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Old 01-08-2014, 08:59 AM   #1
no694terry
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Default My 98 Forester FrankenTurbo project

I had a few motors laying around. Currently in my forester is a High Compression Frankenmotor. Here on my tool bench is the low compression version, 22e block with 25d heads. Mines slightly different since i'm using 96 heads for the HLA's and sligthly larger combustion areas.

specs:
Walbro 255
STI 550cc side feeds injectors
38mm Tial EWG dumping, current has the 13psi Green spring in it.
Emanage Ultimate engine management
bosch/glowshift wideband
VF43
Perrin FMIC
TurboXS RFL BOV
Clutch South Bend Stage 2
Transmission is a Legacy Outback 5mt with 04 H6 LSD rear end (4.11)

Motor on bench, just making sure all the peices are there before i tear i back apart for cleaning and all new gaskets.



Here's a pile of goodies I got from my brothers friend who just sank a bunch of money into his STI.



As i learned more about EWG's i discovered that the old owner never removed the turbos internal gate, this probably explains why theres a large green spring in the Tial, He could never figure out why he couldn't increase his boost, LOL. So i went ahead and welded the gate shut, so now the Tial can do it's job. First i cut off the arm, clampes the gate closed, and ran some weld around its shaft.





I'm starting to second guess which head gasket I want to use. Generally I would use the one specified for block but with these 96 heads, the 2.5 gasket seems to be a better fit.

97/98 EJ25D Head (left) 96 EJ25 HLA head (right)


96 head with Phase 1 2.2 gasket


96 head with phase 1 2.5 gasket


97/98 head with phase 1 2.2 gasket, This heads design allows for it to be used on a much smaller bore while still sealing the bore size gasket.


Just look at all this room.


I still need to get the downpipe off the STi guy, he forgot to bring it over last time I saw him. Once i have it I can cut it apart and decide on where turbo will fit. Then I will weld downpipe back together and make an uppipe. I also have to find an aluminum nipple that i can tig welg into the bottom of the right head for an oil return.

More to follow but I'm short on cash so progress will be slow.
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Last edited by no694terry; 08-02-2014 at 02:04 PM.
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Old 01-08-2014, 09:58 AM   #2
Patrick Olsen
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Interesting shot of the HLA heads vs later EJ25D heads. One of the replacement JDM engines that has cycled through my '97 2.5GT had the HLA heads - it put up solid numbers on the dyno, we were pleasantly surprised.
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Old 01-12-2014, 04:52 PM   #3
no694terry
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cant make much progress bein broke so I at least fit up the fmic today. Sadly the fog lights are gonna have to go unless I lower the intercooler about an inch. And I need to raise my lower rad hose to get intercooler pipes to fit. I just need a front outlet water pump like on the 06+ 2.5i




Last edited by no694terry; 01-12-2014 at 06:28 PM.
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Old 01-17-2014, 01:17 PM   #4
no694terry
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Drilled and tapped the RH head yesterday to accept the oil return. Also got a spool of ER308L wire to start welding together all the stainless exhaust and intercooler piping.

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Old 01-18-2014, 09:16 AM   #5
no694terry
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why do good clutch kits have to be so bloody expensive?
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Old 01-18-2014, 09:48 AM   #6
beaviscih
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Cool looking project. I just picked up a '98 Forester but will be keeping it stock since it will be my teenager's first car. I like the pictures of the heads / gaskets too.

I have a set of the same 2.2 heads in my basement. I ran these on my '93 GF8 track car for several season before moving to the EJ25D. The 2.2 heads were great. We pushed the redline to 7K and never had a problem but I wouldn't go any higher than that for fear of floating a valve. It will be interesting to see the final results.
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Old 01-18-2014, 10:58 AM   #7
no694terry
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The 2.2 heads on my 25d block won't rev past 5500. I mainly built that motor for traffic. Having peak torque right off throttle makes lanes changes right on que. Plus the 98 forester is the only model with the GC ecu. Its maf and easily manipulated.
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Old 01-19-2014, 06:14 PM   #8
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Have you ever seen a ej257 in the first gen?
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Old 01-19-2014, 07:39 PM   #9
no694terry
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Quote:
Originally Posted by Pandasaur View Post
Have you ever seen a ej257 in the first gen?
Not that I remember but I'm sure its been done.
Every time I drop a motor in, I start on the next on. Next is gonna have an ej255 or 257 bottom end and forged pistons with an RA transmission.
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Old 01-20-2014, 01:33 AM   #10
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What transmission would you recommend to use. Would the jdm 5 speeds would be compatible?
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Old 01-20-2014, 08:17 AM   #11
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Anything with RA width gears. Theres a few options out there that dont require a full driveline swap. Even the newer 5mt's +06 plus i believe are all upgraded to RA width gears. However the 6mt's are still the top dog but come with the price to match. Also for the cost of a good clutch to fit an NA transmission, your better off spending more on a turbo transmission to take advantage of the pull style clutches.
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Old 01-20-2014, 02:52 PM   #12
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Sweet thanks. O and the wiring harness did you merge the two together or just bought a whole separate one
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Old 01-20-2014, 05:12 PM   #13
no694terry
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EManage has a b84/gc8 connector for the pre99 ECU's but I'm cheap, I'll wire mine in under glove box.

I think you misunder stand my swap. I'm not doing the traditional wrx swap. To put it simply, I'm putting a 2.2 bottom end and a turbo in. Just took the long way there
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Old 01-20-2014, 05:31 PM   #14
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Ahh okay okayy. O no lol I was just asking question about putting a ej257 in a sf5 because I'm getting my buddies engine
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Old 01-22-2014, 09:18 AM   #15
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this looks very cool!
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Old 01-22-2014, 09:39 AM   #16
no694terry
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Quote:
Originally Posted by Pandasaur View Post
Ahh okay okayy. O no lol I was just asking question about putting a ej257 in a sf5 because I'm getting my buddies engine
If i were to be given an ej257 i would probably take the block and put it between the stock heads and turbo it. Using stock heads means stock manifold which means stock wiring until you install a piggyback. Hooking up some oil/coolant lines is much easier than trying to get all the extra pieces needed to run the 257 heads.

My build is painfully slow right now mainly because i didnt get a bonus i expeced. and now i'm trying to decide between buying the emanage or 18" tires for my wheels.
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Old 01-22-2014, 06:05 PM   #17
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I bet man. But it's all going to be worth it in the end. And yeah I'll be getting the turbo as well. He might leave the 20g or the stock one.
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Old 03-12-2014, 07:16 PM   #18
no694terry
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bought the tires, and a RFL BOV and all the gaskets I need to put the 8:1 motor together. I think I'm going to hold off on an emanage and go the FMU route, the transmission cant handle much anyway, I don't know how to tune, and the cars is my DD. I'll still have the wideband but going to start around 5psi and work my way up until I start getting higher than 11:1 afr's. I also picked up my matte black paint today to paint the body one of these weekends
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Old 03-15-2014, 09:21 AM   #19
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I've always thought of the older Forester chassis as underused/underappreciated, props to you. What sorts of power #'s are you hoping to hit with your setup? Can't wait to see pictures of her painted up!
-Art
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Old 03-15-2014, 09:56 AM   #20
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Ya i think people think they're heavy. My 98 weighs just over 2900 and is basically a 98 2.5rs that accepts GD chassis parts. I'm not going for crazy numbers, would just like to match a stock sti. I been over on rs25 a lot since its the closest i got and a lot of them do turbo swap. Debatting rrfpr fmu vs electronuc emu now.
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Old 03-15-2014, 03:28 PM   #21
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Quote:
Originally Posted by no694terry View Post
Ya i think people think they're heavy. My 98 weighs just over 2900 and is basically a 98 2.5rs that accepts GD chassis parts. I'm not going for crazy numbers, would just like to match a stock sti. I been over on rs25 a lot since its the closest i got and a lot of them do turbo swap. Debatting rrfpr fmu vs electronuc emu now.
Exactly. It's the "looks heavy=heavy" mentality. That's a good plan, STI power in one of those is more than enough to enjoy yourself. I have an EJ205 laying around that may get stroked and put in an old Fozzy at some point.
-Art
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Old 03-16-2014, 07:03 PM   #22
no694terry
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got the block on a stand today, makes life so much easier. I resealed oil pump and oil pan, getting ready for final assembly when gaskets get here. While I had the oil pan off, two things surprised me. One, the pickup tube support is way better than my 2.5 blocks. And two, there was a small rock in the pan, about the size of a marble.

Yesterday while is got above freezing for a little bit, I repaired a large dent in my driver side quarter panel and filled some other dings. The paint is still on the shelf just waiting for the day.
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Old 03-17-2014, 09:37 PM   #23
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This looks like its gonna be fun!
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Old 03-20-2014, 08:24 AM   #24
no694terry
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I started final engine assembly last night. Got the heads on and the cams in. These hydraulic lifters are making me nervous. I had them all in a box flat side up and i guess they all bled down into there tallest position. When i went to put cams in, the lifter held the cams up out of their seat. I continue to torque the caps down and the lifters just open the valves up. I'm hoping today they are all squeezed back in and i can get a good feel for the cams moving freely.

Tonight i plan on getting the timing together and put all the covers on.
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Old 04-08-2014, 09:01 PM   #25
no694terry
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motors all together but I cant quit thinking about engine management.

Why isn't there a Subaru anywhere running a MAF translator, granted they might be best suited for pre-99 3 wire MAF's but still. A gen 2 will allow you to swap in a GM maf blow-thru style and let you run a vented BOV. it will also autotune and allow fuel adjustment. all for $250
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