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Old 02-17-2007, 08:02 PM   #1
rst4me
Scooby Specialist
 
Member#: 108286
Join Date: Feb 2006
Default Suggestions wanted RSti hybrid project

Hi all, I have decided to scrap the idea of trying to tubo my phase II RS engine. I decided to do an STI/SOHC RS hybrid.

Here is what I am starting with:
STI short block

04 SOHC 2.5RS long block

Bare WRX intake manifold

Notched coolant cross over to accommodate the extra crank case vent tube.

After market wrx down pipe
FMIC kit
Perfect power SMT6
HKS blow off valve
Borla RS header

Here is the genral plan:
Build up the STI short block
Build up the SOHC RS heads
Use the wrx intake manifold with TGV delete risers, and possibly mount it backwards for that rally look. (modified for MAP sensor)
Use a ported RS throtal body
Use 00 style RS power steering pump (top mounted fluid reserve tank)
Use RS alternator, and AC pump.
Use RS oil pan (possibly modified for turbo oil return) oil pick up, and dipstick tube.
Custom up-pipe, to turbo, wrx down pipe to modified aftermarket STI exhaust
After market fuel pump
Modified WRX fuel injectors
After market fuel rail
After market oil cooler kit
STI oil pump
Possibly WRX or STI water pump (for turbo coolant supply)
After market RS flywheel, clutch and pressure plate.
One day a dog box trans but for now stock RS 5speed running gear.


STI short block:
Perchesed on ebay.
Description stated that it was removed with 10k miles on it.




Cylinders showed hone marks but bearings showed massive heat damage.



Crank was grooved but not too badly.

The plan:
Get crank ground, and pick up over sized bearings to accommodate.
Build up short block with TWE forged pistons, light weight wrist pins, and possibly stronger rods.

Quick question #1; People have been reporting 450+ reliably on stock STI rods. At its max I plan to tune to 500ish horse power. Is it just a waste of money for after market rods? I like piece of mind as much as the next guy but I donít know about $500+ for after markets.

Heads:
Stock roller 2.5RS SOHC heads, removed from an 04 2.5RS long block with 62K miles.
Heads look great, very little wear, no signs of abuse.

The plan:
Port out the castings to gasket exhaust and intake diameters.
TWE stage II cams
TWE springs and titanium retainers

Quick question #2; Should I go for better valves? What ones are recommended?


Turbo:
This is still up in the air.
Dead bold recommended TD06 super 16G, clipped and ported.
I want something that will spool up quick but I donít like the idea of it weezing by 5K RPM. I also want something that I can hit the 450HP mark with.

Quick question #3; turbo recommendations.

Fuel system:
This is all up in the air.

Quick question #4; What size injectors will I want to run with a smt6?
Quick question #5; What fuel pump should I go with?
Quick question #6; What type of fuel regulator should I run?
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Old 02-17-2007, 08:17 PM   #2
rst4me
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Member#: 108286
Join Date: Feb 2006
Default

Progress:
The hard decision has been made... what color to powder coat every thing.
The heads will be mirror chrome with high temp silver around the exhaust ports.
The block and most of the brackets will be Mirror chrome.
Other smaller brackets, coolant pipes, and dipstick tube will be black.
The valve covers, intake manifold, throttle body, alternator, pulleys, and oil pan will be candy blue.




The block, and heads have been totally stripped.
Work will start on the heads shortly, and I will get started on the powder coating (out of work so free stuff first)
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Old 02-22-2007, 05:32 PM   #3
rst4me
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Member#: 108286
Join Date: Feb 2006
Default

more parts fresh out of the oven!


FMIC kit showed today, Im impressed with the quality


The engine wiring is all done, after some soldering that is.

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Old 02-23-2007, 12:37 AM   #4
IllNastyImpreza
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Member#: 36333
Join Date: May 2003
Chapter/Region: NESIC
Location: East Kingston NH
Vehicle:
DIY project: life
I need more TIME!

Default

wow lookin good !
who did you powerder coating? I'm lookin to do some of that myself...

how are you gona "chrome" your heads?
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Old 02-23-2007, 01:05 AM   #5
Derk1127
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Member#: 9134
Join Date: Aug 2001
Chapter/Region: NWIC
Location: Seattle, WA
Vehicle:
2000 Impreza RS-T
BRP w/Hydra+EJ257

Default

the wrx intake manifold fits on the sohc heads? that gives me some interesting ideas.
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Old 03-02-2007, 07:12 PM   #6
rst4me
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Member#: 108286
Join Date: Feb 2006
Default

Quote:
Originally Posted by IllNastyImpreza View Post
wow lookin good !
who did you powerder coating? I'm lookin to do some of that myself...

how are you gona "chrome" your heads?
I do.
I run www.smallbatchcoatings.com
It started off because I got sick of powder coating shops in my area charging me an arm and a leg because I didnít have big batch quantities. I made the decision to invest in some good equipment (none of that home coating kits and conventional oven crap) and people have been hitting me up to do some of there stuff ever since. I figured at the point where all my friends told all there friends about me, that I should just start doing it as a business on the side.

My heads are currently totally stripped down. What I am going to do is glass bead blast the entire head, mask off the sealing surfaces, coat, and bake. This was one of the main reasons I went out and found an extra motor to build slowly.

Quote:
Originally Posted by Derk1127 View Post
the wrx intake manifold fits on the sohc heads? that gives me some interesting ideas.
Thatís what I was told. Apparently the intake ports on the sohc and dohc heads are in the same place except for the sti ones. Apparently the sti ones are set farther apart. We will see!
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