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Old 12-03-2010, 01:50 PM   #51
Britain
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With the engine mounted, it was time to address some necessary items on the chassis. First off was the radiator. Here is my first mock-up of the radiator location. This one is 16x22, however I went with a 14x22 to add some additional clearance. It will mounted it at about a 30deg angle in the front trunk and vent it out the hood. It will also have a Spal fan mounted to help with cooling while sitting in the pits between runs.

My tiny 5 gallon fuel tank is just not going to fit properly and I will probably have to make a new one that is narrower and wider.



The radiator lines are Gates Yellow-Strip hose snaked throughout the body. In the front, I opened up some of the body panels and run the lines thru.



In the cabin, the lines jog over to the frame rails and down what used to be the heater ducting tubes.



In the engine bay, they come out of the heater duct tubes and will connect to the engine.



One issue with the engine mount bar that I fabricated was the clearance for the thermostat housing cover.



After a little sleuthing around ebay, I decided to take a chance on a Subaru 3.0L engine thermostat housing which was for sale for pretty cheap. Here you can see the differences.



Low and behold, it fits and gives me just enough clearance...

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Last edited by Britain; 10-23-2012 at 01:01 PM.
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Old 12-03-2010, 01:55 PM   #52
Britain
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While waiting on more parts, I decided to start tackling the wiring nightmare. Unlike a lot of swaps on here, I have no WRX to compare to. Nor was I able to initially locate the proper wiring diagrams. Therefore, I started by mapping out the entire engine harness. This should be all the wires that I need to make it run.



Here is my daughter lending me a hand.



Here is the harness about 90% done. I have a few more issues to work out in regards to main power and ignition power, but it is basically ready. I will clean all of this up and make it look nice and pretty after the engine is running.



Here is the engine with the harness back installed and just about completed.


Last edited by Britain; 10-23-2012 at 01:02 PM.
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Old 12-03-2010, 02:07 PM   #53
Britain
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Ok, this brings me up to date with the work that I have done so far. Yesterday I received all the stainless exhaust pipe as well as the most expensive box of parts so far...the beautiful pair of Turbosmart wastegates, Turbosmart Blow-off Valve, and Turbosmart Fuel Pressure Regulator...pure works of art.



I will make an effort to update this thread as I progress. I got about 6 boxes of parts in this week so I should make significant headway over the next week.

-Britain

Last edited by Britain; 10-23-2012 at 01:02 PM.
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Old 12-03-2010, 02:29 PM   #54
Token-Negro
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Can you post a few pic's of the alt bracket and your impressions on how strong it will be looks interesting. How do you adjust it.
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Old 12-03-2010, 02:56 PM   #55
Britain
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Here is another view of the alternator bracket. It is plenty strong and you adjust it with the slotting upright and bolt arrangement. The only issue that I see with it is that it interferes with the coolant pipes coming up from the thermostat housing. I will be modifying those this weekend and will post some pictures.



-Britain
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Old 12-06-2010, 12:08 PM   #56
Britain
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From this weekend.

First order of business was rerouting the water coolant lines coming off the waterpump housing. The Outfront Motorsports bracket interferes with the stock routing of the heater hardline and the line that goes to the coolant reservoir tank was pointing in the wrong direction after it was relocated. Therefore I got some extra hardlines and starting cutting and welding away.



Here is the pipe off the back of the water cross-over pipe. I am obviously bypassing the heater core but that line was interfering with the bulkhead.



Fab'ed up a small bracket to secure the Turbosmart FPR to the intake manifold. Had to order some additional AN fittings for the fuel line routing $$



Finally got started on the exhaust downpipe routing. Here is the front section, however I still have to stuff two wastegates in here.



Here is the routing down the length of the car. You can also see the bracket I made to secure the Coast Fabrication Muffler.



This muffler weighs less than 5lbs. This one was scuffed a bit so I got it less than half off...gotta love the scratch and dent sales. I sure hope it is quiet enough to pass sound regulations...if not, I might be adding another.



Got to get some additional flanges cut at the waterjet place today and then I can finish up the wastegate routing.

-Britain

Last edited by Britain; 10-23-2012 at 01:03 PM.
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Old 12-06-2010, 12:33 PM   #57
piknockout
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This is exactly one of the projects that I would love to do, I'm very jealous. I look forward to watching the progress of the build and good luck!
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Old 12-06-2010, 02:02 PM   #58
krauser2
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holy crap...this thing is going to FLY
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Old 12-06-2010, 05:52 PM   #59
wrxtremeWGN
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this is an awesome build!!!! i remember a 914 swap i saw in member's gallery a few years ago that i fell in love w/ but cant find the thread anymore. i cant wait to show this thread to the local PCA auto-x 914 guys.

cant wait to see more!
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Old 12-06-2010, 07:15 PM   #60
K.Linchpin
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This is inspirational. I put a EJ207 in my WRX wagon (3100+ lbs) and it moves! You're 1200 lbs less. I can only imagine... This thing will be a bullet!

How come you didn't go bellmouth on the downpipe side of things?
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Old 12-06-2010, 09:45 PM   #61
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Very nice build. I look forward to see you and the car at Nats (please bring it). I'll be #155 in XP.
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Old 12-06-2010, 10:19 PM   #62
Britain
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Quote:
Originally Posted by K.Linchpin View Post
How come you didn't go bellmouth on the downpipe side of things?
Didn't need the internal wastegate as I am running dual external Turbosmart UltraGate38's. They will give me better boost control and response.

-Britain
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Old 12-09-2010, 02:55 PM   #63
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Soooo sexy!!!1
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Old 12-10-2010, 03:06 PM   #64
Britain
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Few updates. Took a few days off work to make some progress before the holiday season gets underway. I also got a lot of parts in and I couldn't wait to get them mounted.

First off was to mount the pair of Turbosmart wastegates and finish the exhaust plumbing. Here you can see the general location of all the components.



Both wastegates will dump back into the exhaust stream so that I can control the output noise levels due to sound restrictions at some venues. Both wastegate dumps are 1.5" and then merge into 1.75" before being dumped into the exhaust. After several hours of fab work with a "metal master" buddy of mine, it was all completed. Just have to get it professionally tig welded to call it done.





Here it is mounted in the car to ensure that everything clears and fits in its respective location.



The location of the turbo and the mess of the header and exhaust plumbing has made it impossible to run the stock shifter bar. Therefore, I have adapted parts of a cable shift set-up to handle the shifted duties. If you remember, I only have 2 gears in my transmission and therefore only need to shift forward and back...pretty simple. Here is the transmission side.


Last edited by Britain; 10-23-2012 at 01:04 PM.
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Old 12-10-2010, 03:10 PM   #65
Britain
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Because this engine is "special" and has the TGV delete manifold, the Aeromotive fuel rails interfer with the AVSC solenoids (blue plug).



However, by spacing the intake manifold up ~16mm I was able to clear the plug. I order a set of 16mm phenolic spacers from KSTech and everything clears like it should.



The second problem with the Aeromotive fuel rails are the mounting brackets. Again, because they are supposed to be mounted to a TGV they don't fit my Spec-C manifold. Therefore I had to fab up a pair of brackets to secure them. Here you can see the difference between the new brackets and the ones that came with the kit.



Here they are on the engine...all good.


Last edited by Britain; 10-23-2012 at 01:05 PM.
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Old 12-10-2010, 03:13 PM   #66
Britain
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I usually don't like to show new parts until they are installed, but I had to show off the custom Griffen radiator I got in yesterday. It is going to fit perfectly.





I also got in the ice box from Frozenboost.com. If you get to take a ride, this will be between your legs. Maybe I can hook up a "cool" suit for that hot days...hmmmm.



Ok, back to the garage to continue working.

Last edited by Britain; 10-23-2012 at 01:05 PM.
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Old 12-12-2010, 12:45 AM   #67
RSti_Spyder
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Very nice build. I have already absorbed your 3.0L water thermostat housing find on my STi Meyers Manx build. You help my project stay motivated.

Thanks
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Old 12-12-2010, 05:20 AM   #68
Britain
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Thanks...glad I could be of service. I will post more updates once I have completed a few more items.

-Britain
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Old 12-12-2010, 09:49 AM   #69
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random thought
had you considered that changing from a TGV to the 16mm spacer would change the volume of the manifold - although this may be less of an issue with forced induction
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Old 12-12-2010, 01:42 PM   #70
Britain
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Quote:
Originally Posted by Jaxx View Post
random thought
had you considered that changing from a TGV to the 16mm spacer would change the volume of the manifold - although this may be less of an issue with forced induction
I didn't have TGV's before as this is a Spec-C engine. The addition of the 16mm spacers would increase the volume slightly, but this is not an issue.

-Britain
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Old 12-15-2010, 01:40 PM   #71
Britain
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Couple of updates while the engine is out a shop getting all the exhaust tig welded.

Some of you might have noticed in the previous picture of the radiator that the fan was mounted about an inch from the radiator. Not sure why they built it that way, but I modified the fan mounts to move it about 1/4" from the radiator. This will be much more efficient. I also had some tabs welded on for the mounts to the chassis.



Also made a bracket to hold the three master cylinder reservoirs in the front. I am mounting a Tilton brake pedal assembly and converting the clutch to a hydraulic throw-out bearing hence the need for this set-up.



-Britain

Last edited by Britain; 10-23-2012 at 01:05 PM.
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Old 12-19-2010, 12:03 AM   #72
Britain
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Made a lot of progress today. It is always nice to start bolting things back up to the car.

To mount the radiator, I had tabs welded on the core and made some nice brackets that I welded into the car. Here are the brackets:



And with the radiator installed and radiator hoses hooked up.





I made the bottom radiator support elevated off the floor to ensure that if the car bottomed out or the floorboard got dented then it wouldn't destroy the radiator. The center section of the mount bar was notched to clear the tow hook hump in the sheetmetal.



Then I worked on how I was going to fit the fuel tank. Admittedly, the fuel take was small to begin with however this was too big to fit in the small space left in the front trunk. I therefore cut off the back of the fuel tank to follow the contours of the trunk floor.



I need to get some more aluminum, but this will be welded up and will work perfectly.



There will eventually be a nice shroud to vent the radiator out the hood. As you can see here, everything should clear nicely. I will make a fuel tank filler neck that will extend back and enable filling the tank without having to take off the shroud.



I also was found a nice place to mount the accusump tank. This will be activated by a manual pull release that is just long enough to route to the front.



Ok, headed back out there now to continue working.

-Britain

Last edited by Britain; 10-23-2012 at 01:06 PM.
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Old 12-19-2010, 12:11 AM   #73
Britain
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Quick question...for the fuel tank I would like to be able to determine the fuel level without having to put a stick in there. Does anyone know where I can get one of those liquid level sight tubes like the one below...preferably in aluminum and compatible with fuel.

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Old 12-21-2010, 04:23 AM   #74
Britain
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I had the day off work and was able to get a couple of things done.

First off, I had the backside of the fuel tank welded up and some tabs mounted.



With a set of brackets made, the fuel tank now fits perfectly in the available trunk space.



I also got the engine back to my garage after having all the exhaust all tig welded up. I added a flex joint in-between the two wastegates to aid in installation.



Overview shot of the engine...almost ready to go, just a few more things to do.



Some of you might know, but I have a special 2-speed transmission in this car. In addition, the placement of the header and turbo make it virtually impossible to pass a shift bar through to the transmission. Therefore I have converted to a cable shift set-up. Here is my new shifter I built today.



I will need to have a pair of small spacers made tomorrow at the machine shop to correctly position the hem joint, but the functionality works. Here is a short video of the motion.


Finally, I started working on the placement of the pedal assembly.



More to come...
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Old 12-21-2010, 11:17 AM   #75
ZeroDrift
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Looking good! Keep up the good work!
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