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Old 07-04-2011, 04:25 AM   #1
e85monster
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Alright so I bought my car when I was a junior in High school. I had a choice between a 2004 WRX with 50k or a brand new 2007 2.5i. I bought the 2.5i only to regret not having boost. Its been a long time in the making but I finally finished my project build. I waited until I had all of the pictures to write up a build list. I hope this inspires other people that are in my situation. It just shows that this type of build is possible. My main motivation to build my car was people saying I couldnt do it. Ill show you pictures of the car when I first got it till now when its fully built. I hope you enjoy.
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Last edited by e85monster; 07-04-2011 at 05:23 AM.
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Old 07-04-2011, 04:39 AM   #2
GDB FAN
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I see no pictures.
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Old 07-04-2011, 04:49 AM   #3
jonnylin1
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WHITE FTW - AW e92 335i

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me eitherrrr
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Old 07-04-2011, 04:50 AM   #4
Entaille
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im going to go ahead and guess that even if you did this in spite of people saying you 'couldn't', that you spent way more then you probably should have and could have saved a grip of money just selling and buying a wrx to build up : P

either way interested to see the build
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Old 07-04-2011, 04:56 AM   #5
future_subaru_owner
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^+1 I see this about to happen.
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Old 07-04-2011, 05:29 AM   #6
e85monster
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This is the very first day I brought the car home from the dealership. Brand new 2007 2.5i outback sport.


After a couple years of owning the car I didnt do too much. I baked the head lights, put a lip on it, rear WRX wing and a $10 set of dyno ridges for the back


A good friend of mine and I were talking about doing a full build on my car but we werent sure exactly how we could do it. After talking to a couple of local tuners and thinking it out we started.

IMAG0028 by imprezagic, on Flickr

The stock block hanging from the chain.

IMAG0032 by imprezagic, on Flickr

After getting all the internals for the motor we were ready to build. The STI EJ257 crank with eagle H beam rods

IMAG0008 by imprezagic, on Flickr

empty EJ257 short block...not for long lol

IMAG0007 by imprezagic, on Flickr

After plasti gaging the the crank with the bearings and rods we started to put it together

IMAG0009 by imprezagic, on Flickr

sorry for the blurry picture. The crank and rods in one half of the block.

IMAG0010 by imprezagic, on Flickr

After installing the rods and crank it was time for the CP pistons. With this engine we did a 100mm over bore so the block came out to basically be a 2.6L

IMAG0013 by imprezagic, on Flickr

The CP pistons!!

IMAG0014 by imprezagic, on Flickr

Last edited by e85monster; 07-04-2011 at 05:46 AM.
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Old 07-04-2011, 05:31 AM   #7
e85monster
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After installing the CP pistons we torqued down the ARP head studs.

IMAG0019 by imprezagic, on Flickr

Getting the long block ready to go after installing the cometic head gaskets

IMAG0035 by imprezagic, on Flickr

Brand new wrapped GT spec UEL headers

IMAG0036 by imprezagic, on Flickr

After installing the oil pan we tapped into the top of it for the oil return.

IMAG0038 by imprezagic, on Flickr

APS SR56 chrome polished turbo getting ready to be put on the GT spec up pipe

IMAG0005 by imprezagic, on Flickr

Long block all put together with the GT spec headers, GT spec up pipe, APS SR56 turbo, Cosworth high pressure oil pump.

IMAG0037 by imprezagic, on Flickr

For the clutch we decided to go with the ACT street light fly wheel and the ACT 6 puck sprung clutch

IMAG0040 by imprezagic, on Flickr

After dropping the engine back into the car this is how it looked...basically it was a mess

IMAG0041 by imprezagic, on Flickr

After realizing the 2.5i has a much larger intake manifold and a different throttle body we had to clock the turbo in order for it to fit. The APS SR56 and the APS hard inlet pipe.

IMAG0044 by imprezagic, on Flickr

There were so many problems we ran into a long the way but theres always a way to get around them. The fuel system in the stock 2.5i N/A cars is internally regulated. The most amount of boost we could push through the car was around 8 until it hit fuel cut. The best way around this problem was to switch my fuel plate out with a WRX fuel plate that had the fuel return option. I went down to the local race shop and picked up an aeromotive fuel pressure regulator with all stainless steel lines. The gold fuel plate on the left is the WRX one that has the fuel return. The silver fuel plate is my stock one that we had to get rid of.

IMAG0012 by imprezagic, on Flickr

Last edited by e85monster; 07-04-2011 at 06:00 AM.
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Old 07-04-2011, 05:33 AM   #8
e85monster
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After swapping fuel plates we started to build all of the fuel lines.

IMAG0013 by imprezagic, on Flickr

On the far right you can see an AN fitting that goes into the aeromotive fuel pressure regulator. The stainless steel lines are going into the turbo XS fuel rails.

IMAG0016 by imprezagic, on Flickr

For the TIAL Q BOV we tapped into the intake manifold for vaccum.

IMAG0017 by imprezagic, on Flickr

Fabbing up the intercooler and piping to work with the clocked turbo.

IMAG0042 by imprezagic, on Flickr

After starting the engine up and pulling the car out of the garage this is how it sat.

IMAG0045 by imprezagic, on Flickr

I forgot to mention that I bought seibon carbon wide body sedan fenders and 18x9 rotas

IMAG0027 by imprezagic, on Flickr

wheel fitment is a little wide...getting carbon rear fender flares in a couple of weeks

IMAG0020 by imprezagic, on Flickr

Last edited by e85monster; 07-04-2011 at 06:07 AM.
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Old 07-04-2011, 06:10 AM   #9
e85monster
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I will take more pictures tomorrow when we finish the build. We did a full wire tuck so you can see the entire intake manifold. I will update everyone as I go. Next is a full STI drive train with a seibon carbon rear trunk and STI side skirts with carbon fiber Bride seats that I havent put in yet. Just remember. This car was a 2.5i. If you have any questions about how we did certain things just message me and ill be glad to help.

This is it for now...until tomorrow night lol
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Old 07-04-2011, 06:20 AM   #10
michael_cano
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:( STi

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wow, that's an impressive build. nice to see you stuck with it.
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Old 07-04-2011, 06:49 AM   #11
wcc5
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really nice build! cant wait to see more pictures!!
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Old 07-04-2011, 07:20 AM   #12
mth4life
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Looks real good so far, hope to see more pictures soon.
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Old 07-04-2011, 07:23 AM   #13
subieguy87
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Just goes to show, u can take any subie, and still have it run boost
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Old 07-04-2011, 09:11 AM   #14
dhahn1012
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Congrats on the build! Everything looks awesome. Good for you. I love when people say things cant be done
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Old 07-04-2011, 09:26 AM   #15
aps_sti1
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Good job bro, very nice build. U do better work than most race shops u guys need 2open a suby shop n make akilling. This community needs more ppl like u to instill some confidence into all these ppl who are told builds like this either can't or shouldn't b done. Great job bro!
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Old 07-04-2011, 09:52 AM   #16
sooch
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plans with the carbonfiber? you going to leave it as is or paint?
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Old 07-04-2011, 11:11 AM   #17
blakkboxer
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keep the 2.5i badge to trick people

Very nice build dude!
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Old 07-04-2011, 11:46 AM   #18
Kovs04sti
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This is sick I wanna see your numbers when it's all done!
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Old 07-04-2011, 11:49 AM   #19
wrXmon
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That's a good build so far. Keep it up.
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Old 07-04-2011, 01:09 PM   #20
SubieRSjustin
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Beautiful build! Keep the updates coming!
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Old 07-04-2011, 01:15 PM   #21
rolzrex
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awesome build, looking forward to seeing the finished product!
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Old 07-04-2011, 02:22 PM   #22
Matt515
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subscribed! Nice job man
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Old 07-04-2011, 02:32 PM   #23
01rs25
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What are you going to tune it with?

Why not swap the heads, the stock SOHC heads are going to be an extremely big limiting factor.

Good progress so far though
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Old 07-04-2011, 02:53 PM   #24
mac1124
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Quote:
Originally Posted by blakkboxer View Post
keep the 2.5i badge to trick people
I agree.

Also awesome build. Looking forward to completed pictures. Great job.
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Old 07-04-2011, 02:54 PM   #25
Patrick Olsen
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Damn, man, did you graduate from high school and get a job growing money trees? That's a helluva build you've got going on!

Quote:
Originally Posted by e85monster View Post
With this engine we did a 100mm over bore so the block came out to basically be a 2.6L
Either you got one of the ultra-rare stroker EJ257 cranks, or you need to work on your math.
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