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Old 03-01-2013, 03:51 AM   #1
akfmx
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Member#: 226059
Join Date: Oct 2009
Chapter/Region: AKIC
Location: AK
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Icy Silver
Legacy

OMGHi2U 2000 Fozzy, custom rotated TD04...Wut



The list:

-Stock block
-rotated and clocked TD04
-06-07 wrx wastegate actuator
-02-05 wrx intercooler w/ custom inlet
-Custom 2" up-pipe
-Custom 2.5" Downpipe
-Borla replica UEL headers
-ACT HDSS clutch
-2.5" intake pipe with AEM Dryflow
-wrx 440cc injectors
-Stock wrx fuel pump
-Emanage Ultimate
-2004 wrx hoodscoop
-2004 wrx struts with tein springs


The car: I originally had an 03 WRX for two years...long story short, sold it and wanted to find a NA subie for a reliable DD. I figured I wouldn't do much besides lower it and upgrade the sound system. Another long story made short; I found a 2000 Forester, 5 speed, 190k with a recently replaced engine for sale... I was stupidly in a rush to buy a car after searching for about a month. This was being sold by those russian folk on craigslist that are always buying broken Subies and reselling them. Of course, he made up some story about buying the car for his wife, but she didn't want it blah, blah, blah...I knew the real story because I had talked to him previously when he wanted to buy my wrx. So I was a bit leery. After driving the car around the block and looking it over, I was surprised at how well it drove and the cleanliness of it.



Bought it, and then the problems started showing up. On the way home from Anchorage to Anchor Point, the CEL came on and the cruise control didn't work. Also, since the factory plastic undertray was on the car, I couldn't see the massive oil leak under the car, which turned out to be the headgaskets.

A little later I bought some 04 wrx struts and some Tein S-Techs to get rid of the nasty wheel gap.




Then it was time to fix the headgaskets. I had done a ton of research and found out you could do it with the engine in the car (I had never pulled an engine before). But to me, that didn't seem like the best way to do it. And after more research I decided to pull the motor myself and do a complete headgasket and engine seal overhaul. Pulling the engine was a lot easier than I had imagined.




I used EJ257 headgaskets because they are multi-layer steel (unlike the standard EJ251 gaskets) and are a direct fit to the EJ251. All the passages line up the same. Considering I didn't know the mileage of the engine (since it had been replaced), I did the timing belt, idlers, water pump as well as most of the engine seals including cam, crank, rear main seals.

Had the heads checked and machined for flatness. I took my sweet time with this project because I wanted to do it right the first time. That and waiting for parts, it took me a few weeks to complete.

All ready to go back in



Put it all back together and threw on some borla replica uel headers I got from ebay. I *thought* these were gonna give me the subie rumble... nope. Need a catback exhaust or atleast a cat delete pipe. Oh well, they look cool.

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Last edited by akfmx; 04-05-2013 at 09:39 PM.
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Old 03-01-2013, 03:52 AM   #2
akfmx
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Chapter/Region: AKIC
Location: AK
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Icy Silver
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Built a slot ported box to match my Boston G1 10" sub. A lot better sounding than the prefab sealed box I was using before.



I started to miss having a turbo...and after doing too much forum surfing, I had a brilliant plan on how to turbo my car. I say brilliant because the way I had it worked out in my mind I had a relatively small parts list....the actual parts list has more than tripled in size

I started gathering parts. Kirk donated his old TD04 to the cause. My original plan was stock wrx turbo placement, using a stock downpipe, FXT slim intercooler, and custom making an uppipe that mated to the NA headers.

Sometime during this point I had Seth at P3 install an ACT HD clutch, in preparation for boost.



After more thinking, I figured it wouldn't be much harder to customize a downpipe since I am already making a custom uppipe. This way I could rotate the turbo and have a better turbo intake that avoids the intake manifold all together. So my brother and I chopped up a stock downpipe and got here.






BUT, after more thinking, I scrapped that idea and went another direction. I picked up an 02-03 TMIC as well as a wrx fuel pump and stock wrx 440cc injectors from Mike (Nomad). My new, and current plan is to weld an inlet into the side of the intercooler and clock the TD04. It will be similar to the Ludespeed turbo kit. Picked up some exhaust pipe from napa and some mandrel bends from mandrel-bends.com. Cut up a stock up-pipe and downpipe for the flanges and got to work.

Here is the mockup of the turbo placement



Up-pipe


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Old 03-01-2013, 03:53 AM   #3
akfmx
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Icy Silver
Legacy

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And here is how the charge pipe will look.



Started working on the downpipe. I can't finish the downpipe until I get a wrx catback, as it is a different length than my NA exhaust.





And here they are semi finished. They are made out of aluminized steel, but I think I will eventually coat them with VHT high heat ceramic paint.



And that is currently where I am right now.

My room is littered with boxes full of parts waiting to be installed. I'm still waiting on a couple more things before I can really install all of it. Hopefully in the next week or two...

For engine management I will be using Greddy Emanage Ultimate. Still have to hardwire it in.

I will be running on the stock internals while only boosting wastegate pressure, 6psi. The combination of boost and high compression should (according to other peoples builds) yield me some decent fun. And staying low boost seems to be pretty safe for these engines. I hope to someday drop in an EJ257 shortblock and larger turbo...but thats a ways down the road.


blownout by rmbfilms, on Flickr
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Old 03-01-2013, 04:00 AM   #4
Racer Dubya
some old guy
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1985 78 HP of Rage!
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Love the look of the 1st Gen.
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Old 03-01-2013, 05:55 AM   #5
05GDF
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Nice build and beautiful car.
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Old 03-01-2013, 06:02 AM   #6
Nomadgene
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Location: above 8000 rpm!
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2002 EJ207 V8 1.5xtr
TWIN-SCROLL Black Bugeye

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Love that you've put some of my old parts to work in a new machine of your own making. It's like organ donation. The gift of life!
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Old 03-01-2013, 06:10 AM   #7
BackflipJeff
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Satin white

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This is an awesome build love the innovation and just pure fab of this build keep up the good work can't wait to see it!!!!
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Old 03-01-2013, 06:39 AM   #8
Dominator
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Location: Fairbanks, Alaska
Vehicle:
1991 Legacy SS
Pearl White

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Great project so far. Lots of ingenuity. I too like the looks of the 1st gen Fozzies.
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Old 03-01-2013, 06:51 AM   #9
insane_one
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2010 Subaru WRX
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I love these build threads!! How much hp would this be pushing once all setup? I know its not a huge monster im just curious how it would compare to a wrx or so. Please keep us updated!
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Old 03-01-2013, 07:17 AM   #10
D. FiSioN
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2006 WRX STI
and a 12 Forester XT

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He'll YeA! Props!
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Old 03-01-2013, 01:05 PM   #11
akfmx
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Icy Silver
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Thanks guys

Quote:
Originally Posted by insane_one View Post
I love these build threads!! How much hp would this be pushing once all setup? I know its not a huge monster im just curious how it would compare to a wrx or so. Please keep us updated!
No monster...yet Based on other peoples builds, about 10hp per psi could be gained. So, in stock form my car is around 165 and should be up around 210-225 at the crank when all said and done. Pretty close to a stock wrx. And the high compression/low boost should make it quicker than a stock wrx. I'm not really concerned with numbers though, just hoping it will be fun


I'm hoping to bring it back in the shop this coming week and start putting it together. I've got a laundry list of things to do; install the hood scoop, boost gauge, oil return fitting, etc..
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Old 03-01-2013, 01:10 PM   #12
insane_one
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Nice!!! Well keep us updated!
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Old 03-14-2013, 11:24 PM   #13
akfmx
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Icy Silver
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Made some progress this week.

Started with installing the hood scoop. Went through 3 cutoff wheels on the dremel. Took a long time cutting the hole, but it was worth it to me to have a nice looking cut. As far as attaching it to the hood, I followed this thread http://www.sl-i.net/FORUM/viewtopic.php?f=39&t=24703 and used clip on speed nuts and m6 bolts which I cut to proper length.







And today I tackled the boost gauge. Wasn't too hard. I found out the bulb that was in it was dead. The picture shows a bulb I stole from the cluster just for test purposes. I plan on ordering some LEDs soon for the cluster and boost gauge...





This weekend I will hopefully be putting everything together and firing her up for the first time with the turbo. I think I have all the parts finally. I still need to have my friend weld the intercooler though. I might take it around the block *slowly* and stay out of boost as the car still has stock injectors and no engine management. Once I get the eManage wired in and working I will need to get the car to anchorage to get the injectors installed and car tuned.
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Old 03-14-2013, 11:57 PM   #14
MOBBiN
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Join Date: Oct 2006
Chapter/Region: AKIC
Location: Prudhoe Bay / Eagle River
Vehicle:
2006 STi WRB
01 BRP RS, 01 Silver XJ

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I love love love silver cars with gold wheels <3

Great build so far ill be following it
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Old 03-15-2013, 02:56 AM   #15
insane_one
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OBP Hatch

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awesome progress! in for more updates
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Old 03-15-2013, 03:24 AM   #16
cosseywrx
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OBP

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Lmk how the led cluster goes! I wanna do this once i get an sti cluster
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Old 03-15-2013, 02:54 PM   #17
P3Auto
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Location: 907-355-6655 text or phone
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2014 P3 Import Auto
AWD Dyno, Mods, etc

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Looks very good. Glad to see you doing this! Bring it by when ready and we can toss it on the dyno for a little output test!






Seth
P3 Import Autowerks 907.355.6655
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Old 03-15-2013, 04:53 PM   #18
AkWrx99556Srr
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Bling Blang

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Old 03-15-2013, 05:12 PM   #19
akfmx
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Quote:
Originally Posted by cosseywrx View Post
Lmk how the led cluster goes! I wanna do this once i get an sti cluster
For sure. I'll post in here when I do it. I plan on ordering from superbrightleds.com. I haven't heard ALL good things about them but the particular LEDs I'm looking at seem to be good.


EDIT: Since I still have my cluster out, I decided to go ahead and order the LED's



The 194's are for the cluster, the red 74 is for the boost gauge and the warm whites are for the HVAC controls.

Quote:
Originally Posted by P3Auto View Post
Looks very good. Glad to see you doing this! Bring it by when ready and we can toss it on the dyno for a little output test!

Seth
P3 Import Autowerks 907.355.6655
Thanks Seth. Whether you realize or not you have helped me a lot answering my questions and giving advice


Ayyy Kirk I'm starting to realize I need to fill out those fenders more...where those DPTs at?

Last edited by akfmx; 03-15-2013 at 05:37 PM.
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Old 03-15-2013, 05:43 PM   #20
sicotic
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Wow man, looks awesome. I have always liked the foresters.
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Old 03-15-2013, 05:57 PM   #21
GrimmSpeed
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Cool project! very nice progress so far!

Mike
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Old 03-15-2013, 09:11 PM   #22
insane_one
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superbright FTW!
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Old 03-16-2013, 03:26 AM   #23
granny
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- PowerflexUSA - Moore -

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Wow I've been off the forums too long! Didn't even see this thread! Looks great!
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Old 03-16-2013, 02:16 PM   #24
akfmx
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Quote:
Originally Posted by GrimmSpeed View Post
Cool project! very nice progress so far!

Mike
Thanks!

Quote:
Originally Posted by insane_one View Post
superbright FTW!
I assume you have had a positive experience with them?

Quote:
Originally Posted by granny View Post
Wow I've been off the forums too long! Didn't even see this thread! Looks great!
Haha thanks, now update your thread!!
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Old 03-17-2013, 01:37 PM   #25
granny
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Quote:
Originally Posted by akfmx View Post
Haha thanks, now update your thread!!
Still probably a month away before I can update it.
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