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Old 04-09-2014, 12:54 AM   #1
STiSomeday
Scooby Specialist
 
Member#: 265430
Join Date: Nov 2010
Chapter/Region: MWSOC
Location: NE Ohio
Vehicle:
2005 OBP WRX STi
2002 PSM WRX - DD

Default Kyle's 2005 STi build - KMT bulit motor/Dom3xtr/meth/ELH/EWG/FMIC/etc - Picture heavy

For anyone here for the build only and not the story leading up to it, skip to where the list formatting/pictures begin.

I'd like to preface this build thread by explaining the original thoughts I had when looking for an STi. I looked at Subarus for over a year until I found my 2005 WRX STi, and I spent over 8 months actually searching for one until I bought mine. I told myself that I wanted a STi because it was AWD and could be driven year-round, and it was fast enough/handled well enough that I wouldn't really need to change much. I drove my 2005 STi home from VA on March 7th, 2011, with 61,000 miles on it and it was stock aside from a few bushing/shifter upgrades, ss braided brake lines, DBA 4000 rotors and tinted windows. That lasted one week before I was going "stage 2," and one winter before I picked up a daily driver. A year after that, I sorted out the suspension, and last year I went "stage 2+" with TGV deletes, injectors/pump, and a protune done by Eric and Cody of Kill Mode Tuning in Vermillion, OH.

I have run in to multiple cooling issues with my STi throughout my ownership. A few months after buying the car, the upper radiator hose blew on a hot day and the needle hit the red before I realized what happened (cruising at highway speed, started smelling coolant at the same time I noticed the needle). I flushed the cooling system after replacing the hose and reversed the high and low pressure caps. I drove the car with the caps reversed for over a year. I never drove the car hard enough for it to matter, apparently. I took a trip to Southern Ohio to cruise on the nicer roads down that way. Halfway through the trip, the car started pushing coolant out of the low pressure cap which was on the radiator instead of the upper reservoir. The car got hot multiple times on this trip, which is where I believe my issues this past year came from. After switching the caps back and it seeming fine, I did the "stage 2+" setup. I put ~4000 miles on the car, (~1300 of which were the round trip to WBM 2013). I went to the dragstrip and made a few passes, and also tried the accessport's LC/FFS settings for the first time, which cased me to run slower, but that's fairly common from what I've read on the forums.

One day I was sitting in the driveway idling and noticed my temp gauge was halfway between its normal spot right above the first line and the red. I found that my radiator was half full, which was strange because I hadn't noticed any external leaks and the exhaust showed no signs of coolant. After topping the radiator off, I noticed that there was oil floating on top of the coolant. We leak tested the oem oil cooler/warmer, flushed the coolant and refilled it, I drove the car ~100 miles in which it ran perfectly, but again ended up with oil in my coolant. I did a compression test and got good numbers, I parked the car in August 2013 and that leads to this build.

At first I was planning on just doing a stock rebuild, maybe throwing pistons in. I started talking with my tuner, Eric at Kill Mode Tuning (hereinafter referred to as KMT) as he also builds engines, and we worked up a rebuild with a few upgrades. The plan has changed a few times, things like going from a 20g to dom3, UEL to EL, TMIC to FMIC, stock rods with ARP bolts to aftermarket rods, and the final result is what we feel is a very solid build.

Some of you may ask why I didn't just go rotated/reverse manifold/"all out". I didn't want to. Big power isn't my goal, I'm not out to set records, just to have a well done build that is fun to cruise in. In 50k miles or so when the block needs to be refreshed due to inevitable wear from forged pistons I will reconsider my turbo choice and location (the KillerB low mount header has my attention...)


Anyhow, on to the build.

Engine Build

KMT bore and hone block
KMT mill the heads
KMT valve job
KMT flywheel resurfacing
KMT spec Wiseco 8.9:1 99.75mm coated pistons
Carrillo Pro-H connecting rods 3/8 WMC bolts SB-2LTR>-65137H-04
King XPG Rod bearings CR4125XPG
King XPG Main bearings MB5382XPG
ARP headstuds 260-4701
New OEM main bolts (8) 800210990 & (2) 800610010
OEM gasket kit 10105AA590
Extra OEM TGV-head gasket for GS spacers (2) 14035AA421
OEM 10 mm oil pump 15010AA300
OEM flywheel bolts (8) 800610740
Manley titanium retainer set 23180-16
Manley valve spring set 22180-16
Manley inconel exhaust valves 11137-8
Manley stainless intake valves 11138-8
Crower Stage 2 264 cams 62591-4
OEM lifter buckets (16) various
Killer B oil pan windage tray KIL EJWT
Perrin AOS PSP-ENG-607BK
OEM magnetic oil pan drain plug 32103KA000
NGK one step colder spark plugs (4) NGK LFR7AIX/2309
Gates racing Timing Kit w/water pump TCKWP328RB


Fueling/Ventalition

Aeromotive sidefeed fuel rails AER-14136
Aeromotive Fuel pressure regulator AER-13109
-8AN pressure -6AN return fuel lines & fittings
-8AN fittings pressed in to valve covers


Engine Cooling

Koyo aluminum radiator VH091672
Silicone radiator hoses GMS-RAD-HOSE-BLK


Power and Drivetrain Modifications

Dom3.0 XTR 10cm Turbocharger 3 inlet - SUB-DOM3.0XT-R
Swain Tech White Lightning Turbine Housing Coating
GTSpec EL header/EWG uppipe used, 6000 miles.
Swain Tech White Lightning Header/Uppipe Coating
Tial MVS 38mm Black EWG TIALWGMVS38-BLK
P&L FMIC PL-SUB601
Tial QR recirculating Black BOV TIAL-QR-BOV
Auqamist hfs-3 Water/Methanol injection 806-083
KMT Water/Meth tank
KSTech MegaMAF 73mm intake KST-CAI-73mm-2-02/07-APS
Omni-power 4 bar MAP sensor MAP-STI-4BR
AMR hard inlet TIH-SUB
Spec Stage 3+ clutch SU303F
Goodridge SS clutch line - GR24215-clu-sti
Cusco Motor/trans mounts 660911 SET
Torque solution V3 Pitchstop TS-SU-011


Suspension, Steering and Chassis

TurnInConcepts/Carlabs Development X-Brace
Techna Fit SS braided PS line TF PSH-S-WRX


Interior Accessories

SMY Gauge Cluster SMYCLSTR27
STI Duracon Shift Knob C1010FG400


Exterior Accessories

OEM fender plug 46059FA000
OEM right front inner fender liner 59110FE062


Fluids/Gaskets

Subaru Genuine Full Strength Coolant (2) SOA868V9210
Grimmspeed manifold to head gasket (pair) 020001
Grimmspeed turbo to downpipe gasket 028001
Grimmspeed uppipe to turbo gasket 024001
Grimmspeed 3 bolt uppipe gasket 034001
Grimmspeed 3 2 bolt exhaust gasket 022001


Parts already installed that will be retained

Cobb Accessport V2 - KMT Protuned
Invidia Bellmouth downpipe
Full 3" Borla XR-1 Catback exhaust
TGV deletes
Grimmspeed 3mm phenolic TGV spacers
Grimmspeed EBCS
Deatschwerks 850cc sidefeed injectors
Deatschwerks DW200 255lph fuel pump
Killer B oil pickup tube


I don't currently have pictures of the assembled turbo or the header, the hotside and the header/uppipe are at Swaintech getting coated.

Pulling the motor:

(the other STi belongs to my friend Matt)

The motor on a transportation stand that Eric from KMT welded up quickly to get the motor from my place to the shop.


I didn't have access to a truck so we pulled the passenger seat out of my GC coupe and I drove the motor up to the shop.


Here's the turbo taken somewhat apart before I sent the hotside to Swaintech:





I will be color matching the cold side to the same blue that my intake manifold, brembos, and a few other pieces were done in last year.
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Old 04-09-2014, 12:55 AM   #2
STiSomeday
Scooby Specialist
 
Member#: 265430
Join Date: Nov 2010
Chapter/Region: MWSOC
Location: NE Ohio
Vehicle:
2005 OBP WRX STi
2002 PSM WRX - DD

Default

Reserved for table of contents and milestones as thread progresses.
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Old 04-09-2014, 01:02 AM   #3
STiSomeday
Scooby Specialist
 
Member#: 265430
Join Date: Nov 2010
Chapter/Region: MWSOC
Location: NE Ohio
Vehicle:
2005 OBP WRX STi
2002 PSM WRX - DD

Default

Just pictures of parts in the next few posts, for those of you like me who like pictures more than reading.










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Old 04-09-2014, 01:05 AM   #4
STiSomeday
Scooby Specialist
 
Member#: 265430
Join Date: Nov 2010
Chapter/Region: MWSOC
Location: NE Ohio
Vehicle:
2005 OBP WRX STi
2002 PSM WRX - DD

Default

The AMR inlet and KSTech CAI are going to be prepped and powdercoated wrinkle black to match the P&L FMIC pipes, Perrin AOS, valve covers, and a few other parts.










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Old 04-09-2014, 01:06 AM   #5
STiSomeday
Scooby Specialist
 
Member#: 265430
Join Date: Nov 2010
Chapter/Region: MWSOC
Location: NE Ohio
Vehicle:
2005 OBP WRX STi
2002 PSM WRX - DD

Default







And these were taken with a tablet, so quality isn't that great, but here's the FMIC and header/uppipe before coating (don't mind the blue carpet, it's the basement and it's bad haha):


Last edited by STiSomeday; 04-09-2014 at 01:13 AM.
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Old 04-09-2014, 08:46 AM   #6
Delphi
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Member#: 239335
Join Date: Feb 2010
Chapter/Region: W. Canada
Location: Edmonton, Alberta
Vehicle:
2011 WRX
WRB

Default

This is pretty close to what I am going to be building over this coming winter. Subbed!
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Old 04-12-2014, 10:42 PM   #7
STiSomeday
Scooby Specialist
 
Member#: 265430
Join Date: Nov 2010
Chapter/Region: MWSOC
Location: NE Ohio
Vehicle:
2005 OBP WRX STi
2002 PSM WRX - DD

Default

I'm also leaning toward throwing a set of top feed TGV deletes in there in place of my side feeds and upgrading to 1000cc ID's. I could sell my side feed deletes, DW850's, and my sidefeed rails. With the meth my 850's would work but we wouldn't have any head room, where the 1000's will, and then I'll also already be top feed in case I decide to change the setup at some point in the future and need bigger injectors.
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