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Old 07-05-2009, 11:23 PM   #1
CKxx
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Join Date: Feb 2003
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Your BOV sounds lame
93 RX7+09 Forester

Default My GT3076R Bugeye Build...

Hello,
I have been working on this pile for a few months now. Collecting parts, making small mods. After having the motor out for 2 months, I've finally begun assembly of my "new setup" so I thought I may go ahead and document it for those who are interested. This is the first time I've pulled a motor from my own vehicle and done all the work, though I have helped others with their projects in the past.

The motor consists of:
  • --EDIT-- New short motor in the works...
  • ARP Head Studs
  • EJ205 Heads
    -Ported, Crower Valves: +1mm Intake, +1mm Exh, DPR 264 cams, Crower Springs, Crower Ti Retainers
  • Impreza 2.5i Intake Manifold
    -Modified for use of Cable TB and WRX Fuel Rails
  • Borla UEL Header
  • P&L Rotated Up-Pipe and downpipe
  • --EDIT-- New turbo coming soon...
    -0.82 A/R Turbine Housing
  • TiAL 44mm WG
  • Turbo XS Intercooler Modified for CC Flow
  • TiAL 50mm BOV
  • GS EBCS
  • Bosch 1000cc Injectors
  • Perrin Fuel Rails
  • Aeromotive FPR
  • Walbro Pump
  • UTEC running in SD
Other:
  • ACT Clutch
  • 2004 STi Drive-line
    -Transmission, DS, Rear Axles, R180, Rear Hubs/Brembo's
  • Stoptech Front Big Brake Kit
  • Group N Motor/Trans Mounts
  • Custom Coolant Tank Relocation Bracket/ EBCS Mount
  • Tein Hood Dampers
    -My favorite mod
  • Some Gauges
    -Greddy: Boost, EGT, Oil Pres., Oil Temp., Fuel Press.
    -AEM: WB02
  • Tein Super Street Coilovers
  • Rotas
  • Braided PS line

The old 18G managed a best of 12.60@108 pushing 306/296 on Turbo XS's Dyno. My goal now is 400whp on that same dyno or at least 11 second 1/4 mile passes.

I will be updating this thread as I go, and trying to add any useful information I pick up along the way. If you have any questions, let me know. I may even know the answer!

As it sits today, 7/5/09:


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Last edited by CKxx; 03-05-2010 at 10:30 PM.
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Old 07-05-2009, 11:33 PM   #2
JSarv
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Join Date: Nov 2007
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Location: Effingham IL (Central IL)
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l33t *******
12.07@115.9mph-EJ205

Default

Its going to be teh slowest evar.



Did you go with a Tial V-band turbine housing?? If so please post pictures for my masturbating session!

Looks good man keep the pictures coming! Glad to see a 2.0 and big turbo done right!

-Jerod
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Old 07-05-2009, 11:40 PM   #3
Midwestrider
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Nice... good luck in your build and goals!
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Old 07-05-2009, 11:44 PM   #4
CKxx
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Your BOV sounds lame
93 RX7+09 Forester

Default

7/5/09:
Today I chased the threads on the block with my nifty chaser tool (see below), cleaned the old gasket remains off the deck, installed the ARP studs, installed the new gaskets (OEM) and torqued down the heads.

ARP Studs: Threaded into the block only "hand-tight." (I used the little end of an allen key.)


New OEM Head Gaskets:


Heads Torqued:

Last edited by CKxx; 04-26-2010 at 02:18 AM.
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Old 07-05-2009, 11:49 PM   #5
CKxx
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Your BOV sounds lame
93 RX7+09 Forester

Default

Quote:
Originally Posted by JSarv View Post
Did you go with a Tial V-band turbine housing?? If so please post pictures for my masturbating session!

-Jerod
Sorry, no v-band housing. It is a newer GT housing (T3 inlet/GT outlet), though, and not the older T-31. I'll have pics of it posted by next weekend, hopefully. I plan to re-install the motor at that point.
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Old 07-05-2009, 11:59 PM   #6
JSarv
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l33t *******
12.07@115.9mph-EJ205

Default

Sweet - .82 housing should be bitchen' on the 2.0 - Nice flow and moderate lag!

I've always used a tap for chasing threads... But that looks to work just as good.

What heads are those?

-Jerod
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Old 07-06-2009, 12:12 AM   #7
CKxx
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Your BOV sounds lame
93 RX7+09 Forester

Default

Quote:
Originally Posted by JSarv View Post
Sweet - .82 housing should be bitchen' on the 2.0 - Nice flow and moderate lag!
I'm hoping for 20psi at around 4600rpm.

Quote:
Originally Posted by JSarv View Post
I've always used a tap for chasing threads... But that looks to work just as good.
I didn't want the razor sharp tap to cut the "good parts" of the threads.

Quote:
Originally Posted by JSarv View Post
What heads are those?
Regular EJ205 with porting from DPR, as well as the other parts mentioned. A gentleman in Puerto Rico had the same 264's in a 10-flat STi, so I figure they should work pretty well.
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Old 07-06-2009, 12:28 AM   #8
jason miller
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2003 WRX
PSM

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This build looks awesome, and I'm betting you meet or exceed your spool expectations.
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Old 07-06-2009, 12:54 AM   #9
TDagen
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Location: Minnesota, mpls
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2002 Wrx,2.5L,HTA86
E85,2007 6mt,No traction

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Looks Nice, another nice bugeye build... Keep it up
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Old 07-06-2009, 01:28 AM   #10
zac5
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Location: Windsor, Ontario
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06 apex silve Evo9
Wrong Fitment Crew #054

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Sweet. Im patiently waiting for the next update. Good luck on the build
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Old 07-06-2009, 11:26 PM   #11
CKxx
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Your BOV sounds lame
93 RX7+09 Forester

Default

7/6/09:

More fun today. Drilled and tapped my Borla Manifold for for the EGT gauge, then wrapped that beast, as well as the Perrin up-pipe.

Wrapped Mani:


Following that I installed my cams, and test fitted it all, along with my intake manifold. I was afraid that the turbo inlet would not clear my Old-School Perrin fuel rails, but that ended up not being an issue due to my 3" tapered turbo inlet. A full 4" inlet will NOT clear these rails, for the record. I also found out that with the 2.5I manifold I'll need to either 1) remove the intake manifold gasket alignment dowels, or 2) grind away some of the base of the manifold itself. I tried to yank the dowel, but that sucker was stuck, so it looks like I'll be grinding the manifold.

Last edited by CKxx; 04-26-2010 at 02:18 AM.
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Old 07-07-2009, 11:22 AM   #12
skimobile
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03 WRX (Neon Blue)
in"Special Ed." Run Group

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Make sure you paint the header wrap really well before you go putting the engine/exhaust piping in the car.
Mine just plain disintigrated form all the heat/cooling and moisture evaporation.
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Old 07-07-2009, 11:35 AM   #13
Token-Negro
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Ice Silver Metallic

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I had the same problem with those rails, i was able to order another side from Perrin and run both in the front of the TGV's. Id look for new rails at this point.
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Old 07-07-2009, 12:06 PM   #14
bigolrig
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2002 EVO3 bugeye wag
EG33 Swapped 2 dr RS

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Nice build!
Too bad its not in a wagon
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Old 07-07-2009, 01:07 PM   #15
scprs
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damn very nice build!
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Old 07-07-2009, 02:15 PM   #16
CKxx
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Your BOV sounds lame
93 RX7+09 Forester

Default

Wirelessly posted (BlackBerry9530/4.7.0.148 Profile/MIDP-2.0 Configuration/CLDC-1.1 VendorID/105)

Quote:
Originally Posted by Token-Negro
I had the same problem with those rails, i was able to order another side from Perrin and run both in the front of the TGV's. Id look for new rails at this point.
Was that a custom order? My two rails are mirrors of one another.
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Old 07-07-2009, 06:40 PM   #17
stamps31757
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2002 WRX Sedan
PSM

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subscribed
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Old 07-07-2009, 06:51 PM   #18
blakkboxer
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Vehicle:
2k3 WRX MBP
black & gold is pimpin'

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wow, subscribed buddy.
















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Old 07-07-2009, 06:54 PM   #19
Kyle13
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1993 Ford
Seafoam Green

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Subscribed! This is gonna be awesome!
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Old 07-07-2009, 07:06 PM   #20
scby rex
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aw, MPS 2.34 breaking in

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Looks good, but why the egt probe in the #4 cylinder instead of the #3?
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Old 07-08-2009, 12:36 AM   #21
CKxx
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Your BOV sounds lame
93 RX7+09 Forester

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Quote:
Originally Posted by scby rex View Post
Looks good, but why the egt probe in the #4 cylinder instead of the #3?
I read a ton of posts, and even found a poll. It seemed that cyl4 was the most prone to failure.

Heck, I even purchased one or two of my parts from someone who blew cyl4 and was parting out the car.


EDIT: As far as work done today...not much. I did drop off my PS line at the hydraulic shop so they can make a braided stainless model for me. I also ordered a whole mess of these press-connect pneumatic fittings (2 can be seen on top of manifold, above). They are made to operate around 150psi, and won't blow off until over 300psi. I'm going to run them for my Wastegate, EBCS, BOV, and FPR.

Last edited by CKxx; 07-08-2009 at 12:46 AM.
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Old 07-08-2009, 12:42 AM   #22
Ammata
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PSM

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nice......
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Old 07-08-2009, 01:06 AM   #23
SubeN'Siren
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Subscribes....
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Old 07-08-2009, 05:40 AM   #24
G-See
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Nice and refreshing change vs the usual 2.5 builds. Bet it revs hard when done!

Subscribed.
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Old 07-08-2009, 09:29 AM   #25
Big_DeWeY
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Blue-ish

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I'm in! I'm doing a similar build myself but not quite as large of a turbo. This might be a peek into the future.
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