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C30 Upgrade Path - School Me

13K views 12 replies 5 participants last post by  paradoxicallymodified  
#1 ·
Not that I'm ready to start throwing $$$ at my newly acquired '09 T5 R-Design 6MT just yet, but just starting to brainstorm for the future. Been seeing a lot of impressive results in some of the threads here, so wanted to get your thoughts based on your experiences. Would love to know what specific parts you like or what you haven't. Please school me, because I'm entirely new to the P1 platform. Here's where my head's at so far in thinking about the future, prioritizing from first to last, saving some of the dream stuff for last. Bummer part (not really) is that some of these items have very recently been done but not upgraded by former owner, so it kills me to swap out basically new, perfectly serviceable parts. Haha. Anyway, here goes:

1.) Brakes - Not impressed with whatever's on there. Not sure if factory or just cheapy pads. Maybe go with some of those fly Wilwoods? I'm thinking bigger rotors, beefier calipers, better pads.

2.) Tires - Came with Falkens. My last performance car had Michelin Pilot Sports. Tough going to these. Limits are not much. Could be what's effecting my lackluster braking too.

3.) Engine Torque Mount - Self explanatory.

4.) Front & Rear Sway Bars - Think I'd tackle these next as it's a cheap, easy-ish upgrade. Would this help address the vehicle's understeer?

5.) Suspension - Car's coming up on new struts. They're not shot yet, but I can hear them talking. I really do appreciate the factory's compliant ride, but would like to eliminate some of the squishiness. Hoping I can find a nice middle ground that's both comfortable, but can hug the road better. I want less body roll. I had an Audi A4 quattro where a previous owner lowered it slightly and did some great suspension work. No idea what it had, but the handling was next level and didn't beat you up. I want something like that again.

6.) Intake/Downpipe/Exhaust - All the breathing bits, likely at once. Liking the stuff I'm seeing from Elevate.

7.) Tune - Not only would I like something like a Polestar or Elevate tune to begin with, but thinking I kinda need to do it so all the exhaust stuff doesn't give me a CEL. Is that right? Perhaps this can be moved up the list. Might do that somewhere more up top since it's so attainable.

Now on to the more dream sheet items I may never do, but would be sweet:
Beefed up cylinder sleeves before...
Upgraded turbo before the car reaches its final form, being...
AWD from V50 donor

Final thoughts: The factory M66 is open diff, not LSD, right? If not LSD, is that worth the upgrade? Also, how about factory clutch/flywheel? Worth upgrading or just leave it alone. From what I've heard, the factory setup is pretty stout and I do like it's feel. On a previous car, I upgraded both and clutch pedal was so heavy, it was just a chore, although engaged crazy good and revved a bit freer. Still. Didn't like the one I went with overall. This is a family daily driver, so might just keep that close to factory. Clutch was replaced within last 30K or so and still feels like new. Will prolly wait til this one's burnt up before even thinking about swapping to anything else.
 
Discussion starter · #3 ·
I've had my C30 for 3 years and have done the following mods recently:

-JBR .250 Tru Torsion Rear Sway Bar and Meyle Endlinks
Honestly, the first upgrade you should do. The sway bar (and the .125 variant most people run) is off a MazdaSpeed 3 and is adjustable. It's also discontinued, so you'll have to find one secondhand (which I can say takes time and effort, from personal experience) or go with another brand (Whiteline, Elevate, etc.), which I can't vouch for. Even on the "softest" setting (one of 3), the bar completely changes the numb turn in and understeer FWD cars are well known for. I can keep my foot on the gas throughout the turn, assuming my tires (Pilot Sport A/S 3+ I need for visiting family in the snow, otherwise, I'd run Pilot Sport 4s) can maintain traction. I haven't had any issues with snap oversteer after 1+ month of pretty aggressive driving on windy roads. You don't really need a front bar, but you can always get a front strut brace/bar if everything else has been stiffened up.

-Wilwood 4 Pot kit from Elevate with Elevate stainless lines
I bought a set of Wilwood 4 pot front calipers, Elevate pads (which I think are proprietary, unfortunately), and the accompanying Elevate stainless lines from a Volvo specialty dealer had pulled off a wrecked C30. After installing them a week ago and testing them on twisties, the highway, and my daily commute (mix of city and highway driving), these make braking much more predictable and immediate. They dust a good amount and do squeal, so keep that in mind. You can also do the Brembo Focus RS upgrade (requires drilling out the bracket, if I'm not mistaken) or the 320mm V50/C70/S40 "upgrade." It's a bigger rotor, but still a heavy 1 piston caliper and I have my doubts on how different it is from the smaller, stock 300mm rotor. Elevate also sells a 6 pot Wilwood kit.

-do88 Intercooler and Big Pack Pipe Kit
Did this earlier this week on ramps on a 90+ degree day with no shade and this upgrade really allows your engine to be utilized to it's full extent. If you live anywhere kinda warm, you will notice how quick the stock intercooler becomes heatsoaked and will pull timing from your engine. If you want to go big turbo/tune in the future, you definitely want a do88 intercooler and probably the pipe kit (since all the rubber bits are 10+ years old and 1/2" smaller in diameter than the do88 pipes). The Elevate unit is more expensive and not as well reviewed. There are other options (again, aftermarket Focus RS units), but those are mostly overkill for 99.99% of C30s and require some type of bracket fabricating/cutting of the bumper.

I'm going to do DP and exhaust myself next and then a tune (required with most downpipes, but not catback exhausts).

Don't bother with the intake itself (unless you go with the do88), as the stock airbox is the best at getting cold air into the engine.

You can upgrade the intake pipe that runs across the engine though (would recommend the do88 or Snabb units, as the Elevate pipe has a huge dent in it that looks/feels like an afterthought).

Hope this helps!
SO much good info. Thanks!
RE: Suspension - So essentially start by stiffening up the rear before bothering with the front, huh? Makes sense. I'll start there then. Also, yeah. I need some Pilots for this guy.
RE: Brakes - Great! So another vote for the Wilwoods! I'm sure 4 piston would be substantial on a car this size. One of my old cars had 6 piston fronts, 4 piston rear Brembos and so that's kinda my benchmark for braking, but that was a bigger car. No wonder I don't like the stock C30 brakes. Haha. Even the upgraded brakes I put on my old XC70 are miles better than this one. And that's a heavy old boat too. Stock calipers (which are huge) but better pads & rotors.
RE: Intercooler - Woah! Now THAT'S something I hadn't put any thought into before. This is my first turbo car ever, so I'm learning. Now that the temps have been hitting triple digits here lately, I HAVE noticed a substantial decrease in consistent performance. I had no idea about heatsoak and its effect on engine timing. So perhaps even with sticking with stock turbo but a tune, this upgrade could be well worth it.
 
Discussion starter · #9 ·
There are a few different brake upgrades. I didn’t like the Wilwood set up. Many swear by them.
What didn't you like about the Wilwoods? You went with Brembos, right?

I love the Do88 and rear sway bar upgrades, and it is a must. I have done the lowering and stiffening. This is on the V50 But some thing still apply. Going with the K16 turbo, forged internals, bigger injectors, LSD, turbo back exhaust, aluminum upper intake, bigger cold air intake, and tune , etc. There is much you can do with your sled. GlĂĽck
Alright! Another vote for the Do88 and rear sway bar. I have a feeling with the extreme temps we suffer from like half the year, the intercooler's going to be a bigger priority than I formerly knew.