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Old 06-21-2013, 01:12 PM   #751
Z0rr0
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Member#: 23123
Join Date: Aug 2002
Chapter/Region: SWIC
Location: Gilbert, AZ
Vehicle:
15 WRX 6MT
07 Legacy SpecB

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Ha!..
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Old 06-21-2013, 01:21 PM   #752
kpluiten
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Chapter/Region: SWIC
Location: AZ
Vehicle:
06 WRBWRXWGN
Now with 100% more Spec-C

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Quote:
Originally Posted by Psirene View Post
I do not have enough caffeine in my blood to make a proper joke out of shifty + manual transmission, but it's there, clearly.
Careful! My thread is a pun free zone.
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Old 06-21-2013, 01:31 PM   #753
Psirene
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Location: Mesa, AZ
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2011 WRX Limited
Obsidian Black Pearl

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Quote:
Originally Posted by kpluiten View Post
Careful! My thread is a pun free zone.
*looks dubious*
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Old 06-21-2013, 03:20 PM   #754
Masta Splint
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Join Date: Sep 2008
Chapter/Region: SWIC
Location: Peoria & Surprise, Arizona
Vehicle:
2005 18g WRX wagon
Aspen White

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Very nice build!
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Old 06-21-2013, 04:59 PM   #755
lox
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Chapter/Region: SWIC
Location: going through your purse
Vehicle:
08 FXT Sports
DGM

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it's a "bought"
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Old 06-24-2013, 04:58 PM   #756
sleepysubie
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Member#: 81069
Join Date: Feb 2005
Chapter/Region: RMIC
Location: The land full of Bounty
Vehicle:
1998 ej257 gm6 ewg
A/R .60 Rotated

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Old 06-26-2013, 07:16 PM   #757
KP
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Location: PM SkimSTI for FREEEEEEEEEEEEE
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HJ's Ask
Hobbs. He knows.

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Sooo......
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Old 06-26-2013, 08:41 PM   #758
Evil Imports
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Location: Global
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+ 13 B8

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Quote:
Originally Posted by KP View Post
Sooo......
you forgot the N,

Soooon...
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Old 08-18-2013, 05:58 AM   #759
kpluiten
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OK, time to resurrect this thread. The push is on to get this car back together so I can take it to SEMA in November. For those who are unaware, the car has been sitting for about a year now with very little work being done. Weak.

Either way, last week, after work, I dragged a table inside and started in on the wiring harness. I am using the EJ255 engine harness from my WRX, but adapted for the EJ207. The adaptations include the removal of non-needed connectors as well as the swapping of a few connectors to fit the EJ207 AVCS solenoids.

All totaled, I removed around 8-10 connectors for things like the TGV's and other deleted mechanisms. I then rewrapped the harness and used new expanded plastic loom and shrink wrap on all the leads out to connectors.

Connectors to be removed are marked in blue tape. Not all are shown.


The battle station:


Every connector on the harness was de-pinned to put the loom and shrink wrap on. I am now adept at removing any connector in the engine bay.




Finished product:








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Old 08-18-2013, 07:04 AM   #760
kpluiten
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Join Date: Jul 2006
Chapter/Region: SWIC
Location: AZ
Vehicle:
06 WRBWRXWGN
Now with 100% more Spec-C

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As some of you may know by now, I had a terrible experience with my go-to powder coater. There were significant delays, damaged parts (a stupid amount of damage to brand new parts), poor workmanship, and outright lying. It was enough that it burned me out on the car for a good while. As it turns out, Jay (Evil Imports) had similar trouble with the same coater on his Forester build during the same time. After some commiserating, we finally decided to take a stab at coating our own parts as we felt that we could produce a quality product with enough effort. We were right.

After over 8 months of research into the science of powder coating, design and building of equipment, hundreds of hours of trial and error and practice, and thousands invested, we were able to produce some great parts for both our builds to kick off our operation.

For my build, I coated the following parts:

Intake Manifold - shaved (see earlier in thread)
Valve covers
Oil Pan
Coolant Cross-over
Alternator
Fuel Rail Adapters (my own design; see earlier in thread)
DBW Throttle Body Adapter (my own design; see earlier in thread)
Compressor Housing
Upper Coolant Tank
Accessory Brackets
Fan Shroud

Jay one-upped me with some other parts, but you’ll have to check out his build to see what they are.

Here are some pictures. Sorry for the poor picture quality.

Valve covers:


Intake manifold and valve covers:


Coolant Cross-over:


Top, bottom, and sides of the motor all match.


Crisp masking lines:


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Old 08-18-2013, 07:04 AM   #761
kpluiten
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Member#: 120273
Join Date: Jul 2006
Chapter/Region: SWIC
Location: AZ
Vehicle:
06 WRBWRXWGN
Now with 100% more Spec-C

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Upper coolant tank lid:


AC idler pulley bracket. The finish is like glass:


Alternator housings. This green matches my brakes and suspension:


All together:




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Old 08-18-2013, 07:05 AM   #762
kpluiten
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Join Date: Jul 2006
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06 WRBWRXWGN
Now with 100% more Spec-C

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The EJ207 manifold uses different fuel rail mounting points than the EJ205/255/257. This is due to it’s lack of TGV’s. The rails are actually similar to those on the TGV-less NA 2.5’s. Since I already had USDM rails, I designed some adapters to fit the USDM rails on the EJ207 manifold.

And, of course, I powder coated them:


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Old 08-18-2013, 07:06 AM   #763
kpluiten
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Member#: 120273
Join Date: Jul 2006
Chapter/Region: SWIC
Location: AZ
Vehicle:
06 WRBWRXWGN
Now with 100% more Spec-C

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This past week/weekend, I worked on assembling the motor. In reality, the long block was already assembled (except for the camshaft/sensor work I have already done for the 32-bit ECU compatibility. Most of the work was mounting the freshly powder coated parts and wrapped harness, and figuring out how I wanted to run various lines and hoses. This was such a headache and it always involves assembly and disassembly many, many times.

I installed a Moroso oil pickup. I figured this was the best time while the motor was out of the car.




Valve covers, belt covers, and oil pan installed. My chief mechanic, Mac, was planning how to route the breather lines.


I hate how cluttered these motors can get. Here are some pictures of our prototype breather lines and routing. Phenolic spacers are also installed:


Big port head goodness on this motor.
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Old 08-18-2013, 07:06 AM   #764
kpluiten
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Join Date: Jul 2006
Chapter/Region: SWIC
Location: AZ
Vehicle:
06 WRBWRXWGN
Now with 100% more Spec-C

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I wanted to clock the turbo so that I could eliminated 18 to 24” of IC pipe that normally goes up and around the turbo near the fire wall. With this orientation, the piping should come right out the left side of the motor and out the fender wall. You can also see the adjustable Kinugawa/Kamak wastegate actuator; a very neat piece that is all but required on the VF36/37 turbos. The stock wastegates tend to blow open easily. There is not much room in there to turn the compressor housing...

Here is the intake manifold sitting in place with the fuel lines and inlet. Everything is tight. Super frustrating, as always.




This is the motor almost entirely together:




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Old 08-18-2013, 07:06 AM   #765
kpluiten
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Join Date: Jul 2006
Chapter/Region: SWIC
Location: AZ
Vehicle:
06 WRBWRXWGN
Now with 100% more Spec-C

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Old 08-18-2013, 07:07 AM   #766
kpluiten
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06 WRBWRXWGN
Now with 100% more Spec-C

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While the exhaust manifold was off for the oil pan, I decided to hit it with a coat of high-temp paint to freshen it up. Here is the underside of the motor with the twinscroll manifold, group-N engine mounts and oil pan installed. In this picture you can see where the external oil filer line connect to above the oil filter.


External oil cooler hard lines on the motor side:


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Old 08-18-2013, 07:08 AM   #767
kpluiten
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Join Date: Jul 2006
Chapter/Region: SWIC
Location: AZ
Vehicle:
06 WRBWRXWGN
Now with 100% more Spec-C

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For this build, I decided to replace the stock radiator which was getting a little long in the tooth. I picked up a Koyo. The one I got was the second revision with the thinner, more efficient core. I also picked up a Mishimoto fan shroud to go with it. There was no reason for the fan shroud other than they were lower profile and would make the FMIC pipes a bit easier to route.

And of course, I powder coated the shroud green.

Wiring the stock connector onto the fan harness for plug-n-play install:




Finished product. For what it is worth, I had a VERY difficult time using this shroud and radiator combination. They DO NOT fit together easily. Fabrication was required to make the fit. :angry:


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Old 08-18-2013, 07:12 AM   #768
kpluiten
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Member#: 120273
Join Date: Jul 2006
Chapter/Region: SWIC
Location: AZ
Vehicle:
06 WRBWRXWGN
Now with 100% more Spec-C

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Time to drop this thing in without scratching the fresh paint. Or crushing a core support. Total time to actually pick the place the motor? About 1.5 hours. No bad, I've had worse times in the past.















Crappy pictures:




Now I get to spend the next month chasing down odds and ends and gremlins. Then it is off to Kent at precision chassis to get custom FMIC and intake piping, and for exhaust fabrication for the twinscroll turbo setup.
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Old 08-18-2013, 10:47 AM   #769
bdj238
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Member#: 207561
Join Date: Apr 2009
Chapter/Region: South East
Location: Oak Ridge, TN
Vehicle:
2005 WRB WRX WAGON
PPG Trans

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You have put an incredible amount of work into this. I can't wait to see what your results are. Glad to hear you started working on the car again. Could you post a link to your friends build? I'm curious

Also please keep us updated how the radiator/shroud combo works out for you. I had the mishimoto radiator with the fans and shrouds and chased heat gremlins for 2 summers. I finally solved my heat issues by going to the mishimoto radiator and stock fan combination. I suspected possible heat soak on the metal shroud but never could prove it.
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Old 08-18-2013, 11:47 AM   #770
coyotesfan
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Member#: 321690
Join Date: May 2012
Location: Chandler
Vehicle:
2009 STi hatchback
white

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Wow Ken this looks good. I like the green/blue. Did you think about priming the engine prior to install? I fabbed up some bolt spacers so that you can mount the starter with the engine out, so you can check for oil leaks while the engine is out. Not sure how that'd work with your external oil cooler set-up (I guess you could temporarily hook up the cooler, but then you'd have a mess once disconnecting. Nevermind.).

I got 20 psi according to my maddad oil press gauge just cranking the engine with the starter. Seemed reasonable at the time.

Also do you have red and or gold powder coat paint?
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Old 08-18-2013, 11:53 AM   #771
kos
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Member#: 118334
Join Date: Jun 2006
Chapter/Region: SWIC
Location: Bouncing off Kerbs
Vehicle:
2005 AW RS + 2006
Time Attack WRX

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Phenomenal work as always Ken, I wouldn't expect any less!
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Old 08-18-2013, 11:54 AM   #772
blkscooby
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Member#: 44422
Join Date: Sep 2003
Chapter/Region: SWIC
Location: Gilbert, AZ
Vehicle:
2009 G8 GT
Cammed, sprayed, stalled

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Let me know if you want to black ceramic coat any exhaust parts. I still have plenty left.

And hit me up for that tuning assistance
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Old 08-18-2013, 12:00 PM   #773
blkscooby
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Member#: 44422
Join Date: Sep 2003
Chapter/Region: SWIC
Location: Gilbert, AZ
Vehicle:
2009 G8 GT
Cammed, sprayed, stalled

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And your work is amazing and well thought out as always. Wouldn't expect any less from another ME
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Old 08-18-2013, 12:44 PM   #774
EvileyeZ88
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Member#: 233501
Join Date: Dec 2009
Chapter/Region: MAIC
Location: Fairfax Va
Vehicle:
07AD 337/335SAXWAGON
99 outback sport

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Man I love this build, and I really love that you brought the green up into the engine bay
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Old 08-18-2013, 02:56 PM   #775
kpluiten
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Member#: 120273
Join Date: Jul 2006
Chapter/Region: SWIC
Location: AZ
Vehicle:
06 WRBWRXWGN
Now with 100% more Spec-C

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Quote:
Originally Posted by bdj238 View Post
You have put an incredible amount of work into this. I can't wait to see what your results are. Glad to hear you started working on the car again. Could you post a link to your friends build? I'm curious

Also please keep us updated how the radiator/shroud combo works out for you. I had the mishimoto radiator with the fans and shrouds and chased heat gremlins for 2 summers. I finally solved my heat issues by going to the mishimoto radiator and stock fan combination. I suspected possible heat soak on the metal shroud but never could prove it.
Thanks for the kind words. It feels good to start working on it again as having an unfinished car in the garage for so long has been weighing on me.

Jay's thread can be found here: http://forums.nasioc.com/forums/show....php?t=2416791

I'll keep an eye on the fan/radiator combo for sure. I'm hoping I got the wiring correct. I'll have a lot of cores to cool/draw air through with the FMIC, oil cooler, condenser and radiator. I hope these fans are up to the task. If not, well, I saved the stock fans at the least.

Quote:
Originally Posted by coyotesfan View Post
Wow Ken this looks good. I like the green/blue. Did you think about priming the engine prior to install? I fabbed up some bolt spacers so that you can mount the starter with the engine out, so you can check for oil leaks while the engine is out. Not sure how that'd work with your external oil cooler set-up (I guess you could temporarily hook up the cooler, but then you'd have a mess once disconnecting. Nevermind.).

I got 20 psi according to my maddad oil press gauge just cranking the engine with the starter. Seemed reasonable at the time.

Also do you have red and or gold powder coat paint?
Thanks, I'm happy with the color scheme as well. I will be priming the motor a few times before start-up, but in the car. I only worked on the oil cooler lines, the oil pan, and the valve covers. The block itself is factory sealed. So as far as oil leaks, I'm thinking that they *should* be minimal. Well, if there are any, they will be slow weeping leaks cause by gasket/Fujibond problems. That is good thinking to start it outside the car on a fresh block assembly. I might give that a try when I put a motor together from scratch.

We can order from over 6500 colors and finishes. We do have gold and red.

Quote:
Originally Posted by kos View Post
Phenomenal work as always Ken, I wouldn't expect any less!
Thank you. Now I just need to drive the damn thing.

Quote:
Originally Posted by blkscooby View Post
Let me know if you want to black ceramic coat any exhaust parts. I still have plenty left.

And hit me up for that tuning assistance
Quote:
Originally Posted by blkscooby View Post
And your work is amazing and well thought out as always. Wouldn't expect any less from another ME
Thank you. I'll definitely be picking your brain on tuning.

Quote:
Originally Posted by EvileyeZ88 View Post
Man I love this build, and I really love that you brought the green up into the engine bay
I'm liking the green as well. I have a bit more in the bay to do in green so stay tuned.
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