jtrakel's 04 sleeved & O-ringed-GTX3582

[jtrakel]

I’ve always looked through other peoples build threads and have finally decided to start my own. I wish I’d taken more photos along the way but no going back now! Here is my 2004 STI it has gone through a few “face lifts” I bought the car stock minus the wheels, coilovers, and exhaust. Almost all the work has been done myself with the help of a few friends. My car should finally start in the next few days and I can start on my break in miles. I have a power goal of 550whp on E85. I have no idea why I wanted to push my car this far but hey I’m here now! The last set-up I had on before made really good power but I knew it would not last with a stock block everything was tuned on speed density from Mike at PIA running E85. I owe so many thank you's to Mike for the countless hours he has spent on the phone answers questions and coming in during non-work hours! Also many thanks to the rest of the crew at Pacific Import Auto a true family ran live up to their word shop!




Old set-up:
Garrett 3076R .63ar
TIAL 44mm EWG
Rotated STI manifold with A/C delete
Turbo XS FMIC
Rotated manifold piping black w/crushed glass
TGV deletes
Mishimoto race radiator
Mishimoto 170 degree thermostat
Perrin fuel rails w/steel braided lines
FIC 1100cc top feed High-z injectors
Walbro E85 400lph in tank pump
AEM fuel pressure regulator
HKS titanium axle back
Race Ready electronic exhaust cutout welded into downpipe
Crawford V2 A/O seporator

Car made 470whp and 438tq with my cut-out open not to shabby for a stock block on E85!

04 Sti exhaust cut-out 475whp - YouTube

04 Sti exhaust cut-out 475whp - YouTube

Now time to move on to what I'm currently working with I'm going to add photos of the build process after the specs hope you all enjoy. I cannot wait to get this thing back on the dyno after the break in!

I picked up the block already sleeved and o-ringed from a member on here, once everything arrived it went to the machine shop to get the sleeves inspected and bored to fit the pistons. I decided against doing any type of head work because I do not spin out my motor very often. I understand that with a larger turbo I will be in the higher RPM range. The GTX35 is a trial more or less ff I do not like the spool time etc. I will pick up a GTX30 and tune off that. I got a great deal on the 35 which is the reason why it's installed.

Current set-up:
Go fast
Darton sleeved EJ257 bored to 100.5mm
CP 100.5mm pistons
Manley Trubo Tuff "I" beams
OEM forged heat treated crank
Clevit main and rod bearings
A1 Technologies H11 Head Studs
Fluidampr crank pully
GSC S2's 272 cams
GSC behive springs and retainers
OEM intake and exhaust valves
Blueprinted 11mm Sti oil pump
Balanced rotating asseymbly .01 grams
Rotated STI manifold with A/C delete
Gates racing timing belt
New water pump, pulleys, blah blah blah
Turbo XS FMIC
Custom Rotated manifold piping originally done to keep AC but that's gone now
TGV deletes
Mishimoto race radiator
Mishimoto 170 degree thermostat
Aeromotive fuel rails with custom steel braided lines all -6 AN fittings
FIC 2150cc top feed High-z injectors
Walbro E85 400lph in tank pump
AEM fuel pressure regulator
Garrett GTX3582 w/ TIAL .82ar exhaust housing (not running BOV just using compressor surge for now)
TIAL 38mm EWG dumping to atmosphere 1.0 bar springs for break-in tune
V-band rotated up-pipe
V-band rotated down-pipe
HKS titanium axle back
Race Ready electronic exhaust cutout welded into downpipe
Killer B oil pickup
Killer B oil windage tray
killer B oil pan
Crawford V2 A/O seporator
Other random custom bits througout engine bay (alaskan amber bottle, patrone bottle)

Handeling/XMSN
Sitting on some ****ty K-sport coilovers
Perrin 23mm front and rear sway bars
Rallispec pillow ball front and rear end links
Whiteline steering rack bushings
Whilteline rear subframe lockdown bolts
Whiteline shifter bushing (front and rear)
Whiteline "race" anti-lift kit
Excedy twin disc performance clutch
Kartboy transmission crossmember bushings
TQ solution transmission bushing
TQ solution pitch stop
Group-N transmission mount
Mike T. custom spec motor mounts
Some sort of XXR wheels with some ****ty tires
EBC slotted and dimpled front rotors
EBC red stuff front brake pads
Stainless steel brake lines
COBB short throw adj shifter
1 1/2lbs shifter ball (mobile weapon!)

Electronics
Defi BF series- boost, EGT, oil press, oil temp, water temp, and fuel pressure (all imperial)
Inovations wideband o2 sensor


Starting assembly


installing the O-rings


Some killer-b love


Mock up for my custom fuel lines (wife choose colors)



How she sits right now!

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[WhatTurboLag?]

Very nice I want to see how reliable this will be!!!


I like the coolant lines

[TheColorCute]

Looks great! Can't wait to see what it puts down!

[snake32]

looks like it's gonna be fast dude! i'm putting a bone stock 04 sti longblock in my car this week, shooting for 400whp on the perrin rotated gt3076r .63, it's php and have the same injectors, last time i couldn't go that far on the E85 bc of the fuel pump, wondering how hard is to install the walbro 400 in place of the stock one?

[jtrakel]

Originally Posted by WhatTurboLag?

Very nice I want to see how reliable this will be!!!


I like the coolant lines

Thanks it should be very reliable it's not a daily so the beatings will not be frequent for the most part after the initial break-in miles.

Originally Posted by snake32

looks like it's gonna be fast dude! i'm putting a bone stock 04 sti longblock in my car this week, shooting for 400whp on the perrin rotated gt3076r .63, it's php and have the same injectors, last time i couldn't go that far on the E85 bc of the fuel pump, wondering how hard is to install the walbro 400 in place of the stock one?

I totally forgot to mention I'm running E85 I ran it on the last set-up as well will edit OP

[Ballistic1350]

Is that the stock header I spy? how come?

[jtrakel]

It has a grimmspeed x-over pipe. I was never a fan of the way some aftermarket exhaust manifolds sound or I have not found the right one yet. But the OEM halves did pretty well with my last set-up so ill run them until I find something better.

[jtrakel]

Originally Posted by snake32

looks like it's gonna be fast dude! i'm putting a bone stock 04 sti longblock in my car this week, shooting for 400whp on the perrin rotated gt3076r .63, it's php and have the same injectors, last time i couldn't go that far on the E85 bc of the fuel pump, wondering how hard is to install the walbro 400 in place of the stock one?

hand tools will take care of the fuel pump swap it's a drop in replacement!

[fastblueufo]

I love your build. Almost exactly like my new build minus the sleeves and o-rings. I've got an ej22t being sleeved and o-ringed now. What type of o-rings? O-ring heads and block or just block? What type head gaskets are you using?

If you don't like the spool of the 35r (I didn't) look at the precision 5858. On my ej22t it put down over 450 at just over 25 psi. I've got it on a 2.5 hybrid now and it hits 20psi at 3900 rpm and still puts out old 35r numbers. I see your using the gtx 35 so you may like it better as its supposed to be a better spooler than an original 35r.

Great build man. Congrats!!!

[jtrakel]

Originally Posted by fastblueufo

I love your build. Almost exactly like my new build minus the sleeves and o-rings. I've got an ej22t being sleeved and o-ringed now. What type of o-rings? O-ring heads and block or just block? What type head gaskets are you using?

If you don't like the spool of the 35r (I didn't) look at the precision 5858. On my ej22t it put down over 450 at just over 25 psi. I've got it on a 2.5 hybrid now and it hits 20psi at 3900 rpm and still puts out old 35r numbers. I see your using the gtx 35 so you may like it better as its supposed to be a better spooler than an original 35r.

Great build man. Congrats!!!

Thanks I'm looking forward to starting it I thought it was going to turn over today but my tuner was not able to make it to my house. We are not sure how it's going to idle with those huge injectors so I'm just waiting on him so he can do his magic! I only have the block o-ringed the heads have not been touched at all minus the valve train. I used a 18 gauge bare copper wire and we just tapped it into the groove and made sure it had a good amount coming out the top so it had some good "squishing" with the head gasket. I used OEM head gaskets as well no need to do anything crazy!



I've looked at other turbos but we will see how this GTX35 works I'm hoping it makes me happy because otherwise it will bug the crap out of me until I find something different!

[spintheground]

Very interested in results, subbed!

[spintheground]

Update on this?

[jtrakel]

Sorry I've been busy! It's running ill take a video later and some photos but I'm about 600miles into my 1k break-in period. Everything is looking good so far hopefully ill be on the dyno within a week!

[spintheground]

Awesome, can't wait to see your results!

[NSFW]

Cool project! Looking forward to results...

[Black07STiGuy]

Man I miss WA. Mike, Steve and all the guys at PIA are awesome. I remember just going there and watching them do their magic. They taught me a lot about the platform, and even explained install instructions over the phone for small things when they could have had me come in and pay them to do it. Awesome guys. Good luck on your full tune, hope you reach your goal.

[jtrakel]

ya the shop is great I'm hopefully going to tune this week I finished up my break in miles this past friday!

Cut out idle - YouTube

Cut out idle - YouTube

[shadowmd]

I like the cluster! Black outlines around the gauges!! Not to mention the sick build!

[jtrakel]

Originally Posted by shadowmd

I like the cluster! Black outlines around the gauges!! Not to mention the sick build!

Thanks I forgot I did that! It's like a re-discovery!

[shadowmd]

Originally Posted by jtrakel

Thanks I forgot I did that! It's like a re-discovery!

Lol you've inspired me to do that. Weekend project! Haha

[jtrakel]

Well just a update for anyone that was/is following this thread I was just told a few days ago that I will be leaving home for a few months so the car has to wait. I've been so busy I have not had time to install my new 11mm oil pump and get it tuned so now I must wait! I did have it professionally detailed yesterday though so at least it will sit looking pretty! Well talk with you all later! I hope to have some amazing numbers on the dyno when I get back. Sucks that my car is running so well and I'm so close to being done with this phase that I have to wait now! I'll depart with some current photos!



And just because!

[john 1badSTI]

Are you going on a duty trip?

[jtrakel]

Originally Posted by john 1badSTI

Are you going on a duty trip?

Yes I am to the wonderful land of Afghanistan