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Old 03-11-2014, 11:51 PM   #1
Boxer4turbo2004
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Member#: 106190
Join Date: Jan 2006
Default Element/FuLL-Race/ E85/ 4088R /General Zod

BOXER BROTHERS GARAGE (Fabrication)
BUFFPRODUCTIONHD (Photography)
Element Tuning (Engine Build/Tune)
Full-Race (Rotated Turbo Kit)
Treadstone Performance (Rotated Intercooler Kit)


Presents


"General Zod"


I started this project with the help of Phil at Element Tuning which built all internals of engine with Pro Comp long block build/ Full Race for supplying Garrett 4088R Twin Scroll Rotated turbo kit/ Treadstone Performance for supplying rotated mount intercooler kit /and 3WDistributing for taking the time to put all us 5x100 guys on a group buy that took 6 months on a waiting list then followed by a 4 month build time and 2 month shipping from Japan not many companies will go through that to get five STI/WRX guys sets of wheels due to our lug pattern that no one wants to supply..


Element Tuning Pro Comp Long block Engine

ELT-CP-STI CP Custom Spec Forged Race Pistons OEM Bore (10.0:1)
ELT-CP-STI-Ring CP Piston Rings STI OEM Bore
ELT-BigValve-He... Element Tuning Big Valve STi Heads (+1 mm Stainless Intake and Inconel Exhaust Valves, Head Port Blended into Seat, Element Competition Valve Springs)
BC 280 Cams
Subaru 11mm Oil... 2008 Subaru STi 11mm Oil Pump modified
Element Competition Air Oil Separator Catch Can
ELT-Engine-Kit Element Tuning Engine Assembly Kit (Engine Gaskets, Rod Bearings, Main Bearings, ARP Head Studs, Oil, filter, Coolant, AC)
ELT-ETRODS-STI Element Tuning H Beam 4340 Forged Rod STi misc Gates Racing Timing Belt, bearings, tensioner, water


FuLL-Race Rotated 4088R Twin Scroll Turbo Kit

GRT-TBO-007 Garrett GT4088R Ball Bearing, T4 divided with 3.00" V-BAND exit. Large style compressor
housing with 4.00" inlet and 2.50"outlet. 1.06AR
WRX/STI T4 Twin Scroll Turbo Kit
Add extra O2 Sensor Bung for wide band
Full Race Subaru STI Dumptubes for Twin Scroll
Twin Wastegates 38mm Blue w/ Full-Race logo
Subaru Up Pipe Ceramic Coating 2000 Degree Turbine Color
Subaru Lower Manifold Ceramic Coating 2000
CTG-APC-HS... Turbine Housing High Temp Coating Turbine Coat w/ 2000 Degree Threshold
Downpipe High Temp Coating Turbine Coat w/ 2000 Degree Threshold
Dump tubes High Temp Coating Turbine Coat w/ 2000 Degree Threshold




TreadStone Rotated Front Mount Intercooler

4.5" deep core, 28" long and 10.5"
Custom WRB Powder Coat Intercooler Piping
TiaL Blow Off Valve


E85 Fuel System

Hydra EMS Stand Alone Management System
AELT-FP-Bosch044 Element Tuning Twin Bosch 044 Fuel Pump Kit
ID 2000cc Fuel Injectors (manifold, injectors, welding, spacers, fuel rails, lines, regulator, gauge)
custom fuel system wiring by Boxer Brothers Garage

Tranny

ACT 6 puck sprung Race Clutch
ACT Lightened Flywheel
6 Speed STi Transmission w/DCCD


Cooling

Koyo Radiator
SubTLe Radiator/Alternator Shrouds
Perrin Overflow Tank
Moroso Expansion Tank

Wheels/Tires

Volk TE37 SL +22 Hyper Blue 18x9.5
Dunlop Direzza ZII 255/35/18

Suspension/Fenders

Tokico struts
RaceComp Engineering yellow coils
Group N Tophats front and rear
ABW Fender Flares (paint by Boxer Brothers Garage)

Gauges wiring (Boxer Brothers Garage)

Defi Link Oil Pressure
Defi Link Oil Temperature
Defi Link Fuel Pressure
Defi Link Boost Pressure
AEM Wideband
EBoost2 Electronic Boost Controller

Intake/Exhaust

Custom 4 inch Cold Air Intake / K&N (Boxer Brothers Garage)
Custom Exhaust Turbo XS RFL










step #1 Let's Pull the Engine (Completed)





Step #2 Lets take a trip to Element Tuning in Jersey for Engine drop off for Pro Comp Build .. CP Race Pistons 10:0:1 ..Big valve Port Polish ...BC 280 Cams... Modified 08 STi 11mm Oil pump... Hbeam 4340 Forged Rods ...Gates Racing Timing Belt ID 2000cc Injectors, Fuel Rails, and Regulator 2.5RS Cast Intake Manifold with TGV deletes Custom Wrinkle Black Powder Coat (Completed)






Step #3 Reinstall Pro Comp Long Block (Completed)




Step #4 Purchase and Install TreadStone Rotated Turbo Intercooler Kit custom Rally Blue Powder Coat / Tial BOV (Completed)



Step #5 Rewire Car with 12 gauge wiring/ 30 Amp relays and Install Twin Bosch 044 Internal/External Fuel Pumps (Completed)


Step #6 Purchase and Install Full-Race Garrett 4088R Twin Scroll Turbo Kit 2000 degree Titanium Powder Coat with Twin Tial 38mm External Waist gates and Element Catch Can (Completed)










Step #7 Deliver Assembled Car to phil at Element Tuning for Installation of Hydra EMS Stand Alone and engine first Pressure tests and Engine Start up for break in Tune (Completed)








Step #8 Engine Break in tune adding 1000 miles to engine on low boost and low rpm not to exceed 4000 rpm and changing oil with Shell Rotella 15w40 non synthetic oil x3 times (Completed)




Step#9 Install Hyper Blue Volk TE 37 +22 Offset which with 04 STi is custom order which took a year to receive on Waiting list from 3W distributing wrapped in Dunlap Direzza 255/35/18 Tires (Completed)




Step#10 Hella Horn Installation (Completed)



Step #11 Install Defi Link Controller /Oil Pressure/Oil Temperature/Fuel Pressure into dash pod for Monitoring of engine safety (Completed)

step #12 Install TurboSmart EBoost2 6 stage Electronic Boost Controller custom vent location for multi stage boost settings (Completed)

step #13 Install Add Defi BF Boost Pressure, Defi Indicator Master Warning Lamp and AEM Wideband into Perrin column mounted 60mm pod for added safety of engine monitoring (Completed))

Step #14 Install Koyo Radiator, Samco Hoses (Completed)

Step #15 Install Subtle Shroud, Subtle Alternator Cover (Completed)

Step #16 Install Radiator Overflow tank and Killer Bee Oil pickup (completed)

Step #17 Deliver Car back to Phil for Final Tune (Incomplete)

Step #18 Fender Flare Installation (Complete)

Step #19 Suspension Installation (Complete)

step #20 Projector Retro headlights

Step #21 Kneel Before Zod (Incomplete)

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Last edited by Boxer4turbo2004; 09-18-2016 at 11:57 PM.
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Old 03-12-2014, 12:17 AM   #2
jam007
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Member#: 174706
Join Date: Mar 2008
Chapter/Region: SCIC
Location: Camarillo, California
Vehicle:
2008 LGT-B
DGM

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nice!
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Old 03-12-2014, 01:38 AM   #3
manz79
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Member#: 111505
Join Date: Apr 2006
Chapter/Region: MAIC
Location: silver spring, md
Vehicle:
07 STi
Black GT3076

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You have put alot of time, effort and $ into this project. I really like what I see so far, subscribed
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Old 03-12-2014, 10:17 AM   #4
boostkreeep
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Member#: 209880
Join Date: Apr 2009
Location: Knoxville,TN
Vehicle:
2006 STI
white

Default

Nice ,700 whp or bust
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Old 03-12-2014, 10:18 AM   #5
milab21
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Member#: 157833
Join Date: Aug 2007
Chapter/Region: Tri-State
Location: NJ Jersey Shore
Vehicle:
2017 WRB STI
2007 WRB STI-sold

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Looks awesome! Nice work!
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Old 03-15-2014, 11:23 PM   #6
Boxer4turbo2004
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thanks guys I'll keep you all updated on car I have added some small clips from initial start up with Phil at Element Tuning going over water/oil/and fuel pressure tests at first start up of build and some break in running on low boost ..when I get my 30psi tune I will have a video made this summer
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Old 03-16-2014, 05:22 PM   #7
toph
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Member#: 78640
Join Date: Jan 2005
Chapter/Region: NESIC
Vehicle:
14 KTM SuperDuke R
16 Tacoma | 02 STi Wagon

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Wow awesome build dude.
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Old 03-23-2014, 11:40 PM   #8
Boxer4turbo2004
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Quote:
Originally Posted by toph View Post
Wow awesome build dude.
thanks
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Old 04-01-2014, 08:13 PM   #9
manz79
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Member#: 111505
Join Date: Apr 2006
Chapter/Region: MAIC
Location: silver spring, md
Vehicle:
07 STi
Black GT3076

Default

Quick question man. How many miles do you have on the chassis?
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Old 04-08-2014, 01:13 PM   #10
Boxer4turbo2004
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70,000 miles on chassis
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Old 04-08-2014, 01:16 PM   #11
Boxer4turbo2004
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Step #12 and #13 (COMPLETE)


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Old 04-18-2014, 12:50 PM   #12
Boxer4turbo2004
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Step #14 Install KoYo Radiator and Samco Hoses (Completed)



Last edited by Boxer4turbo2004; 05-03-2014 at 12:27 AM.
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Old 05-03-2014, 12:26 AM   #13
Boxer4turbo2004
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Step #15 Install SubTLe Shrouds (Complete)


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Old 05-13-2014, 05:56 PM   #14
Boxer4turbo2004
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Old 04-17-2016, 02:17 AM   #15
Boxer4turbo2004
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Old 04-17-2016, 02:18 AM   #16
Boxer4turbo2004
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Old 04-17-2016, 06:12 AM   #17
toph
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14 KTM SuperDuke R
16 Tacoma | 02 STi Wagon

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Why did the engine come out?
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Old 09-18-2016, 11:06 PM   #18
Boxer4turbo2004
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step #18 fender flare install


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Old 09-18-2016, 11:10 PM   #19
Boxer4turbo2004
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step#16 killer bee pan and pickup


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Old 09-18-2016, 11:15 PM   #20
Boxer4turbo2004
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Quote:
Originally Posted by toph View Post
Why did the engine come out?
oil return line had a leak upgraded to silicon hoses..while it was out I installed the Killer bee pick up and Pan I posted new pictures...also reworked entire engine bay ,,relocated 2nd fuel pump to inner fender..relocated battery to trunk along with fuel pump relays ..relocated oil seperator ..deleted stock expansion tank added Moroso expansion tank ..added custom 4 inch cool air intake ..new pics will be posted soon

Last edited by Boxer4turbo2004; 09-18-2016 at 11:22 PM.
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Old 09-18-2016, 11:25 PM   #21
Boxer4turbo2004
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battery fuel pump relays custom wiring relocated to trunk


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Old 09-18-2016, 11:29 PM   #22
Boxer4turbo2004
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sparco


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Old 09-18-2016, 11:30 PM   #23
Boxer4turbo2004
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