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Old 04-04-2013, 12:49 PM   #1
toph
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08 STi SSM 3.5XT-R
15 WRX 6MT Limited CBS

Default 08 STi, Element Tuning, DOM 3.5XT-R, Closed deck, BC 272's, Big valve heads

Edit:

Many things have changed since my initial post. I got a garbage shortblock from Wicked Innovation and a group of guys who just didn't seem to care about my car/build in the least bit. I spent thousands and thousands of dollars with their company and the way I received my car back was completely unacceptable (70% leakdown, CEL, 95-105PSI compression, gauges installed wrong, wheel studs used as plugs in the inlet, dents throughout the car that weren't there prior, 4th gear now grinds occassionally, etc). I went with WI because my thought process was that if they built the block, broke in the motor, and tuned the car, there couldn't be any fingers pointed. Obviously when the issues I had arose, they blamed the 1 variable, the stock heads, which mind you, had no issues whatsoever prior to removal and re-install. It turns out the block ended up warping (who knows why? Tuning? Coincidence? Improper assembly?) and I received new case halves from them after 3 months of waiting, and even threatening a lawsuit. They offered to reassemble the new shortblock but I told them I would pass as I had lost all faith in their abilities and would not feel comfortable selling a shortblock that they assembled. WI had the rotating assembly shipped from their machine shop to my house (instead of a 6 hour round trip drive). It was comical how they packaged it. Basically wrapped everything in packing paper and shipped it, shouldn't have even bothered using anything it was that bad. In turn, this allowed all the pieces to shift around, hitting each other, the ACL race bearings that I bought from them were shot due to this. I decided to have Jay Perry from The Subaru Shop build me the motor with the new case halves and the ~800 mile parts from the previous block. This shortblock will be done soon and ready for sale if anyone is interested

After getting 1 garbage motor, I decided I wouldn't allow it to happen again. I decided to go through Phil from Element Tuning for a complete Pro-comp longblock, ready to be dropped in. I shipped my stock heads to them and 3 months later I had my longblock in my garage, ready to go. I got started with the exhaust manifold and found that the Perrin header would not mate to either of the Grimmspeed Uppipes that I had. After trying to flatten both flanges and get them to sit properly (unsuccessfully), I did some research and found out other people had issues with the GS UP and Perrin header. Personally I would place the blame on Perrin, there were many other issues with the header. I've never had an issue with anything else from GS. After this debacle, I decided to do it right (common trend) and get the KillerB Holy Header. After a 3-week wait I received it, what an amazing piece! Absolutely beautiful. Chris told me that if it doesn't just slip on their 2 shop engines it doesn't ship, no fighting like I did with the Perrin one. He was absolutely correct, it infact did just "slip on".

So overall the build is pretty similar to before minus the whole Element tuning longblock and KillerB header thing lol. I will update the parts list in the near future to reflect the current state of the car.



My name is Chris and I am currently in the process of getting everything I will need to build my 2008 STi (I am picking up the shortblock and most other parts today). The car has 115,000 miles on it and is my current (and future) daily driver. It is stage 2, dynoing 275WHP and 330WTQ and all original down to the OEM clutch. The motor has never been touched! I actually plan on using this shortblock (assuming good compression numbers) in a project car in the future. Me and a good friend of mine will be doing all the work ourselves in my garage! I hope to have everything done within 2 weeks, although most things don't work out as planned, so the end of April is the goal. I will be mostly using this thread as a journal for my own records, but love to hear constructive criticism and ideas.

Goals:

First and foremost this car is my DD, so reliability is my main concern. I put about 20,000 miles a year on the car, and while I do plan on getting a second car, this will be my sole DD for atleast the next six months. I don't do any Auto-x, time-attack, or road courses with this car, the only sanctioned racing it will see is the 1/4 mile a few times a year. That being said, I will be having the car tuned on 93 octane as well as Sunoco 110 octane for a few tanks a year and 1/4 mile passes. The car will be tuned via accessport for the easy map switching, LC, and FFS, it is OS tuned right now, but I prefer the accessport functionality. The WHP/Trap speed goal on 110 octane is high 400's and mid-high 12xMPH trap speeds. It will be tuned by Matt Miner at Dynotech tuning in Seekonk, MA on their Mustang Dyno.

Build:

I have contacted Wicked Innovation in West Kingston, RI to put together the shortblock. I was originally going to use a rallispec block, but when I mentioned that to Matt at Wicked, he said they could build a better block for a better price, I was sold, plus when you have the person tuning your car, build the motor, there are less fingers to be pointed. It will be brand new case halves and all forged parts. Below I will list the details and parts selection:

- Element tuning Pro-comp longblock
- Closed deck EJ25
- OEM heat treated crank
- Manley Pistons 99.5mm
- Element Tuning rods
- ACL Main and Rod bearings
- Element tuning "big valve" heads
- Ferrea +1mm valves
- Ferrea springs/retainers
- Brian Crower 272 DAVCS cams
- ARP Head studs
- KillerB Oil pan
- KillerB Oil pickup
- KillerB baffle
- OEM T-belt
- OEM waterpump
- OEM 11mm Oil pump
- OEM Gasket kit
- NGK 1-step colder plugs
- Blouch Dominator 3.5XT-R 10cm
- Grimmspeed EWG bracket
- KillerB Holy Header
- Tial MV-S 38mm EWG
- TurboXS 2-Piece Bellmouth downpipe
- Maddad Whisper 3" catback
- Grimmspeed EBCS
- Motive auto composite TGV deletes
- TurboXS TMIC DEI gold thermal tape
- Perrin 3" inlet
- Custom intake
- ACT HDSS
- Resurfaced OEM flywheel
- Perrin crank pulley
- ID1000cc injectors
- DW65C Fuel pump
- AEM 3.5 bar map sensor
- GD FPR
- GroupN engine and tranny mount

Non-engine related mods:

- BC Racing BR coilovers
- '11 STi Enkei's
- Racecomp engineering 25MM F/R swaybars
- Kartboy F/R endlinks
- SMY Clustermaker with AEM Wideband O2 sensor and Defi boost gauge

Questions:

I am still unsure what I should do with my higher mileage heads. I was thinking about getting new OEM springs/retainers, or possibly upgrading so I can rev a little higher. I have received many opinions on this, but it is all hearsay in my opinion. Not many people seem to have information for me on higher mileage heads. I am probably going to just adjust them properly and call it a day, but I am open to opinions. The heads I would want are close to $4,000 and right now that is just not feasible. I plan on redoing a few things next season, and built heads will be on the list then (along with rotated turbo, flipped intake manifold and a few other things I have on my mind. My main goal is to just get this up and running as quickly as possible so I can enjoy it for the summer.

Thanks for looking, and here are some pictures to keep interest. I will be updating this as the build progresses, I should be starting it on Saturday!

Chris





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Last edited by toph; 04-29-2014 at 09:57 AM. Reason: Title change
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Old 04-04-2013, 08:18 PM   #2
Boostedbob
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Sounds like a fun build, While my 08 Sti didnt have as many miles as yours does(blew at 68k) I just had the heads resurfaced with new oem valves springs and retainer's. Have not had any issues at all with it.
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Old 04-05-2013, 01:59 AM   #3
allblacksti
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Nice! I have plan on almost the same build on my '05 that has 110k. with Blouch 3.5, Turbo Xs FMIC. 850cc, Walbro Pump 255.
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Old 04-05-2013, 07:10 AM   #4
A-man07
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What will you be driving for the 2-3 months the car is down for the build?
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Old 04-05-2013, 07:54 AM   #5
toph
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Quote:
Originally Posted by allblacksti View Post
Nice! I have plan on almost the same build on my '05 that has 110k. with Blouch 3.5, Turbo Xs FMIC. 850cc, Walbro Pump 255.
Yea it should be fun, I can't wait to get it started!

Quote:
Originally Posted by A-man07 View Post
What will you be driving for the 2-3 months the car is down for the build?
It should be no more than a month (hopefully) and ideally less than 2-3 weeks. It's pretty straight forward. I also have a lift so that makes things much easier. My friend who will be helping me has an 09 Spec B and 02 forester that we will be switching on and off driving.
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Old 04-05-2013, 08:02 AM   #6
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Save your money Nd do everything you want the first time ,it will save u from headaches later on trust me I kno you should get good numbers with that set up its very siniliar to my setup now
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Old 04-05-2013, 09:05 AM   #7
toph
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Quote:
Originally Posted by devyn339 View Post
Save your money Nd do everything you want the first time ,it will save u from headaches later on trust me I kno you should get good numbers with that set up its very siniliar to my setup now
I'm not even sure if I will do the heads and other parts yet, I've never driven a 4xxWHP car so this will be more than enough for the time being. It's not like saying save an extra thousand bucks, everything else would be $5,000 atleast, I want to make sure I'm good with the drivability at this level before I go further.

Want to elaborate on your setup/numbers?
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Old 04-06-2013, 07:13 AM   #8
devyn339
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Blouch dom 3, perrin fmic, perrin inlet, fuel rail, 1000cc injectors, 272 coswprth cams, Manley pistons rods, stock valve train, header uppipe ewg catless dp cat back , 4 bar map sensor aeromotivr high pressure fuel pump, I'm sure I'm missing things , Egr tgv deleted ......
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Old 04-07-2013, 03:45 PM   #9
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sik whip! 272 cams sound so rad too. Thats going be a beast hatch no doubt
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Old 04-07-2013, 04:04 PM   #10
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Subscribed. Looking forward to updates.
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Old 04-07-2013, 08:40 PM   #11
timeXlost
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please update this thread. if i keep the sti the dom 3.5 and dom 3 twinscroll are 2 turbos on my list of possibilities. i cant find much info on either, and matt is my tuner so im very interested in this.


subscribed.
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Old 04-07-2013, 08:55 PM   #12
toph
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Update:

I decided to do a compression test on the 115k mile OEM block (stage 2 for 35k miles) prior to pulling it. Not just because I plan on using it in a project car, but because I was genuinely curious because of how many people talk negatively about these motors. I drive this car, I wouldn't say super hard, but harder than the average owner. The numbers were:

Cylinder 1 - 135
Cylinder 2 - 127
Cylinder 3 - 130
Cylinder 4 - 125

I was pretty happy with the results so the block will definitely be going in a project car in the future.

We started work getting the motor out yesterday around 10PM. We got everything stripped off the long block and around 2:30AM called it a night. Got started this afternoon prying the block from the tranny, and after hammering at it for 45 minutes, we finally got it separated and pulled. This is what my face looked like (yes there are 5 Subaru's in the driveway):



We got all the timing and waterpump components taken off as well as the oil pan and valve covers. We then got to the DAVCS head setup and decided to call it a night. Neither of us have ever worked with a DAVCS head so we were unsure what to do. Decided to do our research to make sure we get it done right the first time without messing anything up. Tomm we should have the heads off and tuesday have them cleaned up and pressure tested.

Quote:
Originally Posted by RallySoob View Post
sik whip! 272 cams sound so rad too. Thats going be a beast hatch no doubt
Thanks man! My tuner recommends just sticking with the stock heads for my goals, so I am going to take his word, they do sound sick though.

Quote:
Originally Posted by ringlander View Post
Subscribed. Looking forward to updates.
I'll try to update as frequently as possible.

Couple pictures:

Coming out



OUT!!

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Old 04-07-2013, 08:58 PM   #13
toph
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Quote:
Originally Posted by timeXlost View Post
please update this thread. if i keep the sti the dom 3.5 and dom 3 twinscroll are 2 turbos on my list of possibilities. i cant find much info on either, and matt is my tuner so im very interested in this.


subscribed.
I will try to as frequently as time allows.

Manitou on here has a Dom 3.5, his is completely different than what I am doing, but even if it's 100WHP shy of his, I'll be super happy. I'll definitely update when it is going to the dyno and maybe you can stop down and check it out if you're in the area.
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Old 04-11-2013, 11:36 AM   #14
toph
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Original motor has been stripped and we are cleaning the heads up today. Hope to get the new block on the engine stand today, and if everything works out right, get the heads bolted on as well.

My turbo came in yesterday from Blouch, ordered on Monday and here on Wednesday, they build to order as well. Pretty happy with the turn around time.

Bolted up the front mount last night (looks awesome) and installed my Kartboy short shifter and Group-N tranny mount, both very straight forward installs.

If everything goes according to plan, I hope to have the motor in and everything together on Saturday. As soon as it's done, I'm trailering it to Wicked Innovation for them to make me a custom intake and tune the car.

What I'm driving while my car is being built:



Engine mostly disassembled on the stand:



Heads:



Front mount bolted up:


Last edited by toph; 04-11-2013 at 11:54 PM.
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Old 04-11-2013, 10:09 PM   #15
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Subscribed
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Old 04-12-2013, 06:25 AM   #16
devyn339
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While the motors out do this !
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Old 04-12-2013, 07:11 AM   #17
toph
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Looks okay, but it's not me.
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Old 04-12-2013, 07:24 AM   #18
devyn339
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I like the clean look
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Old 04-18-2013, 03:24 PM   #19
sysco
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ide get the heads checked out for good measure. shouldnt be anything wrong with them.
i have a similar setup but with bc 280 cams and made 430. should be fun! recommend valve seals. Note turbo pulls strong all they through 8k for me at least.

Last edited by sysco; 04-18-2013 at 03:31 PM. Reason: added stuff
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Old 04-18-2013, 05:42 PM   #20
toph
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Well the longblock is assembled and in the car! Tonight I will be attaching all accessories and if everything goes as planned, starting her! It's been a long(er) process than I anticipated, but I see the light at the end of the tunnel and I am pumped. If she starts tonight I am dropping her off to get tuned tomorrow!
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Old 04-24-2013, 12:02 AM   #21
toph
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And she runs! Dropping her off at Wicked Innovation tomorrow to get a few finishing pieces and a tune. I will do a better update when I get a chance, it has been 18 days of endless work, but it will all be worth it soon.
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Old 04-28-2013, 09:14 AM   #22
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Any updates?
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Old 04-28-2013, 09:25 AM   #23
toph
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At the shop currently. Getting a few things finished up and waiting on dyno time.
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Old 05-12-2013, 02:45 PM   #24
toph
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The car is up and running well! I had some issues getting it to start after the initial startup. Wicked Innovation has it currently, doing the break in and some road tuning and hopefully this week we can get some dyno time and I'll have her back!

The starting issues were related to the DW fuel pump we installed so WI sorted that out as well as some vacuum issues. They have been great. While it has taken longer than I anticipated I am very happy with everything they have done so far, just can't wait to get the car back and put some miles on.

I will be running the car at Lebanon Valley Dragway within a couple weeks of getting her back and some miles on the motor. Hoping for low-mid 11's on pump gas. The week after I will bring it over and run it on race gas. Shooting for Low 11's, although I doubt I have the skill to drive it to that ET. Trap speed is my main concern, looking to get in the low-mid 120's.

I had to opt for the TurboXS TMIC I had on the car prior to the build. I bought a used Perrin FMIC from someone and didn't realize that the WRX and STi intake manifold was that much different. I have it for sale, although if it doesn't sell I will just use the core and buy new piping from Perrin either later this year or early next.
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Old 05-14-2013, 02:14 PM   #25
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Quote:
Originally Posted by toph View Post
The car is up and running well! I had some issues getting it to start after the initial startup. Wicked Innovation has it currently, doing the break in and some road tuning and hopefully this week we can get some dyno time and I'll have her back!

The starting issues were related to the DW fuel pump we installed so WI sorted that out as well as some vacuum issues. They have been great. While it has taken longer than I anticipated I am very happy with everything they have done so far, just can't wait to get the car back and put some miles on.

I will be running the car at Lebanon Valley Dragway within a couple weeks of getting her back and some miles on the motor. Hoping for low-mid 11's on pump gas. The week after I will bring it over and run it on race gas. Shooting for Low 11's, although I doubt I have the skill to drive it to that ET. Trap speed is my main concern, looking to get in the low-mid 120's.

I had to opt for the TurboXS TMIC I had on the car prior to the build. I bought a used Perrin FMIC from someone and didn't realize that the WRX and STi intake manifold was that much different. I have it for sale, although if it doesn't sell I will just use the core and buy new piping from Perrin either later this year or early next.
Glad to hear man. A little advice. Sounds like you're a drag racer. I'd spend the extra dough and get that IC piping, unless you plan on throwing bags of ice on that IC after every run..this is what I had to do.
The reason why I say that is after drag runs, in the staging lane, the heat will rise from the block and heat soak the ever living crap out of that top mount. Car will stop adding timing and retard it due to the high intake air temp, as a result trap speeds will fall and consequently so will your ET.

Also, it's good to get some pressure on those rings with some road/dyno tuning like you're doing, but i'm not sure if i'd go beating the balls off of it just yet. Get some seat time with that clutch and the new power band of that turbo before you take her to the track. Do a few oil changes, more than normal, before she gets to the track and see's higher RPM for extended amounts of time. You want those rings to seat nice with minimal engine wear.

Good luck!
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