View Single Post
Old 07-23-2010, 10:48 PM   #1
tino
Top Scoob 019
 
Member#: 43630
Join Date: Sep 2003
Location: Down Under
Vehicle:
2004 GT40R-built 2.5
604 whp @1.8 BAR on VP109

Default Congratulations Tino !! Nasioc's Top Scoob 019 !!


This has been a work in progress over the last five years, I bought the car brand new in 2004 after trading in my mildy modified WRC blue MY99. I was determined to keep it standard but this didnt last long at all and i found myslef slowly morphing into many guises from when it left the showroom floor. It first started with simple engine bolt on modifications like exhaust, turbo and intercooler to gain more power over standard, but then improvements were always one step away to aim for higher power levels and better handling.

The last two years has seen the most modifications completed on the car. This included the biggest step of upgrading from a stock 2.0ltr STI engine to a purpose built and engineered 2.5 ltr STI engine, with large rotated turbo setup and aftermarket Motec engine management system. The reason for the length of time is primarily due to the fact that alot of research both over the internet and discussion with people and workshops has taken place. Nearly every single nut and bolt in the engine and ancillaries has been either changed to better off the shelf items or complete custom fabrication which has been engineered such as the custom billet aluminum intake manifold, Aluminium V-mount setup to custom aluminum resivoir tanks.

The car has been built primarily for drag and large track combinations. The engine has a relatively large garret turbo which has two different sized rear housings the bigger one for drag applications and smaller rear housing for track setup. Headwork that includes camshafts, valves, springs and retainers have also been changed so that the engine can be revved out to 8500 rpm to allow for a larger useable power band for track applications.

Interchangeable suspension and diff settings also allow the car to utilize both drag and track combinations.

This car was never built to be a show car, but one that would see apart from the occasional drag run, alot of track work and targa events. Apart from improvements in suspension and power, there have also been custom cooling enhancements, such as more efficient raditator and V-mount intercooler setup to installation of power steering and oil coolers to ensure that oil levels stay at normal operating levels.

The engine bay appearance was not setout on purpose to turn out into a show piece. But once the engine was out i decided to get the engine bay shaved by Beyond Custom removing the wiring loom from the firewall and re-routing the loom out of sight. It is very hard to make pretty a subaru engine bay due to the messy layout, but i think using alot of custom parts has enabled wiring and non-functional parts to be hidden and removed from sight. Then there was the extended time and headache to find and deliver the very rare 1/600 made subaru STI s203 Carbon backed Recaros which came from an actual subaru s203with build number 462.

In the end the car has turned out to be multi-taskable, with the addition of complete interior retrim in alcantra material with carbon fibre trim and S203 limited edition carbon fibre racing seats and turned into a daily driver, show car, drag racer and circuit racer.

it seems though the build may never end as there are still many improvements that i want to do before i can be completely satisified..




















Here is a link to my NASIOC threads:

http://forums.nasioc.com/forums/show....php?t=1470621

http://forums.nasioc.com/forums/show....php?t=1989479

Photos taken by Rick McDowel, heres a link to his blog:

http://www.facebook.com/#!/photo.php...15277915153388


ENGINE
2.5ltr STI semi-closed deck block.
Complete CNC close Deck of Subaru block.
Machined to suit darton Ductile Iron Flange Sleeves.
ARP case bolts.
PBMS 14mm high tensile head studs.
STI 2.5ltr crank. Machined and balanced. Cross drilled for better oiling of bearings.
Custom 99.5 mm CP pistons.
Pauter rods.

HEADS
2.0Ltr AVCS Big port heads.
CNC grind to custom head ported map and finish hand polished to suit 2.5ltr bore.
Cosworth Billet 278/274 AVCS Camshafts.
Cosworth inconnenl 1mm oversize exhaust and inlet valves.
PBMS exhaust cam wheels.

ASSOCIATED ENGINE BAY PARTS
Custom fabricated and mounted aluminium radiator tank.
Custom fabricated and mounted power steering tank.
Custom fabricated and mountedwindow washer.
Custom fabricated and mounted coolant overflow.
Custom fabricated and mounted brake assembly.
Custom fabricated and mounted clutch reservoir.
Custom Mocal Power steering and engine oil cooler.

TURBO SETUP
Polished Garrett GT40R twin scroll turbo 1.06 rear housing HP ceramic coated.
Custom low mount turbo manifold IDA 44mm which sits underneath the engine in a twin scroll configuration. True twin scroll turbo manifold which merge as twin pulses at collector.
Dual tial 44 mm V-band external waste gates.
Custom 3.5" v-banded stainless steel dump pipe.
Custom 4" v-banded exhaust with SBM 4" muffler.

INTAKE
Billet 70mm single throttle body with custom aluminium reverse throttle linkage.
Custom billet aluminium reversed mount intake manifold.
Custom V-mount intercooler/radiator setup.
Custom reversed carbon fibre intake intercooler piping.

FUEL SYSTEM
Custom carbon fibre in boot fuel system.
2 x Walbro in tank 265l/ph fuel pumps feeding a 5ltr stainless steel surge tank by -8an teflon braided lines to bosch x2 044 fuel pumps.
Dual custom billet fuel rails with 8X WRX decap top feed injectors.
Custom billet aluminum fuel distribution block running 8X Injectors with Twin SARD Fuel Pressure regulators.

IGNITION
MOTEC M800 plug and play ECU.
Re-wired ecu engine harness.
DCCDpro DCCD diff controller.

DRIVETRAIN
Subaru 05 STI 6-speed DCCD.
Custom modified Tilton twin plate 215 mm carbonetic clutch.
Cusco front plated and RZ rear plated diff.
Ohlins competition PCV coilovers height/damper/angle adjustments.
STI Brembo 6 pot brakes.
STI RA-R braided brake lines.
Brembo STI RA-R slotted rotors front and DBA4000 rear.
Brembo STI RA-R front and DS2500 brake pads rear.
5x114.3 complete hub conversion swap.
MSI adjustable lateral links.
MSI rear subframe.
MSI PSR kit and castor links.
MSI rear 23-25mm adjustable swaybar.
Whiteline front NA 22mm adjustable swaybar.
Cobb heavy duty swaybar mounts.
Cobb front and rear spherical links.

EXTERIOR
White 18x8.5 +30 Enkei RCT4 rims.
Genuine STI centre caps.
Dunlop Direzza R compound r specs 245X40.
Genuine STI titanium strut tower bar.
Genunine STI front lip.
Genuine S202 carbon fibre rear spoiler .
Genuine STI RA roof vent.
WRC carbon fibre mirrors.
Custom mounted WRC bonnent vent.
Custom carbon fibre bonnent vent shroud for custom WRC V-mount.
Custom shaved engine bay and engine loom tuck.
Custom mounted Braille lightweight battery in the front gaurds.
Custom mounted ABS unit in the front gaurds.

INTERIOR
Genuine subaru STI S203 limited (Number 462/600) front seats and rear seats.
Custom alacantra wrapped dash.
Custom alcantra wrapped interior panels and headliner.
Custom carbon fibre interior dash and interior pieces.
Motec ADL sports Data logger dash and Motec Shift lights with custom carbon fibre housing.
Pioneer DVD/Navigation touch screen display.


Performance:

535 WHP@1.8 bar on 93 pump
604 WHP@1.8 bar on VP109
11.3@134 mph on old setup



* Registered users of the site do not see these ads.

Last edited by Ferg; 09-02-2010 at 12:27 PM.
tino is offline   Reply With Quote