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Old 04-17-2013, 11:35 PM   #1
jdogma
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Default Subaru EZ 30R mid engined track day car

I have really enjoyed reading on this forum and have learned a lot due to my prior ignorance about Subarus. I have been building a mid-engined, open 2 seat track day/road car for use as a fair weather sports car and club racer. It is designed to use a WRX engine with a 5 speed WRX gearbox.

some specs:
Wheelbase - 102.5 in.
OAL - 172 in.
OAW - 79 in
Height - 43 in (top of rollbar)
weight - 1660 lb 40/60 F/R%
Engine - 2007 EZ 30R from a Tribeca, 8.5:1 Supertech Pistons
Transaxle - 2008 WRX
Engine Management - Hydra
Turbo - Forced performance FP HTA GT3582R
Suspension - unequal length A-Arms, front; 5 link rear Len Terry type rear.
Spring/shocks - Niprotek Nitrogen gas springs w/ 5 way damping and infinitely adjustable spring rate.
Tires - Hoosier R6 205/45-16 front; 275/45-16 rear
body - carbon fiber with Nomex honeycomb core

I have built other mid engined high performance cars (my old company was Evans Automobiles), mostly Chevrolet powered, but wanted to do an open 2 seat car using a FWD engine/trans combo to make it affordable and to take advantage of the import tuner aftermarket that we have. https://plus.google.com/photos/10818...842?banner=pwa

The reason for choosing the Subaru drivetrain are the low engine and the longitudinal layout. I thought Honda or Mitsubishi (really wanted that paddle shift) initially, but the engine requires that the rear bodywork has to be pretty high (ugly). Also, both engines are almost directly over the axle, which is less than ideal for a mid-engine layout.

About that time, I had just read about Jeff Perrin's EZ 30R swap in a WRX and thought that would make a great flagship car. I would have saved a lot of time money and headache with an STI engine, but that's hindsight now... Another EZ 30 one would be easy now... Thanks to Jeff for helpful advice, thanks also to Phil Grabow of Element Tuning and the great guys at Outfront Motorsports who answered endless questions and supplied the headers, fuel rails and lots of other stuff. They seem to have more Subaru 6 cylinder turbo experience than anyone on the planet.

I am happy to share any information about the engine mods, specs, etc.

John
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Last edited by jdogma; 10-30-2013 at 05:51 PM. Reason: more info
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Old 04-18-2013, 03:16 AM   #2
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I am intrigued.
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Old 04-18-2013, 11:27 AM   #3
K.Linchpin
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Subscribed.
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Old 04-18-2013, 01:10 PM   #4
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pics? forged internal? what ECU? Why single turbo instead of twin turbo?

Nice project!
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Old 04-18-2013, 02:40 PM   #5
Evan
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Sounds like an awesome project. What's the current status? It would be great to see some photos. I clicked your photos link and it said I needed permission, so I clicked the button to request access.

The Niprotek website doesn't have any information. Do you have any links to details on the shock/springs?
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Old 04-18-2013, 03:58 PM   #6
jdogma
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Quote:
Originally Posted by juanmedina View Post
pics? forged internal? what ECU? Why single turbo instead of twin turbo?

Nice project!
Sorry, forgot to make the photos public. They are now. https://plus.google.com/photos/10818...865?banner=pwa

The pistons are forged. The rods are stock. I copied Jeff Perrin's 440 whp build as far as turbo size, pistons, rods, and Hydra ECU. We use an updated turbo, I think our intercooler is larger, and we should have less drivetrain loss due to not driving 4 wheels. There are lots of other minor differences too.

Single turbos are superior for maximum power because there is less heat loss. They are not as quick to spool as twin setups, but Jeff said there were no lag issues at these boost levels with the 3582. I'm not sure if twin turbos would be easier or harder as far as packaging and plumbing, but there would be more plumbing. A single turbo is less expensive and cost is an issue (for me anyway). I think if we start looking at 600 - 700 whp builds, a twin turbo setup would make sense, but then the whole build would be way more expensive, and another transaxle would be needed.

Last edited by jdogma; 04-18-2013 at 05:22 PM.
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Old 04-18-2013, 05:20 PM   #7
jdogma
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Quote:
Originally Posted by Evan View Post
Sounds like an awesome project. What's the current status? It would be great to see some photos. I clicked your photos link and it said I needed permission, so I clicked the button to request access.

The Niprotek website doesn't have any information. Do you have any links to details on the shock/springs?
You now have access. I screwed up and did not make it public, but it is now https://plus.google.com/photos/10818...865?banner=pwa

The Niprorek units are prototypes. I added a couple more photos of them. They consist of a hydraulic ram, a nitrogen spring with a rate adjuster and a valve body with external adjusting screws. The prototype units are additionally fitted with an adjustable reservoir that can be used to adjust ride height slightly, but is mainly to provide for a super wide range of adjustments for testing of these prototypes. The units are cool because you can adjust ride height and spring rate independently and because you have a rising rate which is why I wanted them. Since I expect pretty high aero loads (they increase with the square of the speed), any constant rate spring would be a compromise. If it was stiff enough for the high speed sections it would be too stiff for the slow speed corners, and if it was soft enough for the slow stuff it would bottom out at high speed. With these I can adjust the rising rate curve. I also have lots of damper adjustability with medium and high speed adjustable blowoffs for compression and rebound (compression is red, rebound is blue). They are also lighter than a coilover unit. Even the rod is aluminum.
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Old 04-19-2013, 12:33 AM   #8
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While I really REALLY still want one of Pook's TR-42 Exo-cars, I have to ask..... Are you planning on making more than one of these? If so, Cost??
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Old 04-19-2013, 12:49 AM   #9
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Looks awesome. What does the schedule look like for getting it finished?

What are you using for motor mounts? I noticed the exhaust is bolted to the chassis.
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Old 04-19-2013, 01:55 PM   #10
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Quote:
Originally Posted by GreenMarine View Post
While I really REALLY still want one of Pook's TR-42 Exo-cars, I have to ask..... Are you planning on making more than one of these? If so, Cost??
Yes, there are molds, planning is underway for production. Will offer them as rollers, finished cars or frame + body + suspension. Not sure if other than carbon body will be offered. Maybe woven glass epoxy, but the carbon bodywork is so light and stiff...

Pricing will be very reasonable. The car was designed for ease of servicing and ease of build too. It is also designed to be configured in different ways. For instance the fairings in front of the passenger and driver are added on so that they can be left off for different windscreen options or added on left or right only. Got to do a lot of figuring based on the realities of doing business these days, but should know very soon.

BTW, what does a TR-42 Exo cost?
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Old 04-19-2013, 02:06 PM   #11
jdogma
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Quote:
Originally Posted by Evan View Post
Looks awesome. What does the schedule look like for getting it finished?

What are you using for motor mounts? I noticed the exhaust is bolted to the chassis.
Road testing should start this month. One of the big things on the finish list is wheel tubs for the rear and they are started. Next up are running lights, brake and turn signals - headlamps might have wait a bit (investigating some LED options).

The motor mounts are stock Tribeca.

The exhaust appears bolted, but there is a stover locknut on a bolt through a steel bushing and allows the exhaust to grow ~ 3/8 in length and swing side to side. If the 2 degrees of freedom are not adequate the bushing will be replaced with a larger silicone rubber bushing.

Last edited by jdogma; 04-19-2013 at 02:43 PM.
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Old 04-19-2013, 04:35 PM   #12
Evan
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Quote:
Originally Posted by jdogma View Post
BTW, what does a TR-42 Exo cost?
I asked over on his forum and here's the response I got:

Quote:
The kit runs 13900 as a powder coated roller.
You can opt out of my wheels and tires to provide your own by subtracting 800.00
You can also upgrade and add a windshield, cluster, etc...
Source: http://forums.velocityofky.com/post/Prices-5890324
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Old 04-19-2013, 05:30 PM   #13
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Just saw the pics... FRICKEN AWESOME!!!!!

Keep us updated; that thing looks like a beast!!!
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Old 04-19-2013, 09:33 PM   #14
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Awesome project! That engine and chassis combo is going to equal one scary fast ride!
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Old 04-20-2013, 04:02 PM   #15
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Very nice. You should get a Photobucket account and post photos here. I have been building the Meyers Manx STi dunebuggy for years so very interested in others projects. I am always looking for ideas.

Thanks
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Old 04-20-2013, 06:00 PM   #16
jdogma
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Quote:
Originally Posted by RSti_Spyder View Post
Very nice. You should get a Photobucket account and post photos here. I have been building the Meyers Manx STi dunebuggy for years so very interested in others projects. I am always looking for ideas.

Thanks
http://i1284.photobucket.com/albums/...psb3f08839.jpg

http://s1284.photobucket.com/user/jo...?state=replace


Took your advice and tried photobucket. I see the photobucket link when I edit, but don't see the photo...

I get a lot of ideas from other people's conversions. I got the idea (and NAPA belt #) for simplifying the belt system from a guy who put an EZ 30 engine in an airplane.

I had a Meyers Manx (splash copy probably) that I used to autocross back when I was 17. Cut the windshield down so it was only about 8 inches high and it was much faster. I bet it will be super fast with an STI engine, but you may have trouble keeping the front down. I could pull a wheelie with mine (about 5 inch), a 1600 cc w/ twin solex and mild cam. How much heavier is the STI engine? Maybe with a front radiator, battery, etc. it will be good...



Last edited by jdogma; 04-21-2013 at 01:01 AM.
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Old 04-20-2013, 07:32 PM   #17
RSti_Spyder
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Copy the IMGcode and command V to place it in post. Doing this for me puts the photo itself in place. I am on a Mac...
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Old 04-20-2013, 10:28 PM   #18
Patrick Olsen
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Quote:
Originally Posted by jdogma View Post
Took your advice and tried photobucket. I see the photobucket link when I edit, but don't see the photo...
Because you're not using the [IMG ][/IMG ] tags. It's something new they started using on these boards just 10 or 12 years ago.

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Old 04-21-2013, 01:02 AM   #19
jdogma
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Quote:
Originally Posted by RSti_Spyder View Post
Copy the IMGcode and command V to place it in post. Doing this for me puts the photo itself in place. I am on a Mac...

Thanks!
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Old 04-21-2013, 01:06 AM   #20
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Quote:
Originally Posted by Patrick Olsen View Post
Because you're not using the [IMG ][/IMG ] tags. It's something new they started using on these boards just 10 or 12 years ago.
I'm slow...
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Old 04-22-2013, 01:20 PM   #21
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Nice. Subscribed.
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Old 04-22-2013, 02:15 PM   #22
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I'm still wondering about the engine choice. If you are only looking to make 450 whp or so, why did you choose the EZ30? It just seems like a lot of added cost and weight when compared to an EJ. Torque and power will be marginally different, for the same turbo and boost, because of RPM difference...I guess we can assume the EZ to perhaps has less frequent rebuilds because of power density.

Just curious,
Micah
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Old 04-22-2013, 05:13 PM   #23
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Very Very cool. Any reason behind not using an aftercooler?
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Old 04-23-2013, 12:23 PM   #24
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Old 04-23-2013, 08:08 PM   #25
jdogma
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Quote:
Originally Posted by Metzenw View Post
Very Very cool. Any reason behind not using an aftercooler?
Thanks! The intercooler is in the sidepod like on an Indy Car. The gas tank is notched out to allow for the plumbing.





The radiator is in the left sidepod and the intercooler is in the right sidepod.

Last edited by jdogma; 04-23-2013 at 09:31 PM.
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