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Old 09-27-2010, 02:19 AM   #1
kpluiten
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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
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Last edited by kpluiten; 10-11-2013 at 10:57 AM.
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Old 09-27-2010, 02:20 AM   #2
kpluiten
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Saved for future use.
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Old 09-27-2010, 02:20 AM   #3
kpluiten
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Saved for future use..
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Old 09-27-2010, 02:21 AM   #4
Evil Imports
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YeaHhhhh
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Old 09-27-2010, 02:24 AM   #5
Evil Imports
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I will save this space to talk **** later
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Old 09-27-2010, 02:25 AM   #6
Evil Imports
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and this one for even more
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Old 09-27-2010, 02:38 AM   #7
kpluiten
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Quote:
Originally Posted by Evil Imports View Post
I will save this space to talk **** later
Quote:
Originally Posted by Evil Imports View Post
and this one for even more

I wouldn't expect any less.
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Old 09-27-2010, 02:53 AM   #8
kpluiten
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The Brembos I purchased came from a New Jersey car and they were in very rough condition when I got them. Three of the four bolts holding the front calipers to the hubs broke off in the calipers and could not be removed. Additionally, one of the bleeders broke off in the caliper. Surprisingly enough, the rears were in excellent condition despite coming off the same car.

I finally got some time to start rebuilding them this weekend. Dis assembly is surprisingly easy as long as you take your time. I will be installing helicoil in the mounting holes to repair the fronts. I will also need to figure out the repair for the bleed screw situation. After that, they are off to Liquid Powder Coats to be powder coated. I'm thinking green.

Broken off mounting bolts:


Removing seals and pistons:


Drilling out bolts:


Bagged Seals and dust boots:


Mounting tabs ready to be tapped for Heli-coil Installation:


All the calipers stripped down and ready for powder coating:


Rear caliper parts:


All the pistons:
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Old 09-27-2010, 03:07 AM   #9
amroof
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Its About Time You Attempt To Finish This Thing
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Old 09-27-2010, 03:16 AM   #10
kpluiten
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Quote:
Originally Posted by amroof View Post
Its About Time You Attempt To Finish This Thing
You see your cowl braces on that list?
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Old 09-27-2010, 03:19 AM   #11
amroof
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I did and i chuckled cause they are going to be the best part on your car.
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Old 09-27-2010, 03:39 AM   #12
CavemanAZ
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Oil cooler...?
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Old 09-27-2010, 04:25 AM   #13
OHARA
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Excited to see this progress. Good Luck! Subscribed
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Old 09-27-2010, 08:25 AM   #14
ASU
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Blahhhh
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Old 09-27-2010, 10:44 AM   #15
SaabaruMike
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Nice work Ken. Just don't give up on it. Also, make sure you set a point where you say "I'm done" and you'll be much happier in the long run. I've had plenty of friends lose interest due to major scope creep with their projects. Either they never finish, or they end up building something that is not very streetable and get bored with it because they don't want to take it out. Jay's purple car is a prime example. He put a ton of work into it and it turned out fantastic, but he rarely takes it out. I'm sure Jay will vouch that he has way for fun with his wagon.
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Old 09-27-2010, 11:14 AM   #16
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Quote:
Originally Posted by SaabaruMike View Post
Nice work Ken. Just don't give up on it. Also, make sure you set a point where you say "I'm done" and you'll be much happier in the long run. I've had plenty of friends lose interest due to major scope creep with their projects. Either they never finish, or they end up building something that is not very streetable and get bored with it because they don't want to take it out. Jay's purple car is a prime example. He put a ton of work into it and it turned out fantastic, but he rarely takes it out. I'm sure Jay will vouch that he has way for fun with his wagon.
honestly, i do have more fun with my wagon, because its the car i ALWAYS wanted, and you can't buy it, i would take my sti out more but i am to lazy to move the wagon to pull the sti out, otherwise i would drive it,

If ken losses interest in him car and doesn't wanna finish it, i will buy it off him
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Old 09-27-2010, 11:49 AM   #17
kpluiten
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Quote:
Originally Posted by STiCaveman View Post
Oil cooler...?
No plans for one yet. I've done just about zero research into those.

Quote:
Originally Posted by OHARA View Post
Excited to see this progress. Good Luck! Subscribed
I hope I don't disappoint.

Quote:
Originally Posted by ASU View Post
Blahhhh
hhhhalB

Quote:
Originally Posted by SaabaruMike View Post
Nice work Ken. Just don't give up on it. Also, make sure you set a point where you say "I'm done" and you'll be much happier in the long run. I've had plenty of friends lose interest due to major scope creep with their projects. Either they never finish, or they end up building something that is not very streetable and get bored with it because they don't want to take it out. Jay's purple car is a prime example. He put a ton of work into it and it turned out fantastic, but he rarely takes it out. I'm sure Jay will vouch that he has way for fun with his wagon.
Honestly, I know exactly what you're saying and I agree. To some extent, it has already happened (the loss of interest). But every time I see Jay do a burnout in his wagon, my drive is rekindled. I'm also tired of having the ****tiest car at the meet.

Quote:
Originally Posted by Evil Imports View Post
honestly, i do have more fun with my wagon, because its the car i ALWAYS wanted, and you can't buy it, i would take my sti out more but i am to lazy to move the wagon to pull the sti out, otherwise i would drive it,

If ken losses interest in him car and doesn't wanna finish it, i will buy it off him
Not for sale. Yet.
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Old 09-27-2010, 12:04 PM   #18
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Ken, i don't wanna buy it, just saying if you were going to sell it before finishing it, i would, LoL, i am sure i am the only one around that gets a cloud of smoke out the back of there wagon on launch
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Old 09-27-2010, 12:43 PM   #19
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subscribed.
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Old 09-27-2010, 12:54 PM   #20
SaabaruMike
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I haven't driven my GN in almost 5 years now. Not a day goes by that I don't hit up CL and look for something else that I'd be willing to part my GN out for. It's tough because I still have ALOT of work to do and the budget is about to dry up. I decided to just put it back together and deal with the trashed paint and interior later. At least I will enjoy it for awhile and get motivated again. Hopefully I will have it back on the road by the end of the year.
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Old 09-27-2010, 12:55 PM   #21
fastnoypi
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Quote:
Originally Posted by kpluiten View Post
Honestly, I know exactly what you're saying and I agree. To some extent, it has already happened (the loss of interest). But every time I see Jay do a burnout in his wagon, my drive is rekindled. I'm also tired of having the ****tiest car at the meet.


I guess Jay will have to do more burnouts to keep you inspired!
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Old 09-27-2010, 03:37 PM   #22
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Not that you need any help, but if you need any supplies for the leveling harness let me know, we still have lots of harness building stuffs here in the shop.

Be more than happy to help... Looks to be a quality build.
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Old 09-27-2010, 05:51 PM   #23
kpluiten
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For those that are interested, the Group-N part numbers for the suspension links are:

Lateral Links:

Front/Rear Outer: ST2022044020 or B0220FE020 (Qty: 4)
Front Inner: ST2022044030 or B0220FE030 (Qty: 2)
Rear Inner: ST2022044040 or B0220FE040 (Qty: 2)

Trailing Arms:
Rear: ST2022044010 or B0220FE010 (Qty: 2)
Front: ST2022044000 or B0220FE000 (Qty: 2)

The total price for these is between $175 and $225. Relatively cheap considering the huge boost in rear end stiffness and responsiveness.

Here's a diagram. I've circled the ones listed above. This should tighten up the rear end considerably.



A lot of people have asked me why I chose the rubber Group-N units over Whiteline or PolyPro. The answer would be personal preference. The Group-N's are rubber which should hold up longer without needing to be greased or re-packed. Polyurethane is stiffer, but often needs to be cleaned and repacked with grease from time to time to prevent squeaking and wear. There is a debate on whether or not to use polyurethane in rotational applications as well with good points being made on both sides. Basically I like rubber because of it's set-it-and-forget-it nature and it doesn't transmit quite as much vibration/harshness. Currently, my swaybar bushings, which are polyurethane, squeak/groan like crazy about every 10K miles. This is eliminated with a re-greasing.

Either option is WAY better than the stock bubble gum units.
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Old 09-27-2010, 06:24 PM   #24
blkscooby
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Great thread Ken.

I think you should get MNY PIT as a new plate when its finished
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Old 09-27-2010, 06:36 PM   #25
kpluiten
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Great thread Ken.

I think you should get MNY PIT as a new plate when its finished
Already taken. I tried "BROKEN" too. No dice.
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