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Old 02-03-2013, 10:29 PM   #1
jtrakel
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Member#: 242647
Join Date: Mar 2010
Chapter/Region: NWIC
Location: Lacey, WA
Vehicle:
04
PSM

Default jtrakel's 04 sleeved Full Race Twin Scroll GTX3582 build

I’ve always looked through other peoples build threads and have finally decided to start my own. I wish I’d taken more photos along the way but no going back now! Here is my 2004 STI it has gone through a few “face lifts” I bought the car stock minus the wheels, coilovers, and exhaust. Almost all the work has been done myself with the help of a few friends. My car should finally start in the next few days and I can start on my break in miles. I have a power goal of 550whp on E85. I have no idea why I wanted to push my car this far but hey I’m here now! The last set-up I had on before made really good power but I knew it would not last with a stock block everything was tuned on speed density from Mike at PIA running E85. I owe so many thank you's to Mike for the countless hours he has spent on the phone answers questions and coming in during non-work hours! Also many thanks to the rest of the crew at Pacific Import Auto a true family ran live up to their word shop!




Old set-up:
Garrett 3076R .63ar
TIAL 44mm EWG
Rotated STI manifold with A/C delete
Turbo XS FMIC
Rotated manifold piping black w/crushed glass
TGV deletes
Mishimoto race radiator
Mishimoto 170 degree thermostat
Perrin fuel rails w/steel braided lines
FIC 1100cc top feed High-z injectors
Walbro E85 400lph in tank pump
AEM fuel pressure regulator
HKS titanium axle back
Race Ready electronic exhaust cutout welded into downpipe
Crawford V2 A/O seporator

Car made 470whp and 438tq with my cut-out open not to shabby for a stock block on E85!




Now time to move on to what I'm currently working with I'm going to add photos of the build process after the specs hope you all enjoy. I cannot wait to get this thing back on the dyno after the break in!

I picked up the block already sleeved and o-ringed from a member on here, once everything arrived it went to the machine shop to get the sleeves inspected and bored to fit the pistons. I decided against doing any type of head work because I do not spin out my motor very often. I understand that with a larger turbo I will be in the higher RPM range. The GTX35 is a trial more or less ff I do not like the spool time etc. I will pick up a GTX30 and tune off that. I got a great deal on the 35 which is the reason why it's installed.

Current set-up:
Go fast
Darton sleeved EJ257 bored to 100.5mm
CP 100.5mm pistons
Manley Trubo Tuff "I" beams
OEM forged heat treated crank
Clevit main and rod bearings
A1 Technologies H11 Head Studs
Fluidampr crank pully
GSC S2's 272 cams
GSC behive springs and retainers
OEM intake and exhaust valves
Blueprinted 11mm Sti oil pump
Balanced rotating asseymbly .01 grams
Rotated STI manifold with A/C delete
Gates racing timing belt
New water pump, pulleys, blah blah blah
Turbo XS FMIC
Custom Rotated manifold piping originally done to keep AC but that's gone now
TGV deletes
Mishimoto race radiator
Mishimoto 170 degree thermostat
Aeromotive fuel rails with custom steel braided lines all -6 AN fittings
FIC 2150cc top feed High-z injectors
Walbro E85 400lph in tank pump
AEM fuel pressure regulator
Full Race twin scroll rotated piping
GTX3582 w/ 1.06ar
twin 38mm TIAL MV-R waste gates with 14psi springs
invidia Race exhaust
Killer B oil pickup
Killer B oil windage tray
killer B oil pan
Crawford V2 A/O seporator
Other random custom bits througout engine bay (alaskan amber bottle, patrone bottle)

Handeling/XMSN
Rota Torque 18x10
BFG Sport Comp 2 255/40/18
Sitting on some ****ty K-sport coilovers
Perrin 23mm front and rear sway bars
Rallispec pillow ball front and rear end links
Whiteline steering rack bushings
Whilteline rear subframe lockdown bolts
Whiteline shifter bushing (front and rear)
Whiteline "race" anti-lift kit
Excedy twin disc performance clutch
Kartboy transmission crossmember bushings
TQ solution transmission bushing
TQ solution pitch stop
Group-N transmission mount
Mike T. custom spec motor mounts
Some sort of XXR wheels with some ****ty tires
EBC slotted and dimpled front rotors
EBC red stuff front brake pads
Stainless steel brake lines
COBB short throw adj shifter
1 1/2lbs shifter ball (mobile weapon!)

Electronics
Defi BF series- boost, EGT, oil press, oil temp, water temp, and fuel pressure (all imperial)
Inovations wideband o2 sensor


Starting assembly


installing the O-rings


Some killer-b love


Mock up for my custom fuel lines (wife choose colors)



How she sits right now!
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Last edited by jtrakel; 10-16-2013 at 07:34 PM.
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Old 02-03-2013, 10:43 PM   #2
WhatTurboLag?
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Very nice I want to see how reliable this will be!!!


I like the coolant lines
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Old 02-03-2013, 10:43 PM   #3
TheColorCute
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Looks great! Can't wait to see what it puts down!
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Old 02-03-2013, 10:49 PM   #4
snake32
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looks like it's gonna be fast dude! i'm putting a bone stock 04 sti longblock in my car this week, shooting for 400whp on the perrin rotated gt3076r .63, it's php and have the same injectors, last time i couldn't go that far on the E85 bc of the fuel pump, wondering how hard is to install the walbro 400 in place of the stock one?
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Old 02-03-2013, 11:00 PM   #5
jtrakel
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Quote:
Originally Posted by WhatTurboLag? View Post
Very nice I want to see how reliable this will be!!!


I like the coolant lines
Thanks it should be very reliable it's not a daily so the beatings will not be frequent for the most part after the initial break-in miles.

Quote:
Originally Posted by snake32 View Post
looks like it's gonna be fast dude! i'm putting a bone stock 04 sti longblock in my car this week, shooting for 400whp on the perrin rotated gt3076r .63, it's php and have the same injectors, last time i couldn't go that far on the E85 bc of the fuel pump, wondering how hard is to install the walbro 400 in place of the stock one?
I totally forgot to mention I'm running E85 I ran it on the last set-up as well will edit OP

Last edited by jtrakel; 02-03-2013 at 11:11 PM.
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Old 02-04-2013, 09:36 AM   #6
Ballistic1350
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Is that the stock header I spy? how come?
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Old 02-04-2013, 09:47 AM   #7
jtrakel
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04
PSM

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It has a grimmspeed x-over pipe. I was never a fan of the way some aftermarket exhaust manifolds sound or I have not found the right one yet. But the OEM halves did pretty well with my last set-up so ill run them until I find something better.
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Old 02-04-2013, 10:32 AM   #8
jtrakel
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04
PSM

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Quote:
Originally Posted by snake32 View Post
looks like it's gonna be fast dude! i'm putting a bone stock 04 sti longblock in my car this week, shooting for 400whp on the perrin rotated gt3076r .63, it's php and have the same injectors, last time i couldn't go that far on the E85 bc of the fuel pump, wondering how hard is to install the walbro 400 in place of the stock one?
hand tools will take care of the fuel pump swap it's a drop in replacement!
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Old 02-04-2013, 10:13 PM   #9
fastblueufo
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02 billet crank
pauter rods, pt5857, E85

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I love your build. Almost exactly like my new build minus the sleeves and o-rings. I've got an ej22t being sleeved and o-ringed now. What type of o-rings? O-ring heads and block or just block? What type head gaskets are you using?

If you don't like the spool of the 35r (I didn't) look at the precision 5858. On my ej22t it put down over 450 at just over 25 psi. I've got it on a 2.5 hybrid now and it hits 20psi at 3900 rpm and still puts out old 35r numbers. I see your using the gtx 35 so you may like it better as its supposed to be a better spooler than an original 35r.

Great build man. Congrats!!!
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Old 02-05-2013, 12:34 AM   #10
jtrakel
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Quote:
Originally Posted by fastblueufo View Post
I love your build. Almost exactly like my new build minus the sleeves and o-rings. I've got an ej22t being sleeved and o-ringed now. What type of o-rings? O-ring heads and block or just block? What type head gaskets are you using?

If you don't like the spool of the 35r (I didn't) look at the precision 5858. On my ej22t it put down over 450 at just over 25 psi. I've got it on a 2.5 hybrid now and it hits 20psi at 3900 rpm and still puts out old 35r numbers. I see your using the gtx 35 so you may like it better as its supposed to be a better spooler than an original 35r.

Great build man. Congrats!!!
Thanks I'm looking forward to starting it I thought it was going to turn over today but my tuner was not able to make it to my house. We are not sure how it's going to idle with those huge injectors so I'm just waiting on him so he can do his magic! I only have the block o-ringed the heads have not been touched at all minus the valve train. I used a 18 gauge bare copper wire and we just tapped it into the groove and made sure it had a good amount coming out the top so it had some good "squishing" with the head gasket. I used OEM head gaskets as well no need to do anything crazy!



I've looked at other turbos but we will see how this GTX35 works I'm hoping it makes me happy because otherwise it will bug the crap out of me until I find something different!
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Old 02-05-2013, 02:43 PM   #11
spintheground
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02 MR2 EGM

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Very interested in results, subbed!
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Old 02-13-2013, 11:49 AM   #12
spintheground
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Update on this?
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Old 02-13-2013, 12:48 PM   #13
jtrakel
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PSM

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Sorry I've been busy! It's running ill take a video later and some photos but I'm about 600miles into my 1k break-in period. Everything is looking good so far hopefully ill be on the dyno within a week!
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Old 02-13-2013, 12:52 PM   #14
spintheground
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02 MR2 EGM

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Awesome, can't wait to see your results!
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Old 02-17-2013, 02:27 AM   #15
NSFW
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Location: Near Seattle, WA
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05 Stage Free LGT
ATP 3076, 6MT, AVO FMIC

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Cool project! Looking forward to results...
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Old 02-18-2013, 06:06 AM   #16
Black07STiGuy
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Location: Reno, NV
Vehicle:
2008 WRX Josh Tuned
VF39+JoshTune=330hp/350tq

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Man I miss WA. Mike, Steve and all the guys at PIA are awesome. I remember just going there and watching them do their magic. They taught me a lot about the platform, and even explained install instructions over the phone for small things when they could have had me come in and pay them to do it. Awesome guys. Good luck on your full tune, hope you reach your goal.
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Old 02-18-2013, 09:49 PM   #17
jtrakel
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ya the shop is great I'm hopefully going to tune this week I finished up my break in miles this past friday!






Last edited by jtrakel; 02-18-2013 at 09:55 PM.
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Old 02-18-2013, 10:48 PM   #18
shadowmd
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2.5 hybrid 367whp/363wtq

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I like the cluster! Black outlines around the gauges!! Not to mention the sick build!
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Old 02-18-2013, 11:07 PM   #19
jtrakel
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Quote:
Originally Posted by shadowmd View Post
I like the cluster! Black outlines around the gauges!! Not to mention the sick build!
Thanks I forgot I did that! It's like a re-discovery!
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Old 02-18-2013, 11:09 PM   #20
shadowmd
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2.5 hybrid 367whp/363wtq

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Quote:
Originally Posted by jtrakel View Post

Thanks I forgot I did that! It's like a re-discovery!
Lol you've inspired me to do that. Weekend project! Haha
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Old 02-26-2013, 09:16 PM   #21
jtrakel
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Well just a update for anyone that was/is following this thread I was just told a few days ago that I will be leaving home for a few months so the car has to wait. I've been so busy I have not had time to install my new 11mm oil pump and get it tuned so now I must wait! I did have it professionally detailed yesterday though so at least it will sit looking pretty! Well talk with you all later! I hope to have some amazing numbers on the dyno when I get back. Sucks that my car is running so well and I'm so close to being done with this phase that I have to wait now! I'll depart with some current photos!



And just because!
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Old 02-26-2013, 09:37 PM   #22
john 1badSTI
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on e85@ 30psi--spinning

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Are you going on a duty trip?
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Old 02-26-2013, 10:43 PM   #23
jtrakel
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Quote:
Originally Posted by john 1badSTI View Post
Are you going on a duty trip?
Yes I am to the wonderful land of Afghanistan
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Old 06-19-2013, 11:36 PM   #24
jtrakel
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Some major updates have happened since my last post. I got back from overseas in May and have done a few new things to the STI. I started tuning about 3 weeks ago and ran out of time at the 511whp range on a Mustang dyno.

Since last update one of my best friends died 2 days after my return home he was in the process of building a identical motor that I have. But with a different turbo set-up. He went with a Full Race twin scroll 3582 1.06ar. So now the car is going to his long time girlfriend and we are building the original motor for a good daily 400hp car. So with that I inherited the twin scroll set-up. I kept my GTX 3582 and I'm now using the 1.06 hot side. So i'm going to get more power than originally planned!

Now the down side of it all I'm currently working through a misfire/ cylinder number 1 roughness. I've done every single trouble shooting thing I possibly can. This up coming friday I will be removing the valve covers to check clearances to rule out any type of mechanical problems. Trouble shooting that I have done so far is as follows: compression was 130 on all cylinders, leak down was less than 5% on all cylinders, swapped, checked gap and changed spark plugs from 1 step colder to normal NGK, swapped injectors from 1 to 3 from 1 to 4 etc., swapped coil packs in the same fashion that I did with the injectors, verified timing 2 separate times, replaced cam sensor, ensured cam gears do not have any type of chipped, bent, messed up teeth, and my tuner has looked through the tune as much as he can adjusted fuel, timing, tip in's and all sorts of other things that I don't exactly understand

So pending what the valve clearances show I'm not sure what the hell else to look at. I'm running speed density so it's not a MAF issue I have a stock flywheel so it should not be that either, I have a fluidamper pulley as well. If the valve clearances check out I think we are going to just go with it.

I should probably give a situation first but I'll do it now. The cylinder roughness only happens on #1 and never has a count while under boost. While in gears 1-4, if I hold a sustained RPM around 2-4.5k it will start counting like crazy all the way to 100 and start over again. 4th gear tends to be the worst for whatever reason so I drive in 5th whenever I do actually drive the car. If I do a hard 4th gear pull with my old set-up from around 2.5-7k no misfires but after pushing in the clutch the check engine light will blink at me anywhere between 5-15 times. From my understanding its the ECU telling me I'm having some misfire issues. You never feel a misfire at any point in time during all this process The check engine light also does not stay on due to all my misfire codes being disabled at the moment. A audible misfire is periodically herd at idle but you cannot feel it in the car at all. I've recently decided to swap around some 02 sensors as well. With a brand new out of the box 02 sensor it does it's normal thing with all my issues as stated above. When I use a old one I have laying around (it's broken) it throws a P0031 code within about 5 minutes of starting the car. Before the ECU detects the bad sensor my misfires do what they have always done, BUT once the check engine light goes on it no longer registers a rough count no matter what I do to the car. WTF!?

Pheww so once I get this figured out I'm going to tune this car and hopefully make it to the 600 club I have the equipment to do it. Other items I've changed since last post is my wheel set-up I went with some crappy rota's 18x10 though to get some more meat on the ground 255/40/18. Now onto some recent photos the black STI is my friends that passed away on May 5th love you Nick!






Last edited by jtrakel; 06-20-2013 at 10:28 AM.
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Old 06-20-2013, 06:42 AM   #25
StIGC11
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2006 SGM BW88-75
E85

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I would try a leak down and compression test if you already havent. I run into the problem of having cylinder rough at idle with those injectors on 92oct with anything above 13.0afr however cruising and WOT are fine (has nothing to do with this but yea).
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