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09-27-2010, 02:19 AM | #1 |
Scooby Guru
Member#: 120273
Join Date: Jul 2006
Chapter/Region:
SWIC
Location: AZ
Vehicle:06 WRBWRXWGN Now with 100% more Spec-C |
kpluiten's Build Thread: Almost driveable again...
UPDATE: 10/11/2013
The car has seen a significant overhaul since 2010. The current modification list is below under the heading "2012 Version". To see the previous configuration, see the list below "2010 Version". My goal for this 2012 build was to address the engine/engine bay. The under-carriage/suspension/braking/steering of the car were now nice and sorted and clean from my 2010 project, but the engine bay was a mess. There were hoses everywhere, connectors hanging from long removed parts, dirt, dust, and general clutter. I've found that cars built part by part like mine, tend to have this look to them. It comes from tweaking a single part at a time rather than considering how they all come together as a whole. You're left with wires running to and from, improperly routed hoses, etc. So, after a few months of thinking about it, I realized that to properly sort out the bay, I wanted to start from scratch with everything out of the car. Around this time, I also started to grow a bit tired of the whole big(ish) turbo thing. The car was a monster and exploded with power, but it was a different type of fun than I wanted from the car. I missed the old "stage II" crazy quick spool and long power band. I wasn't really feeling the "meh" 0-4500 rpm followed by 4500-7200 rpm "OMG". All the big turbo setups that resulted in more useable power bands were costly and I wasn't sure if my forged motor was up to the task of high RPM. So I bought an EJ207 "Ver. 8" from a 2003 Spec-C with 17,000 miles. My goal is to see how far I can go with the stock VF-36 ball bearing turbo and e85. If I am left wanting more, there are plenty of stock location, TS turbos hitting the market these days (18G's, 20G's, 2.5XT's, and even DOM 3's). I figure this motor install would be the perfect opportunity to do the work I wanted on the engine bay and take the car in a new direction. This is how the car sat/looked prior to this 2012 build: 2012 Version Engine: EJ207 Spec-C Ver. 8 ***8226; Factory Sealed Long Block ***8226; 32-bit Conversion ***8226; USDM Intake Cams ***8226; Original Exhaust Cams ***8226; Gates Racing T-Belt Kit ***8226; Gates Racing Accessory Belts ***8226; Group-N Motor Mounts VF-36 Twinscroll Turbo ***8226; Kinugawa Adjustable Wastegate Actuator ***8226; Factory TS Header & Uppipe ***8226; AngryRoo EBCS ***8226; Perrin Inlet ***8226; TurboXS FMIC w/ Custom Piping ***8226; Rotated & Powder Coated Compressor Housing Long-runner Intake Manifold - Ver. 8 ***8226; Shaved unneeded mounts and holes ***8226; Powder Coated ***8226; No TGV's ***8226; Custom DBW adapter - Self-designed ***8226; Custom fuel rail adapters - Self-designed Oil Cooler ***8226; Spec-C Factory Adapter Plate ***8226; Hayden Aluminum Core ***8226; Custom AN Lines/Fittings KoyoRad Radiator ***8226; Powder Coated Tanks ***8226; Perrin Silicon Hoses ***8226; Misimoto Fans & Shroud (Powder Coated) Exhaust ***8226; OEM Twinscroll header/uppipe ***8226; eBay DP with Kinugawa bell mouth ***8226; Greddy EVO II exhaust ***8226; V-band Junctions Misc. ***8226; Powder coated valve covers and intake manifold ***8226; JDM STi light-weight AC compressor Fuel System: ***8226; TurboXS Rails ***8226; -6 AN Hardlines on Engine ***8226; ID1000 Injectors ***8226; Aeromotive FPR ***8226; Golan Stainless Filter Drivetrain: ***8226; EVERYTHING completely rebuilt/painted/powder coated ***8226; 5x114.3 Hubs - Completely Rebuilt ***8226; STi Axles - Completely Rebuilt ***8226; R180 - Completely Rebuilt ***8226; Custom One-piece Drive Shaft w/ DS loop ***8226; Clutch Slave and Master Cylinders w/ Dampener Valve Delete ***8226; Motul Fluids ***8226; OEM 2008 STi BBS - Gold ***8226; OEM 2005 STi BBS - Graphite ***8226; Kartboy Pitchstop Mount ***8226; Kartboy Shift Linkage Bushings ***8226; Subaru OEM SS Linkage ***8226; DCCDPro Controller w/ OEM switches Brake System: ***8226; Brembo Calipers - Completely Rebuilt/Powder Coated ***8226; Stop-Tech pads ***8226; Speed Bleeders ***8226; 1 1/8th Master Cylinder ***8226; Racing Brake Slotted Rotors ***8226; Cusco Master Cylinder Brace Suspension/Steering: ***8226; EVERYTHING completely rebuilt/painted/powder coated ***8226; KW V3 Coilovers ***8226; RPM Front Subframe ***8226; 2005 STi Rear Subframe ***8226; STi Aluminum Lateral Links ***8226; STi Aluminum Control Arms ***8226; Group-N Lateral Link Bushings ***8226; Group-N Front & Rear Trailing Arm Bushings ***8226; Group-N Control Arm Front Bushings ***8226; Group-N Top-hats F&R ***8226; Unibomber's Sexy Rear-end Kit ***8226; Kartboy Outrigger Bushings ***8226; Kartboy Trans-cross Member Bushings ***8226; Whiteline Roll-Center Kit ***8226; Poly-Pro PS Bushings ***8226; Amroof Cowl Braces ***8226; 225/45/17 Hankook RS3's ***8226; WRX/OEM Steering Linkage Damper Delete Exterior: ***8226; Spec-C Roof Vent () ***8226; Rip-off V-limited Lip ***8226; JDM Spec-C Grill inserts ***8226; OEM STi Rear Diffuser with OEM Mounting ***8226; Custom Harness for STi HID's and Levelers ***8226; Redline Hood Lifters ***8226; McGaurd Lugnuts Interior: ***8226; 2003 Prodrive STi Cluster (9000 RPM, MPH, & DCCD!) ***8226; eBay Twin gauge cluster ***8226; Mad Dad Boost gauge ***8226; LC-1 Wideband w/ integrated calibration switch ***8226; XD-16 Wideband gauge ***8226; Clear Shift Knob ***8226; OEM STi Mats (black) ***8226; Jazzy Engineering Aux Input ***8226; Plasti-dip trim ***8226; V8 JDM STi Front Seats ***8226; V7 JDM STi Wagon Rear Seats (!) ***8226; Diagnostic Mode switch (Self-designed) ***8226; Travis Pastrana's endorsement (signature ) Other: ***8226; Hella Supertones ***8226; Deka light-weight battery ***8226; The ENTIRE undercarriage was cleaned and painted/recoated ***8226; Wheel-wells were stripped and rubberized ***8226; The engine bay was stripped and painted WRB ***8226; New wiring was wrapped into the factory harnesses and fuse boxes ***8226; All harnesses in the front clip of the car were re-wrapped and heat shielded. Companies/People who have provided me with support in the form of parts or services during this build:
2010 Version Background: It's been almost 10 months since I last drove my 2006 WRX wagon. Since then, my wagon has sat, the number of parts on the car decreasing by the month while the list of parts waiting to replace them growing ever longer. The state of the car with a complete parts list when it was parked can be found in my "Proven Power and Bragging" thread here: http://forums.nasioc.com/forums/showthread.php?t=1824106 In a nutshell the car has a forged short block, 6 speed swap, e85, and a DOM II turbo along with a host of other modifications. It ran exceptionally well and I was very pleased with the state of the car... but the modification bug bit again and I ended up purchasing the entire drivetrain and suspension out of a 2005 STi. As the build planning progressed, I experienced scope creep (and still continue to). Grand ambitions along with the desire to perform all the work myself, a busy job, and losses in the family set me back significantly from where I had planned to be. The good news is that it looks like things are starting to calm down a bit and I should have more time to focus on this build. Purpose: The purpose of this thread is to loosely document some of the things I'm doing for those who may be interested. It is also my hope that having a thread to update might motivate me to make progress. I will be adding to this thread as things get done. My list of planned upgrades is listed below. I will update the list to include links to relevant posts. Here is how the car sits now: Parts Purchased For This Round: Engine: 2.5i Intake Manifold (soon) Stainless Feed and Return PS Lines Group-N Motor Mounts Odyssey Light-Weight Battery Fuel System: Aquamist HFS-6 System Spec-C Meth Tank Second In-tank Walbro Fuel Rails Aeromotive FPR Golan Fuel Filter Charcoal Canister Delete Drivetrain: 5x114.3 Hubs - Completely Rebuilt STi Axles - Completely Rebuilt R180 - Completely Rebuilt STi Drive Shaft Clutch Slave and Master Cylinders w/ Dampener Valve Delete Motul Fluids OEM STi BBS - Gold OEM STi BBS - Graphite Kartboy Pitchstop Mount Kartboy Shift Linkage Bushings Subaru OEM SS Linkage Updated DCCDPro Controller Brake System: Brembo Calipers - Completely Rebuilt Stop-Tech pads Speed Bleeders 1 1/8th Master Cylinder Racing Brake Slotted Rotors Cusco Master Cylinder Brace Suspension: 2005 STi Rear Subframe STi Aluminum Lateral Links STi Aluminum Control Arms Group-N Lateral Link Bushings (soon) Group-N Front & Rear Trailing Arm Bushings (soon) Group-N Control Arm Front Bushings (soon) Unibomber's Sexy Rear-end Kit Kartboy Outrigger Bushings Whiteline Roll-Center Kit Whiteline PS Bushings KW V3 Coilovers (soon) KW Linear Spring Conversion (soon) Ground Control Tophats (soon) RPM Front Subframe Amroof Cowl Braces Exterior: [size=2]Spec-C Roof Vent () Full 2006 STi Sedan Front Clip (Fenders, bumper, hood, scoop) 02-03 WRX Side-skirts Rip-off V-limited Lip (soon) Rip-off Rear Aprons (soon) Custom Harness for STi HID's and Levelers Hood Lifters McGaurd Lugnuts Last edited by kpluiten; 10-11-2013 at 10:57 AM. |
09-27-2010, 02:20 AM | #2 |
Scooby Guru
Member#: 120273
Join Date: Jul 2006
Chapter/Region:
SWIC
Location: AZ
Vehicle:06 WRBWRXWGN Now with 100% more Spec-C |
Saved for future use.
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09-27-2010, 02:20 AM | #3 |
Scooby Guru
Member#: 120273
Join Date: Jul 2006
Chapter/Region:
SWIC
Location: AZ
Vehicle:06 WRBWRXWGN Now with 100% more Spec-C |
Saved for future use..
|
09-27-2010, 02:21 AM | #4 |
Scooby Guru
Member#: 14732
Join Date: Jan 2002
Chapter/Region:
SWIC
Location: Global
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YeaHhhhh
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09-27-2010, 02:24 AM | #5 |
Scooby Guru
Member#: 14732
Join Date: Jan 2002
Chapter/Region:
SWIC
Location: Global
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I will save this space to talk **** later
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09-27-2010, 02:25 AM | #6 |
Scooby Guru
Member#: 14732
Join Date: Jan 2002
Chapter/Region:
SWIC
Location: Global
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and this one for even more
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09-27-2010, 02:38 AM | #7 |
Scooby Guru
Member#: 120273
Join Date: Jul 2006
Chapter/Region:
SWIC
Location: AZ
Vehicle:06 WRBWRXWGN Now with 100% more Spec-C |
|
09-27-2010, 02:53 AM | #8 |
Scooby Guru
Member#: 120273
Join Date: Jul 2006
Chapter/Region:
SWIC
Location: AZ
Vehicle:06 WRBWRXWGN Now with 100% more Spec-C |
The Brembos I purchased came from a New Jersey car and they were in very rough condition when I got them. Three of the four bolts holding the front calipers to the hubs broke off in the calipers and could not be removed. Additionally, one of the bleeders broke off in the caliper. Surprisingly enough, the rears were in excellent condition despite coming off the same car.
I finally got some time to start rebuilding them this weekend. Dis assembly is surprisingly easy as long as you take your time. I will be installing helicoil in the mounting holes to repair the fronts. I will also need to figure out the repair for the bleed screw situation. After that, they are off to Liquid Powder Coats to be powder coated. I'm thinking green. Broken off mounting bolts: Removing seals and pistons: Drilling out bolts: Bagged Seals and dust boots: Mounting tabs ready to be tapped for Heli-coil Installation: All the calipers stripped down and ready for powder coating: Rear caliper parts: All the pistons: |
09-27-2010, 03:07 AM | #9 |
Scooby Specialist
Member#: 211224
Join Date: May 2009
Chapter/Region:
RMIC
Location: Aurora, CO
Vehicle:2005 Saabaru Who knows |
Its About Time You Attempt To Finish This Thing
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09-27-2010, 03:16 AM | #10 |
Scooby Guru
Member#: 120273
Join Date: Jul 2006
Chapter/Region:
SWIC
Location: AZ
Vehicle:06 WRBWRXWGN Now with 100% more Spec-C |
|
09-27-2010, 03:19 AM | #11 |
Scooby Specialist
Member#: 211224
Join Date: May 2009
Chapter/Region:
RMIC
Location: Aurora, CO
Vehicle:2005 Saabaru Who knows |
I did and i chuckled cause they are going to be the best part on your car.
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09-27-2010, 03:39 AM | #12 |
Scooby Newbie
Member#: 142258
Join Date: Mar 2007
Chapter/Region:
SWIC
Location: So easy... Even I could do it
Vehicle:2005 SWRT Replica |
Oil cooler...?
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09-27-2010, 09:22 PM | #13 |
Scooby Specialist
Member#: 164516
Join Date: Nov 2007
Chapter/Region:
SWIC
Location: Northern AZ STI hence username
Vehicle:2004 STI PSM |
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09-27-2010, 04:25 AM | #14 |
Scooby Specialist
Member#: 71615
Join Date: Sep 2004
Chapter/Region:
SWIC
Location: Phoenix, AZ
Vehicle:2002 Bugeye PSM |
Excited to see this progress. Good Luck! Subscribed
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09-27-2010, 08:25 AM | #15 |
Scooby Specialist
Member#: 164551
Join Date: Nov 2007
Chapter/Region:
SWIC
Location: Baumholder, Deutschland
Vehicle:2006 Brotastic STi Land of beer and laws |
Blahhhh
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09-27-2010, 10:44 AM | #16 |
Scooby Specialist
Member#: 113342
Join Date: Apr 2006
Chapter/Region:
SWIC
Location: AZ
Vehicle:2014 WRX WRB |
Nice work Ken. Just don't give up on it. Also, make sure you set a point where you say "I'm done" and you'll be much happier in the long run. I've had plenty of friends lose interest due to major scope creep with their projects. Either they never finish, or they end up building something that is not very streetable and get bored with it because they don't want to take it out. Jay's purple car is a prime example. He put a ton of work into it and it turned out fantastic, but he rarely takes it out. I'm sure Jay will vouch that he has way for fun with his wagon.
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09-27-2010, 11:14 AM | #17 | |
Scooby Guru
Member#: 14732
Join Date: Jan 2002
Chapter/Region:
SWIC
Location: Global
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Quote:
If ken losses interest in him car and doesn't wanna finish it, i will buy it off him |
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09-27-2010, 11:49 AM | #18 | ||
Scooby Guru
Member#: 120273
Join Date: Jul 2006
Chapter/Region:
SWIC
Location: AZ
Vehicle:06 WRBWRXWGN Now with 100% more Spec-C |
No plans for one yet. I've done just about zero research into those.
I hope I don't disappoint. hhhhalB Quote:
Quote:
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09-27-2010, 12:55 PM | #19 | |
Scooby Guru
Member#: 6886
Join Date: May 2001
Chapter/Region:
Tri-State
Vehicle:MY01 EJ207 HTA35r AVCS ON! |
Quote:
I guess Jay will have to do more burnouts to keep you inspired! |
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09-27-2010, 12:04 PM | #20 |
Scooby Guru
Member#: 14732
Join Date: Jan 2002
Chapter/Region:
SWIC
Location: Global
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Ken, i don't wanna buy it, just saying if you were going to sell it before finishing it, i would, LoL, i am sure i am the only one around that gets a cloud of smoke out the back of there wagon on launch
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09-27-2010, 12:43 PM | #21 |
Scooby Specialist
Member#: 197856
Join Date: Dec 2008
Chapter/Region:
SWIC
Location: 'merikuh
Vehicle:2010 FJ Cruiser Sandstorm |
subscribed.
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09-27-2010, 12:54 PM | #22 |
Scooby Specialist
Member#: 113342
Join Date: Apr 2006
Chapter/Region:
SWIC
Location: AZ
Vehicle:2014 WRX WRB |
I haven't driven my GN in almost 5 years now. Not a day goes by that I don't hit up CL and look for something else that I'd be willing to part my GN out for. It's tough because I still have ALOT of work to do and the budget is about to dry up. I decided to just put it back together and deal with the trashed paint and interior later. At least I will enjoy it for awhile and get motivated again. Hopefully I will have it back on the road by the end of the year.
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09-27-2010, 03:37 PM | #23 |
Scooby Newbie
Member#: 210165
Join Date: Apr 2009
Chapter/Region:
MWSOC
Location: N. Ridgeville, OH
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Not that you need any help, but if you need any supplies for the leveling harness let me know, we still have lots of harness building stuffs here in the shop.
Be more than happy to help... Looks to be a quality build. |
09-27-2010, 06:39 PM | #24 |
Scooby Guru
Member#: 120273
Join Date: Jul 2006
Chapter/Region:
SWIC
Location: AZ
Vehicle:06 WRBWRXWGN Now with 100% more Spec-C |
Hmmm... Do you have connectors? Shrink tube and wire shrouding? We might be in contact.
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09-29-2010, 03:58 PM | #25 | |
Scooby Newbie
Member#: 210165
Join Date: Apr 2009
Chapter/Region:
MWSOC
Location: N. Ridgeville, OH
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Quote:
Lots of protective braided sleeving, and heatshrink (shrink tubing) just got a sample of some really neat 3M stuff, thats 3:1 shrink ratio and adhesive backing (adhesive flows @ 80*C) in Red and Black... Just let me know |
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