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Old 09-04-2012, 10:54 PM   #726
brcewane
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I made lots of progress on the manifold tonight... One more evening should have it stripped down to the bare bones. There will be some aluminum welding patch work to be done before it goes to polish.

We're going to test fit everything and make any modifications to use the DBC throttle body before I get it out to Sami for polishing.

If we need to make them shorter for hood clearance we should be able to chop the runners and weld them back together. This manifold will replace my TGVs.

I'll try and post some progress pictures tomorrow night once I'm done.
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Old 09-05-2012, 01:35 AM   #727
Dr. Balog
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Good luck with the rebuild. Sucks to hear that a true grease monkeys hard work was just molested like that. Ill be looking forward to the rebuild.
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Old 09-05-2012, 09:56 AM   #728
brcewane
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Quote:
Originally Posted by Dr. Balog View Post
Good luck with the rebuild. Sucks to hear that a true grease monkeys hard work was just molested like that. Ill be looking forward to the rebuild.
I know.. I feel so violated
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Old 09-05-2012, 10:52 PM   #729
brcewane
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I was able to finish off the 2.5 rs intake manifold tonight. I'm too tired to post up the pictures, but I'll try and get them up tomorrow.

Cleared everything off the manifold except for the couple vacuum lines that I'll need for my brake booster, fuel pressure regulator etc. This should look pretty cool polished up and replacing my TGVs.

I'll also have to drill and tap some new holes for the throttle body. Since I have a 73mm throttle body now, I'll bust out the die grinder and open up the inlet to match

There are 4 holes to weld up and smooth out. I've probably spent 5 hours on it so far

Last edited by brcewane; 09-05-2012 at 11:03 PM.
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Old 09-06-2012, 08:26 AM   #730
brcewane
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OK... now for the pictures.

This is what the 2.5 RS JDM manifold looks like with all the junk attached to it



After clearing off all the bolt on pieces you end up with something that looks like the following




After two and a half hours of cutting and grinding you end up with something that looks like the pictures below. You can see where I started grinding off the lower runs that end up going to a tube that sticks up right in the center of where the inlet is.





After another two and a half hours the following night I ended up getting it all finished. There are a couple holes that will be patched/welded and then ground down smooth. Once all the test fitting is done it will go out to the polisher





I left the two threaded tabs on the bottom because they line up with where the throttle body cable will need to run. I figure these will make good mounting points for a bracket holding the cable on the bottom of the manifold.
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Old 09-06-2012, 08:46 AM   #731
waynoSTI
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Good job bro! She's going to look sick once Sami get his hands on it
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Old 09-06-2012, 02:16 PM   #732
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I just saw that post about the stuff bein stolen... That's terrible . Good luck with the rebuild!
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Old 09-07-2012, 09:18 PM   #733
brcewane
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Ordered the same oil filler and cap as Wayne today and some 10mm dress up bolts

http://www.outfrontmotorsports.com/oil_filler.htm


Last edited by brcewane; 09-07-2012 at 09:29 PM.
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Old 09-08-2012, 11:04 AM   #734
brcewane
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I had forgot to ask Ultimate Racing.. does anyone know if the T3/T40E is water cooled? Or is it oil cooled only?

I'll give them a call on Monday to make sure, but I was curious if anyone knew off hand. It will help me plan out my engine bay on whether or not I need the top coolant reservoir
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Old 09-09-2012, 10:26 AM   #735
brcewane
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So it looks like my DBC Throttle body isn't going to fit/work without a bit more fabrication on the 2.5 RS intake manifold. For one the bolt pattern doesn't match up, and they aren't the same size bolts either.

Plus if you look at the back of the WRX throttle body you'll see that there is a little channel that matches up with the intake manifold to let air up into the top sensor. Of course this isn't there on the RS manifold.



First I posted in Cribbie's thread to see if he had an adapter plate, because it looks like he ran into the same scenario. Then I realized I could just cut the mounting area off of a junk stock WRX intake manifold and weld it onto this new 2.5 RS one.



Looking to pick up a spare WRX intake manifold tomorrow and do the cutting tomorrow night.
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Old 09-09-2012, 01:27 PM   #736
scby rex
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water jetting one would be a better option I think. Theres a bunch of crap behind the wrx opening for the iacv and getting that all in the 2.5i manifold would be a huge pita.
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Old 09-12-2012, 10:59 PM   #737
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Quote:
Originally Posted by brcewane View Post
OK... now for the pictures.

This is what the 2.5 RS JDM manifold looks like with all the junk attached to it
I can't remember your setup and I'm too tired to search but somebody mentioned that the 2.5 manifold isn't the same as the wrx 2.0 heads. You know if there is any truth to this?


...and I don't know why I'm not sub'd already...sooooo yeah subscribed
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Old 09-13-2012, 12:03 AM   #738
waynoSTI
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Call up IAG bro and see if they can make you a spacer on there CNC machine.

It would be cheaper and a better option.
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Old 09-13-2012, 08:37 AM   #739
brcewane
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Quote:
Originally Posted by waynoSTI View Post
Call up IAG bro and see if they can make you a spacer on there CNC machine.

It would be cheaper and a better option.
Talked to Frank and we're going to make something out of 1/2" aluminum
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Old 09-13-2012, 12:37 PM   #740
waynoSTI
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Quote:
Originally Posted by brcewane View Post
Talked to Frank and we're going to make something out of 1/2" aluminum
Awesome! That's good news bro.
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Old 09-14-2012, 07:19 AM   #741
brcewane
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Dropped off the UR turbo stuff yesterday.. We're going to fix up all the flow, flange and welding issues... Yikes!
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Old 09-20-2012, 04:32 PM   #742
waynoSTI
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How you making out bro? any good news
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Old 09-20-2012, 06:01 PM   #743
brcewane
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Quote:
Originally Posted by waynoSTI View Post
How you making out bro? any good news
Everything has been sourced, planned and assembly started happening this afternoon
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Old 10-08-2012, 09:50 AM   #744
brcewane
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Intake Manifold has been now been fitted, throttle body mounted and alternator flipped.

Had to hole out the feet of the Intake manifold to match the spread of the STi block and WRX heads.
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Old 10-12-2012, 07:54 PM   #745
brcewane
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Heading to the shop tomorrow morning to check-out the progress so far. I'll bring the camera with me
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Old 10-14-2012, 12:05 AM   #746
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F@@K!! sorry to hear about that happened! Hope everything turns out good!
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Old 10-14-2012, 08:41 AM   #747
brcewane
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Paid a visit to the shop yesterday. Things are coming along. Need to get some fuel rail mounts machined and run the fuel lines and we should be almost ready to go.

Ended up going with 2" intercooler piping
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Old 10-14-2012, 09:29 AM   #748
waynoSTI
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Where's the pics bro?
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Old 10-14-2012, 09:32 AM   #749
brcewane
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Franks been taking some progress pics that I'll post up soon.
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Old 11-04-2012, 07:47 AM   #750
brcewane
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Getting closer to getting the car back.. hopefully this week
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