Project Car: 2002 Impreza Wrx Sti Greek Monster

[leoimpreza]

Hi guys, my name is George and I am owner of this modified 2002 WRX STi.

The Story:
At the time I did not have big plans for the car but, the things quickly changed though as i started build the suspension set up. I started slowly building the car with the basic bolt on upgrades and was content with the car.

Over the past couple years it went390hp with SSF ported & polished Heads, Unorthodox Racing pulleys (3 pieces set), Magnus intake manifold, APS 8 Injector Set Up (4 x 550cc STI & 4 x 198cc BOSCH), APS auxiliary 8 injector manifold housing and fuel rails, 255lph fuel pump in tank, HKS F-Con SZ ECU, Apex-I AVC-R boost controller, AEM air intake system, STi air intake duct, APS SR55 Turbo, Invidia 4-2-1 Stainless-Steel Exhaust Manifold, Turbo XS 4inches downpipe, Turbo XS 3” high flow catalytic converter pipe, Power Enterprise V-mount intercooler and radiator, Greddy Oil Cooler etc...

The car was a blast on the street and handled well on the back roads. Also I had a great time working on the car and doing all of the installs myself. After running the SR55 setup for a little over a year I was eager for more power. Over the next couple of years the car went through many changes.
The latest round of mods started about 3 years ago when the engine went out. “I put the best of everything on as i went along”. One thing led to another and it raced out of control!

Here some old pics

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[green rims]

Always like seeing the cars that America never got.

[leoimpreza]

THE NEW SET-UP

The Highlights:

The block:
• EJ20 closed-deck block (w/ oil squirters)
• Arrow 81mm-stroke cross-drilled billet crankshaft
• ACL race series main & rod bearings
• Extreme Arrow H-beam connecting rods (RCM-spec)
• Custom Omega forged pistons electroless nickel-coated (92.5mm)
• Omega heavy-duty gudgeon piston pins
• Omega high-performance piston rings
• ARP block bolt kit
• Cosworth H11 ultra high performance head studs
• Power Enterprise heavy metal head gaskets
• OEM Subaru engine gasket & seal kit

The heads:
• STi Version7 cylinder heads
• Kelford custom-spec camshafts
• Custom ported & polished work by Sevdalis Super Flow
• Supertech oversized stainless-steel black-nitride intake valves (+1mm)
• Supertech oversized inconel exhaust valves (+1mm)
• Supertech dual valve springs
• Supertech titanium valve retainers & seats
• RCM/WRC bronze intake and exhaust valve guides
• Subaru shimless buckets
• Flow bench tested by Sevdalis Super Flow

Engine/turbo/dress up:
• HKS GT32-40R .82AR ball-bearing turbo (modified)
• HKS turbo heat shield
• HKS oil line turbine filter
• HKS 100mm turbo suction funnel
• Blitz 100mm SUS power air filter
• Blitz Carbon fiber cold air box
• Billion air funnels 75mm (x2)
• HKS 50mm super racing external wastegate
• Greddy Type-R BOV (w/ custom funnel)
• Invidia equal length 4-2-1 stainless steel header (modified)
• Turbo XS 4” downpipe (modified)
• Ceramic coating & DEI extreme heat wrap for exhaust manifold & downpipe
• X-Force 3.5” metallic high flow catalyst
• Blitz Nur touring 82mm exhaust system (modified)
• Cusco exhaust hangers
• Goodridge heat proof hose wrap
• RCM high flow modified oil pump
• RCM Alloy/Titanium vernier pulley set (w/ big tooth profile)
• RCM/WRC R-profile high-wrap timing belt system
• ATI super damper crank pulley
• Unorthodox Racing lightweight pulleys (2 pieces)
• Power Enterprise super kevlar accessory belts
• Carbing carbon alternator cover
• Race modified high output alternator (polished)
• Custom alloy vacuum block
• Magnus intake manifold (modified)
• APS tumbler delete bodies
• Port matched intake manifold and tgvs
• Gizzmo thermal intake manifold spacers
• Thermal spacer bolt kit
• Infinity Q45 90mm throttle body (w/ custom inox stretching stopper)
• Custom thermal throttle body gasket
• Pace Products custom V-mount race type radiator
• Twin SPAL high performance slim fans
• Custom high-flow V-mount intercooler
• Custom automatic/manual intercooler water spray system
• Custom water header tank by Hercules Parts
• ARC reserve tank
• Brand new STi water pump
• Sard 68°C low temp racing thermostat
• Samco silicon hoses throughout
• STi 1.3 bar radiator caps (x2)
• Setrab 25-row oil cooler (w/ SPAL cooling fan driven by ECU)
• Brand new oil cooler modine
• Greddy oil filter block adapter
• STi competition oil filter
• 2x FilterMag SS300
• Accusump oil accumulator (w/ electric valve)
• Alloy oil catch tank
• Custom oil breather system
• ARC high-capacity oil pan (w/ modified bafflers)
• Tomei baffle stiffener
• WRC cork sump gasket
• Greddy 10W-60 racing motor oil
• Zero/Sports oil cap
• Syms brake & clutch reservoir caps
• Custom 2.5liters radiator breather tank & 2.8liters windshield washer tank by Hercules Parts
• Trico windshield washer pump
• Beatrush forged pitching stopper
• Cusco heavy duty engine mounts
• 5-Zigen pro racer engine mount damper (modified for LHD)
• All powder coating done by Pavlos Pettas
• All chroming and polishing done by Mr. Nikos

Water/Methanol Injection System:
• AEM 150psi water/methanol pump
• AEM progressive pump speed controller
• AEM stainless injector assy
• AEM stainless jet (630ml/min)
• Aquamist high speed stainless inline valve
• Aquamist water flow sensor 80-1200ml/min
• Aquamist DDS3-v8 + flow sensor (BLUE Bargraph)
• RGM pillar gauge mount
• ACL 2 way inline valve
• Goodridge inline filter
• 6mm high pressure nylon hose (black)
• 70A Flosser power relay w/ base
• Hercules Parts custom alloy 11liters tank w/ fluid level sensor & level indicator
• Water/Methanol Injection System driven by ECU

Fuel system:
• 8 injector set up (w/ 4x 550cc STi & 4x 525cc Rochester injectors)
• Modified APS fuel distribution block
• Custom alloy fuel return block
• APS fuel rails (x4)
• In line fuel check valves (x4)
• Custom Alfagomma L-671 AA 240psi fuel lines
• Custom braided stainless steel fuel lines
• Goodridge heat proof wrap for fuel lines
• Sard RJ fuel press regulators (x2)
• In line fuel dampers (x2)
• Custom 4.8liters fuel Surge tank by Hercules Parts
• Sard 280lph fuel pump in-tank
• Bosch 044 externals fuel pumps (x2)
• WIX WF8037 inline fuel filters (x2)
• Setrab 25-row fuel cooler on return line
• SPAL fuel cooler cooling fan w/ 40A Hella power relay w/ base & 10A fuse

ECU/Electronics:
• Motec M800 Gold Box ECU
• ODG instruments Full Temp
• Blitz turbo timer
• HKS EVC6 boost controller
• HKS twin power DLI ignition system
• HKS circle earth grounding system (w/ Connection 8-gauge power cable)
• Zero/Sports V-Two point muffler ground
• Zero/Sports V-earthing ground Kit
• Zero/Sports V-effector voltage stabilizer
• Directed electronics 67500 - 50 farad digital power cap
• Okada Projects plasma direct ignition coils
• Okada Projects plasma sparks
• NGK racing spark plugs (R7434-9)
• Optima blue top marine battery (trunk mounted)
• Audison Connection battery clamps
• Prodrive battery hold down
• Custom alloy battery box
• Stinger 150 Amp circuit breaker
• Modified Stinger ground distributions (x2)

Transmission/Drivetrain:
• ATS triple-plate carbon clutch and flywheel
• Custom gearbox oil cooler inside the water radiator
• STi short throw shifter
• Cobb 6-speed shifter busing
• Super Pro transmission crossmember bushings
• STi braided stainless clutch line
• Cusco heavy duty transmission mount
• Motul 75W-140 racing gearbox oil
• CTG Torqline carbon fiber propshaft
• ARP propshaft bolts
• ARP extended wheel studs
• STi 1.5way front LSD differential
• Cusco 1.5way center and rear LSD differentials
• Cusco 80W-140 racing LSD oil
• STi rear cooling differential case cover

Suspension/Chassis:
• Tein super racing coil-overs
• Tein racing spec springs
• Tein adjustable top mounts
• 2x Tein EDFC
• Prodrive quick ratio steering rack
• Setrab 7-row power steering fluid cooler
• Billion racing power steering tank
• STi carbon fiber front strut tower bar
• Cusco carbon fiber rear strut tower bar
• Cusco rear V-brace
• Carbing floor brace (modified)
• Carbing trunk pillar bar (modified)
• Summit rear trunk bar (polished)
• Beatrush floor performance bar
• Summit front lower tie brace
• Cusco lower arm bar
• Modified front subframe (powdercoated)
• Summit subframe reinforcement brace (2 piece set)
• Do-Luck aluminum floor support bar
• Cusco lower center power brace
• Cusco lower rear power brace
• Do-Luck rear T-brace
• STi rear diff. member assy
• Beatrush diff. support brace
• Summit fender reinforcement brace
• Prova ball joints end links (F/R)
• Cusco adjustable trailing arms (powdercoated ''samco'' blue)
• Cusco adjustable lateral links (powdercoated ''samco'' blue)
• Cusco adjustable 22mm sway bars (F/R) (powdercoated ''samco'' blue)
• Cobb adjustable rear sway bar mounts
• Cusco rear stabilizer bar (modified and chromed)
• Zero/Sports tierod angle adjuster
• Zero/Sports ball joint protector
• Pleasure Racing roll center adjuster
• Perrin anti lift kit
• Cusco front wishbone pillow ball bushings
• Powerflex steering rack mount bushings
• Powerflex rear beam mount
• Whiteline & Powerflex rear tie bar bushings
• Powerflex tie bar to hub front bushings

Brakes:
• Front: Endless 370mm disc rotor racing w/ 6pot racing brake calipers
• Rear: Endless 345mm disc rotor racing w/ 6pot racing brake calipers
• Endless type CC-R race compound brake pads (F/R)
• Endless stainless steel braided brake lines
• Endless RF-650 racing brake fluid
• Perrin master cylinder brace
• Syms brake line cramps
• Prova carbon fiber brake cooling ducts
• Custom front brake cooling plates

Wheels/Tires:
• ADVAN RC II, 18x8.5-Inches +45 offset
• Pirelli P Zero 245/40/18
• STi gold lug nuts

Exterior:
• Zero/Sports front bumper (modified)
• Zero/Sports rear bumper
• Voltex side skirts
• Charge Speed L-size carbon fiber canards
• Vertex L-size carbon fiber front under canards
• Dcuatro ground effectors GE-1
• Beatrush tow hooks (F/R)
• STi Spec-C lightweight front bumper beam (modified)
• STi ‘07 side diffusers (modified)
• STi ‘07 rear diffuser
• Prodrive rear diff. guard
• Prodrive Group-N under tray
• Custom front/side under diffusers
• Custom exhaust heat shield
• Tein hood dampers
• Aero Catch hood pins
• Seibon CWII-style carbon fiber hood
• Seibon CW-style carbon fiber reverse hood scoop
• Seibon carbon fiber trunk lid
• Charge Speed 3D carbon fiber rear wing
• STi fog lamps set CIBIE
• Narva gold multilayer H1 110W fog lamps
• PIAA pure silicon wipers
• PIAA platinum super white HID bulbs
• Target HID Xenon lighting system
• Osram chrome headlights indicator bulbs
• Philips chrome taillights indicator bulbs
• STi genuine pink ''I'' grille emblem
• Varis carbon fiber pillar garnish
• Zero/Sports carbon fiber blink covers
• STi rear window sticker windshield
• JDM white side repeaters
• JDM side visors

Interior:
• Bride Gias Low Max kevlar seats in Hyper blue Gradation (x2)
• Bride lumbar pads (x2)
• Bride seat rails
• Bride matching door cards inserts and rear seats
• Takata 5-point harness (x2)
• Works Bell short hub
• Works Bell black quick release II
• Momo speed 3 steering wheel
• Cusco 6-point roll cage
• Cusco carbon fiber side bars for the roll cage
• Cusco/Custom harness bar (w/ camera mount)
• IRS sun visors for roll cage (Cusco)
• Custom sun visors blanking plates
• Subaru RA-R handle deletes
• Beatrush rear division plate
• STi Genome center triple gauge pod
• STi Genome 60mm gauges (boost, oil temp, oil press)
• Defi control unit II (x2)
• Defi-Link display (x2)
• Cusco water spray controller
• STi stainless steel manual pedal set
• STi competition gauge cluster (w/ 260km/h & 10.000rpm/min)
• STi titanium shift knob
• Custom black leather shift boot (w/ red stitching)
• Sparco polished hand held fire extinguisher (FIA approved)
• Lifeline 2.4ltr AFFF hand held fire extinguisher (FIA approved)
• FIA approved master cut-out switch kit
• STi aluminum door sills
• JDM STi key blank
• Prodrive floor mats
• OEM carbon printed dash kit
• OEM auto-dimming mirror with compass
• Custom LED map light
• Custom LED dome light


Thanks to:
Sevdalis Super Flow (machine work) / http://www.sevdalis.gr/
NT racing division / www.ntracingdivision.com
Hercules Parts / www.herculesparts.gr
ITS power / www.itspower.com
Stelios Chaldeos / www.jmattis.com
Roger Clark Motorsport / http://www.rogerclarkmotorsport.co.uk/
Auto Ergonomics / www.autoergonomics.com
Japan Tuning / http://www.japantuning.gr/
Louis Autotuning / http://www.louis.com.gr/
City Sound / www.citysound.gr
Tasos Pagonas (Screws, hoses, …etc)
George Rapatas Body Workshop
Pavlos Pettas (Powdercoated) / http://www.pavlospettas.gr
Mr. Nikos (Chrome & Polished)
Filippidis Turbodiesel / http://www.turbodiesel.gr
Kanakis George (Handing)
Many friends from Nasioc, www.subamaniacs.gr, www.scooby.gr

[EJ20_lee]

me like

[RR02wrx]

That is an absurd mod list. Nice job.

[leoimpreza]

Here are some pics of my new fuel system set up!

[soon2bblackongold]

is that a typo or did you say you have 6 pot's on the front AND rear ?


very nice fuel system diagram...I am sure there are some guy's on the forum that would like to see how it's all laid out

[leoimpreza]

[naggg]

Wow Beastly!!!

[leoimpreza]

[leoimpreza]

[leoimpreza]

Some pics of:

Modified Magnus intake manifold
Custom water header tank by Hercules Parts
Infinity Q45 90mm throttle body (w/ custom inox stretching stopper)
Custom thermal throttle body gasket
8 injector set up (w/ 4x 550cc STi & 4x 525cc Rochester)
APS tumbler delete bodies (ported & polished)
4x APS fuel rails
Custom alloy fuel return block
Custom braided stainless steel fuel lines
Goodridge heat proof wrap for fuel lines
2x Sard RJ fuel press regulators
2x fuel dampers
etc...

[iRick.]

wow...

[mister hashimoto]

that is amazing work right there man..nice job

[whiteGDB]

that really is a monster........good job

[vaj]

I just drank a whole cup of coffee reading the fuel system diagram. Nuts! Is this going to be a track car? Regardless... I'm in for updates. This is crazy **** right here.

[WRX2FAST4UFOOL]

Mechanical Genius!

[jordanretro1223]

Wow, what a build!

[Raul04STI]

Damn, nice!

[soon2bblackongold]

WOWWWW, this is one of the nicest setup's I have EVER seen


<-----in awe.....

[willow]

Oh wow. That's just crazy and maxed out mods. Good job! Can wee the dyno and some video clips?

[axelthrasher]

Keep the pics coming. Looks like one hell of an intense build.

[donniebrasco]

huwow!mad scientist yo!

[trex616]

.....WOW

Good work my friend.

[N'CTRL]

That's awesome. I was wondering what all those braces would look like installed. Do you have any shots of the i/c set up? I'd like to see what you did to snake the piping around the a/c radiator (or did you put an aftermarket one in).