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Old 03-30-2009, 03:00 PM   #1
hustleshark206
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2000 MPS Built RS
1991 Leggy Turbo EJ22t

Default HustleShark's Project GC

It's been a long time comming but I finally worked up the motivation (and ballz) to make a thread for my GC project.

A little Background

When I was young I was fascinated by rally racing and looked up to drivers like Colin McRae. I loved the subaru's the most and It was a dream of mine to own a WRC 555 factory rally car. Well years have passed but I still have always loved that car so two years ago I bought a 2000 2.5RS coupe. I feel lucky as these are getting hard to find and they are definately my favorite body style of the whole Impreza family.

The car:









Don't worry I have new plates

These pics are a few months old. The car now has gold SSR 17"s on it and that g-reddy lip is looooooong gone. It was sweet while it lasted (about 2 months ) but a pothole made quick work of it

I also have c-west side skirts and a JDM rear bumper and spats that will go on when I have a chance to get them painted. Apprearance mods are great and all but you don't post in built motors to show off your rims so without further ado.....

On with the show

After A LOT of research and even more thinking and talking to the pro's I decided to build up an EJ22T motor and get my little GC to roar! I am lucky to have some really great contacts so one phone call to my friends in tacoma and I got this.


They were even nice enough to leave some sensors for me


Dirty but in very good shape!



Backside

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Last edited by hustleshark206; 04-01-2009 at 02:24 PM.
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Old 03-30-2009, 03:01 PM   #2
hustleshark206
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1991 Leggy Turbo EJ22t

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The Teardown

Since this is my first Subaru build I took lots of pictures for me to reference later if needed.

Breather hose. The elbow will be removed and the hole will be plugged later on.


Oil pressure sender



Removed Ilder pulleys and timing gear



Removing water pump assembly



Water pump removed and the T. Belt tensioner assembly comming off.





Taking off the oil pump


Last edited by hustleshark206; 03-30-2009 at 04:26 PM.
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Old 03-30-2009, 05:05 PM   #3
jeffmoorman
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hooray for another PAC NW build!
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Old 03-30-2009, 05:51 PM   #4
hustleshark206
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1991 Leggy Turbo EJ22t

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Engine Teardown

A helpful link for removing the pistons. Thanks reddevil!

http://www.youtube.com/watch?v=TR0Ed6qTIVQ

I used a 3 foot long 1/4" aluminum rod for the task and it works like a champion.

Block split apart.



Seeing the crankshaft for the first time



Cylinder block in halves



You can see the nice crosshatch the cylinder bores still retain



Crankshaft and connecting rods out. No signs of any damage to the crank or the block. Quite pleased with my $500 shortblock!



Pistons in good shape





Main Bearing Surfaces



Everything was then sent to the machine shop for cleaning, inspection, and machine work.
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Old 03-30-2009, 05:52 PM   #5
benw
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and hopefully a hot tank!

can't wait to see more
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Old 03-30-2009, 05:55 PM   #6
hustleshark206
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1991 Leggy Turbo EJ22t

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well you won't have to wait long..... I know the worlds fastest machinists.
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Old 03-30-2009, 06:29 PM   #7
hustleshark206
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2000 MPS Built RS
1991 Leggy Turbo EJ22t

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Goals and Timeline-

Well since I can't have a factory WRC 555 (in my price range) I thought I would build a streetable, semi-reliable GC8 that I can take to the track and have a lot of fun with. Once the project is done my goal is to not have to drive it everyday. My mom will be moving up north soon and if I register my car through her adress I won't have to worry about passing any emissions

The plan is as follows:

EJ22T shortblock bored 0.020" over
Wiseco stroker pistons
Eagle STI (5.138") connecting rods for a slightly shorter stroke than the phase I (5.167") rods
Brand New STI crankshaft
ACL race main and rod bearings
Brand new STI 10mm oil pump
New water pump and themostat
Phase I DOHC heads from MY98 2.5RS
Grimmspeed P&P exhaust manifold and high flow cross-pipe (coated)
Grimmspeed up-pipe (uncoated)
Invidia TBE
Gimmick Turbo Inlet
Perrin lightened Crank Pulley
DW 800cc topfeed injectors (custom fit to side feed manifold)
MRT Fuel Rails
Fully Custom SS Fuel Lines
Prosport Gauges (EGT, Boost, Oil Pressure)
WBR FMIC (custom fit)
Blouch 18g TD05 8cm^2

Calculated compression ratio 8.6:1
Target Power: 350whp
Target torque: >300ft/lbs.

I have talked to a reputable engine builder and rally driver who said this motor generates rediculous amounts of torque. I like the idea of having a relatively quick spooling turbo to get me power but good low end grunt as well. I would like to have this project done in time for at least the second half of the track season. I definately want to get her going this summer. I bought the shortblock in May 2008 so hopefully everything takes me a little over a year.

Everybody feel free to chime in. I have taken my time and done my homework but that doesn't mean I am doing everything perfectly. Any ideas/ suggestions just let me know









Last edited by hustleshark206; 04-03-2009 at 02:10 AM.
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Old 03-30-2009, 06:59 PM   #8
nme187
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Awesome build! What are you doing for EM?
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Old 03-30-2009, 07:06 PM   #9
hustleshark206
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2000 MPS Built RS
1991 Leggy Turbo EJ22t

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The Build

Part One: Shortblock

After inspection the machinist said everything was in excellent shape and I got the green light to continue the build. At this point I ordered the wiseco stroker pistons, eagle rods, ACL bearings, ARP headstuds and the STI crankshaft. The block was machined 0.020" over and the pistons were fitted to the block. Machine shop also fully balanced my whole rotating assembly at this time.

Assembly:

New connecting rods and Crank



How about one more. mmmmmmmmm yeah



Crank and rods inside cylinder block and halves torqued together



Another



New pumps bolted on and pistons in the block



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Old 03-30-2009, 07:10 PM   #10
hustleshark206
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1991 Leggy Turbo EJ22t

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Quote:
Originally Posted by nme187 View Post
Awesome build! What are you doing for EM?
Thanks! For EM my tuner recommended the Haltech E8 with the flying lead kit. Says that the wiring will be pretty straight forward and all the sensors will be plug and play! I also plan on running a MAP system instead of MAF like you STI guys have. Much easier to deal with from a tuning point of view.
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Old 03-30-2009, 07:26 PM   #11
hustleshark206
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1991 Leggy Turbo EJ22t

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Minor Setback

Ok after I completely assembled the shortblock I realized I had made an error. The STI crank is made to run the thrust bearing in the # 5 position while my EJ22T block has the thrust in the #3 postion. Ah, Crap! Disassembled the entire engine (at the price of new oil seals) and went back to the machine shop. The machinist took a look at the crank and recommended maching the crank to accept thrust on #3. Basically they took a series of tiny ridges off of the crank that would have chewed up the bearing. I have no pics but if you look at a Phase II EJ25 crank you will see what I am talking about. I was worried that my crank walk would be out of spec so I PM'ed some very knowledgable people to get some first hand experience. Turns out crank walk will be out of spec but not by too much. People have done this before with success. This may effect the longevity of my engine but seeing as this is my first Subaru build I am guessing something else will fail before this catches up with me.

The alternatives are:

Running a phase I crank; don't want to do that cause phase II is stronger, and better (52mm journals instead of 48mm IIRC). Plus you will have to get phase I rods which are expensive to say the least.

Machining the block to accept thrust on #5; A lot of extra work and money, but the best way to do it. Good to know in the future.

The shop I go to does all machine work for Carter subaru so I trust they know what they are talking about. The shop foreman told me to use less fujibond so in the end my teardown benefitted my engine positively. The machine shop fitted my crank at no cost to me and I am back in business!
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Old 03-30-2009, 07:46 PM   #12
hustleshark206
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1991 Leggy Turbo EJ22t

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Engine Painting

The good thing about doing things on a budget is you have plenty of time to pay attention to details. After I re-assembled the shortblock and was confident with all my specs I decided to paint the block with a little help from my room mates. It took forever to tape everything off but it turned out really well



Yup bell housing gets some love too





Roomate expressing his enthusiasm for some nice work!



Waited until it dried and took some tape off



Finished Product



Now it's ready for the engine stand and building the long block!



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Old 03-30-2009, 09:09 PM   #13
AWDWRXLOVER
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sr55/meth/sick speed

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the motor is too badass to put a 18g on. go bigger!
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Old 03-31-2009, 12:37 AM   #14
hustleshark206
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Quote:
Originally Posted by AWDWRXLOVER View Post
the motor is too badass to put a 18g on. go bigger!
Well the heads are not built so I thought a smaller quicker spooling turbo would be fun and be able to produce plenty of power. Did you have any specific turbo in mind? My tuner said a 20g would be perfect but I aldready have the 18g.
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Old 03-31-2009, 03:28 AM   #15
ReubenH
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Black

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*ENVY*

I want a CD 2.2 block so bad. Looks mint man. What heads you going with? I've always wanted to do a 2.2 + EJ207 heads build. Still intend to when i save up some proper cash for it.
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Old 03-31-2009, 07:09 AM   #16
AWDWRXLOVER
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Quote:
Originally Posted by hustleshark206 View Post
Well the heads are not built so I thought a smaller quicker spooling turbo would be fun and be able to produce plenty of power. Did you have any specific turbo in mind? My tuner said a 20g would be perfect but I aldready have the 18g.
tod6 20g or dom3
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Old 03-31-2009, 07:45 AM   #17
scprs
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i was wanna see more....
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Old 03-31-2009, 08:25 AM   #18
Vid_Maye
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I envy anyone who has the time and the money to do this. Hopefully I can do something similar to my 06 WRX. But all in all, great work, keep the pics flowing!
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Old 03-31-2009, 01:39 PM   #19
hustleshark206
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1991 Leggy Turbo EJ22t

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Quote:
Originally Posted by ReubenH View Post
*ENVY*

I want a CD 2.2 block so bad. Looks mint man. What heads you going with? I've always wanted to do a 2.2 + EJ207 heads build. Still intend to when i save up some proper cash for it.

Yeah I guess i am lucky having such easy access to EJ22T blocks. I am running phase I DOHC heads off MY98 2.5RS. They were cheap and they are supposed to flow pretty well. I would like to play around with porting/ building heads but for this project I will have to make due with freshly rebuilt but stock heads. Delta quoted me almost $200 per cam for a more aggresive grind. I guess they have to weld extra material onto the cam before they grind it. I just didn't want to delay the project any more by dropping that kind of cash on heads. I know you can make lots of power with built heads but for now I will make due with what I have.
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Old 03-31-2009, 02:37 PM   #20
hustleshark206
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1991 Leggy Turbo EJ22t

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Assembly

Part 2: Longblock

I bought some DOHC 2.5RS heads and intake manifold cheap and brought them to the machine shop for inspection. Inspection passed but there were two bent valves so I had a full rebuild done. I had the heads milled flat for a nice seal with the head gasket and buckets installed for proper valve lash.

Headsgaskets: OEM Subaru 0.058cm (0.0228")
Fasteners: ARP Headstuds

I was a little worried about timing using thinner headgaskets but everything went together very smooth, almost like it was meant to be.

Pics:

Assembled Shortblock on the engine stand. ARP Head studs


Freshly Rebuilt heads Ready to go on



Headstuds in the block awaiting the heads



I have followed Mick the Ginges build pretty regularly and he recommended using copper spray for the head gaskets so....... here it goes



Copper Sprayed Gaskets on the block



Heads on with no cams



Front View



Top



Heads on. Timing covers fitted.

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Old 03-31-2009, 02:37 PM   #21
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If I were to do it all over again, I would have gone the 22 route. Sounds like a fun project, good luck.
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Old 03-31-2009, 03:00 PM   #22
DrewDeezy
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looking great man. hopefully see this car at a WA meet!
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Old 03-31-2009, 03:17 PM   #23
mr soul
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Nice build, you get the block from Frantic Four?
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Old 03-31-2009, 05:03 PM   #24
hustleshark206
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Quote:
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Nice build, you get the block from Frantic Four?

I sure did. Thanks for the hook up Keith! Does it do you guys justice?
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Old 03-31-2009, 10:04 PM   #25
QksilverRS
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Impressive! Good Job Doing It On Your Own!
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