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Old 06-11-2020, 06:45 PM   #1
Quick
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Join Date: Apr 2002
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Default Quick's 2006 STi build - track car

Thought I should start posting about the rebuild on my 2006 STi.

The backstory is that my buddy and I built two nearly identical cars - a 2009 and a 2006 STI. What started as a friendly competition turned into all-out track car builds - including Cosworth long blocks, dry sump, etc. It got extreme quickly.

Life changed and I ended up moving away and parted/sold my 2009. We finished his car and took it to the track, where a failed factory cam sprocket caused an engine failure within 10 minutes on track.

We took it home, pulled the motor for diagnosis and then lost motivation. The car sat for 5 years.

My buddy decided to sell it, and I wanted to see it live again so I brought it home. The car is currently in the process of being brought back to life.

In the time I've been gone from these boards (8 years!), it appears that nasioc has nearly died. I started an instagram to chronicle this rebuild (as well as other things I like), so it might be easiest to follow there. Though this is my first instagram so be patient.

A few pics to start posted already
https://www.instagram.com/quickmock/

Anyone know how I link instagram posts directly here? Life was easier when photo bucket didn't suck.
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Old 06-11-2020, 11:42 PM   #2
BlueSTI4Me
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Member#: 34361
Join Date: Mar 2003
Chapter/Region: MWSOC
Location: MI
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04.7 STI
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Quote:
Originally Posted by Quick View Post
Thought I should start posting about the rebuild on my 2006 STi.

The backstory is that my buddy and I built two nearly identical cars - a 2009 and a 2006 STI. What started as a friendly competition turned into all-out track car builds - including Cosworth long blocks, dry sump, etc. It got extreme quickly.

Life changed and I ended up moving away and parted/sold my 2009. We finished his car and took it to the track, where a failed factory cam sprocket caused an engine failure within 10 minutes on track.

We took it home, pulled the motor for diagnosis and then lost motivation. The car sat for 5 years.

My buddy decided to sell it, and I wanted to see it live again so I brought it home. The car is currently in the process of being brought back to life.

In the time I've been gone from these boards (8 years!), it appears that nasioc has nearly died. I started an instagram to chronicle this rebuild (as well as other things I like), so it might be easiest to follow there. Though this is my first instagram so be patient.

A few pics to start posted already
https://www.instagram.com/quickmock/

Anyone know how I link instagram posts directly here? Life was easier when photo bucket didn't suck.
If you use the book of faces, join Track Subies - Group, there are some serious competitors there. NASIOC has a free image hosting site, choose IMAGES in the above Banner. I've used the IG url here and that is about it.
Interested in seeing your rebuild. I'm got2boostit2 on IG.

Last edited by BlueSTI4Me; 06-11-2020 at 11:58 PM.
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Old 06-12-2020, 09:08 AM   #3
Quick
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Default

Nice. Didn't realize that nasioc had img hosting. Will use that for this thread.

Ok, here's the car to start. As it sat before we took it to the track and blew the engine.




Next was to yank the motor. The original build was somewhat conservative as it had a Dom 1.5XTR turbo in the stock location. The idea was a wide power band, and attempt to keep it reliable.






Bye bye engine


Gratuitous fuel cell and dry sump tank shot


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Old 06-12-2020, 09:09 AM   #4
Quick
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Engine in pieces





Empty engine bay
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Old 06-12-2020, 09:14 AM   #5
Quick
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This is where we lost motivation. The car sat for the next 5 years until my buddy decided to buy a new M3 CS.

I decided to bring the car back to life. It's just too good to let it go to waste.

So, brought it home to my shop.




My petite wife attempting to help with the steering


An immobile car and lack of friends to help push required some creative parking with my trailer to get it on the lift.


Here it sat as I began working on other stuff while waiting on the engine. My GT3RS is in the foreground - this is the STi's competition

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Old 06-12-2020, 09:21 AM   #6
Quick
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Engine was ordered a few weeks before I picked the car up. Took the Cosworth long-block over to IAG for a complete rebuild. They threw the book at it. Billet crank, fire-lock gaskets, closed-deck block, 14mm head-studs, Cosworth big-valve heads with new valves, 272 cams - everything. James nicknamed it the "road racer's wet dream" build.




I didn't have my engine hoist at the house, so I had to improvise to get it out of the crate and onto the stand. I need more friends






Not wanting to waste the cool container, I made a little rolling table out of it. I haz skillz

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Old 06-12-2020, 09:29 AM   #7
Quick
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Before the engine showed up, however, I decided to take care of some chassis mods.

The car already has the MSI subframe that we put in the rear, so I decided to add the front subframe as well. Also swapped out the 06 steering rack for the faster '15 STI rack.





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Old 06-12-2020, 09:32 AM   #8
Quick
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Also decided that the Dom 1.5 turbo just wasn't going to cut it for my goals. Called up Full-Race and had them build me a rotated twin-scroll setup. Running a EFR 8374 with an aluminum CHRA.

First step was to wrap the piping to control the heat. Partial pics here - didn't get them after wrapping everything.


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Old 06-12-2020, 09:35 AM   #9
Quick
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Then the motor assembly started








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Old 06-12-2020, 09:45 AM   #10
Quick
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I moved into my new commercial space as my garage was just too small to fit everything. Really got time to space and started getting the engine together.





Turbo alignment proved to be incredibly challenging due to the clearance available. I wanted to run the AN oil return line, but it doesn't clear with the FR piping.




But, I got her done

Next up - install the Tilton carbon clutch and stuff it back into the car. This was a royal pita to do on my own, but, you know, covid-19...







That's where the car sits today. I glossed over A LOT of details, but I'm not particularly good at documenting via pics.

Next up is reinstalling the Process West V-mount intercooler and radiator, building new intercooler pipes, new fuel lines, new dry sump lines, new power steering lines, new fuel pumps (Radium setup), new fuel cell bladder... The list goes on and on and on.
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Old 06-12-2020, 09:59 AM   #11
Stretch18
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That garage tho...

nice car too.
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Old 06-12-2020, 12:56 PM   #12
Gigs90
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@jn_garage

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Quote:
Originally Posted by Quick View Post
This is where we lost motivation. The car sat for the next 5 years until my buddy decided to buy a new M3 CS.

I decided to bring the car back to life. It's just too good to let it go to waste.

So, brought it home to my shop.




My petite wife attempting to help with the steering


An immobile car and lack of friends to help push required some creative parking with my trailer to get it on the lift.


Here it sat as I began working on other stuff while waiting on the engine. My GT3RS is in the foreground - this is the STi's competition

Wait how do you have my dream garage !


This thread is wonderful , its the embodiment of doing this correctly even if they are expensive.

I love it
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Old 06-12-2020, 01:10 PM   #13
moosen
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Looks absolutely fantastic! Can't wait to see more!
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Old 06-12-2020, 01:32 PM   #14
Barge
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How do you like that "simpler" style dry sump?
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Old 06-12-2020, 02:08 PM   #15
Quick
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Quote:
Originally Posted by Barge View Post
How do you like that "simpler" style dry sump?
What do you mean by simpler? Because it’s still using the stock-like oil pump?

I think it works well. This has the larger oil pump in it, so pressure isn’t an issue - supply is always there. Also scavenges the heads nicely.

A wet sump is far far far simpler, but I already have all of the pieces needed so might as well run it.
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Old 06-12-2020, 02:47 PM   #16
Barge
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Quote:
Originally Posted by Quick View Post
What do you mean by simpler? Because it’s still using the stock-like oil pump?

I think it works well. This has the larger oil pump in it, so pressure isn’t an issue - supply is always there. Also scavenges the heads nicely.

A wet sump is far far far simpler, but I already have all of the pieces needed so might as well run it.
Yes, compared to like a Dailey 4 stage and such.

It's hard to even shop/compare them because every company has their reasons for why they do something.

Dailey was adamant that the stock pump was terrible... but lots of what i've read seems to indicate that the stock pump actually flows quite a bit.
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Old 06-12-2020, 03:02 PM   #17
Quick
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Quote:
Originally Posted by Barge View Post
Yes, compared to like a Dailey 4 stage and such.

It's hard to even shop/compare them because every company has their reasons for why they do something.

Dailey was adamant that the stock pump was terrible... but lots of what i've read seems to indicate that the stock pump actually flows quite a bit.
Yeah, I've heard mixed views as well. In the original setup for this car, the Killer B header wouldn't allow the fitment of the Dailey unit (which I'm not even sure was available when we bought these systems in 2010).

I do full logging of oil pressure (via Life Racing ecu) and haven't ever seen a pressure drop with the 12mm high-volume pump. If I have issues with that in the future, I'll swap the oil pump and the dry-sump pump for a 4 stage unit.
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Old 06-12-2020, 09:34 PM   #18
Token-Negro
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Looks like a great build, we are working on one very similar for my Forester. Let us know how the 8374 does with the internal gate. I have one for the Fozzy also! Motors are very similar we will have to compare notes when I get this thing running.
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Old 06-12-2020, 11:11 PM   #19
BlueSTI4Me
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Quick,

Build is seeing quite a few hits on Track Subies. Thanks for sharing your build here.
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Old 06-13-2020, 07:37 AM   #20
Quick
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Quote:
Originally Posted by BlueSTI4Me View Post
Quick,

Build is seeing quite a few hits on Track Subies. Thanks for sharing your build here.
I asked to join the group, but haven’t been accepted yet. I’m not worthy!

I never use facebook though, so unlikely I’ll be on there often.
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Old 06-13-2020, 09:39 AM   #21
milab21
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Very nice build, subscribed!
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Old 06-13-2020, 10:37 PM   #22
BlueSTI4Me
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WRB IG @got2boostit2

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Quote:
Originally Posted by Quick View Post
I asked to join the group, but haven’t been accepted yet. I’m not worthy!

I never use facebook though, so unlikely I’ll be on there often.
You are in. There is also a @track_subies Instagram
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Old 06-15-2020, 08:26 AM   #23
Barge
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Quote:
Originally Posted by Quick View Post
Yeah, I've heard mixed views as well. In the original setup for this car, the Killer B header wouldn't allow the fitment of the Dailey unit (which I'm not even sure was available when we bought these systems in 2010).

I do full logging of oil pressure (via Life Racing ecu) and haven't ever seen a pressure drop with the 12mm high-volume pump. If I have issues with that in the future, I'll swap the oil pump and the dry-sump pump for a 4 stage unit.
I log as well via my Link and I've seen very stable oil pressure so far with my wet sump setup... but i'm also just now switching to a 200TW tire. With the amateur aero i'm hoping to get some decent gforces with some stickier tires.

I'm currently in process of building a long rod ej22t and I'm planning on some kind of dry sump for it. I have killerB headers as well currently and anything but a stock pump kind of style dry sump is going to require some custom headers. I've been itching to build some headers for a while though so this may be a good excuse.
Just need to figure out where to put the oil tank in my Forester. Not having a trunk makes some things trickier.
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Old 06-15-2020, 08:35 AM   #24
Barge
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2004 #LesboRacer
#TunedbyBarge

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Quote:
Originally Posted by Token-Negro View Post
Looks like a great build, we are working on one very similar for my Forester. Let us know how the 8374 does with the internal gate. I have one for the Fozzy also! Motors are very similar we will have to compare notes when I get this thing running.
I have to say im interested in those t4 twin scroll internal gates as well. It seems to be really well designed... and saves a lot of extra componentry and plumbing.
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Old 06-15-2020, 11:35 AM   #25
Quick
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2009 STi
Silver

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Quote:
Originally Posted by Barge View Post
I log as well via my Link and I've seen very stable oil pressure so far with my wet sump setup... but i'm also just now switching to a 200TW tire. With the amateur aero i'm hoping to get some decent gforces with some stickier tires.

I'm currently in process of building a long rod ej22t and I'm planning on some kind of dry sump for it. I have killerB headers as well currently and anything but a stock pump kind of style dry sump is going to require some custom headers. I've been itching to build some headers for a while though so this may be a good excuse.
Just need to figure out where to put the oil tank in my Forester. Not having a trunk makes some things trickier.
Keep in mind with the Cosworth setup, the supply is fed directly into the oil pump from the dry sump tank. A -12AN line leads directly to the pump supply - so as long as the tank is mounted higher in the car than the oil pump, you'll always have oil supply (regardless of G-force). The real question is does the pump supply enough pressure to handle it.

I had a 2009 STI hatch that I installed one in as well. Installing it in the back corner, and building a bulkhead around it isn't too bad. Running the lines is a pain though.

I'll have some pics shortly on mocking up the lines on my 2006.
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