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Old 07-18-2011, 01:57 AM   #376
morrocco88
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Join Date: Jan 2006
Chapter/Region: NWIC
Location: Eastern WA
Vehicle:
97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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^^^It will never be done

But yeah, it feels good to be able to just jump in and drive. It just runs so good and feels like it revs out so effortlessly. I have to keep an eye on the tach because it feels like it just keeps pulling, and doesn't "nose over" like smaller turbos I've driven. I've been runner her out to 7500 and it feels really good. I think having everything balanced goes a long way for having a smooth revving engine. I had the clutch and flywheel balanced as an assembly too.

Yesterday evening I took my neighbor for a ride (07' spec B owner) and he was shocked at how fast it was. We were heading back towards home and I was really on it. I was at about 7k in 3rd and heard a loud bang followed by clunking underneith the car and saw a part tumbling down the road in the rearview

I pulled over popped the hood and noticed my power steering pulley was gone . No damage was found, and it looks like it made a clean exit straight down to the ground spinning 7k. We found it out in a farmers field and it was pretty hammered. I need a new pump now because it stripped the splines on the shaft when it was loose and rattling around.

It must have been my fault, becaue I took the pulley off to powder coat it. I zipped the nut back on with my Snap-On impact gun and just tried to hold it from spinning with a leather glove on. Apparently I didn't get it tight enough, and after 4k miles of driving, it came off

So if anyone has a spare wrx PS Pump, I'm in desperate need.

Other than that, she's still running great!
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Old 07-18-2011, 08:28 AM   #377
httrdd
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At least it was not something major. I tightened the **** out of mine when mine went back on. Plus you are reving that so much higher then the stock engine would.
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Old 07-18-2011, 12:51 PM   #378
amcn831
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2007 2.5i CGM

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You sure like PCing don't you? You've obviously heard it before^^^^^^but truly incredible work. Very subtle, very clean and an amazing professional job. I've read all eight pages in the last hour or so, and the entire build is amazing. Very fun to follow and keep up the incredible work. GL with that pump by the way. Haha
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Old 07-18-2011, 01:19 PM   #379
morrocco88
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Rotated BW S256 6speed

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^^^ Hey thanks!

Yeah, I did go crazy with the powder coater, but the satin black just looks so nice, and it stays on way better than paint. It was just too easy when I had the oven and the powder coater from Harbor Freight. It was probably one of the best additions to the shop.
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Old 07-18-2011, 01:39 PM   #380
Maxwell Power
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I gots pumps yo.
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Old 07-18-2011, 08:41 PM   #381
morrocco88
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Rotated BW S256 6speed

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Called the shop and your off on Mondays. Sending PM to hopefully have you ship me one Tuesday.
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Old 07-22-2011, 04:07 PM   #382
Honest Bob
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Sweet build! I just wanted to see what was up with the 2.1 strokers but found so much more goodness in this thread. Hows the PCV delete treating you? I would love to get rid of my AOS.
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Old 07-23-2011, 03:03 PM   #383
morrocco88
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Rotated BW S256 6speed

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^^^ Thanks!

The PCV delete is the best part of my build. So far 5k miles and I have absolutely ZERO residue in the intercooler pipes, IC, turbo inlet ect. I also have ZERO oil vapor smell from the engine bay, ZERO oil residue of any sort on the engine/engine bay from reverse flow of the head port breathers/filters. That tells me that there is always vacuum on the crank allowing only fresh air to enter the head ports and never get reverse flow. I have since installed a nipple on the bottom of the catch can with a hose attached, so I can drain it without taking it off. I simply pull the plug on the hose and let it drain into a plastic cup. Everything is working better than I thought!

My setup also seems very efficient since it's making great power on less boost, so it's possible I'm actually getting better ring seal on boost due to the crankcase EVAC setup and that's helping a little....I don't know for sure.
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Old 07-24-2011, 08:57 AM   #384
Honest Bob
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Cool, I'm gonna look into doing a similar setup except without the pump. I dont really have space for it.
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Old 08-08-2011, 12:02 AM   #385
morrocco88
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Join Date: Jan 2006
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97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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Update:

Car is running really well. I borrowed an early 02' 03' wrx Power Steering pump so I could get her back on the road while I was looking for the proper 04' and later pump. I also want to make a custom line for the high pressure line to get rid of the formed metal part that goes up and over the turbo inlet. I might do that down the road though.


Oil pressure:
I noticed the pressure wasn't getting high enough at higher rpm, although the pressure was fine at cruise (60 psi @ ~3300rpm) and great at hot idle (25-30 psi). When revving it out, it only goes to ~65 psi and that's a bit short of the 10psi per 1k rpm rule of thumb. It's a "blueprinted" 10mm pump with no shims. I thought it might be just the Mobil 1 15-50 breaking down, so I changed it and switched to Schaeffers 5-50, and it's pretty much the same. The plan is to add two shims and see what happens.


Exhaust:
My e-bay exhaust has officially driven me crazy! The packing has completely disintegrated leaving me with a full blown Gymkana exhaust . She is supposed to be a sleeper and people can hear me driving easy from three blocks away. I bought a Dynomax Super Turbo muffler that I will weld on and see how it sounds. It has a 3" side entrance and 3" center outlet, so the exhaust does a big "S" shape through the muffler with perforated tubing and lots of glass packing. My buddy has one on his 72' 240Z with a v8 and it sounds really good. It should flow pretty good, but I think it will add a little back pressure.


New exhaust housing:
I will finally get time to install the new Blouch 8cm exhaust housing.


Touch-up tune:
Since my quench was changed a bit after changing the head gaskets, and now a new muffler which will change the VE a bit, I'm going to head over and have Dom do a quick touch-up and make sure she's dialed.


Cliffs:
New parts going on this week!
Power Steering pump
Adding 2 shims to the oil pump
new turbine housing
new, more quiet/stealthy muffler
Touch-up tune

I will report back!
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Old 08-18-2011, 12:40 PM   #386
05subysti
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i just read this whole thread, 16 pages lol my eyes are burning! but must i say your legacy is an amazing car. Your car is why i love this generation of legacy
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Old 01-08-2012, 06:00 PM   #387
anothernord
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Bump. I love this car; it's an inspiration for pretty much all of my projects.
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Old 03-05-2012, 11:50 AM   #388
V8Slayer
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Boosted & meth injected!!

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Cars looking killer, another bump for updates
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Old 03-07-2012, 01:26 PM   #389
morrocco88
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Rotated BW S256 6speed

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Well, the update is that the car has been in winter storage, but I've been doing a few upgrades

I sold the Dom 3 and I'm building my own rotated kit based on a Borg Warner S200SX-56, which is rated at 58lb per min. That places it between a 30R and 35R size wise, and should be able to easily hit 450whp and maybe 500whp with more boost and Meth. I'm building this kit on my buddies bugeye so it will fit 02'-07' wrx and sti's, and also a swapped 97' LGT . When done, I plan to build some jigs so I can crank out a few more kits for a few friends.

The S200SX actually comes fom BW with twin scroll housings, but I found a place that sells single scroll turbine housings with a T3 inlet, and either a 4 bolt outlet like Garrett turbos, or a 3" v-band, in either a .63 or .82 A/R. I'm building my kit using the 3" v-band on the down pipe and bought the .82 A/R for my turbo. So you basically get a genuine BW/Airwerks center section with their compressor housing, and the aftermarket turbine housing so you don't have to use twin scroll. The best part is the S200SX line has anywhere from 300hp to 580hp output based on what size compressor wheel it has which will all work with my kit. They also have the same turbine aero as the new EFR turbos, but just aren't made of the fancy Gama-Ti material. These are also twin dynamic journal bearing and are cheap to rebuild. They cost ~$700 brand new!!!! It's basically a 7670 but non-EFR.

I'm planning to sell the couple extra I make for ~$800, and then ~$700 for the turbo and your now rotated for ~$1500. All that's left is an oil feed and drain line, a couple clamps and build an intake to suite your setup. That's about the same price as a new stock location Blouch turbo! I just got tired of seeing all these high priced rotated kits and decided to do something about it...build my own!

Anyways, I'm going to run this on the 2.1 for the short term and see how it does. I probably won't push it too hard, but would like to hit 400whp and stop there.

Long term, I'm building a 2.34 de-stroker block which will be paired to some 08' wrx D25 heads. I will be adding the wiring needed to run the AVCS, and probably doing some GSC or Kelford 272 cams. I'm planning to run it to 8K and try to get full boost by 4k to have 4k wide power band. I think this will be a wicked setup with the short JDM gears and a smooth revving, high redline motor . I plan to run at least 25psi and see what this BW turbo can do. I hear they really move the air at higher pressure ratios.....500whp maybe?

Sorry for the long winded update, but that's what I've been up to. Also, pics of the rotated kit in progress hopefully tonight. If your interested in one of the extra kits I make, send me a PM
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Old 03-07-2012, 01:47 PM   #390
V8Slayer
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Great detailed update and looking forward to your new set up!

On another note, this car makes me proud to be a BD owner, well done sir.
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Old 03-07-2012, 10:36 PM   #391
morrocco88
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Join Date: Jan 2006
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Location: Eastern WA
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97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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^^^Thanks! Yeah anybody can go buy a wrx, but a fast BD legacy is hard to come by. Plus, the body style is so sexy IMHO


Anyways, here are some progress pics of the rotated kit and the BW turbo. This is on my buddies 02' wrx, because I want it to fit some friends cars, and it should fit my car too.



I'm really happy with how centered the inlet is between the strut tower crap and the fuel rail







Measured 12* of tilt!












I'm also happy with the down pipe so far......plenty of room to the A/C lines, firewall and drain tube, not close the the CV boot, and pretty tight to the tranny x-member for as much ground clearance as possible.


More to come!
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Old 03-20-2012, 10:12 AM   #392
NITROS
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04 GT3076 2.1
Stroker = Broken 3rd

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Nice, I pieced my rotated kit together myself.
I was able to do it for ~$2800.
$800 for Perrin rotated up and down pipes including 44mm tial wastegate.
$1500 for Garrett GT3076r
$140 for oiling kit and coolant.
$340 for kstech rotated intake.

I thought that was an awesome deal. So at $1500 your solution would provide a very nice savings. I thought about running a Holset 35hx, they can be found $300-$400 used.
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Old 03-23-2012, 01:34 AM   #393
morrocco88
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Join Date: Jan 2006
Chapter/Region: NWIC
Location: Eastern WA
Vehicle:
97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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^^^yeah it's really a nice turbo and they are so inexpensive. They also sound totally awesome when they spool!


Here is a few more progress pics.


All welded up



Building some jigs to make a few extra kits!



They will get Cermaic Coated next!


Pm me if interested
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Old 03-23-2012, 08:13 PM   #394
Maxwell Power
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want a bunch...
let's verify fitment on the GC chassis as well as GD.
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Old 03-23-2012, 08:36 PM   #395
morrocco88
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97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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Yeah, if you have a GC we can test fit one on, I will take care of the test fit on the BD Legacy

I'm also adding a nice stainless flex section with the interlocking liner to the end of the down pipe, but they won't be here until Tuesday. I'm hoping to bring a kit with me on Wednesday or Thursday!
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Old 04-01-2012, 01:04 AM   #396
morrocco88
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Rotated BW S256 6speed

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I tweaked the design on the down pipe and got it tucked up as tight as possible for perfect ground clearance even on slammed cars. I also added a high quality flex section. First production piece was built from the finalized jig and it fit absolutely perfect.


Pics:











Next up is to get my buddies bugeye back together and out of the shop, then pull my Legacy back in and see if the kit fits. I'm pretty sure it will be good to go.

My plan is to get the Borg Warner turbo all setup and re-tune. I will have to remove my A/C lines to clear the rotated setup, so I will need to have custom lines made. Since I need custom lines anyways, I'm going to do a custom narrow radiator and A/C condensor. This will allow me to make new intercooler pipes that are nice and short and go right into the intercooler on either side of the radiator instead of going through the fender and down and around like it is now.
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Old 04-17-2012, 12:30 AM   #397
NW2TONE
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unde your hood makin
your **** go faster

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wait till you see the piping idea i have planned for the forester. woot woot. ****ing sick
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Old 04-17-2012, 01:06 AM   #398
morrocco88
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Rotated BW S256 6speed

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Can't wait to see it.........and to see my sweet rotated kit on there with that Borg whistling Dixie!
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Old 05-22-2012, 02:55 PM   #399
1hotsubaru
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2002 WRB Impreza WRX
2.1 Stroker w/ VF39

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Beautiful build man Your thread helped me choose my next turbo for my stroker. FP Red ftw I did wanna ask one thing. Did you get your oiling problem figured out??
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Old 05-23-2012, 02:27 AM   #400
morrocco88
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97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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Thanks!

Yeah I added 2 shims to the pump, and it stayed the same. I'm now questioning my fancy PLX gauge, so I bought an AutoMeter mechanical gauge to test the pressure against the PLX and see whats what.

The rotated kit will be going on soon, and then a re-tune. I'm not going to push it hard, but just get it on the road......I miss driving her so much! I will then play with the custom Radiator, A/C condensor and lines, and FMIC pipes/setup. I'm stock piling parts for either a 2.3 de-stroker, or a 2.5 long rod motor with AVCS heads

Oh, I also got some JDM wrx seats to install.....I'm getting really excited!!!
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