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Old 05-03-2009, 07:48 PM   #1
Chi_San
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Member#: 53558
Join Date: Jan 2004
Chapter/Region: NWIC
Location: Deadford, OR
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2002 WRX Wagon
Silver

Default Exhaust work [56k, brew some coffee]

A while ago, I purchased an ebay exhaust manifold/UP combo (one piece, Megan Racing knockoff) off a SOIC friend. He owns a turboed 2.5RS, and the WRX manifold/UP doesn't fit his car. He got it off someone else, or something, and the manifold/UP never was run before I put it on my car, so the gaskets and such were all unused. Anyway, I put the thing on, and it had several problems:

The EGT bung didn't have a shoulder in it, so I coudln't run an EGT sensor...

The collector area wasn't welded right (sloppy welds), and it leaked. I started getting boost around 3,000 rpm, full boost at 3,250ish rpm.



So, I decided to throw it in the scrap bin and get a brand new setup for my car.

Irony of ironies, I decided to purchase a Megan Racing UP Pipe, I went through a reputable website, and the UP came direct from Megan Racing, FTW.





I decided to use the stock manifold, the cast iron tends to last longer in the extreme heat next to the exhaust ports compared to the steel that aftermarket manifolds use, from what I've seen. However, I decided to upgrade it a little bit... So, I started by pulling off the heatshields (all of them), and inspected the flex in the crossover pipe.



Then, I purchased this, at Schmucks:



I dropped the heat wrap in a bucket of water, let it soak for a minute, then wrapped the manifold:



And next, the UP itself:



I wrapped the flex very loose, so it will still be able to flex without crushing the weave.

Meanwhile, the manifold has been sitting for a long time outside, and had some rust build up on the flanges.



I purchased a wire wheel while at schmucks for $2, and wire wheeled it.



Next, I wire wheeled the cast iron end pieces of the manifold:

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Old 05-03-2009, 07:48 PM   #2
Chi_San
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Default

I used a little itty bitty wire wheel on my dremel for the parts I couldn't get to with the wheel that I chucked up in my drill.

Next, I attacked my heat shields. The two shields that cover the crossover were done primarily with the big wheel on my drill, and fine work with my dremel again.

Before:





After (before touch up work with the dremel):





And, next step was some high temp flat black exhaust paint. I started with the heat shields, painted the outside, and inside of them, as well as the UP:





After finishing up the UP and heat shields, I moved on to the manifold:





And, here's a finished pic of the manifold with the shields installed on it:



And here's my work area (tools in my car):

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Old 05-03-2009, 07:49 PM   #3
Chi_San
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Paint area:



And a general shot of everything:



And last, a pic of the wire wheel chucked up in my drill, as well as a shot of a brand new wire wheel for my dremel, and the used wire wheel (the brand new one woudln't chuck up right, wrong size collet):





Almost forgot.

Before, my car would spool the turbo around 3 grand (when I could hear it start to spool). Now, after wrapping it, it starts around 1,750 rpm (when I can hear it). I can go up hills in 5th gear now, it's impressive. I will post a few more pics of the ONE problem I had with the Megan UP, and my fix.

Annnnnnd, the problems:

So, the Megan UP came with a hardware kit. The gaskets weren't OEM quality, but where better than I was expecting. They were at least metal, unlike the gaskets on the old manifold.

The studs were really nice, at least I thought that until I tried puttnig the downpipe in. I only put 3 studs in the UP, since I will only be using 3. Well, as you can see, the studs that came with the UP are longer than the OEM studs:



I have an exhaust housing from a TD04L laying around, so I put a stud in the right spot to demonstrate, and put the housing on the old UP and snapped two pics. Imagine trying to put a downpipe on this housing, with this stud in the way:





I ended up putting some tape over the exhaust turbine on my turbo and just cutting the stud shorter. The actual threaded part of the stud is even longer than the threaded part of the original studs, so just cutting the 'easy install' part of the top of the stud doesn't work.

This mod was most certainly worth it, spool is insanly early now.

And, obligatory mod list:

Godspeed Radiator
Megan Racing UP
Wrapped crossover pipe
Mexican muffler mod (washers where the axle back bolts up to the mid pipe)

Last edited by Chi_San; 05-03-2009 at 08:06 PM.
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Old 05-03-2009, 08:38 PM   #4
claycron
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AW

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I had the exact same thing happen to me with the long studs on that side. I just used a bolt instead.
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Old 05-03-2009, 08:51 PM   #5
Docsuby79
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nice work, good documentation. Just wondering, while you had the manifold off did you match the exaust ports on the block to the manifold and cut the gaskets to fit also? (Sometimes this isn't needed, sometimes it is.)
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Old 05-03-2009, 09:14 PM   #6
Chi_San
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Quote:
Originally Posted by Docsuby79 View Post
nice work, good documentation. Just wondering, while you had the manifold off did you match the exaust ports on the block to the manifold and cut the gaskets to fit also? (Sometimes this isn't needed, sometimes it is.)
Thank you. I didn't have anything to port with, so therefore, I did not port. I may send my manifold out to Grimmspeed in the future for porting.
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Old 05-04-2009, 02:21 AM   #7
EsubaruJ
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Couldn't help but laugh when I read that you got the stuff from schmucks... I wonder if they know the traditional meaning of schmuck lol... Regardless... Looks good!
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Old 05-04-2009, 10:54 AM   #8
Chi_San
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rofl They probably didn't have that in mind when they called their store Schucks.

Thanks though. I'm really impressed with it. Going to wrap my downpipe whenever I get it.
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Old 05-04-2009, 12:34 PM   #9
wrxracer519
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Had the same issure with my Megan up-pipe in my last 02. Have you considered the grimmspeed cross over pipe? It is a really nice piece. I am about to do this on my newer 02 and am gonna port out the header collectors.

I like the work area to, looks like mine, especially with the psm bugeye wagon.
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Old 05-04-2009, 08:36 PM   #10
Chi_San
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Quote:
Originally Posted by wrxracer519 View Post
Had the same issure with my Megan up-pipe in my last 02. Have you considered the grimmspeed cross over pipe? It is a really nice piece. I am about to do this on my newer 02 and am gonna port out the header collectors.

I like the work area to, looks like mine, especially with the psm bugeye wagon.
I had considered the Grimmspeed crossover pipe, but I didn't want to spend any more money than I had to on this project, which meant sticking with what I had, other than the UP.

lol Yeah, I would have worked at school, but they said 'No more exhaust work'.
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