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Old 07-30-2014, 12:58 PM   #1
actACCORDingly
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Default High Horsepower Daily Driver

Ok, well I'm building a car for a friend/customer of mine. He bought an 04 Sti and it dropped a valve within 3 days of ownership. So he brought the car to me for a full build. It's nothing special. I'm more of a honda guy (I'm a honda tech as my day job)/mustang guy (i'm building a 91mm turbo lsx swapped terminator cobra for the 8.50 index) but I figured I'd give subarus some attention. This car will be his daily driver, will keep ac, power steering, ect. Every feature the car came with it will retain. It will run on pump e85 and 91 when need be. This is the build I've come up with and everything has already been purchased. Yes, I'm doing this at my home garage on the floor, no fancy lifts or other luxuries here.

Bottom end
- Closed Deck Ej257 Block by Outfront Motorsports
- 2015 sti crank
- Manley Turbotuff I beams
- Wiseco pistons 99.75mm
- King Main bearings +.001 oversized for extra oil clearance
- King Rod bearings +.001 oversized for extra oil clearance
- ARP 2000 rod bolts
- ARP custom age +625 head studs
- Killer b oil pickup and baffle

Heads
B25 Heads off an 05 STi
- GSC s2 cams (was going to go with s3's but after a talk with lance lucas he persuaded me to go with s2s)
- GSC Standard Sized Intake Valves
- GSC Standard Sized Exhaust Valves
- Supertech Dual Valve Springs
- Supertech Titanium Retainers
- P&P heads, 5 angle valve job

Other Goodies
- Cosworth Timing Guide
- Gates Racing Timing kit
- Zerolift tgv deletes
- Rotated replica magnus intake manifold
- Agency power top feed fuel rails
- Fiveomotorsport 2200cc Bosch Ev14’s
- Fuelab fuel pressure regulator
- Fuelab Fuel Pressure gauge
- 2x Walbro 450 intank pumps (second pump is triggered on a 15psi hobbs switch)
- AGP Hobbs Switch
- Omni 4 bar map sensor
- AEM IAT
- Cobb v2 speed density
- Exedy twin disk clutch
- AEM boost gauge
- AEM oil pressure gauge
- AEM wideband

Turbo
- Borg Warner Airwerks s366 67mm .88a/r t4/vband exhaust
- Precision 46mm Wastegate
- Agency power equal length headers
- Custom Rotated Up pipe and down pipe
- Treadstone 5" Intercooler (may install a nitrous spray bar)
- Custom Intercooler Piping for the rotated intake manifold
- Grimspeed ebc

Hopefully i didn't forget anything with the Build.

Other goodies the car has are
- K Sport Coilovers
- Karlton Flares
- JDM Red hazard button (gets all the b*tches)
- Pretty Much stock everything else. It is a street car.

The Car will be getting tuned by Travis at Soulless Performance.

More Pics will come soon, i don't have any on my phone. I just got the heads back from getting milled yesterday.







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Last edited by actACCORDingly; 08-17-2014 at 12:38 PM.
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Old 07-30-2014, 01:09 PM   #2
thisisthenewsic
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check out the gsc/kelford cam thread. a lot of failures lately. i was one with a cam failure.
also check out out fronts motorsports closed deck block instead of sleeving.
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Old 07-30-2014, 01:14 PM   #3
besthaticouldo
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I've never understood balancing to a clutch and flywheel assembly. That seems absolutely stupid. What happens if you change clutch, then everything is off.

Also, this seems like a really bad idea for a daily.

I agree with above for a closed deck block instead of sleeves.
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Old 07-30-2014, 01:28 PM   #4
actACCORDingly
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Low boost on 91 pump gas doesn't sound bad to me at all. If you have a twin disk, why change the clutch and flywheel? They sell rebuild kits for the twin disk. I'll look into the block, thanks.

Last edited by actACCORDingly; 07-30-2014 at 01:35 PM.
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Old 07-30-2014, 01:45 PM   #5
Keaton522
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Looks like an incredible build here... Id like to see how long its "daily driven" for.
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Old 07-30-2014, 01:46 PM   #6
toph
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700whp DD Subaru do not equate. Wrong platform man.
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Old 07-30-2014, 01:51 PM   #7
actACCORDingly
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On high boost with e85. Car will be daily driven on 91 on low boost.
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Old 07-30-2014, 02:10 PM   #8
A-man07
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Quote:
Originally Posted by besthaticouldo View Post
I've never understood balancing to a clutch and flywheel assembly. That seems absolutely stupid. What happens if you change clutch, then everything is off.
Yes but if you don't balance the entire rotating assembly then you aren't fully balanced.
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Old 07-30-2014, 09:18 PM   #9
john 1badSTI
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you will get to a little over 600whp with the 6266 but thats about it unless you are on a high reading dyno.
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Old 07-30-2014, 11:13 PM   #10
BraveSTi
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Quote:
Originally Posted by john 1badSTI View Post
you will get to a little over 600whp with the 6266 but thats about it unless you are on a high reading dyno.
Agreed..I don't even really see the relaibilty of it being a "daily driver" even if you do hit those numbers
Quote:
Originally Posted by toph View Post
700whp DD Subaru do not equate. Wrong platform man.
And honestly exceeding 500HP+ you're rolling the reliability dice IMO
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Old 07-31-2014, 03:44 AM   #11
Joshwrx04
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+1 on checking out the gsc/kelford thread!!

Killer bee or perrin bigtube headers over ap in my opinion.
Ive had bad luck with ap


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Old 07-31-2014, 09:12 AM   #12
FuJi K
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You can have the fw and pp balanced together or separately from the crank

Quote:
Originally Posted by besthaticouldo View Post
I've never understood balancing to a clutch and flywheel assembly. That seems absolutely stupid. What happens if you change clutch, then everything is off.
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Old 07-31-2014, 11:21 AM   #13
actACCORDingly
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I see no reason why we wouldn't reach those numbers. 35lbs on a sleeved block with a 6266 should make well over 700whp. My buddy ran the same turbo on his daily. 27lbs on e85 with stock sleeves and put down 630whp. I understand the reliability concerns. But I think it'll be fine. As long as it's not beat on all of the time it will hold up. The parts aren't that drastically crazy. It's a simple build imho. A few more of my friends have made over 500whp on an old style green, running low 11s on a stock engine, and put 50k+ miles on that setup. You have guys like cj in the 1320videos with the white hawk eye with that 35r on his stock engine running 10s. Have a little faith in your platform people haha.
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Old 07-31-2014, 11:48 AM   #14
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Quote:
Originally Posted by actACCORDingly View Post
I see no reason why we wouldn't reach those numbers. 35lbs on a sleeved block with a 6266 should make well over 700whp. My buddy ran the same turbo on his daily. 27lbs on e85 with stock sleeves and put down 630whp. I understand the reliability concerns. But I think it'll be fine. As long as it's not beat on all of the time it will hold up. The parts aren't that drastically crazy. It's a simple build imho. A few more of my friends have made over 500whp on an old style green, running low 11s on a stock engine, and put 50k+ miles on that setup. You have guys like cj in the 1320videos with the white hawk eye with that 35r on his stock engine running 10s. Have a little faith in your platform people haha.
It comes down to margin of error, just like when things are out of balance.

e.g.) Say you have a tire that's low on pressure. At 30 mph, it may not manifest itself as a huge problem, but at 60, you can really feel it out of whack. With that same token, when a small issue occurs, due to the amount of stress on the parts and importance with such explosive power, those minor blips or misfortunes (lean spot due to injector, etc) can easily be game over. A 300 HP car running lean in boost a couple of times might make it out alright, but when you're pushing 600 to the wheels, good luck, right?

Best of luck to you though, build sounds sexy!
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Old 07-31-2014, 02:35 PM   #15
user1029
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Get outfront closed deck. WAY better alternative to sleeving especially for a daily driver, cheaper too.
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Old 07-31-2014, 04:01 PM   #16
KillerBMotorsport
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Quote:
Originally Posted by user1029 View Post
Get outfront closed deck. WAY better alternative to sleeving especially for a daily driver
^ opinion, not fact.

Looking forward to seeing this coming together.
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Old 07-31-2014, 04:31 PM   #17
uglybetty
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I will have a sleeved twin scroll DD on the road in the next 6 weeks and am pretty confident that I won't have trouble with the sleeves
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Old 07-31-2014, 04:41 PM   #18
bebesito21
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i see the cam failure madness is in full force.....

get a 6466 instead of the 62
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Old 07-31-2014, 09:51 PM   #19
actACCORDingly
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Quote:
Originally Posted by bebesito21 View Post
i see the cam failure madness is in full force.....

get a 6466 instead of the 62
already have a 6266. got it for $750. lets see you find a 6466 for anywhere near that price.
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Old 08-01-2014, 03:37 AM   #20
neb_subi
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Well of course you wouldn't.. Any bigger better turbo is going to be more; that's like me saying ehh I bought this GT35R, maybe I'll find a GTX35 for same cost. If you wanna play big gotta pay big $$

I'm using an Outfront closed deck as well and will be in the same hp range. In my OPINION the closed deck would be the better option (not saying sleeving wouldn't work)
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Old 08-01-2014, 03:42 AM   #21
vicious_fishes
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you want reliable? H6 swap. lowest power density you're going to get.
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Old 08-01-2014, 02:06 PM   #22
actACCORDingly
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Quote:
Originally Posted by neb_subi View Post
Well of course you wouldn't.. Any bigger better turbo is going to be more; that's like me saying ehh I bought this GT35R, maybe I'll find a GTX35 for same cost. If you wanna play big gotta pay big $$

I'm using an Outfront closed deck as well and will be in the same hp range. In my OPINION the closed deck would be the better option (not saying sleeving wouldn't work)
I understand that if you want to play big, you have to pay big. It's not my car, I'm just picking the parts and putting it together. A 6266 was in his budget and the 6466 wasn't. This car was supposed to have a built bottom end, stock heads, and a green originally. When we realized it dropped a valve we decided to build the new heads. The build escalated really quickly after that. Speaking of playing big, my personal car is a terminator cobra with a lsx swap, th400, and a borg warner 91mm. In retrospect, you should be trying to play big
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Old 08-01-2014, 02:21 PM   #23
user1029
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Quote:
Originally Posted by actACCORDingly View Post
Speaking of playing big, my personal car is a terminator cobra with a lsx swap, th400, and a borg warner 91mm. In retrospect, you should be trying to play big
sounds fast
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Old 08-01-2014, 09:03 PM   #24
outfrontmotorsports
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Quote:
Originally Posted by KillerBMotorsport View Post
^ opinion, not fact.

Looking forward to seeing this coming together.

And a very popular opinion at that.

No closed deck blocks have failed.

I have yet to see a sleeved block with decent power and no sleeve issues over prolonged periods of time.
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Old 08-01-2014, 09:24 PM   #25
m.bryant
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Quote:
Originally Posted by actACCORDingly View Post
Speaking of playing big, my personal car is a terminator cobra with a lsx swap, th400, and a borg warner 91mm. In retrospect, you should be trying to play big
It's only $875 to have the closed deck process done, hardly "paying to play big" in the grand scheme of things. I'm a big fan of the 1/2" studs they can machine for at Outfront too...for anything that will be running 30+ pounds of boost.

I've got 14k on my closed deck DD and now running a Full-Race BW EFR 9180 twin scroll. Should easily get the 900 whp mark on the dyno in a few weeks. With no block failures and no added risk of dropping sleeves, the $875 is a VERY good option and should be strongly considered for a build like this!

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