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Old 05-24-2013, 08:48 PM   #1
sysfailur
Scooby Specialist
 
Member#: 135993
Join Date: Dec 2006
Chapter/Region: Tri-State
Location: Lehigh Valley, PA
Vehicle:
08 AW STi GTX3071
V-Mount, 18x12, 335 R888

Default 08_AW_GRB: GTX3071R, V-Mount, 18x12 Forgeline, Meats, Auto-X Purpose Built



Alright NASIOC I've decided to finally post up my car's journey on here for the first time in full. I've been on IWSTI continuing updates there but figured I would consolidate and re-post over here giving you the meat of my build. I have a 2008 Aspen White STi and at around 44,000 hard driven miles during an auto-x run my 3rd piston decided it wasn't going to work any more. So, the car sat for a little while I figured out what I was going to do. Initially I was just going to buy my friend's shortblock, put it in, and be done with it but as it often happens, I went balls deep instead.

My goal for this phase of modification was to make a nearly indestructible auto-x engine with extremely quick response and the ability to rev and boost high with all safety measures taken to ensure the engine will survive. Yes my hotside is small but it's v-band and there are .82 and 1.06 waiting to be used for other applications. What this phase of my car's life entails is power from down low (hopefully ~3300-3500) revving out to 8200 or so safely in 2nd gear with the best response possible. I plan to eventually do further weight reduction, add a cage, strip it down, etc but as of now I'll retain my interior and keep it somewhat streetable.

5/24/2013: Where my car is at now is most fabrication is done and the last parts can not be modified until the engine is back in, the exhaust is back on, and we can route all the plumbing and mount everything. I also still need to purchase my wheels/tires/flares but those will come in time. I'm selling my current wheels to help the purchase of the new setup.... and I'm going BIG.

When will it be done? Not sure. When time/money allows for it to be done! I'm taking things slowly and properly and not cutting important corners. This is my dream car and I'm doing it the way I want! You may notice I don't have a single exterior mod done for looks.... every time I think about buying something I then think... "but it doesn't do anything" and nix it and buy something related to safety, power, or handling. It's just the way I am.... I doubt I'll ever get a Varis body kit for $10K--it's just not for me.

Finally, big thanks to Ryan @ Area 1320 for the build guidance, advice, and fabrication! I've done what I can that are within my abilities but Ryan is the master and will be doing tricky stuff. Also thanks to Adam for pulling the engine with me and helping wield a grinder in a way I have yet to master. And of course, never-ending thanks to my girlfriend for understanding my obsession with my silly, noisy, uncomfortable car that makes her sick when she gets rides in it lol

Thanks also to Toyo and Forgeline for jumping in with sponsorships for this build. My budget isn't massive so the help I've gotten from them is greatly appreciated.

Questions/comments welcomed. Enjoy!

EDIT:
************************************************** *******
What remains to be done as of today:

*Start final assembly/installations/fabrication.

*Front end reinforcing via custom bumper bar.
*Radiator bung modification for -20 AN.
*Fab Intercooler piping + intake piping
*Bungs in downpipe
*Exhaust cut-out install
*Exhaust cut-out side exit... something special in the works
*Add v-band flange to axleback exhaust
*Touch up pie-cuts on inside of downpipe
*Mount accusump + route ss hose to front
*Mount battery in trunk + route electric
*Mount all oil and fuel components + lots of plumbing
*Top off all fresh fluids
*Sand and prep hood one last time, have hood painted professionally
*Install flares
..........
DONE!!!!
************************************************** *******


MOD LIST BREAKDOWN:
(Rally Blue = Installed/Purchased Mods, Red = Coming Soon, Black = Potential Upgrades)

Engine/Power:
Garrett GTX3071R .63 Tial V-band Exhaust Housing
Fully Forged Short Block w/ Darton Sleeves, Stock Nitride Crank, CP Pistons, Eagle Rods, ARP Studs
BC S2 Cams, Springs, Retainers and mild PnP job by myself
Cometic Head Gasket
Gates Racing Timing Belt Kit
Tomei Timing Belt Guide
AVCS Delete, WRX Cam Gears
Supertech Inconel Exhaust Valves, Stainless Intake, Std Size
Area 1320 Custom Rotated Downpipe w/ electronic exhaust cutout (316L medical grade)
Area 1320 Custom Up-pipe / Dump Tube w/ Tial 38mm EWG (316L medical grade)
Area 1320 Custom Intake
Area 1320 Custom V-Mount Intercooler
Mishimoto MR2 Radiator -- modified for v-mount application
AN-20 Fittings and Startlie Hosing for Radiator
Greddy Ti-C converted to v-band
Greddy Mid-pipe has flex connector installed + electric cut-out + turn down
Tomei EL Headers
P&L Air Pump Delete
Hallman Pro RX Boost Controller
Turbosmart RacePort BOV
ATI Super Damper


Electronics:
Carberry Engine Management + Omni 4 Bar MAP speed density
AEM Digital Gauges: Oil Temp, Oil Pressure, Boost, Wideband
Odyssey PC680 Battery relocated to the boot

Racepak IQ3 w/ Data Logging

Fueling:
Aeromotive 340 In-Tank Pump
Deatschwerks 1000cc Injectors (flow tested/cleaned 1050cc+)
Agency Power Fuel Rails
-6AN custom Fuel Lines w/ Russell Fittings
Aermotoive Fuel Pressure Regulator
Integrated Engineering Surge Tank / Bosch 044 submerged (-6AN)
Fuel Lab 40 micron Stainless In-Line Fuel Filter w/ check valve


Oiling:
Killer B Motorsports Oil Pan, Pickup
ACL Oil Pump
Canton Racing Accusump (2QT, -10AN)
Canton Racing Electronic Valve Controller
Aeromotive Billet Check Valve
Mocal 235matrix 25 row Oil Cooler (-10AN)
190F Mocal Thermostat Sandwich Adapter
Aeroquip -10AN stainless lines throughout oiling system
Canton Racing 6" CM in-line oil filter
Peterson Fluid Systems Breather Can


Track Prep / Cooling / Braking / Misc:
Earl's Power Steering Cooler
WRC V-Mount Intercooler Vent
RunCool Hood Louvers 11"x17"
CF style Aerocatch latches
RaceTech RT4009WHR Seat
Planted Technology Seat Bracket
Planted Technology Seat Base
P&L SS Clutch Line
P&L SS Brake Lines
Custom SS Turbo Oil Feed -4AN Russell
Custom SS Power Steering Line -6AN Russell
Hawk HPS Pads
Spare and other misc parts removed


Drive Train:
Competition Clutch + Flywheel
Kartboy Rear Shifter Bushing
Perrin Front Shifter Bushings

Torque Solutions Engine, Tranny, Pitch Stop, Short Shifter
Cusco Rear Diff Inserts
WL Rear Subframe Inserts
TiC Tranny Crossmember Bushings
TiC Holy Shift Set
Kartboy Rear Subframe Bushings


Wheels / Tires:
Forgeline GA3R 18x12 +12 Polished Lip, Titanium Hardware, Satin Silver Center
335/30/18 Toyo R888
3.5" carbon fiber flares via eBay
Project Kics R40 Gun Metal Lugs
949 Racing Gun Metal Anodized Alum Valve Stems


Suspension Upgrades:
Fortune Auto 510 V4 Coilovers 8kF/9kR Swift Springs + Roller Bearing Upgrade
Cusco Rear Adjustable Lower Control Arm
Cusco Front Lower Arm Bar Type II
Cusco Front/Rear Strut Bars
Kartboy Front/Rear Endlinks
Whiteline 22mm Front Sway Bar,Whiteline 20mm Rear Sway Bar
Whiteline Rear Sway Bar Mount Reinforcements
Whiteline Steering Rack Bushings
Whiteline Front Control Arm Bushings
Whiteline Roll Center Kit
Whiteline Rear Toe Arms


Exterior/Misc:
2011 STi Bumper w/o fogs
Perrin Shorty Antenna
25% Tint


Fluids:
Amsoil 5W40 Signature Synthetic Engine
Amsoil 75W90 Synthetic Transmission / Diff
Amsoil 600 DOT 4 Brake Fluid
Amsoil Power Steering Fluid
Amsoil Dominator Coolant Boost
















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Last edited by sysfailur; 06-23-2014 at 09:27 AM. Reason: various fixes to post, pictures added, etc
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Old 05-24-2013, 08:51 PM   #2
sysfailur
Scooby Specialist
 
Member#: 135993
Join Date: Dec 2006
Chapter/Region: Tri-State
Location: Lehigh Valley, PA
Vehicle:
08 AW STi GTX3071
V-Mount, 18x12, 335 R888

Default

AEM gauges testing https://www.facebook.com/photo.php?v...52871992382066

Gauges going in:


Electric cut-out switch added in:

















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Old 05-24-2013, 08:52 PM   #3
sysfailur
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Member#: 135993
Join Date: Dec 2006
Chapter/Region: Tri-State
Location: Lehigh Valley, PA
Vehicle:
08 AW STi GTX3071
V-Mount, 18x12, 335 R888

Default

Some pics of the head work I did... 5 hours of sanding worth.









Valves being lapped:



Process of installing the WRC vent. First let me say that this is not the easiest process for a 2008 STi as they are not meant for this generation. There is not enough room to actually create exhaust ducting for the intercooler because the TMIC scoop is in the way. I didn't want to interfere with that so we put it as far back as possible and the purpose of it will be merely to vent out as much air as possible during idle. My friend Adam did the hood cutting and then I did some cleaning up and bending of the sheet metal to make things line up right. I used 3M panel bond to attach it to the hood which worked wonderfully and then bondoed around the scoop to blend it in nicely to the hood. I figure that with the louvres and WRC vent there will be PLENTY of routes for the air to escape. I may look into the GC WRC style dual-chimney venting style to the louvres but I don't know if there is room for that until everything is back in the car.

All was going well until I went to paint it. The base wasn't an issue but the company I used (touchupdirect) via amazon gave me a clear coat that caused severe yellowing. I was refunded my money and given new paint cans but once the car is done I'm going to just have it professionally sprayed. Oh well, I gave it a good go! haha

The Louvers came pre-powdercoated and those will not be sprayed but the rest of the top of the hood will be sprayed. I'll touch up the bottom myself later.





Shot of the hood bonod'ed and the "wings" I've fabricated for the radiator. I spent a good two-three days forming them to sit just so in the bumper so that it would scoop the air up in the direction of the intercooler/radiator. The wings are also welded in this pic and also supported in the rear with aluminum bars. I taped up the radiator as I also spent 2 hours straightening EVERY single fin even better than factory haha



Base on but no clear. I can't wait for it to look like this in the end. Of course the WRC vent will be meshed. I've also picked up an ebay sports grille which I will have painted white to allow more air into the intercooler.



Yellowing clear *uhg* .... but I got the aerocatch latches in! Once it is painted I will be sure to fully install them.


Last edited by sysfailur; 05-25-2013 at 12:45 AM.
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Old 05-24-2013, 08:53 PM   #4
sysfailur
Scooby Specialist
 
Member#: 135993
Join Date: Dec 2006
Chapter/Region: Tri-State
Location: Lehigh Valley, PA
Vehicle:
08 AW STi GTX3071
V-Mount, 18x12, 335 R888

Default

Pie cut downpipe + better shot of the downpipe/up-pipe assembly. Unfortunately I only have cell phone quality but you get the idea.

I definitely want to swaintech white lightning them at some point.



Early build mock up with blown engine still in car:



Intercooler core is a bell core, 3.5x9x14 I want to say. It can flow around 942cfm or so I believe if memory serves. Again slightly small yes, but I'm doing all this for a reason and actually it can flow more than some bigger but crappy design cores.



Shots of the hood getting cut up for louvres:



80 rivet holes... this was real fun *roll eyes*



Early stage intercooler end tank fabrication. This end tank was made by Ryan who is doing all of the designing/fab work that I haven't done (and he instructs me what to do if I'm doing it). So, he made this one and I replicated it to the best I could the other side and with a little metallurgy Ryan fixed the one I made to make it nearly identical to the one he made. Job done!



I really do want one of these.... but I may have another idea which I'll keep in my head for now unless I find a spare $3000 for a L'aunsport spoiler :P



These are the wheels I am looking to purchase--Forgeline GA3R in 18x12 +18. Of course my car will need flares and initially I plan on going with just rivet-on carbon fiber 240sx flares. Eventually I would love to have some custom work done when I can afford it a'la JGTC open vent flares. The picture I am referncing here to show the meat on the Mercury was something I found when I was searching oddly enough for pictures of 335/30/18 tires which is what I want to run--and this is the exactly the same wheel I want to run, in the same size, with the same size tire. I am looking to either go full polish or matte black center, polish black lip.

Also the article I am referencing here shows one route I may go when having my flares properly produced. I really don't want bolt on flares, but I'll buy em to get by and then have something custom made maybe next year or later.






Last edited by sysfailur; 05-25-2013 at 01:05 AM.
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Old 05-24-2013, 08:57 PM   #5
sysfailur
Scooby Specialist
 
Member#: 135993
Join Date: Dec 2006
Chapter/Region: Tri-State
Location: Lehigh Valley, PA
Vehicle:
08 AW STi GTX3071
V-Mount, 18x12, 335 R888

Default

One more reservation... and shower time. Back with more updates in a few!
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Old 05-24-2013, 09:11 PM   #6
monjarassi
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Member#: 281623
Join Date: May 2011
Location: Houston TX
Vehicle:
06 STI
Obsidian Black Pearl

Default

sexy and intriguing
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Old 05-24-2013, 09:28 PM   #7
Derek11WRX
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Member#: 296224
Join Date: Sep 2011
Chapter/Region: SCIC
Location: California
Vehicle:
2011 WRX Sedan
Satin White Pearl

Default

Damn.
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Old 05-25-2013, 01:09 AM   #8
sysfailur
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Member#: 135993
Join Date: Dec 2006
Chapter/Region: Tri-State
Location: Lehigh Valley, PA
Vehicle:
08 AW STi GTX3071
V-Mount, 18x12, 335 R888

Default

Annnnnddd updated the first couple posts to cover pretty much everything of interest. I'll leave it as such until I have more news to post.

Enjoy your weekend!
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Old 05-25-2013, 01:45 AM   #9
Shipman
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Member#: 312847
Join Date: Mar 2012
Chapter/Region: Tri-State
Location: SNJ
Vehicle:
06 STi/03 Forester
AW/PBP

Default

Dang son, operation go hard engaged
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Old 05-25-2013, 10:30 AM   #10
561wrx
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Member#: 166427
Join Date: Dec 2007
Chapter/Region: South East
Location: boynton bch, fl
Vehicle:
03 wrx

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oh my jeus
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Old 05-25-2013, 10:49 AM   #11
calebtharrell
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Member#: 242113
Join Date: Mar 2010
Chapter/Region: South East
Location: Brevard (Asheville), NC
Vehicle:
2004 STi, 2008 STi
2002 WRX

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Definitely looking forward to how this build turns out! Great work!!
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Old 05-29-2013, 05:58 PM   #12
sysfailur
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Member#: 135993
Join Date: Dec 2006
Chapter/Region: Tri-State
Location: Lehigh Valley, PA
Vehicle:
08 AW STi GTX3071
V-Mount, 18x12, 335 R888

Default

Small update today but it is something... painted the grille I purchased a little ago. I will transfer over the STi logo and add mesh to it.

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Old 05-30-2013, 07:43 PM   #13
sysfailur
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Member#: 135993
Join Date: Dec 2006
Chapter/Region: Tri-State
Location: Lehigh Valley, PA
Vehicle:
08 AW STi GTX3071
V-Mount, 18x12, 335 R888

Default

Heads cleaned up and ready to rock.

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Old 05-31-2013, 03:00 AM   #14
9vapors
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Location: NY
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*

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Awesome setup, I love that you're not afraid to cut the **** out of it and focus on the motor...
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Old 05-31-2013, 03:12 AM   #15
jvsoundwave
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Member#: 66060
Join Date: Jul 2004
Chapter/Region: TXIC
Location: Kingwood, TX
Vehicle:
2007 STI Limited#534
Crystal Gray

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WOW! Bad ass work man!
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Old 05-31-2013, 10:37 AM   #16
alecb
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Member#: 335146
Join Date: Oct 2012
Chapter/Region: MAIC
Location: LaPlata, MD
Vehicle:
2004 STi
PSM

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That's a nice setup man. Can't wait to see it all done.
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Old 05-31-2013, 11:01 AM   #17
besthaticouldo
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wow, just wow. can't wait to see more of this car.

also you bought the wrong grille. you bought an 08-10 grille and not an 11+.

Last edited by besthaticouldo; 05-31-2013 at 12:11 PM.
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Old 05-31-2013, 12:05 PM   #18
9vapors
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Member#: 92582
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Location: NY
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*

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After a re-visit to this thread, do you have any pics of your cutout and location?
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Old 05-31-2013, 07:17 PM   #19
sysfailur
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Member#: 135993
Join Date: Dec 2006
Chapter/Region: Tri-State
Location: Lehigh Valley, PA
Vehicle:
08 AW STi GTX3071
V-Mount, 18x12, 335 R888

Default

Quote:
Originally Posted by besthaticouldo View Post
wow, just wow. can't wait to see more of this car.

also you bought the wrong grille. you bought an 08-10 grille and not an 11+.
Hrmm. I haven't fitted it to the bumper yet. If it doesn't work or looks stupid I guess I'll be selling that! haha *eep*
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Old 05-31-2013, 07:23 PM   #20
sysfailur
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Member#: 135993
Join Date: Dec 2006
Chapter/Region: Tri-State
Location: Lehigh Valley, PA
Vehicle:
08 AW STi GTX3071
V-Mount, 18x12, 335 R888

Default

Quote:
Originally Posted by 9vapors View Post
After a re-visit to this thread, do you have any pics of your cutout and location?
Actually that is one of the remaining parts that has to be put on the car once the engine is back in and the exhaust is on. The location is going to be on the mid-pipe, right after the downpipe. We've also added a flex section to the mid-pipe so it'll be right after that I believe. Not sure exactly where yet as the exhaust needs to be back on the car. I've got it wired but just not yet installed.

The cut-out itself is from Summit Racing, their brand, and we're just gonna weld it right on probaly. I'm not messing with gaskets and crap. As soon as it's done it'll be posted up!

Quote:
Originally Posted by 9vapors View Post
Awesome setup, I love that you're not afraid to cut the **** out of it and focus on the motor...
Glad you guys are enjoying the project. I figured that I would probably never find myself wanting to get rid of my car so why not just go for it and do exactly what I want?


Also.... wheels should be ordered in a few weeks. To say I'm excited is an understatement.
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Old 05-31-2013, 07:30 PM   #21
P-Train
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Location: Randolph, MA
Vehicle:
2008 WRX
OBP

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Quote:
Originally Posted by sysfailur View Post
Small update today but it is something... painted the grille I purchased a little ago. I will transfer over the STi logo and add mesh to it.

That looks like the same cheapo grill I just bought lol.
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Old 06-13-2013, 09:19 PM   #22
sysfailur
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Member#: 135993
Join Date: Dec 2006
Chapter/Region: Tri-State
Location: Lehigh Valley, PA
Vehicle:
08 AW STi GTX3071
V-Mount, 18x12, 335 R888

Default

Alright gents.... updates are not that thrilling but the status is as such:

Engine status = heads were on, bucket to cams were measured and long story short, it's too tight so today I measured everything and the valves are being pulled to be zipped down every so slightly. When it's back we're gonna have to re-do all the measuring and get some buckets for proper clearances.

Sucks but needs to be done. And that's where things are at. I should be ordering my new wheels soon as I sold my old Prodrive wheels.

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Old 06-13-2013, 11:42 PM   #23
stierzy34
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Member#: 92113
Join Date: Jul 2005
Chapter/Region: MWSOC
Location: Belleville, IL
Vehicle:
2013 Mini Cooper S
"Martha"

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This has to be one of my favorite cars. Cannot wait to see more progress!
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Old 06-14-2013, 02:18 AM   #24
djbondoc
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Member#: 343025
Join Date: Jan 2013
Chapter/Region: MAIC
Location: Northern VA
Vehicle:
2008 STi
Aspen White

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Subscribed! Awesome work so far. Excited to see where this goes.
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Old 06-14-2013, 02:51 AM   #25
fuelMuncher
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Chapter/Region: BAIC
Location: California
Vehicle:
2002 WRX Wagon
PSM

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wow. subscribed.
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