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Old 11-28-2012, 04:33 PM   #1
pet3r
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Join Date: May 2011
Location: AZ
Vehicle:
2008 STi AW
550whp - 530wtq

Default pet3r's 08 STi - Rallispec 2.5 - gtx3076r - 550whp 530wtq

So I recently spun a bearing and have been working on a new build. I'm trying to force myself to document the build very well with good photos and descriptions, so figured I'd start a thread here. I'll be posting pics of the install and all the parts as they come in. Hoping to be back on the road by Dec 15!

Website - Blog/Journal of progress & build

Here are some of the details:

Car:
2008 STi - Aspen White
OEM Gold BBS rims

Engine
Rallispec 2.5 Street Block -- ARP studs -- OEM head gaskets -- OEM heads + cams
P&L Rotated GTX3076R w/ .82 A/R, custom ceramic coating (inside and outside of pipes), Tial 44mm EWG w/dump to dp
Spearco TMIC
Five-O 1400cc injectors
Walbro 465 pump (still working on fitment)
Perrin Fuel Rails
Perrin EL Headers
Motive Autoworks Composite TGV deletes
Grimmspeed 3-port EBCS
Crawford AOS
Stock Manifold, Stock trans & gears
Stock catback

Other:
JIC FLT-TAR2 coilovers (came with the car when I bought it)
Kartboy short shifter + bushings
Group-N engine mounts
TIC Tranny mounts
Whiteline Sway bars 24/22
Pitch-stop
V limited lip (replica)





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Last edited by pet3r; 01-17-2013 at 11:59 AM.
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Old 11-28-2012, 04:33 PM   #2
pet3r
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Join Date: May 2011
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Vehicle:
2008 STi AW
550whp - 530wtq

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Parts section:


Rallispec Street Block - 360 Rotational View - click here
Semi-closed deck block, Manley 4340 steel H-beam rods, Cosworth forged pistons, and uprated main and rod bearings. Factory nitrided crankshaft. 8.2:1 CR with EJ257 heads and standard head gasket thickness.



Garret GTX3076R w/ .82 A/R - 360 Rotational View - click here


TiC Motive Autowerks Composite TGV Deletes


Torque Solution Air Pump Delete


Perrin Top-feed Fuel Rail Kit


Five-O Motorsports 1400cc injectors


Perrin EL Headers

Last edited by pet3r; 12-23-2012 at 10:38 AM.
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Old 11-28-2012, 04:33 PM   #3
pet3r
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2008 STi AW
550whp - 530wtq

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Build + Install:

Cylinder heads were attached. New 11mm oil pump, and original water pump. Also, a new heat exchanger was used since the original had bearing debris in it...near impossible to clean those things so starting new with it. New cam covers were used, as the previous ones had a bit of heat damage.




Last edited by pet3r; 12-11-2012 at 11:26 PM.
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Old 11-28-2012, 04:34 PM   #4
pet3r
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550whp - 530wtq

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Power, Dyno & Details:
reserved

Last edited by pet3r; 12-01-2012 at 06:32 PM.
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Old 11-28-2012, 04:52 PM   #5
xluben
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Cool.
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Old 12-01-2012, 06:41 PM   #6
pet3r
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550whp - 530wtq

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Been experimenting with 360* photos for some of the bigger more important parts, not sure how many I'll do though.
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Old 12-01-2012, 08:41 PM   #7
vteclol
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Sweet shots and super clean car. I love the stealth set up. Stock look, beastly power.
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Old 12-01-2012, 09:41 PM   #8
07TexasSTi
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UGM

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Very clean car, good luck with the build!
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Old 12-05-2012, 02:45 AM   #9
99imprezd
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Sick! Love the white on gold..
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Old 12-11-2012, 12:35 PM   #10
pet3r
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550whp - 530wtq

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Cylinder heads installed, might be driving it this weekend!
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Old 12-13-2012, 04:30 AM   #11
pet3r
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2008 STi AW
550whp - 530wtq

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Ran out of space above, but the P&L Rotated kit arrived. Lots of parts, and everything looks very nice.

Kit includes:
-custom rotated downpipe
-custom rotated uppipe, with EWG ported to downpipe
-tial 44mm EWG
-custom CAI w/K&N filter
-TMIC adapter (I'll be running the Spearco TMIC still, maximum spool is priority here)
-oil lines, replacement power steering lines
-misc bolts, gaskets

All of it was packaged very, very nicely. They made sure everything arrived in one piece and undamaged, kudos to them because it was a BIG box. When I called Paul he gave me a shipping date (took about 10 business days to fab, ceramic coat, etc). He shipped right on time!

Here's a few pics.





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Old 12-13-2012, 09:31 AM   #12
xluben
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Is that really how the welds look on the Perrin header?

The turbo kit looks nice, but I wish the EWG came off at a shallower angle than 90 degrees.

The other parts and the photos look great!
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Old 12-13-2012, 09:36 AM   #13
Ultimateone
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ISM

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Great photos!
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Old 12-13-2012, 10:45 AM   #14
99imprezd
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WRB

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Love browsing these high res studio shots & love new parts. Better copyright those babies before perrin starts usin them for product shots in their catalog. haha. Judging by youre equipment, facilities & compositions im going to guess that youre a professional photographer?.. Excellent shots. My EJ257 build is at a standstill after getting questionable measurements for my piston to wall clearances. ;( Back to the machine shop for re-measurements. Meantime Head cleaning and polishing can resume! Cant wait to see this build come together in high res!
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Old 12-13-2012, 11:59 AM   #15
pet3r
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550whp - 530wtq

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Quote:
Originally Posted by xluben View Post
Is that really how the welds look on the Perrin header?

The turbo kit looks nice, but I wish the EWG came off at a shallower angle than 90 degrees.

The other parts and the photos look great!
I'm not overly impressed with the Perrin headers, granted these look like an earlier version...I got them at a great price and they're in really good condition. They are just really lightweight and don't feel substantial.

I agree about the EWG, wish it connected more in line instead of an angle. Perrin's rotated kit pretty much does the same thing though, and I understand from a production/sales pov that its just much easier to do. I don't hear too many people complaining about either design so to me its a wash. But, P&L's method seems a lot more flexible on the install and how the uppipe meets the downpipe, lots of movement available as the dump pump slides in/out and rotates.

Quote:
Originally Posted by 99imprezd View Post
Love browsing these high res studio shots & love new parts. Better copyright those babies before perrin starts usin them for product shots in their catalog. haha. Judging by youre equipment, facilities & compositions im going to guess that youre a professional photographer?.. Excellent shots. My EJ257 build is at a standstill after getting questionable measurements for my piston to wall clearances. ;( Back to the machine shop for re-measurements. Meantime Head cleaning and polishing can resume! Cant wait to see this build come together in high res!
Good luck with the build! I originally was going to reuse my block, but after totaling up the labor and parts, I felt better with going brand new from a highly respected engine builder. Just makes me feel better

Glad you like the photos! While I do make 100% of my living off of photography, the term "professional" photographer is a pretty loose term as lots of people call themselves "pro" just because they've made money from it Also, photo copyright is active the moment you take the photo :P
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Old 12-13-2012, 01:19 PM   #16
99imprezd
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WRB

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Good luck with the build! I originally was going to reuse my block, but after totaling up the labor and parts, I felt better with going brand new from a highly respected engine builder. Just makes me feel better

Glad you like the photos! While I do make 100% of my living off of photography, the term "professional" photographer is a pretty loose term as lots of people call themselves "pro" just because they've made money from it Also, photo copyright is active the moment you take the photo :P[/quote]

Yeah.. I hear ya on the brand new route. I couldnt justify sendin a brand new block off to the machinist to be butchered.. I wanted to go big with the 100mm pistons and got a great low mileage block that needed a borin so couldnt pass it up. I do all the work myself except for the machining part which is best left to the pros.. Besides.. Im also a Full time Professional Designer & Photographer for an aftermarket car company. I dont have time to machine all my own stuff too
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Old 12-23-2012, 10:49 AM   #17
pet3r
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550whp - 530wtq

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She's home! I went down to PSI in the afternoon to pick her up. Archie is an extremely meticulous mechanic and builder and am VERY VERY glad I worked with him. He helped solve a lot of issues that arose with some of the pieces I purchased and made a few custom parts along the way.

Turbo Kit
The rotated turbo kit from P&L had a few issues. The wastegate would hit the factory power steering lines, so the placement of these pipes could have been designed a bit better. P&L says you have to move the lines towards the firewall. No big deal, but I think things could have been designed better. The intake, well, left me less than impressed. It didn't fit between the brake lines and the re-located coolant reservoir. It just wouldn't fit. So we had to fab up a modification to go above it (pics coming), and also welded in some vacuum ports for the AOS, a recirculation port from the BPV, and other vacuum lines (since the P&L was a straight pipe).

Injectors + TGV Deletes
Phatron told me to purchase the Five-O motorsports 1400cc injectors (Delphi). They looked great. At first I bought them with pigtails, as I didn't see a drop-down on their site at the time of purchase to get the plug-and-play adapters. Thankfully they are only 2 days via Priority for shipping so I was able to quickly get them. However, they have these tabs on the side of the injector body that make it so it does NOT slide into the TGV housing. Kind of a pain. So those had to be ground down (I called Five-O and they said its OK to do so). After that they fit pretty well. Perrin fuel rails slid on top just fine.

The Composite TGV deletes are a pretty good piece. Solid build, but very very light. Its basically one BIG phenolic spacer. It had o-rings on top and bottom and looks like it'll hold up well. Once the engine was in, we had a hard time cranking the engine. It seemed it didn't have any power. Archie quickly remembered that the ground connected to the block wasn't reaching the intake manifold because the TGV deletes were plastic. They hooked up a ground to the intake manifold and she cranked right up.

Anyway, cranked her up and it was pure butter. Phatron (Phatbotti Tuning) did an absolutely amazing job. It was a lot of stuff to factor in to the tune, and the car idled smoothly at 1100rpm. NO hiccups on the tune side of it. Let her idle for about 25 minutes after the first crank to inspect everything. NO leaks, which is a relief! Burped the coolant and topped off all the other fluids.

Went on a test drive. I've NEVER had a Subaru engine feel so smooth and perfect before. It felt better than my 2011 WRX the day I bought it off the lot with 15 miles. I'm super impressed with the Rallispec block. It's very quiet (compared to my last motor from RAW Performance that had CP pistons only). It sounds like a dream.

Ran through the break-in from Rallispec and she currently sits with 30 miles on her. Got a lot of break-in driving to do in the next few days

Last edited by pet3r; 12-23-2012 at 10:58 AM.
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Old 12-23-2012, 11:09 AM   #18
99imprezd
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WRB

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sweet.. so im curious what your breakin entails. Seems to be a huge debatable topic im sure alot of us would love to know.. do tell!
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Old 12-23-2012, 11:42 AM   #19
pet3r
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My break-in is what Rallispec told me to do.

Basically it involves 2k-4kRPM revs with light throttle (in 3rd or 4th) with full engine breaking. They say about 10-20 of these. From there you build up the RPM range and progressing to full throttle towards the last few runs (Max boost is 1bar). About 20-30 more pulls, up to 5k rpm now. After each run letting it cool down for a minute or so.

After this is done, then oil/filter change, and for the next 1500 miles keep the RPM under 5500rpm.

It sounds like just about every other builder's break-in guidelines. Basically you want to seat the rings, lots of engine breaking, heat cycles, etc. I'm glad to see they recommend 1bar boost as well
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Old 12-23-2012, 11:54 PM   #20
BoostMasterZero
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308/339 -Tuned by Agile

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Great build so far and amazing photo quality. Keep it up!
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Old 12-24-2012, 01:05 AM   #21
99imprezd
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WRB

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Good to know.. each builder has different break-in procedures they advise... This seems like a slightly harder break-in which im a huge fan of and have had phenominal results wth.. i will definitly take this into account when i get my build in the car.. much appreciated!
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Old 12-29-2012, 03:02 PM   #22
pet3r
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500 miles down and she's been perfect. Spool is very, very similar to my Dom1.5. I'd say it might be spooling to 20psi a hair quicker, but transient response isn't quite as good as the Dom1.5. She's driving pretty well, but the tune is in the very early stages.



Last edited by pet3r; 12-29-2012 at 03:22 PM.
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Old 12-29-2012, 03:44 PM   #23
JordenP
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Great build and awesome pictures! Just out of curiosity what type of driving to do? Wondering why you stayed TMIC on that gtx?
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Old 12-29-2012, 04:16 PM   #24
pet3r
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Just my daily driver...canyon driving and an occasional 1/4 run here and there. Stayed with TMIC for spool mainly.
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Old 01-01-2013, 12:47 AM   #25
pet3r
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First snow of the winter on the mountain, was worth the drive up. Just wish there was a better spot that had more sun. The snow made my car look like a medium gray!

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