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Old 01-25-2008, 03:51 AM   #1
lancelucas
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Member#: 124282
Join Date: Aug 2006
Chapter/Region: NWIC
Location: 30000 ft
Vehicle:
04 WRX Wagon PSM
13 STI Sedan SWP

Default It's out! My DIY swap thread...

Well, quite a few of you already know, but I am in the midst of doing a good ol' EJ257 shortblock swap into my WRX. I decided to make a thread here locally to give thanks to a few different people who have helped along the way and get feedback from the locals...comments and flames welcome and appreciated! I'll continue to edit and add as I remember crap.

This project started back in Mayish 2007 when I acquired a "blown up" EJ257 shortblock from a good friend for a good price. It had two broken pistons (teh notorious ringlang failures) and one pretty ugly cylinder wall as a result. I foresaw that my car would be close to 80k miles within a year and figured I might as well rebuild my purchase into a usable shortblock and do all of the other maintenances and mods my car would soon need anyways -- timing belt, clutch, TGV deletes, injectors, etc. -- all at once. My goal was to increase the OEM SB's strength and reliability without spending significant amounts of money on forged internals because well...I'm poor I was then introduced to an engine builder who was able to use my block as a core and trade me a usable block to mate up with my usable rotating assembly (sans pistons). Through some very good friends and connections, I was able to acquire new OEM STi pistons, rings, wristpins and cams for an outrageous deal, and the build was on. I got the engine back and finally got all of my parts together and began tearing my car apart about a week ago. The frigid weather has kept my work to 2 hours spurts.

Enough babbling, onto teh build--

Current Setup:
OEM EJ205
VF39/565s/Meth/FMIC/3" TBE/APS Inlet/blah blah
Susp/Brakes/Interior/blah blah


New Setup:
EJ257 SB
OEM Crank
OEM Rods, Shotpeened
OEM Pistons, Coated
ACL Street Main & Rod Bearings
JDM 12mm Oil Pump

EJ205 Heads
USDM STi Cams
Brian Crower Springs & Retainers
Light Cleanup of Bowls/CC
Coated CCs/Valves
OEM STi Headgaskets

18G-TD05H 8cm^2 Turbo by TEC
STi Oilpan, Pickup, Baffle & Dipstick
Perrin Topfeed Fuel Rails
Modded & Flowtested WRX Injectors
STi Group N Motor Mounts and Pitch Stop
PE Kevlar Timing Belt
New OEM WRX Water Pump, T-Stat, Clutch
NGK BKR7E Spark Plugs


Day 1 - The beginning:



Day 2



Day 3 -- Another reason for my swap For the last 15k miles or so, the passenger side head has been pushing some oil from somewhere. The headgasket is intact, so could be the valve cover. I hope to find out on teardown:





Today -- Removal!









Tada! Mr. BREWPUBEAVER came by today to help me with the final removal. I will say that this job has been done 100% with hand tools (although a complete assortment) in a garage, so if you are thinking of undertaking a similar job yourself, it can be done! Research and patience are your friends.

Next all exhaust hardware goes off to the coaters and the engine goes for final assembly. I'll be reusing lots of the current parts on the 2L, such as cam gears and such.

BIG THANKS GO TO, in no particular order:

Dave Oathes
Chris Henry
Sean McCormick (RIP Dr. Injector)
Kendrick Gray
Geoff Johnson
Audio Integrations (www.audiointegrations.net)
Peter Ryakhovskiy
Mike Gent
Dale Daugherty (NW Subaru Service Group)
Brian Schutzler (Bearing Service Company)
Pam Johnson (Tufcoat)
Mike Talbot (Pacific Import Auto)
Scott and Ben (Carr Subaru Parts Dept.)
My parents for usage of garage
Lots of other people

Reinstall, coming soon...
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Last edited by lancelucas; 03-26-2008 at 10:58 PM. Reason: teh spellz
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Old 01-25-2008, 03:54 AM   #2
lancelucas
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Location: 30000 ft
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04 WRX Wagon PSM
13 STI Sedan SWP

Default

Sidethoughts:

TGV deletes are not hard, just time consuming. I was able to use a saw to remove the dividers and various bits in an electric die grinder. I took the chance to do mine during the engine removal process-



I used a 10mmx1.5 tap and some set screws and JB weld to plug the ends.

I don't know what I was expecting, but I thought the Group N pitchstop would look "different" for some reason. I know the rubber is much harder, but visually they are identical:

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Old 01-25-2008, 03:59 AM   #3
David Glasscock
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06 sti my $$ pit
05 xt my DD

Default

sweet, glad to see everythings going good for ya. cant wait for you to get her back on hte road. going to be a beast..
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Old 01-25-2008, 04:11 AM   #4
Sinister redlines
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CGM

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Sweet, BTW gaskets are on the way. Cant wait to see her purrr. BTW hows the block running for you Dave?
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Old 01-25-2008, 04:13 AM   #5
kirkeemonster
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WRBP

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Hmm.... iiiiinnnttteeerrreeesting.........
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Old 01-25-2008, 04:17 AM   #6
David Glasscock
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06 sti my $$ pit
05 xt my DD

Default

great, love how she sounds. not sure if it the pistons or cam that gives the tinging sound. kinda reminds me of a muscle car sound. you can really tell the difference when its next to another subie. i know its not the exhaust thats making that sound.. just need to get a bigger intercooler on her so i can get som decent power..
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Old 01-25-2008, 04:21 AM   #7
Sinister redlines
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CGM

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Some sound is from those forged slugs runnin.
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Old 01-25-2008, 04:22 AM   #8
Sinister redlines
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CGM

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Tommorow I will post some pics of my darton sleeved stroker engine that should be runnin VERY soon Sexy, sexy time!!!!!
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Old 01-25-2008, 01:48 PM   #9
geoffj
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Default

Niiiiiice. I'm excited to see how much faster your car is with the 2.5, although I don't think you ever went WOT with me in the car.
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Old 01-25-2008, 01:51 PM   #10
nikswrx
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03 AW WRX wagon
girl powered stg 2 :)

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Sweeet, any ETA on when it will be done?
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Old 01-25-2008, 02:00 PM   #11
Dyno Authority
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01 RS-EJ205, EG33 GM6

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Looks good!

*grabs popcorn & waits for the results*
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Old 01-25-2008, 03:09 PM   #12
gregor2001
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2009 OBS Silver WifeWagon

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Thanks for posting - can't wait to see the next updates.

Good luck the rest of the way!
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Old 01-27-2008, 01:01 AM   #13
twigg107
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Dont you love it when you have everything planned out ant then the cold weather comes..... I know I dont! lol

Good luck with the build man..... cant wait to see it on the read again.
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Old 01-27-2008, 02:02 AM   #14
SedonaScooby
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you've helped me a ton in the past so if you ever need someone to get in the way i'm more then willing to help.
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Old 01-27-2008, 01:12 PM   #15
02WRX2.5
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Tranny time. Might as well replace while you have everything out, or else it will be the next thing in the back of your mind while boosting. "Is it going to hold"
Good luck and good job on the build. Nice parents you have to let you clog up there garage like that. No personal garage sucks.
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Old 01-27-2008, 01:52 PM   #16
olskool_al
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OBP FTW

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I have be wondering how serious it was to get the motor out. I see a lot of people mod all types of stuff. But when it comes to pulling the engine, " lets just take that somewhere". Good luck, can't wait to see it done.
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Old 01-27-2008, 02:19 PM   #17
slvr02scooby
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COBB Tuning Surgeline

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Nice work Lance, good luck with the rest of the swap!

And I do worry about my tranny every time I get on it since my swap Get something stronger asap!
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Old 01-27-2008, 04:08 PM   #18
spoolindc2
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Aspen White

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looks like fun man good luck with the build!!!
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Old 01-27-2008, 04:16 PM   #19
lancelucas
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13 STI Sedan SWP

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Thanks for all of the kind words, I really appreciate it! Can't wait to see everyone this summer and check out everyone's winter projects


Quote:
Originally Posted by Dirty Old Man View Post
Niiiiiice. I'm excited to see how much faster your car is with the 2.5, although I don't think you ever went WOT with me in the car.
We can fix that

Quote:
Originally Posted by nikswrx View Post
Sweeet, any ETA on when it will be done?
Engine parts will head to the assembler within the next few days. The assembly is technically a "day job" but will probably take 2 or 3 total. Hopefully have the car back on the road within 14 days from now (ya right)

Quote:
Originally Posted by 02WRX2.5 View Post
Tranny time. Might as well replace while you have everything out, or else it will be the next thing in the back of your mind while boosting. "Is it going to hold"
Good luck and good job on the build. Nice parents you have to let you clog up there garage like that. No personal garage sucks.
I would like to upgrade now but I can't afford it, so I'll continue saving in the tranny fund and hopefully have enough if I ever do break the 5spd

+1 to the parents thing, they are very supportive of me and I would be paying $1000+ to have this done at a shop if it wasn't for them.
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Old 01-27-2008, 05:00 PM   #20
Audio Integrations
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PDX Tuned 295 hp 265 tq

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Damn all you and your 2.5 swaps! Is there any 2.0's running around still besides me? Looks good though - can't wait to see it on the road again and feel the difference!
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Old 01-27-2008, 05:00 PM   #21
BREWPUBEAVER
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Looking good Lance.

cant wait to get it running again. Was the heat treating place FinishLine?
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Old 01-27-2008, 09:02 PM   #22
Gray Ghost
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Quote:
Originally Posted by Audio Integrations View Post
Damn all you and your 2.5 swaps! Is there any 2.0's running around still besides me? Looks good though - can't wait to see it on the road again and feel the difference!

Still sporting the 2.0 as well. Those guys do make me jealous though I was fine until I drove an STi. Hmmmmm...............Torque!
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Old 01-28-2008, 11:22 PM   #23
lancelucas
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Quote:
Originally Posted by Gray Ghost View Post
Still sporting the 2.0 as well. Those guys do make me jealous though I was fine until I drove an STi. Hmmmmm...............Torque!
Yeah the torque of the 2.5L was just too much to pass up

I dropped off my exhaust manifolds, x-pipe, uppipe, downpipe and turbo heatshield for coatings today. I chose black after seeing some pics of the black coating, it really looks sharp. The manifolds are a set of GrimmSpeed P&P's that I installed about 8 months ago -- after being used, you can really see how rough the OEM castings are in the areas you can't reach with a die grinder. I am hoping the media blasting during the prep process for coating helps clean them up even more.

I also ordered up a set of OBX Fuel Rails I normally don't touch the generic parts, but I just need a basic set of aftermarket rails to get rid of the complicated OEM setup while it is already all apart. They are a knockoff of a Perrin design and have gotten some good reviews. I wish I could have sprung for real Perrin or TurboXS, but I couldn't justify the extra cost. Next time around I'll go for Aeromotive rails & FPR with all AN lines/fittings
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Old 02-08-2008, 02:03 AM   #24
lancelucas
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Exhaust parts are back from the coaters

Grimmspeed P&P Manifolds
TurboXS Catless UP
Titek Catless DP
Cusco Turbo Heat Shield







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Old 02-08-2008, 03:07 AM   #25
olskool_al
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OBP FTW

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Lookin' good. So think it's gonna be a go for next weekend?? Or will we see you as a ride along??
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