Custom EVO X

The Lancer Evo X is one sweet ride that's for sure. But if you would like to make a few upgrades, your going to have to spend quick a few bucks to replace some of the already added features. The Lancer Rallyart would be a perfect candidate, but the 2009 does not have a true manual shifting system.


We have to ask ourselves, "What do I want out of my Evo?". If your answer is to be unbeatable on the track then your going to need a few bucks in the bank to make it happen. Our EVO X Project is estimated to be about 86,000.00 us.

If you are in the market for a lancer than hold out for the 2010 Evo X MR w/ Stock Dual Exhaust and a few extra upgrades to the handling (AYC). AYC is featured in the 08 and 09 models and allows your to corner and take turns a bit faster and harder than the EVO VIII & all stock STi's. The Lancer Evo X weighs about 331lbs more than the Evo VIII, but the increase in torqe (about 11 pounds-feet) and increase in horsepower makes up for the extra weight.

So why does it weigh so much more? The Manufacturer added 7 air bags including various side curtains, passenger and knee bags. Also the sturcture had been altered a bit as well to increase the impact saftey rating. Seeing as how this is not a limited release like the New Nissan GT-R, they need to appeal to a much larger crowd. I'm sure those idiots who consistently get into accidents while street racing had a little to do with it.

Our EVO X Project:

Car: 2009 Lancer Evolution X GSR
Total Budget: 86,000.00



So, lets get down to it. The first thing we did was tear down our brand new block and sent it off to JKS for a 2.4L custom bore and stroker kit. Our friends at JKS were kind enough to push the limits for us and custom forge a stroker kit for the 2.4L bore.

Day1&2:

After we got our block back, we tore down the top half and got right to work on rebuilding the head. Since the 4B11 has not been out long enough for decent valve, cam, and main/head stud kits to be released so we had to use Cosworth Kits increasing our lift to approx 11.6mm intake and 11.0mm exhaust. A little lag on the exhaust side but no matter we will soon change the kit out with a better one when it is released. We also upgraded to some HKS EVO X Head Gaskets 1.6mm Thickness to maintain the appropriate compression ratio to accommodate the bore.

Day3:

Next we are going to upgrade the injectors, rails and the fuel management. For the Fuel Pump we ended up using a modified sending unit with an in tank Walbro 255 lph fuel pump, and an external inline Walbro 255 lph fuel pump. For injectors we are using HKS 1000cc Top Feed Injectors. These are a limited item which requires a special order from HKS directly in most cases. For rails we are using the HKS rail upgrade kit along with HKS's adjustable fuel pressure regulator for added performance.

For fuel management, we will touch on that later. For now, we will continue to power/spark.

We know we needed something a little extra for optimum spark duration and maximum output. We decided to stay within the HKS family. No reason other than quality/longevity. HKS is known for parts that last so if your going to spend the money only spend it once.

We installed our HKS Twin Power CLI II along with the HKS Twin Power Harness which is required for use of the amplifier.

For Air, we upgraded te intercooler piping with the HKS Intercooler Piping Kit for the EVO X. We Also add a Blitz Carbon Suction Box for the stock cold intake which allows for a richer airflow to increase throttle response.

Day 4&5:

Turbo Time!!

We used the GT35R Twin Scroll Turbo with the following:

2 Tial 44mm External Wastegates Oil Lines w/Fittings Water Lines w/Fittings
1 Twin Scroll Header
2 Wastegate Dump Tubes
1 3 inch Downpipe - Replaced with Apexi GT EVO X Down Pipe
1 2piece Upper Intercooler Pipe
1 Turbo Suction Pipe

We are going to use an Agency Power Catback True Dual Exhaust w/ Titanium Tips: EVO X System with an Agency Power Cat Delete Pipe: EVO X, an Apexi GT EVO X Down Pipe and we are going to bring in out exhaust/turbo manifold in a few days.

Ah, so you ask why are you using a cat delete pipe instead of a high low cat? Well the answer is simple. Cause we don't live in California! The cops out here rarely check your cars and when they do they use a ground mirror. To address that issue, we custom welded heat shields from another Catalytic to the cat delete pipe for looks. As for emissions, since the fuel/oxy mix is so rich, we will have to remount the stock cat temporarily for the test. That's why we are using the Agency Power System for the true bolt-on feature. To help with this as well as performance we also installed the Apex'i SAFC NEO Air/Fuel Controller replacing our HKS Fuel Regulator; Muahahahahahaha!!!

We won't actually gain much more from using a cat delete but we enjoy getting away with it.

We needed a way to regulate the boost. So we installed the GreddyPRofec e-01 Turbo Management System. This allows us to adjust start gain, boost, wastegate response and a few other things as well. This sweet little toy came with a remote!

Day6:

Ok, well we realized that the stock intercooler system was a bottle-neck for our current set up so we ordered a Black Perrin Front Mount I/C along with new I/C Pipes. While we waited for them to arrive, we pulled out our ECU and shipped it off for tune flashing and upgraded our Fuel Pump. We ended up using a Modified sending unit with in tank Walbro 255 lph fuel pump, and an external inline Walbro 255 lph fuel pump.

Day7:

Conveiniently, we rested! LOL!!! It just so happens that we are still waiting the ECU so we can't test out our new I/C set up and Fuel system upgrades. :(

So we wait.........and wait...... and......

Day10:

Sweet!!! it's here!!!!

After we put our ECU in we were so excited we took it out on the street immediately!!!! We took it out east of Aurora heading towards Watkins near the Aurora Res. and of course with our luck there just happened to be an Arapahoe Sheriff pulled off the road eating lunch!! The only thing going through our minds was, "Shit!!!!"

We were only going 120 so when the sheriff pulled onto the road to tail and clock us we had slowed down to 95 and received a $250 ticket. Not bad... considering.

So for the rest of the day we basically tweaked our boost, fuel and air to match our ECU's new program.

Day11:

After a few test drives we realized that the stock clutch system was not at all sufficient for our current HP and Torque Levels. So we upgraded our clutch to the ACT XTSS setup. We chose this setup because we would still like have every day drive ability. If you are wondering what the ACT stages are, here is a parts diagram of usages:


Click to enlarge











Well our NO2 -less Evo is now ready for the track!!

Any Mod recommendations? Or do you feel we missed something? Comment on our blog to let us know.

We will be uploading pictures soon so keep checking back!