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Old 09-27-2010, 02:19 AM   #1
kpluiten
Scooby Guru
 
Member#: 120273
Join Date: Jul 2006
Chapter/Region: SWIC
Location: AZ
Vehicle:
06 WRBWRXWGN
Now with 100% more Spec-C

Thumbs up kpluiten's Build Thread: Almost driveable again...

UPDATE: 10/11/2013

The car has seen a significant overhaul since 2010. The current modification list is below under the heading "2012 Version". To see the previous configuration, see the list below "2010 Version".


My goal for this 2012 build was to address the engine/engine bay. The under-carriage/suspension/braking/steering of the car were now nice and sorted and clean from my 2010 project, but the engine bay was a mess. There were hoses everywhere, connectors hanging from long removed parts, dirt, dust, and general clutter.

I've found that cars built part by part like mine, tend to have this look to them. It comes from tweaking a single part at a time rather than considering how they all come together as a whole. You're left with wires running to and from, improperly routed hoses, etc. So, after a few months of thinking about it, I realized that to properly sort out the bay, I wanted to start from scratch with everything out of the car.

Around this time, I also started to grow a bit tired of the whole big(ish) turbo thing. The car was a monster and exploded with power, but it was a different type of fun than I wanted from the car. I missed the old "stage II" crazy quick spool and long power band. I wasn't really feeling the "meh" 0-4500 rpm followed by 4500-7200 rpm "OMG". All the big turbo setups that resulted in more useable power bands were costly and I wasn't sure if my forged motor was up to the task of high RPM.

So I bought an EJ207 "Ver. 8" from a 2003 Spec-C with 17,000 miles. My goal is to see how far I can go with the stock VF-36 ball bearing turbo and e85. If I am left wanting more, there are plenty of stock location, TS turbos hitting the market these days (18G's, 20G's, 2.5XT's, and even DOM 3's).

I figure this motor install would be the perfect opportunity to do the work I wanted on the engine bay and take the car in a new direction.


This is how the car sat/looked prior to this 2012 build:









2012 Version

Engine:
EJ207 Spec-C Ver. 8
• Factory Sealed Long Block
• 32-bit Conversion
• USDM Intake Cams
• Original Exhaust Cams
• Gates Racing T-Belt Kit
• Gates Racing Accessory Belts
• Group-N Motor Mounts

VF-36 Twinscroll Turbo
• Kinugawa Adjustable Wastegate Actuator
• Factory TS Header & Uppipe
• AngryRoo EBCS
• Perrin Inlet
• TurboXS FMIC w/ Custom Piping
• Rotated & Powder Coated Compressor Housing

Long-runner Intake Manifold - Ver. 8
• Shaved unneeded mounts and holes
• Powder Coated
• No TGV's
• Custom DBW adapter - Self-designed
• Custom fuel rail adapters - Self-designed

Oil Cooler
• Spec-C Factory Adapter Plate
• Hayden Aluminum Core
• Custom AN Lines/Fittings

KoyoRad Radiator
• Powder Coated Tanks
• Perrin Silicon Hoses
• Misimoto Fans & Shroud (Powder Coated)

Exhaust
• OEM Twinscroll header/uppipe
• eBay DP with Kinugawa bell mouth
• Greddy EVO II exhaust
• V-band Junctions

Misc.
• Powder coated valve covers and intake manifold
• JDM STi light-weight AC compressor

Fuel System:
• TurboXS Rails
• -6 AN Hardlines on Engine
• ID1000 Injectors
• Aeromotive FPR
• Golan Stainless Filter

Drivetrain:
• EVERYTHING completely rebuilt/painted/powder coated
• 5x114.3 Hubs - Completely Rebuilt
• STi Axles - Completely Rebuilt
• R180 - Completely Rebuilt
• Custom One-piece Drive Shaft w/ DS loop
• Clutch Slave and Master Cylinders w/ Dampener Valve Delete
• Motul Fluids
• OEM 2008 STi BBS - Gold
• OEM 2005 STi BBS - Graphite
• Kartboy Pitchstop Mount
• Kartboy Shift Linkage Bushings
• Subaru OEM SS Linkage
• DCCDPro Controller w/ OEM switches


Brake System:
• Brembo Calipers - Completely Rebuilt/Powder Coated
• Stop-Tech pads
• Speed Bleeders
• 1 1/8th Master Cylinder
• Racing Brake Slotted Rotors
• Cusco Master Cylinder Brace


Suspension/Steering:
• EVERYTHING completely rebuilt/painted/powder coated
• KW V3 Coilovers
• RPM Front Subframe
• 2005 STi Rear Subframe
• STi Aluminum Lateral Links
• STi Aluminum Control Arms
• Group-N Lateral Link Bushings
• Group-N Front & Rear Trailing Arm Bushings
• Group-N Control Arm Front Bushings
• Group-N Top-hats F&R
• Unibomber's Sexy Rear-end Kit
• Kartboy Outrigger Bushings
• Kartboy Trans-cross Member Bushings
• Whiteline Roll-Center Kit
• Poly-Pro PS Bushings
• Amroof Cowl Braces
• 225/45/17 Hankook RS3's
• WRX/OEM Steering Linkage Damper Delete

Exterior:
• Spec-C Roof Vent ()
• Rip-off V-limited Lip
• JDM Spec-C Grill inserts
• OEM STi Rear Diffuser with OEM Mounting
• Custom Harness for STi HID's and Levelers
• Redline Hood Lifters
• McGaurd Lugnuts


Interior:
• 2003 Prodrive STi Cluster (9000 RPM, MPH, & DCCD!)
• eBay Twin gauge cluster
• Mad Dad Boost gauge
• LC-1 Wideband w/ integrated calibration switch
• XD-16 Wideband gauge
• Clear Shift Knob
• OEM STi Mats (black)
• Jazzy Engineering Aux Input
• Plasti-dip trim
• V8 JDM STi Front Seats
• V7 JDM STi Wagon Rear Seats (!)
• Diagnostic Mode switch (Self-designed)
• Travis Pastrana's endorsement (signature )


Other:
• Hella Supertones
• Deka light-weight battery
• The ENTIRE undercarriage was cleaned and painted/recoated
• Wheel-wells were stripped and rubberized
• The engine bay was stripped and painted WRB
• New wiring was wrapped into the factory harnesses and fuse boxes
• All harnesses in the front clip of the car were re-wrapped and heat shielded.



Companies/People who have provided me with support in the form of parts or services during this build:
  • DCCDPro - Jeff at DCCDPro is a tremendous resource for all things involving DCCD controllers and other electronics needed for transmission swaps. He provided me with my most recent DCCD controller and I know I will not be disappointed.
  • Jay (Evil Imports) has been able to get various parts for me at very good pricing. He also knows more about these cars than just about anyone local.
  • Alex, Luke & Erik (Amroof, lukeskywrx, Erik) These guys have way too much knowledge and experience. They pioneered the EJ207 swap into a 32-bit car.
  • Mark of Mark Jones Tuning (brocksdad) - He tuned my car before with great results and will do so in the future.
  • SSC Auto Repair - These guys did my alignment after my entire suspension swap. And it was a bear. They did an excellent job despite the amount of challenges. They banned modified Subarus as a result of my wagon, but that didn't last long.














2010 Version
Background:

It's been almost 10 months since I last drove my 2006 WRX wagon. Since then, my wagon has sat, the number of parts on the car decreasing by the month while the list of parts waiting to replace them growing ever longer.

The state of the car with a complete parts list when it was parked can be found in my "Proven Power and Bragging" thread here: http://forums.nasioc.com/forums/showthread.php?t=1824106

In a nutshell the car has a forged short block, 6 speed swap, e85, and a DOM II turbo along with a host of other modifications. It ran exceptionally well and I was very pleased with the state of the car... but the modification bug bit again and I ended up purchasing the entire drivetrain and suspension out of a 2005 STi.

As the build planning progressed, I experienced scope creep (and still continue to). Grand ambitions along with the desire to perform all the work myself, a busy job, and losses in the family set me back significantly from where I had planned to be. The good news is that it looks like things are starting to calm down a bit and I should have more time to focus on this build.


Purpose:

The purpose of this thread is to loosely document some of the things I'm doing for those who may be interested. It is also my hope that having a thread to update might motivate me to make progress.

I will be adding to this thread as things get done. My list of planned upgrades is listed below. I will update the list to include links to relevant posts.

Here is how the car sits now:



Parts Purchased For This Round:

Engine:
2.5i Intake Manifold (soon)
Stainless Feed and Return PS Lines
Group-N Motor Mounts
Odyssey Light-Weight Battery

Fuel System:
Aquamist HFS-6 System
Spec-C Meth Tank
Second In-tank Walbro
Fuel Rails
Aeromotive FPR
Golan Fuel Filter
Charcoal Canister Delete

Drivetrain:

5x114.3 Hubs - Completely Rebuilt
STi Axles - Completely Rebuilt
R180 - Completely Rebuilt
STi Drive Shaft
Clutch Slave and Master Cylinders w/ Dampener Valve Delete
Motul Fluids
OEM STi BBS - Gold
OEM STi BBS - Graphite
Kartboy Pitchstop Mount
Kartboy Shift Linkage Bushings
Subaru OEM SS Linkage
Updated DCCDPro Controller

Brake System:
Brembo Calipers - Completely Rebuilt
Stop-Tech pads
Speed Bleeders
1 1/8th Master Cylinder
Racing Brake Slotted Rotors
Cusco Master Cylinder Brace

Suspension:
2005 STi Rear Subframe
STi Aluminum Lateral Links
STi Aluminum Control Arms
Group-N Lateral Link Bushings (soon)
Group-N Front & Rear Trailing Arm Bushings (soon)
Group-N Control Arm Front Bushings (soon)
Unibomber's Sexy Rear-end Kit
Kartboy Outrigger Bushings
Whiteline Roll-Center Kit
Whiteline PS Bushings
KW V3 Coilovers (soon)
KW Linear Spring Conversion (soon)
Ground Control Tophats (soon)
RPM Front Subframe
Amroof Cowl Braces

Exterior:
[size=2]Spec-C Roof Vent ()
Full 2006 STi Sedan Front Clip (Fenders, bumper, hood, scoop)
02-03 WRX Side-skirts
Rip-off V-limited Lip (soon)
Rip-off Rear Aprons (soon)
Custom Harness for STi HID's and Levelers
Hood Lifters
McGaurd Lugnuts

Last edited by kpluiten; 10-11-2013 at 10:57 AM.
kpluiten is offline   Reply With Quote
 

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