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Old 06-01-2009, 08:25 PM   #226
beaviscih
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Quote:
Originally Posted by ckcadavona View Post
I'm not sure if you figured your brakes out yet. But in order to bleed them make sure the bleeder valves are facing up and the L on the calipers is on top on the left and the R on the calipers is on top on the right.
Yep the bleeders are facing up. Without checking I'm pretty sure the calipers are the correct side otherwise the bleeders would be facing down. The rear brakes are better, but still not quite right. It did pass the State inspection, but these guys don't even pop the hood. He said the brakes felt different, but thought it was supposed to be that way because of the suspension.
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Old 06-20-2009, 11:06 PM   #227
beaviscih
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Well after several weeks without working on the car due to contracting Typhus - no joke, and it's some nasty stuff (my pet river rat turned on me and let his fleas attack me) and some work stuff, Txoutlaw came over today to help me finish up the POS eBay FMIC. Obviously it was not designed for an EJ20G since the feedpipe to the TB was way too short. I had to buy some extra couplings, an 18" spool piece for splicing and clamps. I also had to pick up a bead form tool so the couplings would stay on the pipe after the cuts. We ended up with a few more cuts / couplers than we wanted, but we had to work with what we had. I also installed an in-fender radiator overflow tank, but still need to fab up a few pieces for it to be finished. Below are some pictures of the finished product.

I had to cut the JDM Bumper Beam a little for the end tanks:








Not Pretty, but it works:


I also installed a Forge Header Tank so I could get rid of the USDM tank that was ghetto rigged and looked pretty crappy. The tank was a little tarnished, but with a little buffing it shines like a new dime, not to mention the fitment is nice. One good thing about the kit my Apexi CAI still fits.




Last edited by beaviscih; 06-20-2009 at 11:19 PM.
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Old 06-20-2009, 11:10 PM   #228
beaviscih
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Before I got sick I did manage to wire up the Link IAT and Map Sensor and got the Analog Input Loom from Link. I still have the stock Map Sensor and Boost controller installed, but will install the Link BC shortly and remove the OEM stuff.



Analog Input Loom on the left side of the ECU:



I also dropped off the JDM Ver 3 bumper at the body shop Friday to see what kind of work they do. The bumper had a few deep scratches that will need to be fixed, but they said it would be ready by next Wednesday. I also dropped off some Ver 3 fog covers (in case I lose my fogs due to the FMIC). The bumper will be Brilliant Red (559) and the fog covers will be Black (47A). I picked up a black trunk lid from another member so I can get rid of the dented blue lid that's on the car now. I already have the matching black spoiler, so it should look nice. If the bumper looks good I'll bring them the hood next and it will be painted black (47A). The goal is to have a red / black color scheme and keep the OEM black side panel trim. More to come...

Last edited by beaviscih; 06-20-2009 at 11:27 PM.
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Old 06-21-2009, 07:29 PM   #229
beaviscih
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Some general housekeeping today. Installed the Link EBC and removed the OEM boost controller and Map sensor, changed the plugs back to 1-step colder ( I reinstalled the DW 650's a few weeks ago) and installed the '02 WRX steering wheel. I changed my seats a few weeks back...big improvement.



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Old 06-27-2009, 07:10 PM   #230
beaviscih
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I got the bumper back from paint. It looked good but I did find a few mistakes so I'm not sure if I'll do any more business with them. It took some work but I got the JDM bumper to work and keep my fog lights. I chipped the paint in a few places, but nothing a little touch up paint won't fix. I still want to trim a little more on the underside of the bumper where it is in a slight bind. I also installed the black trunk and got rid of the dinged up blue trunk.





I still need to have the hood painted black and I'm scheduled for tuning this week.
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Old 06-29-2009, 08:59 PM   #231
beaviscih
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Well I got the car started tonight using the 650cc injectors, 1-step colder plugs set at 0.025 (per my tuner's request) and it ran. I was having issues setting up my Link 2.5 bar map sensor, so I re-installed the OEM map sensor and will let the tuner set up the Link. I made a few adjustments to the master fuel setting to get the AFRs around 14.5 at idle, but once it warmed up the engine started oscillating between 700 and 2200 rpms.

Since I made no other adjustments other than setting the latency values for the 650cc injectors and adjusting the master fuel setting I don't think I can get it any better until we get it on the dyno Thursday (I'm glad I have a trailer to haul it to EngineLogics in Houston). If all goes well I should have dyno sheets by the end of this week.
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Old 06-30-2009, 04:35 AM   #232
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Awesome build, looking forward to seeing the results.
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Old 07-03-2009, 11:01 AM   #233
beaviscih
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Went to EngineLogics in Houston yesterday to have the car tuned. While the weather conditions were not ideal, the car put down 214.3awhp and 213.8ft-lbs of tq at 17psi. I'll post the dyno sheets a little later.

I knew it was going to be hotter than a whore on dollar night, but I needed to get it tuned. We started about 10AM and the temperature was 93 degrees with 53% humidity and 29.92 barometric pressure. By the time we were done, the ambient temperature in the dyno bay was 107 degrees F. No doubt I lost some power due to the heat but the car performed very very well. Brad did a great job tuning her. The eBay FMIC and piping work we did held up with no blown couplings. We did blow off a few vacuum lines in the process but that was no issue. At about 14psi we started to see spark blow out (plugs were set to 0.025). Brad re-set them to 0.022 and had no issues after that.

After Brad was done he figured out why my rear brakes were not working... I had reversed the vacuum line from the manifold to the brake booster. I had no idea there was a 1-way valve in the line and once he swapped it the brakes improved tremendously. I'll probably bleed them again just for good measure. It made for a very long day but overall I'm very pleased.
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Old 07-03-2009, 11:45 AM   #234
scarless ronin
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i bought an EJ20G a few months back, and I have a '00 rs, I want to go full out like this on the car, but judging by how much time and new parts you've put into yours, I'll be broke before I get halfway done, especially with the mechanic bills... how much do you think you've put into it so far? (if you don't mind me asking) she looks beautiful by the way
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Old 07-03-2009, 12:27 PM   #235
beaviscih
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Originally Posted by scarless ronin View Post
i bought an EJ20G a few months back, and I have a '00 rs, I want to go full out like this on the car, but judging by how much time and new parts you've put into yours, I'll be broke before I get halfway done, especially with the mechanic bills... how much do you think you've put into it so far? (if you don't mind me asking) she looks beautiful by the way
You can go cheaper than I did, especially on the interior stuff. I didn't need the seats (but really wanted them) and there are some other corners you could cut without sacrificing the quality. I bought the car for $2500 and probably have $10k in it. That doesn't count the wrong parts I bought and sold for a loss. The new stuff were the gauges, plugs, FMIC, carpet, CAI, Engine Management (most important), various sensors (map, IAT, crank and cam sensors), timing belt, main belt, oil pump, water pump, idler pulleys, wheels, tires and brake pads and hoses. All the other stuff was used.

If you've got a good tuner / installation person, you can get the G4 wire in Engine Management System and probably save a few hundred versus getting a plug-n-play ECU and having the wire merger done. Not to mention not having to pull the dash.
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Old 07-04-2009, 12:48 AM   #236
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It was definitely screaming on the dyno but it sounded rock solid and I was very impressed with the numbers, especially as hot as it was. You better put that baffle back in or you will surely get a ticket. When you and Wooley Booger (aka Brad) went on the test drive we could hear the car a looonnnng ways off. I swear that car is louder than a lot of straight piped V8's I have heard. Can't wait to go for a ride in that little jewel!
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Old 07-06-2009, 08:20 PM   #237
beaviscih
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Here are the dyno charts. Contrary to what the sheets say, the car is a '98 not a '97. While I have a few more things to do to the car (paint, dump the skinny fans for something that will keep up with the Texas heat), the project is pretty much complete. I'll post up pictures once I get it painted.

I appreciate all the positive as well as constructive comments during the swap. Props to Zephyr, Jackie at Annapolis Subaru, Miles at Fine Line Imports, Brad at EngineLogics and countless others that would have made this project very difficult without their useful threads and posts. Last but not least Txoutlaw for countless hours of bench racing, helping me stab the engine, bleed the clutch and install the eBay FMIC.





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Old 07-07-2009, 05:57 PM   #238
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verynice glad everything went well any vids of her now
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Old 07-07-2009, 07:29 PM   #239
beaviscih
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verynice glad everything went well any vids of her now
I have a few issues to work through. The skinny fans don't do well in the 100+ heat, so I'm swapping in a set of Flex-a-Lite 410's. I've got a slight shimmy in the steering wheel at 65+mph, but have an alignment scheduled for Friday, and of course I've got to get it painted. Unfortunately I forgot to bring my video camera to the dyno session.
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Old 07-08-2009, 05:01 PM   #240
dohtem8
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nice project dude. i wanna convert my 99' 2.5rs to an sti. im looking for an ej257 or an ej20t or something xD. if you have any places or suggestions lemme know
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Old 07-09-2009, 04:12 AM   #241
tony_0227
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Quote:
Originally Posted by beaviscih View Post
I have a few issues to work through. The skinny fans don't do well in the 100+ heat, so I'm swapping in a set of Flex-a-Lite 410's. I've got a slight shimmy in the steering wheel at 65+mph, but have an alignment scheduled for Friday, and of course I've got to get it painted. Unfortunately I forgot to bring my video camera to the dyno session.
to bad that would have been nice to see. very nice build. cant wait to swap out my old 1.8. that is going to be fun
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Old 07-11-2009, 10:16 PM   #242
beaviscih
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I thought I'd post a few pictures of the new fans. The previous fans only pulled 4 amps and 1250 cfm and just couldn't keep up in the Texas heat with the A/C running. Brad at EngineLogics recommended I go with a fan set up that had a shroud so I decided on the Flex-a-lite 410 pullers. They ain't cheap, but what a difference. These fans draw 14-22 amps and are well within the stock A/C relay and fuse range. I had to hack the fan shroud for fitment, and fab some brackets, but it worked. I also removed the 160 degree thermostat and went back with the 180 degree. The reason for going to the 180 is I felt the coolant was not getting enough residence time which could have affected cooling. Here are a few pictures.






I also had the car aligned and my garage alignment was really close. The front required not toe adjustment and the rear was only off a slight bit. We could only get -1.1 degree camber in the front with the camber bolts (stock top hats) and I left rear at -0.5 (where I had set it in the garage).

Last edited by beaviscih; 07-11-2009 at 10:44 PM.
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Old 07-12-2009, 02:58 AM   #243
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hey dude, what kinda engine did u get under the hood? i wanna convert my 99' 2.5 rs to an STi :P. and where did you get the engine too. pm me :]
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Old 07-12-2009, 06:52 AM   #244
beaviscih
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hey dude, what kinda engine did u get under the hood? i wanna convert my 99' 2.5 rs to an STi :P. and where did you get the engine too. pm me :]
EJ20G from JHot. You may want to check Millenium Auto (supporting vendor), they usually carry STi engines. http://forums.nasioc.com/forums/show...ight=Millenium
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Old 07-21-2009, 09:22 PM   #245
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Great project!!!
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Old 07-21-2009, 09:27 PM   #246
beaviscih
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Great project!!!
Thanks. I should have the hood, trunk and spoiler back from painting this week. I still have a shimmy in the steering wheel above 65mph that I need to figure out.
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Old 07-25-2009, 09:00 PM   #247
beaviscih
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Well I thought I figured out the steering wheel shimmy. After checking everything in the front, I moved to the back and found the two nuts that secure the rear diff to the cross member had backed off about an 1/8" - obviously I didn't torque them down. I decided to check all the subframe bolts and found one of the main bolts cross threaded. When I removed the bolt it looked like I didn't have the crossmember aligned properly and the bolt hole in the crossmember didn't match up to the bolt hole in the chassis.

With some help from Txoutlaw, we loosened the three remaining bolts holding the crossmember and attached a ratchet strap to the front toe hook and the other end to the crossmember and pulled it forward so the bolt hole in the cross member was aligned properly. I had to tap the chassis bolt hole since the threads were totally ruined. I used a small socket wrapped with duct tape to keep the tap straight and re-threaded the hole. Unfortunately this didn't correct the steering shimmy issue. I thought the loose nuts/bolt was causing vibration to travel up the driveshaft and was causing the shimmy.

These nuts were loose - Now torqued to 70ft-lbs.


Here is the bolt I cross threaded and the tap used to cut new threads.




I got the hood and trunk back from paint and here are the end results. I still need to adjust the IC pipe since it hangs too low, but that shouldn't be a big deal.





Last edited by beaviscih; 07-27-2009 at 01:49 PM.
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Old 07-26-2009, 11:44 PM   #248
tony_0227
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mmmm very very nice came out looking good. did you ever get a vid of the car running. i would like to see that.
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Old 07-27-2009, 02:04 PM   #249
beaviscih
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mmmm very very nice came out looking good. did you ever get a vid of the car running. i would like to see that.
Ill try and get a few video shots this weekend.
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Old 07-27-2009, 02:30 PM   #250
beaviscih
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mmmm very very nice came out looking good. did you ever get a vid of the car running. i would like to see that.
Ill try and get a few video shots this weekend.
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