Jump to content


Photo

Andrew's Green Toaster rebuild - clean and rolling

sf5 gga ej207

  • Please log in to reply
74 replies to this topic

#1 andrew_k

andrew_k

    Regular Member

  • Members
  • PipPipPip
  • 438 posts
  • Location:Kyneton, VIC

Posted 19 October 2015 - 08:32 PM

5 years ago I did various upgrades to my 99 GT forester. All the regular stuff, TD04, TBE, TMIC, brakes, etc etc.
5 years and 2 kids later, It's sitting in the yard with an entirely forked gearbox, 20,000km overdue for its 300,000km timing belt change. 
 
lawn-ornament.jpg
 
See how I mowed around it? Awww yeah.
 
It gets way better under the bonnet. It's been sitting since xmas day 2014 when the gearbox went kapoop. Looks like rats moved into the engine over winter.
 
rats-nest-engine.jpg
 
I cleared the rats nest that was on top of the spark plug leads. Because I care.
 
AAAAAaaanyway
 
My brilliant wife suggested that as useful as our 99 diesel hilux is (much winch. many lift. wow lights), it's pretty bloody miserable to drive and "why can't you just fix the forester?".
 
With the age of the engine and the catastrophic death of the gearbox, I suggested it would only be worthwhile if we got a half cut. (MWUUUhahahahaaaa). I jumped on eBay and found this within 10 minutes of our initial conversation:
 
ebay.jpg
wrx-engine.png
 
A repairable write-off, with a severely under-utilised EJ207 long block and VF30. Everything else in the driveline is stock WRX. Injectors, TMIC, exhaust, the lot. Hence the 160kw atw figure. 
 
A week later it was mine.
 
Now we're here:
 
04_driveline.jpg
interior-stripped.jpg
 
 
Existing SF5 upgrades that I'll keep
  • 3" TBE, 2.5" diff back
  • Walbro 255L fuel pump
  • IC waterspray w/ in-guard reservoir 
  • 6.5mm phenolic manifold spacers
  • STi Group N engine mounts & gearbox mount
  • MY02 WRX STi struts and springs w/ 1/2" rear strut spacers
  • Whiteline 22mm adjustable rear sway bar
  • WRX heavy duty RSB mounts 
  • Whiteline HD RSB endlinks
  • Whiteline rear strut bar
  • Whiteline FSB bushes
  • Gizzmo MS-IBC boost controller + 3 port solenoid... maybe.
  • 52mm boost, oil pressure, water temperature gauges
  • partial wiring harness
 
 
Donor WRX parts I plan to use
  • v7 EJ207
  • Work Emotion 17" rims (need heavy restoration)
  • Front and rear cross members
  • Front and rear axles, rear diff (4.44)
  • Pedal box w/ STi pedals
  • Brakes: 4pot fronts, 2pot rears, discs etc.
  • Most steering components
  • Cruise control
  • Dash, centre console, momo steering wheel (+3hp)
  • carpet
  • front bucket seats
  • ECU + majority of the wiring harness
 
 
Part I've bought (or am about to) for the build
  • Blouch TD05-18GT (8cm)
  • JDM v6 STi 5speed (will keep the WRX box as a spare - might be ok, might be damaged from the rear shunt)
  • STi TMIC
  • GC8 STi alloy control arms
  • SS catless uppipe
  • 850cc injectors (undecided between DW and ID)
  • cold air intake + silicone turbo inlet
  • wideband AFR + EGT probe to DIY TFT display
  • Whiteline HD front sway bar endlinks
  • Cusco front strut bar (thanks Matt :))
  • Some aftermarket pitch stopper (kartboy maybe?)
  • TGV delete
  • lots of poly bushes

 



#2 andrew_k

andrew_k

    Regular Member

  • Members
  • PipPipPip
  • 438 posts
  • Location:Kyneton, VIC

Posted 19 October 2015 - 08:38 PM

When I pulled the drive shaft out it was pretty obvious the surprise attack from the rear that had written off the wrx had made the unis sad. Clunky McClunk.

Today the replacement arrived, a 1 piece alloy drive shaft.

 

drive-shaft.jpg

 

Way lighter than the GD wrx unit, but more importantly it has happy uni's. 



#3 Barbbachello

Barbbachello

    Touring Bruce

  • SubyClub Area Rep
  • PipPipPip
  • 6493 posts
  • Gender:Male
  • Location:Mehico
  • Interests:Docking

Posted 19 October 2015 - 08:39 PM

0e6c12e42465076d0afce605098fc4aa.jpg


tIeW8DE.png


#4 duncanm

duncanm

    wha' who ?

  • Members
  • PipPipPip
  • 2020 posts
  • Gender:Male
  • Location:Sydney

Posted 19 October 2015 - 10:10 PM

this is awesome - when will the wifey work out what she's unleashed ?



#5 andrew_k

andrew_k

    Regular Member

  • Members
  • PipPipPip
  • 438 posts
  • Location:Kyneton, VIC

Posted 20 October 2015 - 06:46 AM

haha, she totally doesn't notice this stuff, somehow :blink:. She didn't notice the volume or power difference when I fitted a td04, 3"tbe and wrx TMIC in one go years back. Nor the ride difference when I replaced the sloppy failed self levelling struts with 02 sti, didn't notice the nvh when I fitted group n engine and gbox mounts, etc etc.

 

She putts around at 4k rpm or less, which is why I reckon the TD05-18GT + 8,250rpm redline will be a perfect combo for both of us. She'll never even hit 20psi full boost, whereas I'll have the "top half" of the rev range available when appropriate   :ph34r: 



#6 Reevesy

Reevesy

    Adriano

  • Members
  • PipPipPip
  • 1597 posts
  • Gender:Male

Posted 20 October 2015 - 07:46 AM

Bet she notices the money you spend though [emoji14]

#7 duncanm

duncanm

    wha' who ?

  • Members
  • PipPipPip
  • 2020 posts
  • Gender:Male
  • Location:Sydney

Posted 20 October 2015 - 10:10 AM

be assured -- she's noticing.  Just keeping her powder dry!



#8 andrew_k

andrew_k

    Regular Member

  • Members
  • PipPipPip
  • 438 posts
  • Location:Kyneton, VIC

Posted 20 October 2015 - 10:53 AM

:walts:



#9 andrew_k

andrew_k

    Regular Member

  • Members
  • PipPipPip
  • 438 posts
  • Location:Kyneton, VIC

Posted 20 October 2015 - 05:12 PM

Last night's progress:

 

05_interior-stripped.jpg

 

This arvo, I got the two main wiring harnesses out. y00000!  :yahoo:

 

06_main-harness.jpg

 

Wiped them down with mild soapy water, and cleaned every socket

 

06a_contact-cleaner.jpg

 

before storing away in a dust-free spot until they're needed

06b_store-harness.jpg

 

Since I've got the whole donor car, and I'm using the entire donor dash, steering, immobiliser etc, I can hopefully get away with not modifying anything in that great big box of wires.

I'd rather make up a little supplementary harness to wire in the forester's heated seats and wing mirror heaters than open up the factory wiring.

 

One other thing on wiring... Now that I've had a chance to get a good look at the multitude of earth points within the circuit, I'm more convinced than ever that there is no possible benefit from any star grounding modification kits. I already thought they were snake oil, as I've designed and built various high voltage, sensitive signal circuits where star grounding is actually needed, and the circuitry of a car shares very little, if any, of the design concerns that lead to that topology.

 

The wrx is grounded allllllll over the place -- clearly a "nearest bit of chassis" grounding scheme. Regrounding a dozen of them via an attempt at star grounding ain't gonna do sh*t  :negative:  :sarcastic:



#10 andrew_k

andrew_k

    Regular Member

  • Members
  • PipPipPip
  • 438 posts
  • Location:Kyneton, VIC

Posted 22 October 2015 - 02:27 PM

EXCITEFACE DELIVERY DAAAYYyyyyyy

 

turbo.jpg

 

animated-amazed-meme-smiley-emoticon.gif

 

TD05H-18G-XT with 8cm turbine housing. I originally planned on using the VF30 that came with the donor car, but this came up for sale and selling the VF30 covered half the cost, so here we are  :wub:



#11 andrew_k

andrew_k

    Regular Member

  • Members
  • PipPipPip
  • 438 posts
  • Location:Kyneton, VIC

Posted 25 October 2015 - 03:40 PM

CountrySpec®

 

moving-shell.jpg



#12 Matt

Matt

    "THERMAL MANAGEMENT SPECIALIST"

  • Members
  • PipPipPip
  • 4380 posts
  • Gender:Male
  • Location:Lake Maquarie NSW
  • Interests:Things, music, stuff & whatchamacallits

Posted 25 October 2015 - 05:16 PM

Blouch turbo love :)

Loved my 20g so much...will get one again one day

Question though...what made you go 8cm rear on a 207?

#13 andrew_k

andrew_k

    Regular Member

  • Members
  • PipPipPip
  • 438 posts
  • Location:Kyneton, VIC

Posted 25 October 2015 - 06:54 PM

I bought it used :)

It just looks new in the pic because it was well looked after and the seller gave me the new 14psi wastegate that came with his DOM 3 as he was using a 20psi wastegate and wanted to keep it.



#14 Bumpty

Bumpty

    My wob dreams are now wet dreams

  • Members
  • PipPipPip
  • 5489 posts
  • Gender:Female
  • Location:Hoga Island
  • Interests:Drinking wine with wob by the legacy side

Posted 27 October 2015 - 11:23 AM

CountrySpec®
 
moving-shell.jpg


Sexcellent!

#15 Matt

Matt

    "THERMAL MANAGEMENT SPECIALIST"

  • Members
  • PipPipPip
  • 4380 posts
  • Gender:Male
  • Location:Lake Maquarie NSW
  • Interests:Things, music, stuff & whatchamacallits

Posted 27 October 2015 - 03:28 PM

Ah yep ok.....should smash on hard once it spools

Throw some e85 in to the mix to get it spooling happy time :)

#16 andrew_k

andrew_k

    Regular Member

  • Members
  • PipPipPip
  • 438 posts
  • Location:Kyneton, VIC

Posted 27 October 2015 - 04:34 PM

Haha it's hard enough getting 98 out where I am let alone trying to source E85. This will be our only car (we'll get rid of the hilux once it's back in action), so probably won't get much benefit from E85 doing the daily school run. Unless we're running late, I guess



#17 comport3

comport3

    New Member

  • Members
  • Pip
  • 50 posts

Posted 31 October 2015 - 12:57 PM

Loving this build, can't wait to see the GT restored to better-than-new!



#18 andrew_k

andrew_k

    Regular Member

  • Members
  • PipPipPip
  • 438 posts
  • Location:Kyneton, VIC

Posted 31 October 2015 - 09:17 PM

Thanks man :)

 

I've been slacking off the past week. A cold turned into a lung infection. Hard to drag my ragged corpse out the the shed at night!

Got back out there tonight and got the TGV deletes done. DAAAAMN what a ***************** of a job that is. Massively CBF'd getting them all perfectly ported and mirror finish. 

I did it on the cheap by cutting out the guts and threading the holes for M10 stainless bolts, but also want it to look stock so there'll be no RWC dramas. If the RWC guy sees I've forked with the emissions system that's going to be bad news.

 

I'll clean up the jb-weld when it cures, but otherwise it turned out how I hoped. From the outside it looks stock.

 

07_tgv-delete.jpg



#19 andrew_k

andrew_k

    Regular Member

  • Members
  • PipPipPip
  • 438 posts
  • Location:Kyneton, VIC

Posted 07 November 2015 - 02:18 PM

Some little jobs while I wait for parts to finish engine refresh...

 

Repairing wheel dings:

dented-wheel1.jpg

 

dented-wheel2.jpg

 

Titanium wrap stainless uppipe:

 

up-pipe-wrapped.jpg

 

I'm not sure why I don't see more people doing this?

 

crossover-pipe-wrapped.jpg

 

Stock heat shield is now oil splash shield :)



#20 Barbbachello

Barbbachello

    Touring Bruce

  • SubyClub Area Rep
  • PipPipPip
  • 6493 posts
  • Gender:Male
  • Location:Mehico
  • Interests:Docking

Posted 07 November 2015 - 03:44 PM

Nice job in the tgvs. One of the benefits of the older tech engines is not dealing with that malarkey

tIeW8DE.png






Also tagged with one or more of these keywords: sf5, gga, ej207

0 user(s) are reading this topic

0 members, 0 guests, 0 anonymous users