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Old 10-11-2009, 04:08 AM   #51
morrocco88
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97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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I got a sweet 96' Impreza L coupe with a 2.2 liter. I had a cheap 95' Nissan Maxima I bought to use while my car was down, but traded it straight across For the impreza.

I only had $800 into the Maxima and the guy I traded with thought it was the end of the road for his Impreza because it had some oil leaks and the front brakes were metal to metal. I just threw on the stock LGT front brakes I had in the shop and it was good to go. I actually love driving it with the little 2.2 N/A motor. It is just a fun car, and could be a project down the road.
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Old 10-22-2009, 11:29 PM   #52
morrocco88
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Rotated BW S256 6speed

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A little more progress:

Got the TGV's deleted and ported the manifold. I bought the Grimmspeed manifold to TGV gaskets and the TGV to head gaskets and used these for my guide. I opened up everything to the gasket line so it's all smooth flowing straight through, and all gasket matched.

Here are some pics:











I don't have any pics, but I glass beaded everything to get fresh aluminum and a some nice tooth for the Techline Coatings Turbo-X black ceramic coating to stick to. I have the parts in the dishwasher right now to get all the dust off them and make sure they are super clean before I apply the coating tomorrow.

Also a couple pics of the TWM short shifter and Weighted stainless steel knob in a gun barrel finish.





After the manifold is all together, I can really get everything assembled and go try out the drivetrain. I can't wait to snap through a couple gears on the 6 speed!
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Old 10-23-2009, 02:56 PM   #53
jaisawn
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Subscribed, this is pretty much what I hope to do with my '96 Outback one day.

Keep up the awesome work and photos!
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Old 10-26-2009, 12:06 AM   #54
morrocco88
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Rotated BW S256 6speed

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More manifold madness!


I got the coating on and it's some nice stuff! Here is some pics.

It is really more of a charcoal black, but the flash on the camera makes it look more gray than it is.
















And then I got crazy and decided to paint it gold!













I love the look of black and gold. There will be a lot of black under the hood along with the IC pipes and I think it will look cool with a gold manifold in the middle instead of the "red" sti maifold. I think I will do the valve covers gold and maybe the center strip of the alternator in gold with the cages powder coated satin black.

I guess it is kind of paying tribute to the O.G. Turbo Legacy RA motor with the gold valve covers. It took me a while to find the right gold color that wasn't cheesy looking, and I think it is perfect. I hope the pictures do it justice.









I think it will look cool when it's done! Am I crazy, or can you see what I am envisioning?
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Old 11-09-2009, 03:39 PM   #55
Poakie
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very nice mr.olive
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Old 11-20-2009, 02:04 AM   #56
morrocco88
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Rotated BW S256 6speed

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Small Update:

I have been crazy busy at work and all kinds off life stuff has been getting in the way. The shop is also a disaster area and it takes me way too much time just to find a tool when I need it. Next priority is clean and organize the shop and then get crackin again.

I got the TWM short shifter installed along with every possible shifter bushing upgrade. I went with the "Holy Shift Set" from TIC. The reverse lock out cable was a little tricky, but it is all in ready to shift. I threw on my heavy weight knob and tried it out. All I can say is . It is so tight, crisp and short. The heavy knob makes it go into gear with just a flick of the wrist and with the super short throws, it is like CLICK, CLICK, CLACK. I have driven stock sti's and there is no comparison. I cannot wait to get this thing on the road and snap through a few gears. It totally recharged my motivation!

Pics:

I painted the stock silver pieces a dark charcoal to better match the Gun Barrel finish on the knob. The flash makes it look lighter than it really is.




I also bought a used sti shift boot and made it work with my stock console piece.


I just peeled the bottom plastic retainer from my 5 speed boot, poked a couple new holes in the sti boot to match up, and installed the 5 speed lower retainer to sandwich it in and it looks factory.


I also got the manifold together and installed the DW 750cc injectors. I also replaced all the factory rubber hose connections on the hard lines with OEM goodness. The last thing I want is fuel spraying everywhere when one of those cracks.








I think the gold in the center of all that black will look good when it's all done. Plus the alternator will be black with the center plates painted gold. So it will be the manifold, center stripe on the alternator and the valve covers and everything else will be black.

Notice how messy my work space is. I need to just stop and clean up and re-group.

more to come!
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Old 11-23-2009, 10:23 AM   #57
HeliKelby
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Subscribed!
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Old 11-23-2009, 01:11 PM   #58
MacintoshMan
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Subscribed =]
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Old 11-23-2009, 08:24 PM   #59
NickWRX
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Holy hell. This is sick! I wish I had half of your knowledge base! Paint, transmission, engine... yikes!
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Old 11-24-2009, 02:40 AM   #60
amroof
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Man this thing is so sick i wish i was closer so i could get a ride when its complete. keep it up!!
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Old 11-26-2009, 12:41 PM   #61
morrocco88
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Rotated BW S256 6speed

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Quote:
Originally Posted by NickWRX View Post
Holy hell. This is sick! I wish I had half of your knowledge base! Paint, transmission, engine... yikes!
Thanks! I grew up poor so I always had to learn how to do things myself because I couldn't afford to pay someone to do it. I was lucky my friend's Dad had an Auto repair shop and was able to learn how to fix all my $200 beater cars in high school. I always wanted to be able to paint cars, so I took some night classes at a local community college to learn Auto Body and Paint.

Quote:
Originally Posted by amroof View Post
Man this thing is so sick i wish i was closer so i could get a ride when its complete. keep it up!!
Thanks! I will try to find a buddy that can do video and have him make a nice vid to show her stuff. That will almost be like going for a ride


I finally got the shop cleaned up and ready to get cracking again, so there should be some updates soon.
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Old 11-26-2009, 10:48 PM   #62
JRach
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Nice local build Looking forward to updates, can't wait to see how this motor does with that turbo set up
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Old 12-12-2009, 09:10 PM   #63
morrocco88
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Rotated BW S256 6speed

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Well I got another big item checked off the list. I started fab work on the EWG and it's all done and tacked together. I need to take the pipes over to my buddies house and use his TIG welder to make it all nice and strong.

I bought some 1.5" stainless U-bends to make the pipes. I'm using an Invidia Up-pipe that I had and turning it into EWG. I got the wastegate flanges from Synapse and also sourced a nice flex joint to make install easier and provide a little stress relief. The tricky part was to get it in the perfect position to avoid excessive heat on the power steering lines and most of all, the CV boot on the STI axle. I really don't want to burn a boot and start slinging grease everywhere. I eventually got it all where I want it and brought it back into the down pipe as far back as I could while still getting a nice entry angle. The whole idea here is to try and get the Vent to Atmostphere gains without the noise penelty.

On to the pics!

I tried to make the entry smooth and got the idea from looking at a Grimmspeed up-pipe.




Here is where it sits




Here you can see trying to get as far away from the CV boot as possible and going around it. I will also do a heat shield that will bolt to the tranny and curve around the axle to make sure it is protected.


I would use tape to hold the cut pieces together until I got them perfect and then peel the tape back and tack it with my MIG welder.




Here is the two pipes and a look at the flex section. This will allow a little give to make the flanges line up perfectly


This shows the angle that it's entering into the down pipe. I also didn't want anything lower than the down pipe to preserve my ground clearance.


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Old 12-12-2009, 09:10 PM   #64
morrocco88
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Rotated BW S256 6speed

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I could only post ten pics so a I had to make another post.

I thought about where to re-enter the pipe for a long time and it looks like right where it bends is best. To me the exhaust is already going around the bend and I'm shooting in right at the same angle, so it looks like it should work, but I'm no expert.




More pics to come, and I also picked up some of the last goodies for this beast, and they are pretty sweet. Anyone want to guess what these two items are?

Last edited by morrocco88; 12-12-2009 at 09:20 PM.
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Old 12-17-2009, 04:55 PM   #65
Gr3en
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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.



Would you be so kind as to tell me how you installed the super pro bushings? I have a set for my 98 impreza and can't quite figure it out visually.
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Old 12-19-2009, 08:25 PM   #66
morrocco88
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Rotated BW S256 6speed

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^^^Well the way I did it was removed the sub frame from the car, and this was easy since I had the entire rear suspension apart anyways. Once removed, I burned the old bushings out by using an Oxy/acetylene torch and basically lit the rubber on fire and walked away. They burn until all the rubber is gone just leaving the outer metal sleeve pressed into the sub frame. I used an air hammer with a chisel type bit in it. You need to carefully peel up the sleeve in a few spots until it folds in on itself and pushes out. Be careful not to gouge the sub frame. I knicked mine a little, but just filed and sanded it smooth.

To press in the Super-Pro bushings, I used a ball joint press. It looks like a big "C" clamp with different size cups and plates and has a worm gear that you use an air gun on to press things in. I just picked a plate bigger than the bushing, greased up the hole and pressed it in with the air gun. After the bushing was in, I greased up the center metal sleeve and pushed those in by hand.

Hope that helps.
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Old 12-20-2009, 08:31 PM   #67
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don't worry to much about the cv, I think you had wayy more clearance than I did on my UR dump tube/tial 38. Now my power steering line on the other hand...that melted/collapsed

awesome build!
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Old 12-20-2009, 11:32 PM   #68
ETacv
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Nice build man, looks great!
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Old 12-21-2009, 02:45 AM   #69
morrocco88
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Rotated BW S256 6speed

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Quote:
Originally Posted by soon2bblackongold View Post
don't worry to much about the cv, I think you had wayy more clearance than I did on my UR dump tube/tial 38. Now my power steering line on the other hand...that melted/collapsed

awesome build!
Yeah, I probably will do the heat shield, because there is an unused bolt hole on the tranny right above the cv, so it will be real easy and give me piece of mind. I don't want the mess and axles are not cheap. Although I could replace the boot and replenish the grease if I caught it in time, but I just don't want to go there. I will be using some heat shield sleeves for the power steering lines.

I've got to get to work on this thing, but life has really been getting in the way lately.

All I have left is to put the manifold back on, put the dash in, bolt the wheels on and go test it out and start shaking it down for bugs. Once I tune the wastegate and all is well, I will pull the stock motor out and swap in the built long block.

More to come......
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Old 12-21-2009, 07:41 AM   #70
25rsti
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nice build. great diy work
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Old 12-27-2009, 01:14 AM   #71
morrocco88
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Rotated BW S256 6speed

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small update:

I haven't been getting much done with all the holiday crap going on.

I did want to post a pic of the mod to the down pipe where the EWG gases will re-enter.




I cut a piece of pipe and welded it in the down pipe to help direct the flow of the re-entering gases. Will this help?, I have no idea, but I did it anyways. In my mind it should help shoot it in with the same direction of flow in that section of the down pipe.







It looks like it would work better than just having the oval hole dumping the gases in and them trying to mix. At least this way it should help shoot it in a bit better. What do you think?


I also have to finish all the welds, and took the pipes to my buddies to use his TIG, but it wasn't working correctly. I will either have to wait for him to fix it, or MIG them. The MIG isn't going to be as good as the TIG especially on the flange welds, as the TIG will get more heat and penetration into those thick flanges.

More to come... HOPEFULLY SOON!
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Old 01-05-2010, 11:53 PM   #72
morrocco88
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Rotated BW S256 6speed

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Update:

I got the EWG pipes all finished welded and all the flanges surfaced to perfectly flat. Now I just have to sand blast them and ceramic coat them. Then I can bolt everything on and go for a test drive!

I did want to show the last two goodies I needed to buy.... any guesses? .... Scroll Down.

































Spiider's DCCD PRO dual mode controller with the OEM switches


The standard controlls are actually quite nice, and probably would've not used the OEM at extra cost if I had seen these in person before hand.



And last but not least: HFS-6


I'm really excited to have the water/meth let me take advantage of the higher compression on this motor along with say 25 psi?
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Old 01-08-2010, 02:39 AM   #73
morrocco88
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Rotated BW S256 6speed

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quick update:

Finally got my $1.99 tent from e-bay, yep $1.99 plus shipping! I needed this to be able to sand blast and reclaim my media. I'm using Aluminum Oxide 70 grit which is what the ceramic coating manufacturer specified. I got my pressure pot blaster for ~$75 from Harbor Freight way back when and never put it together. It worked Awesome and I reclaimed all my media from using the tent. It was a really cheap solution to a blasting cabinet!


I forgot to mention it's HOT PINK! What do you expect for $1.99




Plenty of room for a Down Pipe. I doubt you could fit a whole down pipe in most blasting cabinets, but it's no problem for the "STI Pink" tent . I laid a board down to prevent wearing through the floor of the tent.


The Up pipe all nicely blasted and ready for coating! I wish the welds were prettier, but not too bad for a MIG welder.




Here is the Dump pipe


Blasted and ready to go


This went so well, I'm going to do the Turbine Housing on the Polka Pickle, and the cast headers after i port them. So my whole exhaust from the exhaust ports to the end of the down pipe will be Ceramic Coated!!! I'm also doing the Intercooler pipes to keep radiant heat out and keep the air cool. The Intake manifold is already coated and will be using the Phenolic spacers and the throttle body will have the coolant lines bypassed to keep it cooler.

This might all be overkill, but it's fun and all these little things have to add up to: better spool, cooler air charge, less prone to detonation and MORE POWER

Last edited by morrocco88; 01-10-2010 at 03:14 AM.
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Old 01-10-2010, 03:38 AM   #74
morrocco88
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97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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Got the pipes Coated tonight and thought I would post a couple pics.


Turned out really good, but the flash makes the color look lighter




Down Pipe





My buddy got me a FREE oven and I finally got it hooked up. I made the plug the same as my compressor so I can plug in one or the other. It made it really nice to pre-heat the parts before coating. The main reason I got it was to be able to Powder Coat. I can blast parts with my pot blaster, then spray the powder and bake it in my new oven. This will be really nice to poder coat my alternator and many other little brackets and little parts.
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Old 01-10-2010, 08:43 AM   #75
dropdfocus
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This is seriously a Hella-Awesome build thread!!! Way to think outside the box on this one!
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