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Old 10-08-2013, 04:29 AM   #801
kpluiten
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Next I mocked up the mounting of the FPR and the filter and bend/flared hard lines to go from the firewall to the appropriate locations. I used nifty AN adapters on the factory lines at the firewall so connecting the stainless hardlines to the factory lines was easy. The bending took a LONG time.





Firewall junction:




Here is the plate in black chrome powder coat with the FPR and filter all mounted up:


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Old 10-08-2013, 04:39 AM   #802
kpluiten
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The Spec-C STi came from the factory with an engine oil cooler. As a result, this motor had all the provisions for a cooler, but did not come with the cooler itself. I used a Hayden unit that approximately matches the dimensions of the factory unit.

I mounted it in front of the condenser in approximately the same location as stock. I bend hard lines and had AN fittings installed on the cooler by Kent at Precision Chassis Works after trying to solder them on unsuccessfully myself.



Drilling the AN fittings for the cooler:






Welded up:




Hardlines coming around the condenser/radiator:


My chief mechanic, Mac, making the AN lines to go from the cooler to the engine:


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Old 10-08-2013, 04:44 AM   #803
kpluiten
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Here you can see the cooler feed/return and the motor feed/return:


I didn't want to run line straight across because I was worried that there might not be enough slack in the system and the movement of the motor relative to the chassis might cause stress on the components leading to breaking or loosening. So I made nice big U-bends.



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Old 10-08-2013, 04:48 AM   #804
kpluiten
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Last update for tonight: I finished up the install of the wideband controller. It is mounted on a plate I made for the passenger side strut tower. The plate mounts to existing factory bolt holes and is made from aluminum powder coated black chrome. The boost control solenoid shares this plate with the wideband. The wiring of the wideband was covered earlier in the thread.



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Old 10-08-2013, 01:31 PM   #805
LUMBERZACK
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Ken! You are the man! We need to hang out, I want to see this thing, looks so good!
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Old 10-09-2013, 12:25 AM   #806
bdj238
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wow! every time you do updates I'm inspired by your attitude towards doing things right and doing them yourself. Learning to bend/flare lines, designing brackets, machining things to fit b/c they didn't before, etc. is inspiring and impressive.
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Old 10-09-2013, 02:30 AM   #807
ScoobyJD
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kpluiten, just a tip I just found out not to long ago; glue felt or wrap the tips of the an wrench to double prevent fittings from getting nicked and scratched
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Old 10-10-2013, 03:44 PM   #808
kpluiten
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Quote:
Originally Posted by lox View Post
solid work, diagnostic switch is a great idea

now go to bed
Thanks. I was thinking about making a cleaner design and seeing how cheap I could make them for. You think there is a market for such a thing? Or would people just rather make their own?

And yeah, I was up WAY too late that night posting this stuff. Work was rough the next day.
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Old 10-10-2013, 03:56 PM   #809
kpluiten
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Quote:
Originally Posted by LUMBERZACK View Post
Ken! You are the man! We need to hang out, I want to see this thing, looks so good!
Thanks. Yeah, I'm always down to hang out as time allows. As soon as I'm fully up and running and tuned, I'll be hitting up a lot more meets and get togethers.

Quote:
Originally Posted by bdj238 View Post
wow! every time you do updates I'm inspired by your attitude towards doing things right and doing them yourself. Learning to bend/flare lines, designing brackets, machining things to fit b/c they didn't before, etc. is inspiring and impressive.
Doing it right is my goal, though I don't always get it right on the first try. It seems that every time I cut a corner, it comes back to bite me. I hate half-assed work.

Quote:
Originally Posted by ScoobyJD View Post
kpluiten, just a tip I just found out not to long ago; glue felt or wrap the tips of the an wrench to double prevent fittings from getting nicked and scratched
This is good advice. I bought an AN wrench because they are designed to not mess up the edges of the fittings like normal wrenches, but it still occurs. I sometimes used electrical tape, but the felt seems more robust. I'll have to try that next time.
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Old 10-10-2013, 03:59 PM   #810
lox
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i chose the word 'idea' on purpose, the execution could be cleaner

but yes i would think the market would be broad enough

who here wouldn't want one?
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Old 10-10-2013, 04:20 PM   #811
kpluiten
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Here are some details on the power steering system.

The rack has two lines, supply and return. The supply is high pressure and must use line rated for those pressures! The pressures are generally 1000-3000 psi, but I don't know what Subaru's run at specifically. I do know that standard AN lines are NOT rated for this and while they may work for a while, they will fail and that is a mess and potentially a fire. The return line on the other hand is very low pressure and most oil safe hoses will work for it.

The rack side looks like this: (Ignore the overspray. It wipes right off. I'm not even sure how it got there during painting... :facepalm: )


I used special adapter made by Earl's to convert this interface to AN -6. These fittings technically work, but lack a chamfer on the inside of them that allows them to seal with the tiny oring on the flared portion of the factory line. If you use them as-is, they may seal, or they may not. I've seen many guys use them successfully. I added a small chamfer on the inside of mine so that they closely matched the dimensions of the factory lines.

Here is the factory line interface. It's hard to see, but there is a bevel or chamfer in there that seats up against the hardline flare and oring.


Here is a close-up of the factory rack lines. Notice the flare and the oring on top of the flare.


Here is one of the Earl's adapters installed. I replaced the orings while I was at it.


Here is the low-pressure return line attached to the rack:


For the high-pressure feed line from the pump, I used a PTFE braided stainless steel line with nickel compression fittings. Compression fittings use a ferrule to ensure very good retention of the hose. I also had to purchase an adapter to adapt the pump to AN -6.



The line was run under the manifold. This looked clean and fit nicely. But it might bite me if there ever is a problem that requires disassembly. Like this, I cannot simply unbolt the PS pump and set it aside; I'd have to disconnect the line as well.

Last edited by kpluiten; 10-10-2013 at 04:36 PM.
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Old 10-10-2013, 04:21 PM   #812
kpluiten
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On the back side of the motor, the high-pressure line comes out and takes a nice gradual bend to the underside of the motor to the rack. I covered the line in pyro-shield to keep the heat at a minimum from the downpipe and turbo.


Here you can see the low-pressure line coming up from the rack. It was wrapped in a heat resistant fiberglass/foil tape. Again, to help protect against heat from the downpipe/turbo. A nice big air gap between the two helps as well.


I used a small rubber segment to adapt from the fluid reservoir to the braided line from the rack.



Lastly I added a couple of spring clamps to keep things sealed, and a couple of hose holders off the front subframe bracket to hold the braided line in place.
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Old 10-10-2013, 04:27 PM   #813
kpluiten
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Quote:
Originally Posted by lox View Post
i chose the word 'idea' on purpose, the execution could be cleaner

but yes i would think the market would be broad enough

who here wouldn't want one?
I've looked into a small key switch, but I haven't found anything small enough in my limited research. My other idea was a much cleaner toggle switch with built in LED's. I'm certain I'll find something better.

The real question isn't who wouldn't want one, but who is willing to pay for it.

I've pursued many ideas because everyone wants it, but when it comes time to pay, they are oddly silent.

We'll see what I have time for. I get ideas for products faster than I can produce them. A problem, but a good one.
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Old 10-11-2013, 06:12 PM   #814
kpluiten
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So I dropped the car off with Kent @ Precision Chassis Works a few days ago. He's been working on the car and so far, it's looking very good. I think he has completed the downpipe and exhaust v-banding and is starting on the FMIC pipes and intake.

Here are some poor quality photos of some high quality work:

I never get to put my car on the lift so I took a few lousy photos while it was up there.














Originally I wanted to run the intake into the fender in a CAI fashion, but Kent was unable to get it to fit well with a 3" diameter. So we decided on a short ram setup. Use you imagination there and connect the dots. He also finished the hotside piping and it looks nice and low and tight. This was necessitated by my rotated compressor housing. Doing this eliminates at least 18" of piping.



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Old 10-11-2013, 06:30 PM   #815
lox
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i got nothing but respect

and maybe some jealousy
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Old 10-11-2013, 06:41 PM   #816
05bluesti
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Quote:
Originally Posted by lox View Post
i got nothing but respect

and maybe some jealousy
I've got that too

And a bonner.....



And now a mess
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Old 10-11-2013, 06:46 PM   #817
kpluiten
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Quote:
Originally Posted by lox View Post
i got nothing but respect

and maybe some jealousy
Thanks.

Quote:
Originally Posted by 05bluesti View Post
I've got that too

And a bonner.....



And now a mess
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Old 10-11-2013, 06:48 PM   #818
kpluiten
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Kent just sent me this picture. Apparently he doesn't like floppy pipes.

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Old 10-11-2013, 08:55 PM   #819
lox
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'mericans

expensive, but worth it
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Old 10-11-2013, 09:42 PM   #820
Infantry209
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UGM

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Wow k, looks great man. Keep it up.
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Old 10-12-2013, 10:08 AM   #821
bdj238
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Question for you, what model type front sway bar are you using? Sedan or wagon? I have the aluminum front control arms on my wagon and had a wagon specific Whiteline bar on mine and it never fit right, so someone suggested going to the sedan due to the wider track that the control arms give you but again, it still doesn't fit right. I'm using solid endlinks and plan on swapping over to the ball joint style to try to help but am not sure that alone will solve my issue.
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Old 10-14-2013, 12:20 PM   #822
Z0rr0
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Very Nice, Ken!
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Old 10-14-2013, 12:35 PM   #823
3mlwhly
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great build man, and what are the part numbers for those power steering adapters?
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Old 10-14-2013, 01:21 PM   #824
SaabaruMike
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I'm speechless Ken. Amazing work!
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Old 10-19-2013, 12:01 PM   #825
IVIattIVIan
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Untitled by IVIattIVIan, on Flickr

Untitled by IVIattIVIan, on Flickr
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