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Old 01-04-2013, 05:58 PM   #1
Setaro
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Member#: 143982
Join Date: Mar 2007
Chapter/Region: South East
Location: NC
Vehicle:
2004 Impreza WRX STi
Java Black Pearl

Default Setaro's 2004 STi- losing the bolt on's

It is long overdue that I make this. This is my 2004 Java Black STi. I bought it July 7th 2007. Bone stock. Over the last 5 and a half years, it has become a huge part of who I am. Over the years Iíve done quite a few basic mods, but in October of 2011, I decided to dig in and do something that I have wanted to do for a very long time; rotated turbo, reversed intake manifold.


The very first day I met my STi. July 7 2007 absolutely bone stock.


First day home.


Sometime in 2009




one of my favorite shots before pulling apart.


The last day I drove it before beginning the build.


Here is the mod list as the car stands today:
Cobb AccessPORT (42 Autosports tune)
Braille lightweight battery - 15 lb. Mounted with braille aluminum battery mount kit

Powerslot slotted brake rotors front and rear
Project Mu H12 street/track compound brake pads front and rear
Motul RBF 600 DOT4 brake fluid

ACT 6 puck sprung hub clutch with HD pressure plate and ACT streetlite flywheel

Whiteline Steering rack bushings
Kartboy front and rear shifter stay bushings


Turbo: Borg warner/ Bullseye power S259 Batmowheel Billet compressor wheel.
Compressor: 59mm Inducer / 80mm Exducer BatMoWheel
Turbine: 64mm Inducer / 74mm exducer
70a/r
Oil source same as factory location: banjo bolted from head to a 'T' fitting, running -4 lines from 'T' to turbo and to passenger side avcs

Reverse intake manifold
Aluminum 10mm tgv spacers (between tgv and head)
Aluminum 10mm Throttle body spacer
Tgv deletes
Custom routed intercooler piping
- 2.25 from turbo to I/c
- 2.75 from I/c to tb
Perrin Fmic
Tial 50 mm BOV
Relocated brake booster barb fitting
3.5" maf housing
NGK 1 step colder plugs LFR7AIX

Separate breather and catch can systems (keeping the pcv system and valve cover breathers separate)

Deatschwerks 850cc side feed injectors (flow balanced within 1%)
Walbro 255 fuel pump

Gruppe-s unequal length header
Perrin rotated up pipe- modified to accommodate tial mvs wg.
Custom rotated 3" down pipe with wastegate dump plumbed back in.
Tial MVS wastegate (water cooled)
-6 water lines from head to wg and wg to coolant tank
Gm 3 port boost controller
Invidia N1 race cat-back

Aps coolant overflow tank.
Fluidyne aluminum racing radiator
Drivers side radiator fan changed to slim fan to make room to I/c piping

Setrab oil cooler (vertically mounted behind intercooler; mounted on rubber)
Mocal thermostatic sandwich adapter
-8 lines from cooler to sandwich plate

Stainless steel braided high pressure power steering line

Extended throttle body harness to accommodate intake manifold reversal, and to allow tb to open horizontally

Debadged trunk (kept the STi emblem)
Pillarless grille mod
Spec-c front lip
Rota Grid 18x8.5 Hyper-black
Defi BF series 60mm gauges, white numbers with red needle, metric reading, boost, exhaust gas temperature, and oil temperature, all inside an ATi abs plastic clock replacement gauge pod.
AEM Uego wideband.
Alpine CDA-9856 head unit with iPod cable
Factory option embroidered STi floor-mats - black.
OEM leather STi owners manual case
118 db Hella horns

I decided to go though all this before building the engine so that I could have everything running and shaken down prior to going all out for everything the turbo/fuel system will do. That, and my wallet can only take so much of a beating at a time.
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Old 01-04-2013, 05:58 PM   #2
Setaro
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Member#: 143982
Join Date: Mar 2007
Chapter/Region: South East
Location: NC
Vehicle:
2004 Impreza WRX STi
Java Black Pearl

Default

And so it begins.


Remove intake manifold and reverse. Install TGV deletes, 850cc injectors, TGV spacers, and throttle body spacers. Relocate brake booster line on intake manifold.












TGV spacers


Originally, this was the only orientation I could mount the throttle body due to the lack of clearance from the TB motor.


I didn’t like this orientation. I felt that under part throttle, the blade opening would favor the drivers side cylinders. So I made clearance.


That’s more like it!
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Old 01-04-2013, 05:58 PM   #3
Setaro
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Member#: 143982
Join Date: Mar 2007
Chapter/Region: South East
Location: NC
Vehicle:
2004 Impreza WRX STi
Java Black Pearl

Default

Perrin FMIC core mounted


That means its time to cut this up.


I believe it fits.


The very finest paperweights money can buy


Factory vf39 next to BW/bullseye power S259


Ok, now for the fun part.
The turbo is mounted on a Perrin rotated up pipe. This is one of very few pre made parts on the car.



We decided to run the charge piping the way we wanted, we would need to weld a 90* elbow on the compressor housing. So the turbo comes apart.


This is the batmowheel. It truly is an interesting looking compressor wheel.




Elbow tacked on.
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Old 01-04-2013, 05:59 PM   #4
Setaro
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Member#: 143982
Join Date: Mar 2007
Chapter/Region: South East
Location: NC
Vehicle:
2004 Impreza WRX STi
Java Black Pearl

Default

Starting on the cold side piping. I decided to keep my A/C. It made life pretty difficult, but worth the extra headaches in the long run.


One side down.


Hot side piping.


The bov can bee seen here on the cold side piping.


Mocal thermostatic sandwich plate. -8 lines heading to a Setrab cooler.


Jumping ahead a bit, but hereís the oil cooler mounted.


Catch can system: one can for PCV system, the other for the valve cover breathers.




To the exhaust. I am running an Tial MVS (38mm). For those of you who donít know, the Perrin rotated up pipe is only made for a 44mm WG. More modification! We added a soft 90* bend to pull the WG away from the trans, and allow the WG out to flow more smoothly into the downpipe. In the first shot you can also see the water lines to and from the WG. I was able to easily run water lines here since the new turbo only has provisions for oil.


WG out merging back into the downpipe.
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Old 01-04-2013, 06:00 PM   #5
Setaro
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Member#: 143982
Join Date: Mar 2007
Chapter/Region: South East
Location: NC
Vehicle:
2004 Impreza WRX STi
Java Black Pearl

Default

Built the intake using 3.5” piping and the same sized maf. Yes the maf is huge, yes its definitely too big, yes im considering a smaller one. Also in this shot you can see where we relocated the coolant reservoir tank off of the passenger side strut tower.



putting the final touches on the car before getting it tuned.


At 42autosports. Since this is a stock motor for the time being, the goal was no more than 400whp. Steven and all of his guys at the shop were more than accommodating. It’s easy to tell that these people love their job. They were excited to see an uncommon build, and excited to make future plans.
The car made just shy of 400 on spring pressure (19lbs).


The inaugural drive home!


Brought it up to Ocean City for Cruisin OC.


As it sits today.
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Old 01-04-2013, 06:14 PM   #6
BizzarBoxerXt
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Member#: 77200
Join Date: Dec 2004
Chapter/Region: NESIC
Location: Groton, CT
Vehicle:
2002 WRX
WRB w/BoBo trunk monkey

Default

Looks like crap what a n00b! JK! Looks good bud now get it the hell out of the garage and drive it a bit!
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Old 01-04-2013, 06:35 PM   #7
chadb
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Member#: 198179
Join Date: Dec 2008
Chapter/Region: MWSOC
Location: Cleveland,ohio
Vehicle:
2007 STI
UGM

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Are u going break the motor open and run different cams?
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Old 01-04-2013, 06:41 PM   #8
Setaro
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Member#: 143982
Join Date: Mar 2007
Chapter/Region: South East
Location: NC
Vehicle:
2004 Impreza WRX STi
Java Black Pearl

Default

Quote:
Originally Posted by chadb View Post
Are u going break the motor open and run different cams?
Definitely. I wanted to get all of the fabrication out of the way first, since it is the more difficult part, then drop a built motor in after. I'm hoping to sleeve the block, upgraded pistons, rods, cams and go from there.
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Old 01-16-2013, 10:48 PM   #9
Setaro
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Member#: 143982
Join Date: Mar 2007
Chapter/Region: South East
Location: NC
Vehicle:
2004 Impreza WRX STi
Java Black Pearl

Default

No love?


No, but really, what gives?
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Old 01-16-2013, 10:58 PM   #10
Ballistic1350
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Member#: 156877
Join Date: Aug 2007
Chapter/Region: MAIC
Location: Montgomery Village, MD
Vehicle:
04 sti

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Looking good! do you have the dyno plot?
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Old 01-16-2013, 11:03 PM   #11
Jive Turkey
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gonna go scoop less soon? maybe an RS hood?
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Old 01-16-2013, 11:04 PM   #12
Ballistic1350
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Join Date: Aug 2007
Chapter/Region: MAIC
Location: Montgomery Village, MD
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04 sti

Default

also what brand and size coolant line did you use for your ewg? are the fittings on the wastegate -an or did you need some special fitting?

nm: they're -4 on the wastegate

Last edited by Ballistic1350; 01-16-2013 at 11:06 PM. Reason: looked it up myself...
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Old 01-16-2013, 11:05 PM   #13
Setaro
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Member#: 143982
Join Date: Mar 2007
Chapter/Region: South East
Location: NC
Vehicle:
2004 Impreza WRX STi
Java Black Pearl

Default

i do! bear in mind, its on spring pressure (19lbs). Not too bad for a stock motor. With any luck, it wont be that way much longer.

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Old 01-16-2013, 11:08 PM   #14
Setaro
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Member#: 143982
Join Date: Mar 2007
Chapter/Region: South East
Location: NC
Vehicle:
2004 Impreza WRX STi
Java Black Pearl

Default

Quote:
Originally Posted by Ballistic1350 View Post
also what brand and size coolant line did you use for your ewg? are the fittings on the wastegate -an or did you need some special fitting?
Coolant lines are -6, fittings are an. We took the supplied -4an fittings and modified them to support -6 instead (cut and weld to make a hybrid fitting).
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Old 01-16-2013, 11:14 PM   #15
gmhracer
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Join Date: Dec 2010
Location: Southern California
Vehicle:
2006 STI
White

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how many miles have you put on the stock internals with that kind of power?
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Old 01-16-2013, 11:18 PM   #16
Setaro
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Member#: 143982
Join Date: Mar 2007
Chapter/Region: South East
Location: NC
Vehicle:
2004 Impreza WRX STi
Java Black Pearl

Default

Quote:
Originally Posted by gmhracer View Post
how many miles have you put on the stock internals with that kind of power?
Just over 86k. However, I'll be lucky if I put 2,000 miles on the car all year. Partially due to my job keeping me on the road quite a bit, and the other part a perpetual fear of breaking it before its properly assembled
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Old 01-16-2013, 11:42 PM   #17
Ballistic1350
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Member#: 156877
Join Date: Aug 2007
Chapter/Region: MAIC
Location: Montgomery Village, MD
Vehicle:
04 sti

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wow seems really really laggy
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Old 01-16-2013, 11:54 PM   #18
Setaro
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Member#: 143982
Join Date: Mar 2007
Chapter/Region: South East
Location: NC
Vehicle:
2004 Impreza WRX STi
Java Black Pearl

Default

Quote:
Originally Posted by Ballistic1350 View Post
wow seems really really laggy
It is a bit. We played with the boost controller a little and had it reaching full spool much more quickly, but I really don't want to push my luck with the stock internals.

Also, I'm having some temperature issues since nothing is coated or wrapped yet. So there is also some timing being pulled.

All in the plans for the future.
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Old 01-17-2013, 01:26 AM   #19
xfer107
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Member#: 242932
Join Date: Apr 2010
Chapter/Region: South East
Location: New Orleans, La
Vehicle:
2004 WRX STi
WRB

Default

Love it
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Old 01-17-2013, 07:12 AM   #20
Setaro
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Member#: 143982
Join Date: Mar 2007
Chapter/Region: South East
Location: NC
Vehicle:
2004 Impreza WRX STi
Java Black Pearl

Default

Quote:
Originally Posted by Jive Turkey View Post
gonna go scoop less soon? maybe an RS hood?
I've thought about it. I've also considered fabbing a vent to go in the scoop's place. My under hood temps are a pretty big issue at the moment.
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Old 04-19-2013, 01:01 PM   #21
BizzarBoxerXt
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Member#: 77200
Join Date: Dec 2004
Chapter/Region: NESIC
Location: Groton, CT
Vehicle:
2002 WRX
WRB w/BoBo trunk monkey

Default

Sick build, cant wait to see how it does once you finish everything up!
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