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Old 06-12-2014, 12:23 AM   #1
7ommy7urbo
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'07 Sti Ltd #295/800

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I'm currently in the process of building my '07 Sti Limited and thought I would share build progress with any/all who are interested... First, I guess I'll start with a little background on the car. I purchased my Sti back in 2011 basically with only a Perrin in take and a Sti Genome axle back muffler. Shorty after I swapped out the stock suspension with some Tein Super Street coilovers, purchased an Agency Power short shift and installed my Invidia N1catback from my previous Bugeye. Pretty much how it stayed for the next 2 years... [IMG][/IMG] I guess I always knew something funky was up with the motor from the slight lack of power and the ridiculous amounts of oil consumption (around 1 qt per 500miles if driving hard) so in august of 2013 I pulled the motor and began the project [IMG][/IMG] Just wanted to add I've been working on this build since 8/13 so the rate of posting on here doesn't represent the actual speed of the build, I wanted to make a thread as soon as I started, but like most projects, there were many delays and obstacles to overcome and I didn't want to drag the project out forever on here....

Current parts list:
Blouch 2.5xt-r 8cm 3" inlet
Tomei EL manifold and up pipe
Trust external oil cooler kit
Injector Dynamics 850's
Deatchwerks 300lph fuel pump
DW upgraded fuel pump wire harness
AMR turbo inlet 3"
ACT extreme duty full face clutch
STI 18.1lb flywheel
Cometic MLX .032" head gaskets
Perrin v2 fuel rails
Koyo aluminum radiator

Block Assembly:
Brand new OEM 704 EJ257 case
OEM '12 Subaru heat treated crankshaft
Manley H-beam rods
Manley 99.50mm 8.5:1 CR Pistons
ARP case bolts
ARP heads studs
King XPG main bearings
King XPG Rod bearings
10mm OEM Subaru oil pump
JDM Subaru closed back cast impeller water pump
Killer B oil pick-up
Gates "blue" racing timing belt kit

Heads:
v25b cylinder heads
GSC stage 1 camshafts 268/266
GSC Beehive springs/titanium retainers
GSC nitrided Intake/exhaust valves (standard size)
Build Specs:
All machine work performed by Larry's Auto Machine in Groton, Ct.
Blueprinted/Balanced rotating assembly to 9k RPM
Align honed mains
File fit rings, bearings clearances checked, block cleaned and short block assembled
Oil galleys ported @ oil pump and filter
Cylinder heads decked and cleaned
Mild "Street" PnP of intake/exhaust chambers
Multi angle valve cut
Valve stems tipped- couldn't get the correct valve clearance without
Heads Assembled and clearances checked
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Last edited by 7ommy7urbo; 07-12-2014 at 12:07 AM. Reason: updated
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Old 06-12-2014, 06:40 AM   #2
Bru1212
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Looks good. Still breaking in? When/where is the tune going to be done?
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Old 06-12-2014, 09:20 AM   #3
7ommy7urbo
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'07 Sti Ltd #295/800

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Quote:
Originally Posted by Bru1212 View Post
Looks good. Still breaking in? When/where is the tune going to be done?
Thank you, the motor isn't in yet. I hope to have the car done by the end of July.... Hopefully lol
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Old 06-12-2014, 09:40 AM   #4
HoboBob
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Did you find out what was causing the oil consumption?
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Old 06-12-2014, 09:45 AM   #5
7ommy7urbo
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'07 Sti Ltd #295/800

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Quote:
Originally Posted by HoboBob View Post
Did you find out what was causing the oil consumption?
Yes I had a cracked ring land that put some nice gouges in the cylinder wall... I think it was cylinder 4 IIRC but I'll have to take a look at my old block to be sure.
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Old 06-12-2014, 10:21 AM   #6
7ommy7urbo
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'07 Sti Ltd #295/800

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Some pics of the block/internals




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Old 06-13-2014, 12:52 PM   #7
7ommy7urbo
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'07 Sti Ltd #295/800

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Decided to take apart my AVCS cam gears while waiting to get my heads back from the machine shop a while ago and was surprised by the amount of debris stuck inside them even after using degreaser/cleaner and compressed air while they were together...


My motor wasn't blown when I took it apart, and there was still a good amount of stuff in the gears. Some of the other engines I've done that had bearing failures had a much lager amount of debris/metal inside
The Company 23 socket was probably one of the more useful tools for me to have if rebuilding a motor...
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Old 06-13-2014, 05:59 PM   #8
Steve.804
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Looks like a nice build and should be fun for sure! My situation is similar where my car consumes oil about as fast as it does fuel but drives great I'm still in the parts gathering phase but hope to have it in by the end of this year.

Looking at the fuel set-up it's obvious you're going to burn pump. Is E85 not available in your area?
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Old 06-13-2014, 06:25 PM   #9
uglybetty
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Makes me want to take my cam gears apart too
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Old 06-13-2014, 06:39 PM   #10
7ommy7urbo
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'07 Sti Ltd #295/800

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Quote:
Originally Posted by Steve.804 View Post
Looks like a nice build and should be fun for sure! My situation is similar where my car consumes oil about as fast as it does fuel but drives great I'm still in the parts gathering phase but hope to have it in by the end of this year. Looking at the fuel set-up it's obvious you're going to burn pump. Is E85 not available in your area?
Thank you, it definitely seems like a never ending project, but I just think about the end result and try to enjoy it and learn as much as possible.
Yes it will be just on pump, I have a couple friends that run E85 and they all take turns picking up drums of it, I think the closest place is around 45 mins towards the city...
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Old 06-13-2014, 06:43 PM   #11
7ommy7urbo
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'07 Sti Ltd #295/800

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Quote:
Originally Posted by uglybetty View Post
Makes me want to take my cam gears apart too
I never realized how much stuff gets stuck in them even after cleaning. I think it's definitely worth the money for the socket, even if it's just to do your own motor. It was around $20 I think.
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Old 07-03-2014, 10:57 PM   #12
7ommy7urbo
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'07 Sti Ltd #295/800

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Been slacking a little with posting recently, busy with work and was on vacation

Engine block with the ARP head studs, Killer B oil pickup, and a sweet old school lamp in the background!!


Cylinder heads assembled: port/polished with GSC valve train components
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Old 07-03-2014, 11:09 PM   #13
7ommy7urbo
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'07 Sti Ltd #295/800

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I purchased the OEM 11mm oil pump for the build because I thought that was the better option, but after reading into the use of them on single AVCS engines I'm considering getting the 10mm instead. I know there's different debates/opinions on which to use but would like to hear any recommendations or input...
Is the 11mm not "required" or not "recommended" ????
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Old 07-04-2014, 08:30 PM   #14
BeastianSTI
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Quote:
Originally Posted by 7ommy7urbo View Post
Decided to take apart my AVCS cam gears while waiting to get my heads back from the machine shop a while ago and was surprised by the amount of debris stuck inside them even after using degreaser/cleaner and compressed air while they were together...


My motor wasn't blown when I took it apart, and there was still a good amount of stuff in the gears. Some of the other engines I've done that had bearing failures had a much lager amount of debris/metal inside
The Company 23 socket was probably one of the more useful tools for me to have if rebuilding a motor...
Is the company.23 tool youre mentioning for aligning the avcs gears?
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Old 07-04-2014, 08:35 PM   #15
BeastianSTI
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Quote:
Originally Posted by 7ommy7urbo View Post
I purchased the OEM 11mm oil pump for the build because I thought that was the better option, but after reading into the use of them on single AVCS engines I'm considering getting the 10mm instead. I know there's different debates/opinions on which to use but would like to hear any recommendations or input...
Is the 11mm not "required" or not "recommended" ????
Highly not recommended. Us single avcs ej25 guys dont need the extra flow. It causes oil aeration on our engine.
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Old 07-04-2014, 10:47 PM   #16
7ommy7urbo
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'07 Sti Ltd #295/800

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Quote:
Originally Posted by BeastianSTI View Post
Highly not recommended. Us single avcs ej25 guys dont need the extra flow. It causes oil aeration on our engine.
Ok thanks for the input, I'm going to running an external oil cooler which I think adds around 2 quarts to the system, the 11mm wouldn't have any positive benefits with that??
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Old 07-04-2014, 10:52 PM   #17
7ommy7urbo
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Quote:
Originally Posted by BeastianSTI View Post
Is the company.23 tool youre mentioning for aligning the avcs gears?
Not for aligning the cams, it's a 5 point torx for removing the bolts on the back of the cam gears to separate them
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Old 07-05-2014, 09:52 AM   #18
BeastianSTI
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Quote:
Originally Posted by 7ommy7urbo View Post
Not for aligning the cams, it's a 5 point torx for removing the bolts on the back of the cam gears to separate them
Ok im glad I clarified. You need a special alignment tool to get everything to stay perfectly aligned during reassembly of the avcs gears. If you don't, you could easily seize a cam gear and trash your new sexy motor. Call outfront motorsports - they can explain it in greater detail. Most shops dont know about the caveate, hence a 50 50 chance of success
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Old 07-06-2014, 11:09 PM   #19
7ommy7urbo
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Anyone else care to share their input on the oil pumps? I Wanted to see if anybody had possibly used a 10mm and 11mm on the same vehicle and saw pressure differences between them...
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Old 07-12-2014, 12:16 AM   #20
7ommy7urbo
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'07 Sti Ltd #295/800

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Quote:
Originally Posted by BeastianSTI View Post
Ok im glad I clarified. You need a special alignment tool to get everything to stay perfectly aligned during reassembly of the avcs gears. If you don't, you could easily seize a cam gear and trash your new sexy motor. Call outfront motorsports - they can explain it in greater detail. Most shops dont know about the caveate, hence a 50 50 chance of success
Im confused on what you are referring to as far as the alinment tool, there is a dowel pin built
into the gear so as far as I know there is only one way to assemble it...
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Old 07-12-2014, 01:31 AM   #21
Justin V
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Outfront has a special tool similar to the cam but slightly thicker to ensure the backing plate of the AVCS gear is centered.

I assembled mine with a cam inserted, and while there was a smidge of play it seems to be aligned pretty well. With the cam centering it, the dowel and 6 bolts having to line up, I hope its correct.

I'll know once I've fired up the motor.
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Old 07-12-2014, 08:02 AM   #22
lordsanointed
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Quote:
Originally Posted by Justin V
Outfront has a special tool similar to the cam but slightly thicker to ensure the backing plate of the AVCS gear is centered.

I assembled mine with a cam inserted, and while there was a smidge of play it seems to be aligned pretty well. With the cam centering it, the dowel and 6 bolts having to line up, I hope its correct.

I'll know once I've fired up the motor.
Can it be responsible for some cams failures?
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Old 07-12-2014, 09:28 AM   #23
Justin V
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I wouldn't think so.

Yes the oil enters that cam journal through the AVCS gear, but the buckets are lubed separately and if the gear is stuck, it is stuck in a position where the oil can still flow.
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Old 07-12-2014, 10:18 AM   #24
lordsanointed
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^^ Thanks for the explanation.
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Old 07-12-2014, 12:18 PM   #25
Nokeler
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Why the Manley H-beams instead of turbo tuff I-beams?
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