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Old 12-19-2012, 03:47 AM   #1
Zefy
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Location: Coquitlam, BC, Canada
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1979 BRAT / 01 RSTI
99 2.5TS (DEAD)

Talking Zefy's RS Build thread!

Now that I have been driving the RS for a bit and the part out is well on its way on the TS, I think it would be nice to share.

So I'm pretty sure everybody knows this car from its previous owner. Here is a quick pic I took just now.



The basics... it's a 2001 RS. Has just over 200k km's on it and it is in SUBSTANTIALLY better cosmetic shape than my old TS. It has some nice upsides like a wrx transmission (05) a bunch of mounts, and a nice interior. Unfortunately, this motor suffers from crank walk. I hadn't really noticed this problem until I really romped on it... Now when I slam on the brakes going down hill, the clutch pedal sinks to the floor. The crank is moving back and forth...

Luckily, I have a replacement! It doesn't look like much, but it's a 2003 RS engine that I got "new" and used it for ~55k km in the TS. Been a fantastic motor, but there is some questionable things about it in the bottom end.



So I went out and got this! 2011 sti shortblock with 32000km's on it.





I just got it home from squamish along with some sti head gaskets and some other bits.

I also went and got a complete-ish AVO 320 turbo kit... (most of it not pictured... lots of stuff, just some shiny bits for pictures)



Still a few more things to get and I need to get this damn thing out of the garage so I have the smallest of spaces to work. Poor rusty TS.



I also had this surprise when I pulled the engine out of the TS. Now I know what the clunk was...



So here is my plan! Make an entertaining car with a set budget. (undisclosed, because I'm probably going to blow it...)

-ej257 block w/ stock pistons and sti head gaskets
-SOHC ej253 heads
-AVO turbo kit with the 'stock' 5psi WG spring to start. Will work towards ~12psi.
-PP6 piggyback computer with a 5th injector (this is how the new AVO kits work)

This piston/head combo should give me about 9.16:1 compression ratio.


This, along with all the other fun bits I had on the TS, should make this an entertaining vehicle. Will update as I go.
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Last edited by Zefy; 02-07-2013 at 04:09 AM.
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Old 12-19-2012, 11:26 AM   #2
rs420
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That looks like its gonna be a cool build
I love the project, couple questions:

How come your going with a STi short block & sohc ej253 heads?
I dont know enough about the different pairings, would ej205 heads be better?
would it also involve more wiring? or...?

Im stoked to see you get it in there, should be sweet. The AVO turbo kit has great spool so it should be tons of fun
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Old 12-19-2012, 01:00 PM   #3
KootenayWRX
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Neat build, Lets see what happens.
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Old 12-19-2012, 01:19 PM   #4
Cranker625
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NICE!
I love seeing well-loved RS's get a second lease on life.
And it usually end up being even better than the first time
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Old 12-19-2012, 01:25 PM   #5
Zefy
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Quote:
Originally Posted by rs420 View Post
That looks like its gonna be a cool build
I love the project, couple questions:

How come your going with a STi short block & sohc ej253 heads?
I dont know enough about the different pairings, would ej205 heads be better?
would it also involve more wiring? or...?

Im stoked to see you get it in there, should be sweet. The AVO turbo kit has great spool so it should be tons of fun
SOHC to avoid rewiring everything and I have lots of SOHC heads.

The SOHC heads actually have some impressive flow numbers so I'm not to worried about losing any power because of them. Parts for SOHC are cheaper and they're super easy to work on. For instance, changing spark plugs is a 10 minute operation TOPS. Timing belt can be put on by one person, with no special holding tools, without to much grief.
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Old 12-19-2012, 02:03 PM   #6
kgb
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I wonder about the head gasket issues that seems to plague the SOHC motors - almost everybody has been through it and RR says it's a design flaw. Have fun with the build!
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Old 12-19-2012, 02:28 PM   #7
pope_face
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Right on, I'm excited to see it built... Looks like a great project. Makes me (almost) wish I had time/money to build a new engine.
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Old 12-19-2012, 05:54 PM   #8
alexinvancouver
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quite a project but i'm sure You can do it
after building a Brat You can do anything! =o)
if You need a set of used OEM engine/tranny mounts i have a set for You free of charge
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Old 12-19-2012, 07:10 PM   #9
Zefy
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Quote:
Originally Posted by pope_face View Post
Right on, I'm excited to see it built... Looks like a great project. Makes me (almost) wish I had time/money to build a new engine.
Speaking of money to build a new engine...........

Quote:
Originally Posted by alexinvancouver View Post
quite a project but i'm sure You can do it
after building a Brat You can do anything! =o)
if You need a set of used OEM engine/tranny mounts i have a set for You free of charge
Thanks for the offer! Ken's (i keep calling it Ken's... but it's mine...) RS already has group N engine and trans mounts so I should be good.

The one that is broken was an OEM mount with only 50k km on it. Next time someone is deciding whether or not to get upgrade mounts, tell them it's worth it. I figured brand new OEM would be fine... I was wrong.

Hoping to get some work done today as the power was out at work so I went home early. See what I can get done.
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Old 12-19-2012, 07:23 PM   #10
pope_face
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Quote:
Originally Posted by Zefy View Post
Speaking of money to build a new engine...........
Lol, I was just about to email you...
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Old 12-20-2012, 07:12 PM   #11
minifreak
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Looks like a sweet build!
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Old 12-21-2012, 01:12 AM   #12
FunkMasta
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its an 04 5mt, not 05.


can't wait to see it with turbo!
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Old 12-22-2012, 05:53 AM   #13
Zefy
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alright so there are two things I'm trying to work through with the turbo setup.

Issue 1: the avcs port on the ej257. It's got this stupid breather right where my coolant crossover pipe needs to go. I can either plug the port and get the proper sti crossover (113 bucks from SGP) or I can tap it out and put in a flush plug. Kinda leaning towards option 2 as a plug is 50 cents and I have everything to do it. Just don't want metal shavings in my block!

issue 2: because I'm upping the boost from the stock AVO kit, the piggyback doesn't really work that well. The AVO kit you can buy today comes with a perfect power 6 piggyback and it has a 5th injector installed in the intake manifold. My AVO kit is old and actually has a link g1 ecu which is a standalone that is running in parallel with the stock ECU. This link is OLD. It comes with a controller with 6 buttons on it and a little LCD screen. I would prefer to not use this.

The 5th injector design is simple because it only is active when you're on boost. When you're not boosting, the stock ECU is doing everything. However apparently once you exceed 8psi or so this method tends to leave to fuel starve on certain cylinders and pig rich on others. I find it hard to believe this is actually true because the injector is in the intercooler. This 5th injector does seem a little hokey band-aid fix.

However MY avo intercooler does NOT have a 5th injector. The pp6 apparently does not like running larger than stock injectors without the injector driver module. This I can no longer find as it was a rallitek item and they don't seem to do this kind of thing anymore.

So I can either add a 5th injector and have mild levels of risk associated with it and spend about 100 bucks getting everything to add it to my intercooler. Or I can try and find this injector driver for the pp6 for about 80 bucks and run wrx 440's which are super cheap and have a fairly safe system.

OOOOR I can sell all of the piggyback stuff (link and pp6) and try and get a PnP hydra or something. REALLY blowing my budget up...
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Old 12-22-2012, 03:23 PM   #14
FunkMasta
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wrx injectors sound like a better idea to me....
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Old 12-22-2012, 08:10 PM   #15
alcoolaid
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+1 on bigger injectors
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Old 12-22-2012, 08:21 PM   #16
Drakar
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Vipec standalone with antilag.

Or 80 bucks for the driver either works
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Old 12-23-2012, 12:30 AM   #17
Zefy
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If vipec made a pnp harness for the rs I would seriously consider it. Only one I've found that does is hydra and they are more than a vipec it seems... Maybe in a couple years I will do a wire in, but for now I'm sticking with a piggyback.

Just went and picked up a greddy emanage ultimate! Mildly less intrusive than a standalone because I should still be able to go through air care with it if I need to. It should also have no problem running larger injectors.

More than I wanted to spend, but if I sell the pp6 and link it shouldn't be to bad.

So wtb wrx top feed injectors!
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Old 12-23-2012, 04:41 AM   #18
REED FLEMMMMING
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I'd have to check but I'm sure I got some with rails off an 02-04 you could have for...I dunno maybe a couple bends of a tube
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Old 12-28-2012, 12:31 AM   #19
Zefy
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Thanks for the offer Josh! I found some more local though...

Went and picked up a bunch of fittings, hoses, exhaust flanges, that my 'complete' avo kit didn't come with. This is the kind of stuff that adds up quickly for ANY build. Even if it did come with a lot of this stuff that I bought, I would still be replacing it just for safety sake.

Got my custom oil feed line made and PROPER fittings to make it thread into one of the galley plugs.

Also got a walbro fuel pump and my greddy emanage ultimate piggyback. Ordered the 'greddy' 4 bar map sensor for the more boosts! Annoying that the ecu cannot accept different map sensors. I have a GM 3 bar sitting right in front of me. Apparently it cannot rescale for different sensors.

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Old 12-28-2012, 01:15 AM   #20
REED FLEMMMMING
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Right on good to hear. Lucky guy, when I gotta find parts I can never find them local.

Recently I got the rob tuned ecu with the 550 yellow sidefeed sti injectors. Found a td05-16g and an old slanty intercooler in edmonton for cheap as well. If your setup isn't ready for the 20th I'll have to take you for a spin. A second gear pull will definitely inspire you to get your new em up and running
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Old 12-30-2012, 10:22 PM   #21
Subaruman5
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Looking good Greg. Keep it up.
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Old 01-10-2013, 02:41 AM   #22
Zefy
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so it seemed like a good idea at the time... Pretty sure it still is...



Car is pretty light when you cut it up into pieces... Moved that one by myself...

And these...



So that car is done for... Lots of stuff still available... let me know what you want... Moving on...

So I have been slowly collecting parts and also researching everything. I thought I had figured out what kind of turbo I have. I eventually dug far enough that I have no idea now. I THINK this turbo is a gt25r but there seems to be different versions of this thing kicking around and it's a 'hybrid' that AVO concocted on top of that.

I thought it was a gt2871r but upon further research, only the NEW avo kits use this. And it was pointed out to me that my oil feed line to the turbo was big. Journal bearing big... Well AVO has never sold a JB turbo with their kits so I know it's BB. Then I found this:

http://www.atpturbo.com/mm5/merchant...gory_Code=GTBB

Quote:
1/4" Inverted Flare to 4AN Male to Male, 1/4" inverted flare to 4AN male to male fitting. Unrestricted version of the ATP-OIL-021. Does not have .035" restrictor. Appropriate for non-ball bearing T25/T28 turbo use. CAn also be used on GT25R, GT28R, GT28RS, GT30, and GT35R where not restrictor is needed.
That is what came with my turbo. GT25R? GT28R? I unno... No markings on the center section. Some on the hot size... You look and tell me... Probably going to take it to a shop and have them look at it anyway, but place your bets...?









I also started messing with the fuel injectors... Some people's idea of 'drop right in' are different... WRX 440's DO NOT just drop right in... Not well enought to make me feel comfortable using them with what I have at least. The o-rings were looking kinda tired and one was cracked on the wrx injectors. I also need to cover up the air injection port for the 'air assist injectors' that RS's have. I could use my old TS manifold but I opted to use my new RS one.

So I did more hunting and found out rallitek in oregon used to sell o-ring kits for doing just this swap! Phoned them up, and they still had them. They're waiting for me in point roberts right now.

Messing around with injectors...

The two installed side by side... Long one is the RS...


And one rail mocked up... waiting to get the o-rings...


EDIT: Almost forgot... I also installed my AVCS vent block plug... Turned this up on the lathe and woo hoo my SOHC coolant crossover fits on an AVCS block! Made it a fat flange so it sits under the crossover so if it ever budges loose, it will hit the crossover before popping out. This is a very nice press fit and I'm quite please...



More to come.

Last edited by Zefy; 01-10-2013 at 02:51 AM.
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Old 01-10-2013, 10:46 PM   #23
Zefy
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99 2.5TS (DEAD)

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yay more parts.

TiC super sexy rear end package and grimmspeed header, uppipe, and downpipe gaskets. Made a mistake though... That downpipe gasket is the wrong one. You were right chris!

I thought I had chosen correctly but oh well... it's now FS. Not worth shipping back to touge for the 19 bucks. Will order the correct one ASAP.

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Old 02-05-2013, 01:32 PM   #24
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Any updates? Did you get the o-rings? If so, could you snap a picture? I can't seem to find a picture of them anywhere on the net. I would just like to see what they look like compared to stock.
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Old 02-06-2013, 10:29 PM   #25
Zefy
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99 2.5TS (DEAD)

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Quote:
Originally Posted by akfmx View Post
Any updates? Did you get the o-rings? If so, could you snap a picture? I can't seem to find a picture of them anywhere on the net. I would just like to see what they look like compared to stock.
I haven't taken any pictures yet but for reference the 'kit' is just 8 orings that are (as far as i can tell) identical to the fuel rail oring for the RS injector.

I will post an update soon!
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