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Old 05-23-2012, 01:32 PM   #401
Z0rr0
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Simply. Awesome.

It was nice meeting you @ MPS last week. (I'm the redhead)
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Old 05-24-2012, 12:45 AM   #402
morrocco88
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97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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^^^Nice meeting you too. I saw the sti still there today, so the Hydra issues must not have been resolved . I hope your buddy gets it going soon...I want to see the graph on that bad boy!
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Old 05-25-2012, 06:00 PM   #403
Z0rr0
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Yeah, the hydra was not working properly. It would just decide on it's own to change the idle speed, it would also throw on the backup spark map whenever it felt like it.
and it would not control AVCS properly.

Hydra is going to fix it, but i don't have any faith in their support any more.

I hope that don just decides to do the vipec. seems like a better package all the way around.
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Old 06-04-2012, 11:46 PM   #404
DSMaverick
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I just spent the past hour and a half reading through this thread. Eyes, bloodshot... neck, hurts... must, sleep. But of course, thanks for sharing/continuing to share your story, I feel like I just watched a movie. Good luck on your never-ending journey!
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Old 07-08-2012, 12:33 AM   #405
morrocco88
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Rotated BW S256 6speed

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^^^ Thanks!

Well, I finally found some time to work on my own car! I want to drive it again so bad. The good news is I loaned my turbo to a buddy for testing since my car was parked, and it laid down 470whp at 20 psi on pump gas and a 2.5L...full boost was at ~4500 rpm . I plan to run maybe 25psi and have the meth spraying, so I don't think it's far fetched for me to crack 500whp .

She is back under the knife to get the rotated setup installed, and new custom intercooler pipes! I tried the new welder on some aluminum intercooler tubing and it was stacking dimes no problem, so I will weld everything myself. The plan is to run a custom radiator and AC condensor that are narrower, so I can run short IC piping directly into the intercooler on either side, instead of through the fenders, down and around like conventional.


Start of progress:


Everything had to come off so I can modify the core support and figure all this out.




Borg Warner S200SX-56 in it's new home, sitting on my custom made rotated kit. It was a lot of work, but I'm quite satisfied with the results!




Here you can see the the start of where the piping will be heading. I will delete the factory coolant tank since the Borg is oil cooled only. I will make a custom coolant tank, because my new radiator doesn't have a filler neck. The new tank will be tucked away and be used to fill and burp the system.




I'm really excited to finally go rotated, and especially to be able to weld all my own aluminum. It's been a dream of mine to have a TIG welder for at least 10 years!

Stay tuned for a ton of pics along the way. I will try to document the build process as I go.
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Old 07-08-2012, 12:40 AM   #406
geronimo81
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Yes! Very excited for you
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Old 07-08-2012, 06:17 PM   #407
wtdash
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Please just drop one of these in be done w/it......for a while. Have fun!



Might require a little engine bay modification. :-)
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Old 07-09-2012, 02:24 PM   #408
Maxwell Power
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Quote:
Originally Posted by wtdash View Post
Please just drop one of these in be done w/it......for a while. Have fun!



Might require a little engine bay modification. :-)
and nitrous...

too bad that's just a ventilation fan.
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Old 07-09-2012, 09:34 PM   #409
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I have a impreza. What do you think is better a wrz or impreza
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Old 07-10-2012, 01:42 AM   #410
morrocco88
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Update: A little more progress and some aluminum welding!



My CX Racing Radiator I bought. I searched and searched for a rad that was the correct width and height I needed, with the inlet and outlet the same diameter and close to the same location as factory. I ended up with this one for an RX7.




It also came with a nice 2 fan setup and shroud. It already has the brackets to bolt right up to the rad and everything. The whole thing was $200 shipped!




I then cut the lower part of the core support so I could get the new rad right where I wanted it. I boxed it in real nice and braced it. I think it's stiffer than stock and probably the same in weight.




Here you can see the new lower rad support I made fom aluminum. I'm also replacing the right side of the core support that was a little bent from before I got the car. I've always wanted to replace it, and now seemed like the perfect time. I picked it up from Subaru and just need to weld it in.




A better look at the lower support I made. This rad has the lower pins like factory which will drop into the lower support, and then I will make upper brackets of some sort. It is really cool to be able to weld aluminum now. It's like a whole new world has opened up to me as to what I can make in the shop!




Not a real good picture, but I think a decent bead for an aluminum rookie!


Stay tuned for more updates!
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Old 07-13-2012, 01:44 AM   #411
morrocco88
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Rotated BW S256 6speed

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More progress!



Trying to finish modifying this rad to make it work. I started by cutting off the inlet that was angled down and welded a straight piece back on.




Then I cut off the outlet because it was pointing right at the header. I welded on a 90* or two and braced it, and ended up with this.






With the rad in the car, this is where I ended up. You can see it was nowhere even close to where it needed to be before I modified it.




Added a 90* hose and it works perfect!




I was able to use just a straight hose on the top!




Next I started modifying my IC, and cut off the inlet and outlet.




I then cut down the cast 90* elbows I bought, and welded them on each side




It was tough welding two cast pieces from the high quality supplier of Ebay haha, but it turned out alright.




I also got my shorty oil fill tube assembly from Outfront. This way I don't have to jog around the stocker, and can have a nice straight clean pipe. I'll probably powder coat it before install.



More to come!
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Old 07-14-2012, 12:00 AM   #412
sense of nature
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Very nice!
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Old 07-14-2012, 01:34 AM   #413
Maxwell Power
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You're a stud.
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Old 07-16-2012, 01:32 AM   #414
morrocco88
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Rotated BW S256 6speed

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^^^haha thanks!

A little more progress:



I popped in the shorty fill tube to have a look




IC back on and can start working on the pipes




Got the right side pretty much where I want it, and just need to weld it up.








Stay tuned for more!
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Old 07-16-2012, 07:40 PM   #415
geronimo81
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I'm no expert but those welds look pretty good to me. Nice update, hope you get this done fast so you can enjoy it more
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Old 07-17-2012, 01:32 AM   #416
morrocco88
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Rotated BW S256 6speed

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^^^Hey thanks!


More progress:




I got the cold side piping finished mocked tonight










Here you can see the shorty oil fill tube allows the piping to be nice and straight, and is still easy to fill the oil.




I just need to weld every thing up, and I will probably cut some longer pieces here and there to make as few welds as possible. This will be easy now that I know exactly what I've got. I also need to figure out where I want the Meth jets and BOV, and weld on the jet holders and BOV flange.

After that, I will start on the custom AC setup. I need an AC/Alternator bracket that the compressor bolts to for an 08'-09' Impreza. I have a WTB thread, but please let me know if you have one. The dealer wants $140, and I have to have one to use this 09' wrx AC compressor!

Thanks for reading!
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Old 07-18-2012, 09:20 AM   #417
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OMG!!! I've read thru this whole thread in the last couple days! Props to you sir!!! Makes want to get started on my ej257 short block I got for my '99 lgt
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Old 07-21-2012, 02:32 AM   #418
morrocco88
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Rotated BW S256 6speed

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^^^ thanks!


small update:

I've been working a lot lately, and haven't had much time, but did get to try out some welding on the IC pipes.



I practiced on some scrap and tried different balance and frequency settings to try and get the bead as flat as possible without melting through. This is how the first real bead turned out. Not quite satisfied, but I will keep trying.






I dedcided to move that coupler on the cold pipe lower so it looks better. I like seeing continuous piping without couplers breaking it up.




I also decided to use a wrx AC compressor. I mounted it to have a look and start planning the custom AC lines.


More to come soon........... hopefully.
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Old 07-21-2012, 04:42 AM   #419
Bishop
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Looking good sir!!
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Old 07-22-2012, 02:46 AM   #420
morrocco88
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Rotated BW S256 6speed

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Got a little more done tonight. Finished welding the cold side, marked where I will weld on the bov flange and meth jet holders, and did a re-do on the hot side piping.



Really getting dialed in on the welds, and I'm pretty happy with the results.




Finished the cold side




I don't have access to a bead roller, so I just ran a weld bead around the edge to prevent couplers from blowing off.




still fits good on the car




Re-do on the hot side, because I was worried about hood clearance, and it was too close to the timing cover. I will be running AVCS sooner or later and that cover sticks out even further, so I figured I would change it now. I like the looks of it better now too.







Thanks for looking!
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Old 07-22-2012, 01:53 PM   #421
sense of nature
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Kudos!!
Makes me sad that my Swapped Leggy was in a wreck...
Keep it coming!
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Old 07-22-2012, 04:43 PM   #422
morrocco88
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Rotated BW S256 6speed

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^^^Thanks!

Yeah I have nightmares sometimes that my car is stolen, or I get in nasty wreck that ends her life. I can't even count the number of hours and money I've put into this car. I've already determined I would just build another one, because you just can't beat a sexy BD

The car is getting close to my idea of perfection. Once the 2.3 de-stroker and AVCS are in, and she's making 500whp, I will be done tearing her apart all the time. I just think the short JDM gears and a smooth high revving engine will be absolute magic.

I'm going to tear it apart this winter and do a proper paint job. I also want to finally install my stereo, tint the windows, and do some other cosmetic stuff.
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Old 07-23-2012, 12:01 AM   #423
NW2TONE
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4 coupler piping ftw
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Old 08-04-2012, 04:32 AM   #424
leonbmx
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loving it!!
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Old 08-06-2012, 02:23 AM   #425
morrocco88
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Rotated BW S256 6speed

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Thanks Leon!


Made a little more progress.




Got my meth jet holders from Jeff at Howerton Engineering and welded them on.






I also got a weld on mount for my Synapse BOV. I was using a hose connection before and this will be much better.




It fits real tight to the IC pipe now, me likey




I started making the custom AC lines, and finished the low side line from the firewall to the pump. I was cutting and welding pieces from a bunch of 03' wrx, 09' wrx, and 97' Legacy lines I have. It was hard to get it really clean to wled, but it worked out.




Here is the tricky spot. It's goes up and over now and out of the way!




I actually combined the rubber section of the 09' and 03' line so it's more flexible, and it was just easier to route.




Here you can see the whole line from the pump to the firewall. It is routed nice and clean. Not too bad for welding together a bunch of different pieces of three AC lines



Now I have to get a condensor, because the 09' wrx one I have is not going to fit after closer inspection.

More to come!
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