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Old 08-25-2009, 10:25 PM   #26
NITROS
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04 GT3076 2.1
Stroker = Broken 3rd

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Keep this updated. I got a similar a stroker build going as well. Mild port and 272 cams. expect to rev to 8k. What oil pump did you use? cross the the crank?
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Old 08-25-2009, 11:41 PM   #27
morrocco88
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97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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Yeah I will keep it updated.

I had 272 cams, but Dom at Maxwell Power said that would be a bit much for what I'm doing and would make me lose more low end and mid range power in trade for top end, so I went with 264's. The 264's are a nice compromise and about perfect for a car not looking to go drag racing, but will make more power all through the power band.

I'm running a 10mm oil pump that has been "blueprinted", basically cleaned, de-burred the plunger, honed the passage ect. No shims were used, and they say I can run 9k if I want. I plan to go no higher than 8k, if I have a reason to be up that high, but we'll see how the Dom 2.5 does on this stroker.

The crank is a brand new stock sti crank bought from subaru, stock sti rods and custom cp pistons with ceramic coated crowns and coating on the skirts. I think the main thing is it's all blueprinted and the clearances are all perfect, and the thing is balanced to crazy standards. As far as oil pressure, they assured me it will be just fine at high RPM's.
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Old 09-05-2009, 12:13 AM   #28
Thran
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how much was ur oil pump, because i keep going in limbo with going with someone pump or cosworth
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Old 09-05-2009, 07:54 PM   #29
morrocco88
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97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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I just had a lightly used 10mm STI pump that I bought for my EJ257 I was going to use for a hybrid build that was scrapped in favor for the stroker build.

Maxwell Power charged me $40 to take it apart, clean and inspect it, once confirmed good they honed and deburred the plunger and cylinder, reassemble and packed the gears with assembly lube to make it prime and start sucking oil right when you crank the motor for the first time. $10 for a new seal and it was good to go, so the total was $50.

They have pumps "blueprinted" and ready to buy too, so you could call them and get a price.
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Old 09-12-2009, 03:41 PM   #30
S53089
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hey man good to see the cars lookin good, im workin on gettin somethin new or possibly a project, but ill let ya know when i do.

sam
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Old 09-12-2009, 07:41 PM   #31
morrocco88
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Rotated BW S256 6speed

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Hey Sam thanks again for the hook-up on the swap parts! You can take comfort in knowing the heart and soul of your car will live on and be making some nice power in my car! Let me know if you need any help when you get your next Subaru.
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Old 09-17-2009, 01:29 AM   #32
morrocco88
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Well I finally got the 6 speed in and bolted up, but what a whore that was. I used to be able to get the 5 speed in and out with a floor jack, but there was just no way with the 6. It is shaped differently and heavy. I ended up buying a motorcyle jack and modifying it to hold the 6 speed. It was quite the project, but now have a custom tranny jack and method for getting this thing in and out.

Now my problem is the turbo inlet. I'm really wishing i would have gone rotated so I don't have to mess with this under manifold inlet. It is next to impossible to get on. I had already removed the TGV motors and was continuing to mock things up and just could not get it all the way on the turbo's inlet. I tried shaving some material off the TGV housing to get more room, but still no go. I read that people take the manifold off to get it on, but it doesn't make sense to me becasue the inlet goes under the manifold and over the fuel lines. I had to take the fuel lines off and unbolted the TGV from the manifold. I then put the inlet on by itself and secured it with a clamp, and then bolted on the TGV and it had to push pretty hard into the inlet to line up the bolt holes. What am I missing here? I guess you could leave everything bolted together including the fuel lines, then unbolt the whole manifold and shift it over to get a straight shot onto the inlet, then secure it, and finally shove the manifold back over and push it into the inlet so you can get a bolt started.

Anyways here's some Pics:

There is just no freaking room there, the inlet just bottoms out on the right side and the TGV side will not slide all the way on.


Here is when I put it on first and then bolted the TGV on. See how far it is pushing into the inlet! You can also see where I shaved some of the TGV to make more room between the turbo's inlet and the TGV.


There is no way the TGV motor would fit there, how is it done?


And a little peek at the Polka Pickle in it's new home


You can see the customized motorcycle jack next to the car.
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Old 09-17-2009, 03:47 AM   #33
TheNailman
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<----Subscribed. thanks for the pics and details.
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Old 09-18-2009, 01:43 PM   #34
morrocco88
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Rotated BW S256 6speed

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Well I did some more experimenting and found if I unbolt the manifold and shift it over to the left, I can just get the inlet on all the way and tighten the clamp. Then I have to shove the manifold back over, pushing into the inlet and try to get a bolt started. This is also with no gasket with just masking tape on to protect the mating surfaces. It looks like it will be a real PITA with the gaskets involved.

I think the problem is the Dom 2.5 is much bigger compared to a stock size turbo, so the compressor inlet is not in the same spot as the stock, meaning part of it is behind the TGV housing. This makes it a huge pain in the ass. I had a used Perrin inlet that didn't fit too well and it was blue, so I bought a Gimmick one because i wanted black anyway, and it doesn't fit any better.

I see the APS hard pipe inlets have a nice silicone adapter that is really offset which looks like it would fit a lot better, but I don't feel like shelling out $250 just to try it.

Any suggestions from someone who has had a larger bolt on turbo and used a silicone inlet?
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Old 09-19-2009, 07:15 PM   #35
Dan Cech
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Great work! Awesome to see another BD getting some love.

I have the APS hard inlet and it's definitely still a tight fit even on my vf29. If the turbo inlet is further away from the centerline of the car you're definitely going to have a struggle.

I noticed you're using phenolic spacers, are you using the factory coolant fill tank? Mine hits the heat blanket under the hood without any spacers.
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Old 09-19-2009, 08:13 PM   #36
morrocco88
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Rotated BW S256 6speed

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^^^Thanks!

Yeah I'm using the factory wrx coolant tank, but it doesn't hit. I'm hitting in one place which is the IAC sensor on top of the throttle body. I took the under hood blanket off and had to trim some material by the scoop which you can see in the pictures. I tried to make it look symetrical and like it was that way from the factory. I will re-paint the under side of the hood when I'm done to make it look good.

VF29 is a nice turbo. I was running the same thing, VF28 without the titanium wheel. I was making 240 wtq by 3800 rpm on a mustang dyno.

Thanks for the info on the APS inlet. I'm just going to run the black Gimmick inlet and curse everytime I have to take it off or put it on. I think I will stick the gasket to the bottom of the manifold and it should be able to slide on the phenolic spacer without getting messed up. That way I can slide the whole manifold over to get the inlet on and then slide it over and bolt it down.

More pics to come!
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Old 09-29-2009, 01:50 AM   #37
morrocco88
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Rotated BW S256 6speed

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Well I've been making more progress, but just not as fast as I would like. I'm trying to get it on the road to give the tranny a shake down while still in the 60 day warranty period. I don't think I'll have any issues with it, but I'd rather play it safe.

Been mostly working on the drivetrain and brakes and not so much on the engine bay for a while.

I got the tranny in with new bushings on the cross member and a Group N tranny mount


Rear diff is all cleaned out inside, new side seals and new cover gasket. I installed Super Pro rear diff bushings while I was in there. I also swapped the companion flange to a R160 because i have to use an Automatic driveshaft from a Legacy of the same vintage. This is due to the car being a little longer than an Impreza.


And the rear outrigger bushings were swapped for some whiteline's


Rear knuckle installed and successfully used my stock e-brake cable with the STI parking brakes. Put a caliper on ther to see what it's looking like. These brakes are huge!


This is one of the rear calipers being painted. I decided on satin black with silver logos. I found VHT flat silver header paint which is the base color. I then stuck on my E-bay BREMBO sticker, and painted over it with the satin black.


Here is what it looks like after the sticker is peeled off revealing the flat silver.




More pics and more progress reports to come! Stay Tuned
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Old 09-29-2009, 02:10 AM   #38
reddevil
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goes 12.387 @ 116.5

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Looking good!
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Old 10-07-2009, 12:45 AM   #39
morrocco88
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Rotated BW S256 6speed

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Drivetrain is all done except mounting the calipers and bleeding the system. All four knuckles/hubs are in with the axles. The underside of my car is looking really beefy. Also got the clutch slave cylinder mounted and the line attached, but still need to bleed that too.

I'm going to use Motul 90PA for the rear diff since that is supposed to be the hot ticket for the plated LSD R180's. I was also going to run Motul Gear 300 for the tranny, but I was torn between that and the Subaru Extra S since both are what works best. After pricing out the Gear 300 at $18 per qt., I decided it would be cheaper in the long run to get a 20 qt bucket of Extra S for $146. That makes the Extra S $8.85 a qt after you pay tax and shipping from subaru genuine parts. That's even cheaper than the Valvoline 75-90 synthetic I was running in the 5 speed at $12 a qt., and it's genuine subaru fluid.

Here is a couple pics of the front calipers being painted. I changed my mind and went with flat black instead of the satin. I think it looks better and it has a heat rating of 2000* rather than 900*

The flat silver with the sticker added


After the black and peeled the sticker






I'll have some more pics and progress soon!
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Old 10-07-2009, 01:35 AM   #40
EsubaruJ
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TE72 wagon, Legacy wagon

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Brakes look great! This is an awesome build.
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Old 10-08-2009, 04:55 PM   #41
morrocco88
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Rotated BW S256 6speed

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^^^^ Thanks man!

I made some more progress and got the brakes and wheel clearance issue resolved.

I didn't want to change wheels and these 06' WRX wheels would not clear the brembos, so I did some measuring and found I needed about 13mm of spacing to make it work. So I got some ICHIBA 15mm wheel spacers which are really nice and are hub centric with a hub ring for the wheel too. This makes the whole assembly stay hub centric. The only issue was my studs were hitting the back of the wheel and I didn't want to cut them all down, so I machined a relief hole in the back of my wheels just deep enough to clear the studs. This way if I ever switch wheels, I don't have to replace all my studs.

Here is the ICHIBA 15mm spacer which is like 1/2 an inch, not much at all.


This is the caliper mounted and the wheel spacer installed


And the relief holes machined into the wheel. I'm lucky I have a buddy with a mill.


The wheel installed with a shot of the spacer, 15mm is really not that much.





The other thing that worked out was it brought the tire out just flush with the fender. The 06' wrx wheels are really high offset of +55, so the spacer brought it out where it should be. I haven't set the car down yet but it looks like it will be perfect. I have an Eastwood fender rolling tool coming in case I have to roll the fenders slightly. It should give it a nice stance and no I'm not worried about my bearings , if they wear out faster I will just press in some new ones at work.

Here is a look down the side of the car to see the tire out flush with the fender




And a couple shots of the big brakes inside the wheel.




more to come so stay tuned!
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Old 10-09-2009, 12:33 AM   #42
iluvdrt
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sky blue

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Awesome build man. I am jealous.

I wish my garage was that big!
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Old 10-09-2009, 01:48 AM   #43
morrocco88
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Rotated BW S256 6speed

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^^^ Thanks man!

You know it's funny, this is my first house, and when I was looking at houses my main priority was a small house with a large shop. I had always dreamed of a shop of my own to enjoy my hobby of building cars.

I got was I was looking for with a 3 bed, 1 bath, 850 sq ft house and a 20x40 shop. I was single at the time and then a year later I met my wife and she had no say in it because it was already grandfathered in
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Old 10-09-2009, 07:18 AM   #44
Dan Cech
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White

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Looking great man, so many parallels between our builds it's crazy! The Brembos look super hot, I suspect you'll need that fender roller once it's down on the ground

Another tip, if you want to use the WRX evap system you need a 99 LGT fuel filler neck, which has the correct flange for the 02-04 WRX fill valve and the proper angle to fit the Legacy body. Part # is 42066AC150.
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Old 10-09-2009, 07:43 AM   #45
iluvdrt
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Quote:
Originally Posted by morrocco88 View Post
^^^ Thanks man!

You know it's funny, this is my first house, and when I was looking at houses my main priority was a small house with a large shop. I had always dreamed of a shop of my own to enjoy my hobby of building cars.

I got was I was looking for with a 3 bed, 1 bath, 850 sq ft house and a 20x40 shop. I was single at the time and then a year later I met my wife and she had no say in it because it was already grandfathered in
LOL, that is awesome. I will be pretty much doing the same thing hopefully soon, but in a 1 car garage w/ washer and dryer.

It will suck.

The good news though is that my wife wants me to get a garage bigger than the house; with a loft! She says that way, maybe I'll live in it LOL. She approves of a lift as well.
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Old 10-09-2009, 04:33 PM   #46
gunny11218
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Limited WRB

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great build! keep the updates coming!!
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Old 10-10-2009, 03:38 PM   #47
DarkKnightBaku
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good build looks real nice keep up the good work
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Old 10-10-2009, 04:36 PM   #48
sense of nature
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Way to go Bro ! Looking sweet!
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Old 10-10-2009, 05:23 PM   #49
morrocco88
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Rotated BW S256 6speed

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Thanks for the props guys! I will have more updates soon. Other stuff in life is really getting in the way of progress. I need to be out driving the car on the stock motor by tuesday. Tuesday is the last day of my 60 day warranty on the tranny, and i want to give it a good shake down to make sure there are no issues. I don't think i will have any problems with it, but i just want to make sure.

I just need to put the driveshaft in, put the dash back in, put some stuff back together in the engine bay, bolt some wheels on it and go drive it.

Then I can take my time over the winter and really do everything 100%, like ceramic coating things, painting, detailing ect. I still have to fab up the EWG too, so I will just run on the IWG for the tranny test drive. Built motor will be in and heading to the dyno for tuning early spring. I might even re-paint the car over the winter as well. I have a few rock chips and a spot or two that started peeling from a pressure washer incident last winter. I want to make it really nice this time and fully dissasemble al the trim, handles ect., so there won't be any edges that can strat to peel up. Basically do it better than i did it the first time.
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Old 10-11-2009, 02:47 AM   #50
gunny11218
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what do you drive as a daily?
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