577 replies to this topic

[Barbbachello]

Been a while since updates. Bit of a rush to get lots of small things done ready in time for tuning at the end of October.

Finished putting the car back together


And out of the shed for some test laps to make sure everything is happy


Had 3 issues.

• I tapped in a 3/8NPT to barb fitting to allow for the header tank to be fed from the rear to suit the long runner manifold. This had a tiny coolant leak, basically because the diameter wasnt enough to have flat and straight threads. 
  
  Ended borrowing a mates AC tig and welding it in. Not bad for first go welding ally
  
• Power steering lines leaking from the rack. Generic orings i used werent quite the right size. Some new oem ones sorted the problem out
• Intercooler piping blowing off. The first hotside pipe "fit" but was clearly slightly on the piss and didnt like holding more than 18 psi and would blow off witihout fail. Raided the scrap bin and welded on a slight bend and no issues
  

 

With things sorted i put the HKS heat shield back on. Only held on with 1 bolt as no more 4 bolt flange to pickup the other mounts. Problem for Ron


Rob the tuning mate came down end of October for some road tuning. The intercooler couplers reared their heads again. 24 psi is the limit for couplers on non bead rolled tubing it seems. Pulled all the pipes off and welded on 1" of "bead" at 12,3,6,9 o clock on the pipes, which fixed the issue. 

End result of the tuning is 24 psi on e85 and 20~ on 98. Very hard to bum dyno as the turbo spools very smoothly so there is no sudden rush of power, but it just keeps on pulling very strongly all the way to redline. There is no increased duty cycle in the boost controller to keep the boost flowing. The turbo is very happy. If i had to say a number; more than 250kw less than probably 270. Injectors are currently maxed out at 93% on e85 so theyre the limit now.

As a little treat for surviving tuning i installed some ZeroSports seat covers


And have ordered a JDM Hawkeye STI 6 speed from the motherland. There are a few reasons for this

• Shorter ratio gearing to bring the turbo on faster and to bring the cruising RPM up. Low comp 2L with no avcs hates cruising at 2500 at 110. New box should be 3k at 110
• DCCD
• Front LSD

Thats about it for now. The future ideally holds a set of 1300cc injectors and an R180 diff but that might have to wait for a while

[El_Freddo]

You were busy finishing this off Barbs! I realise it’s not done - builds are never really finished…

Good score on the 6 speed! Was that more expensive than sourcing a box conversion over here (that’s how they all seem to be sold is with the full gambit with shafts, rear diff and hubs etc)?

So now it’s tuned, what’s the first big outing?

Cheers

Bennie

[Barbbachello]

Box was just under $2500 landed.

About 1/3 of the price of a local package and about what a gen 4 box costs locally with no front lsd or dccd so defs a good score. 

Heading up in to the alps again with the OG boys mid December for some camping and thrashing alpine roads

[Barbbachello]

Plenty of stuff has happened

New job so dont have time/ability to write up forum posts at work anymore lol

Box still hasnt arrived from japan

[El_Freddo]

Plenty of stuff has happened

New job so dont have time/ability to write up forum posts at work anymore lol

Box still hasnt arrived from japan

Taking a leaf out of Ben’s playbook without any pics??

Congrats on the new job!

Cheers

Bennie

[allpaw4]

Hahaha, low blow Bennie, low blow!

Valid though.

Looks like a nice score on the box dude. They do take a while to rock up.

[El_Freddo]

The Truth usually hurts a little. Wait a while and that’ll settle down as you begin to accept it

Cheers

Bennie

[allpaw4]

Hahahahaha, oh I accepted it a long time ago lol... It doesn't change the burn though 🤣

[El_Freddo]

Now that the forum is back in business I’m hoping Barbs provides an epic update with a mega load of pics!

Or drip feed us, either way, I’m keen to see what was done to the fridge over the last few months!

Cheers

Bennie

[Barbbachello]

Quite a lot lol

New job so can't post on the forum during work hours as easily unfortunately as I said earlier

The STi box is in and doing everything I wanted it to

Has a new g25 660 turbo
Updated cooler piping

And got married

[El_Freddo]

Congrats on getting hitched mate! Mrs El_Freddo and I are nudging 15yrs of marriage!

I’ll be patient for your non-work posted updates when they come

Cheers

Bennie

[Barbbachello]

Rapid fire summary of whats happened

Wanted a new turbo that would spool a bit faster. Found out Mamba who did my GT30 housing also did G25 housings so chances of direct bolt on were high. It bolted straight on



Makes about 20 psi by 4k, much easier to drive. Little bit less interesting but arguably "better"

Swapped to a gen 4 remote res power steering setup in order to route the intercooler piping down between the chassis rail and the radiator





Made a new 3" CAI and had it all powder coated textured black


STi box arrived


Managed to solo swap it without dying


Cruising RPM is perfect for non avcs 2L


New shifter linkage and NOS v7 STi knob


Changed the muffler from the HKS silent power to an Apexi World Series which could have the tip extended to clear the oem aero lip to fix the soot being spewed all over the car



Also installed a cat back in the car


Took it on a trip into the Alps for a family holiday


Installed some hard race camber arms as running nearly 3 degrees of negative camber isnt it and had maxed out the whiteline bushes


Is now back to around -1.5 all around

Got married in tasmania. Took the car over on the ferry as the "wedding car" and did a bit of a trip around aferwards





2800km total. Thats up to as of 2 weeks ago. Car is still dirty


 

[El_Freddo]

Nice one Barbs and congrats again - Tassie wedding too! I bet some roads were torn up that week…

Thanks for the update and photo drop!

Our RX Liberty is dirtier than your Lib, but yours would whip the pants off ours easy!

Cheers

Bennie

[El_Freddo]

Bump post hunting for an update

[Barbbachello]

Had a big post written up and the forum chucked a wobbly and deleted it.

Will try again later

[Beckers]

Later ??

 

Might be time to try again !!

[Barbbachello]

Short version of a long story
Rear brembos and backing plates are on


Engine came out to fix either a dodgy cam seal or not enough slaz on the front cam caps. Turned out to be installer error and cooked the cam seal putting it in


Converted to a GD style centre entry rad for more OEM ness


Went camping in the alps with the boys



 

Images are massive but youll live

[Barbbachello]

Now several events have transpired. Cant remember if i shared this but 12~ months ago my wife and I picked up a green gen 2 RX wagon on a whim on a Sunday night during a thunderstorm

2 reasons. Its green and still has 99% of its clearcoat. Ive got a manual loom on my shelf and a spare 6 speed


Long story short i have a 98 loom, car its a 97. Subaru changed pretty much everything in 98 so have had to source a climate control setup and 98 spec airbag and abs pump and lines. Its currently completely stripped awaiting an engine bay paint job


The original plan was to acquire another 207 with AVCS for my BH and the non avcs 207 would go into the gen 2. While lying on the floor i realised having 2 EJ20 powered cars is kinda boring, and that ive been wanting to fabricate something again, like an exhaust manifold. Several weeks of research later and a mate parting a car we have this


EZ30R from a gen 4 with pre blown head gaskets. Perfect. Given they go somewhat straight into a gen 3 in an OEM like way seemed like a good idea. 

With that sorted i had to scratch the fab itch so sourced some flanges and steam pipe (which ive been wanting to play with also) and starting making a turbo manifold. Normally the done thing is to buy a set of raptor headers and stick it out the back and snake it up the back of the engine. I like making my life harder and doing it like Perrin did in 2006 with their STi so routing it like a normal turbo subaru. Most of the reason people go up the back is cos its a factory EZ car and they dont want to change the subframe, even less so if theyre paying a shop to do the turbo kit. To make life even harder i want to do a twinscroll setup as well

 

Have tacked up the passenger side bank and am pretty stoked with the result




Ill be welding an extension to the thermostat housing so move the hose further away from the manifold. The heater hose will come around the back. Should be fine in some fire sleave

Crossover pipe is also tacked up, this may change once i make the second bank as it has to do a 180 


90% chance ill be running an external oil cooler so space is left at the front to run lines out.

This wont be going into the car for a while. To do it "right" will need some pretty serious money and i dont want to be without a car at least until i can pull it apart and do it all. Ill be using a wire in ECU like a Link Fury X. Obviously with the head gaskets pre blown theyll need doing which will get head studs and some thicker cometic gaskets to drop the compression a touch.

Turbo wise looking at a G35-900 with a twinscroll 1.01 T4 housing. Did think about a G40-900 for giggles but i dont think it would even fit between the intake and brake master. For reference Perrin used a GT4094 back in the day and it spooled up like a GT30 on an EJ25, which is quick

The red GF8 WRX belongs to a mate that is gathering dust at my place for a while