to remove my AVO exhaust and replace it with the standard cat back. The plan was to then get a track friendly custom exhaust made up over the next couple of months. Unfortunately various issue's happened over the next 6 months which meant this never happened. 

Come August I realised my car needed its 5th year service, plus I'd ordered various parts which also needed fitting in preparation for the next lot of track days. I therefore decide to get everything done a the same time and finally get the custom exhaust I wanted made up.

After a couple of phone calls to various place, I decided to go with a very busy specialist who could fit all the parts, service the car and make an exhaust to match my requirements. 

My exhaust requirements consisted off:

2.5" Catback with a Y pipe design 
2 separate back boxes 
A large center resonator
Catted front pipe with a 200cell race cat and a resonator. 
Track friendly - Most important bit

Interestingly the specialist had a similar design already planned for their own car. The car was then booked in and after 3 weeks the car was ready for collection. 

Here's the list of upgrades that have been installed. 

Engine and Exhaust:

Custom 2.5" Front cat pipe with Resonator
Custom 2.5" Resonated Catback exhaust
Hel Oil Cooler
SPA Design - Oil Temp & Oil Pressure Gauge (Block8Head guage holder)
Cosworth Sump baffle
Cusco Sump plug
HEL Performance braided clutch line
STi Engine Mounts

Exterior:

Verus Engineering Race Splitter with end plates

Future modifications - I planned on getting these installed with the above, but due to various reason I changed my mind:

Verus Engineering Bonnet vents
STi Rear Brembo's

As you can see from the upgrades I had fitted alot of these will help benefit the car when on track. This should mean I can run longer stints without the car over heating. Unfortunately most of these modifications are hidden away in the engine bay, so there are no pretty pictures.

However here are some photo's of the exhaust system I had made up. I'll also get some updated photo's of the car in a couple of weeks.

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I'm planning on meeting with @Deacon over the next couple of days to sound test the exhaust and possibly get a couple of videos, so expect another update soon.

 

 

 

 

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Myself & @Deacon meet up today to perform some quick noise tests and get a couple of videos of the new exhaust.

Here is some DB readings from the exhaust - These are measured using a proper decibel meter, however there will be some variation due to wind noise and other vehicles. 

Static 1m Away - Center of Exhaust: 

101.5db Peak / Blip
90.4db stable at 4.5k
63db warm idle

Static 1m Away - Side of the car:

91.3db Peak / Blip
80db stable at 4.5k

Drive by - Near (Curbside):

Normal cars: 70-85db
BRZ: 88db
BRZ: 3rd-2nd downshift: 91.9bb

Drive by - Far (1 lane from curbside): 

Normal cars: 70db
BRZ: 79db
BRZ: 83db at constant high revs 6-6.5k RPM
BRZ - 2nd-3rd up shift: 92.6db

Inside:

Cabin windows down up to 7k RPM: 86.2 db
Cabin windows up to 5.5k RPM: 84.2db
Normal cruising windows down: 73db
Normal cruising windows up: 72db


These seem like decent readings for a catless manifold, 200cell race cat and 2.5" exhaust. The static and drive by decibel readings should be fine for Bedford Autodrome, however the peak on gear change could cause an issue. The readings were taken relativity close to the roadside and the noise meters at Bedford are a couple of meters away from the track, which should hopefully help. 

Here's a couple of on-board videos - the microphone is attached to the rear number plate.

Through the rev range:

 

Normal driving - between 50 & 60mph:

 

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4 minutes ago, br0wny said:

exhaust sounds worryingly loud from inside :o 

any pics from outside with the new splitter? :D 

It's using an external mic placed on the bottom of the rear numberplate between the tail pipes

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3 hours ago, Deacon said:

It's using an external mic placed on the bottom of the rear numberplate between the tail pipes

ohhhh hahah! I did think it sounded very clean but loud

just read mic placement in the post also haha 

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sorry to resurrect the sound deadening Will, but, what about stuffing the white fluffy stuff in the front door cavities like you did on the rear quarters as well as the tiles and absorber foam? just wandering what your thoughts are as i've ordered the focals so just deciding where to go with the deadening as im probably only gonna do the front doors tbh (possibly rear quarters also)

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51 minutes ago, br0wny said:

sorry to resurrect the sound deadening Will, but, what about stuffing the white fluffy stuff in the front door cavities like you did on the rear quarters as well as the tiles and absorber foam? just wandering what your thoughts are as i've ordered the focals so just deciding where to go with the deadening as im probably only gonna do the front doors tbh (possibly rear quarters also)

No point using the white sound deadening in the doors due to the foam on the door cards, plus it might catch on the window mechanism.

I used about 8 or 9 tiles & 1 box (2 sheets) of absorber foam per door. 

I'd do the doors first and see how you get on. 

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Depends really, I wouldn't say one location gave more benefit than another. 

Rear arches definitely helped, but you need to do the whole car to get the full benefit. I still need to do the backseats and the floor, but it's too cold & wet now to spend the whole weekend outside.

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Update 13/11/18 - Bedford Trackday

On the 5th of November I joined several other members of the club at Bedford Autodrome. My plan for the day was to shakedown/test the new exhaust, oil cooler & Verus aero components. And myself as I hadn't done a track day in over a year, due to one reason or another.

First challenge of the day, the dreaded noise test. I knew the new exhaust was quieter than the last setup but I wasn't sure by how much, the static test hit 89db's. However I passed the static test last time, but failed the drive by, by about 2db's. Considering I had also removed the factory 2nd cat and replaced it with a 200 race cat with resonator, I was still alittle unsure about the drive by.

The good news is this time I didn't have any issues with the exhaust passing Bedfords rather strict drive by limit :D, obvious they don't tell you how much noise it actually makes unless you fail.

The Hel oil cooler managed to keep on top of the oil temps, the highest I hit was 115°c this was after several warm laps. (I wasn't pushing during the day) 

Here's some footage from the day, audio is recorded by an external microphone by the exhaust: 

https://www.youtube.com/watch?v=D6_6CSVrhXc 

Here's a couple of photo's courtesy of Robert Baxtor & @VAD17https://www.rbpsphotography.com/

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7 hours ago, sam534 said:

What is the cat back you now have will?

Sent from my STF-L09 using Tapatalk
 

It's a custom made 2.5" ultra resonated :lol: cat back made by Rogue Motorsport. 

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