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Old 11-25-2014, 09:04 PM   #1
RIBahler
Scooby Newbie
 
Member#: 326537
Join Date: Jul 2012
Chapter/Region: NWIC
Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

Default RIBahler's 05' STi Wagon

***Updated 12/31/14: Stage 2 Heads Complete w/ Valves, Porting, Matching, Knife Edge, & Poncams.***
Direct link to update: http://forums.nasioc.com/forums/show...7&postcount=24

***Updated 12/31/14: Added Picture of the +1 valves seated and installed, pics below***
Direct link to update: http://forums.nasioc.com/forums/show...8#post42926078

***Uptaded 12/24/14: Added Picture of heads in beginning process of porting***
Direct link to update: http://forums.nasioc.com/forums/show...0#post42908270

***Updated 12/19/14: Added Fortune Auto Coilover Pics Below***
Direct link to update: http://forums.nasioc.com/forums/show...5#post42893305

***Updated 12/11/14: Added Tomei Poncam Pics Below***
Direct link to update: http://forums.nasioc.com/forums/show...5#post42866765

***Updated 12/4/14: Added Blouch 2.5XT-R Turbo Pics Below***
Direct link to update: http://forums.nasioc.com/forums/show...3#post42839873

***Updated 12/2/14: Added Engine Building Pics Below***
Direct link to update: http://forums.nasioc.com/forums/show...9#post42831499


Hello All,

Here is my build thread!!!

After paying off the car and saving up money I decided to make my car the way I've wanted it for a while. Everything in RED is being built, ordered and soon to be installed. Stay tuned because the build will take about a month before it is complete. More pictures and Dyno graphs to come!

Vehical: 2005 Subaru WRX STi Wagon
Tuning Facility: FTW Tuning
Type of Dyno: Dynocom 5000

***OLD BUILD***
See Old Build here: http://forums.nasioc.com/forums/show....php?t=2413383
See STi Tranny & Brembo Brakes here: http://forums.nasioc.com/forums/show....php?t=2489333
See Modified Splitter for 05' WRX w/ 10' STI Intercooler: http://forums.nasioc.com/forums/show....php?t=2458117
Boost: 19(previous build)
Fuel: 92 Pump
AFR: 11ish
SAE Corrections: None
Baseline peak HP from previous build: 319awhp
Baseline peak Torque from previous build: 299awtq

Old Build


Old Dyno Graph



***NEW BUILD***
Boost: "Save for editing"
Fuel: "Save for editing"
AFR: "Save for editing"
SAE Corrections: "Save for editing"
New Peak HP at RPM: "Save for editing"
New Peak Torque at RPM: "Save for editing"

New Build
"Save for Picture"

New Dyno Graph
"Save for Picture"


Short Block
2.5 STi Block
• CP Pistons
• Manley H-Beam Plus Rods
• 2011+ Subaru STI OEM Forged Crankshaft (induction hardened)
• Blueprinting
• ACL Bearings


D25 Heads
• Manley +1 Intake and Exhaust Valves
• Tomei Poncam:
- 252 Intake Durration, 252 Exhaust Duration
- Peak Lift: 10.2mm Intake, 10.2mm Exhaust
• Cosworth Cam Angle Sensor Bracket
• Blueprinting
• GSC Power Division Valve Spring Set W/ Titanium Retainers
• Valve Grind
• Cylinder Head Porting
• Seals
• ARP Head Studs


Longblock
• OEM Gasket Set
• Gates Timing Belt kit with Water pump
• OEM Case Bolts
• Subaru OEM 11mm Oil Pump
• Breatrush Engine Mounts
• Perrin Lightweight Crank Pulley
• NGK Iridium Spark Plug (one step colder)


Cooling
• Mishimoto Performance Aluminum Radiator
• BEATRUSH Radiator Cooling Panel - (on backorder)
• Perrin Radiator Hose Kit
• Perrin Oil Cooler Kit w/ Integrated 185 deg F Thermistat
• Killer B Pick Up
• Killer B Oil Baffle Windage Tray
• Process West Top Mount with Shroud


Turbo Specs
• Blouch Dominator 2.5XT-R
- 8cm Exhaust Housing
- 3” Inlet Housing
- Garrett Ball bearing CHRA
- 60mm Turbine Wheel
- 71mm XT Compressor wheel
- 49lbs per min
- Ceramic Coated
• Perrin Turbo Blanket
• Perrin Heat Shield


Fuel
• FIC 1100cc Injector Set (High-Z)
• Walbro 255lph Fuel Pump

Intake
• SPT Intake & Heatshield
• Thermal Coat Intake Manifold
• Porting and Gasket Matching Intake Manifold
• Porting and Gasket Matching Throttle Body
• TGV Delete
• GrimmSpeed Phenolic Thermal Spacer 8mm
• Perrin Turbo Inlet Hose 3”
• AEM 3.5 Bar Map or 50 PSIA Sensor Kit
• AEM Intake Air Temperature Sensor


Exhaust
• Porting and Gasket Matching Stock Exhaust Manifold
• Grimmspeed Cross Pipe
• Perrin Up Pipe
• Perrin Down Pipe
• Modified SPT Mid Pipe
• SPT Axle Back Exhaust
• Exhaust Manifold to Catback Thermal Coated

Drivetrain Mods:
• 2004 STi 6 Speed Transmission
• R180 Rear Differential
• ACT Heavy Duty Performance Street Clutch Kit
• ACT StreetLite Flywheel
• GoodRidge Stainless Steel Clutch Line

• STi Drive Shaft
• STi Shifter Cable
• Perrin Shifter Bushing Kit
• Perrin Rear Shifter Bushing
• Perrin Subframe Differential Lockdown Kit
• Perrin Pitch Stop
• Group N Transmission Mount
• Redline Transmission Fluid
• Redline Differential Fluid
• STi Rear Axels
• STi Rear Hubs
• DCCD Pro Center Differential Controller w/ STi Cluster Harness
• Kartboy Short Shifter

Suspension Mods:
• Fortune Auto 500 Coilovers (Generation 5) w/ Swift Springs and Radial Bearing Upgrade
• Eibach Camber Bolts
• Whiteline Ant Lift Kit
• Whiteline Roll Center Kit

• Whiteline 22mm Adjustable Front Sway Bar
• Perrin Front End Links
• Perrin 22mm Adjustable Rear Sway Bar
• Perrin Rear End Links
• Cusco Front Strut Tower Bar
• Greddy Rear Strut Tower Bar
• SPT Lower Chassis Brace
• Corner Balancing

Brake Mods:
• Brembo Brake Calipers (High Temp Painted Black w/ White Brembo Logo)
• Stoptech Street Performance Break Pads
• Stoptech Slotted Front Rotors
• STi Rear Rotors
• Goodridge G-Stop Stainless Steel Brake Lines
• Perrin Master Cylinder Brace


Gauges
• SMY ClusterMaker Dual Gauge Pod
• 2005 STi Gauge Cluster
• AEM UEGO Failsafe Wideband AFR/Boost Gauge
• Innovative Motorsports MTX-D Oil Temperature/Pressure Gauge


More
• COBB Tuning Map Sensor Adaptor
• STI JDM i (Impreza) Badge Blue
• STI JDM Rear Diffuser
• Cusco Diffuser Bracket
• Cusco Rear Lower Subframe Bar
• 1x V-Limited Style Front Lip
• Grimmspeed Electronic Boost Controller
• Crawford TMIC Air Oil Separator
• Whiteline Steering Rack Bushing Kit
• Oswald Performance Lightweight Bumper Beam (6 lbs)
• GTSpec Fender Reinforcement Brace- (on backorder)
• BEATRUSH Aluminum UnderPanel
• BEATRUSH Pulley Cover - (on backorder)
• BEATRUSH Oil Cap


Wheels and Tires:
• STi Corner Splitters
• 2004 STi BBS Wheels
• Bridgestone Potenza RE960AS Pole Position RFT
• 2004 STi BBS Wheels
• Toyo R888, Hoosier A6 or R6 ??? Researching More Tires



***Thank you to the Awesome Crew at FTW Tuning, Marty the Engine Builder and Andy the MasterTuner***
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Last edited by RIBahler; 12-31-2014 at 09:38 PM. Reason: Updated Build Thread Look and Layout
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Old 12-02-2014, 05:03 PM   #2
RIBahler
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Member#: 326537
Join Date: Jul 2012
Chapter/Region: NWIC
Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

Default

***Updated 12/2/14: Added Engine Building Pics***

Blueprinting oil journals has begun:


Manley H-Beam Plus Rods are on the 2011+ Subaru STI OEM Forged Crankshaft (induction hardened):


Block with Killer B Pick Up and Windage Tray


Block is complete:

Last edited by RIBahler; 12-29-2014 at 04:00 PM.
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Old 12-02-2014, 10:22 PM   #3
john 1badSTI
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on e85@ 30psi--spinning

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I have to ask---what is that stuff squishing out of the rod caps?
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Old 12-02-2014, 11:33 PM   #4
Zefy
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99 2.5TS (DEAD) / 87 GL

Default

Love seeing motor builds! Looks like you're doing it all yourself so that's pretty cool.

But ya... squished stuff? Rod bolt grease? Also, looks like a heat treated crank, not nitrided... We will make you second guess EVERYTHING! haha
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Old 12-03-2014, 12:11 AM   #5
RIBahler
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Join Date: Jul 2012
Chapter/Region: NWIC
Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

Default

Quote:
Originally Posted by john 1badSTI View Post
I have to ask---what is that stuff squishing out of the rod caps?
Quote:
Originally Posted by Zefy View Post
Love seeing motor builds! Looks like you're doing it all yourself so that's pretty cool.
Looks like assembly lube. FTW Tuning's Engine Builder is building the engine. Heads are going to machine shop tomorrow.

Last edited by RIBahler; 12-03-2014 at 07:08 PM.
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Old 12-03-2014, 03:36 AM   #6
2000subie
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WRB

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Quote:
Originally Posted by Zefy View Post
Love seeing motor builds! Looks like you're doing it all yourself so that's pretty cool.

But ya... squished stuff? Rod bolt grease? Also, looks like a heat treated crank, not nitrided... We will make you second guess EVERYTHING! haha

Definitely heat treated crank!
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Old 12-03-2014, 11:36 AM   #7
JWX
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So what rear lateral links are you running?
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Old 12-03-2014, 01:20 PM   #8
RIBahler
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Join Date: Jul 2012
Chapter/Region: NWIC
Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

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Quote:
Originally Posted by JWX View Post
So what rear lateral links are you running?
They are stock. Why do you think I need them? I have Rear Camber Bolts. Any suggestions?

Last edited by RIBahler; 12-03-2014 at 06:03 PM.
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Old 12-03-2014, 06:01 PM   #9
RIBahler
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Join Date: Jul 2012
Chapter/Region: NWIC
Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

Default

Quote:
Originally Posted by Zefy View Post
Also, looks like a heat treated crank, not nitrided... We will make you second guess EVERYTHING! haha
Quote:
Originally Posted by 2000subie View Post
Definitely heat treated crank!
You both are correct. It is a 2011+ Subaru STI OEM Forged Crankshaft (induction hardened). OP has been edited appropriately.

Last edited by RIBahler; 12-03-2014 at 07:09 PM.
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Old 12-03-2014, 06:12 PM   #10
JWX
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Quote:
Originally Posted by RIBahler View Post
They are stock. Why do you think I need them? I have Rear Camber Bolts. Any suggestions?
No, nothing like that. I've just been curious if the sedan width axles fit with the wagon lateral links. I'm planning on doing a very similar build on my 04 wagon, starting with a 6spd.
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Old 12-03-2014, 06:33 PM   #11
RIBahler
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Member#: 326537
Join Date: Jul 2012
Chapter/Region: NWIC
Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

Default

Quote:
Originally Posted by JWX View Post
No, nothing like that. I've just been curious if the sedan width axles fit with the wagon lateral links. I'm planning on doing a very similar build on my 04 wagon, starting with a 6spd.
Look here at my 04' STI 6 Speed and Brembo Swap
http://forums.nasioc.com/forums/show....php?t=2489333
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Old 12-03-2014, 08:28 PM   #12
john 1badSTI
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Join Date: Dec 2004
Chapter/Region: MWSOC
Location: grove city ohio
Vehicle:
04 sti 10.51@138.5
on e85@ 30psi--spinning

Default

Quote:
Originally Posted by RIBahler View Post
Looks like assembly lube. FTW Tuning's Engine Builder is building the engine. Heads are going to machine shop tomorrow.
keep an eye on that, lube on brg and on the bolt threads is ok but normally you do not like anything to get between the rod cap mating surface--it would not take too much to throw off your brg clearances since a few tenths of a thousandths could make a difference.
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Old 12-03-2014, 08:33 PM   #13
RIBahler
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Join Date: Jul 2012
Chapter/Region: NWIC
Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

Default

Quote:
Originally Posted by john 1badSTI View Post
keep an eye on that, lube on brg and on the bolt threads is ok but normally you do not like anything to get between the rod cap mating surface--it would not take too much to throw off your brg clearances since a few tenths of a thousandths could make a difference.

Thanks for the heads up. I will discuss it with the engine builder.


Sent from my iPhone using NASIOC
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Old 12-04-2014, 04:19 PM   #14
RIBahler
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Join Date: Jul 2012
Chapter/Region: NWIC
Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

Default

***Updated 12/4/14: Added Blouch 2.5XT-R Turbo Pics***

Blouch Dominator 2.5XT-R: 8cm Exhaust Housing, 3” Inlet Housing, Garrett Ball bearing CHRA, 60mm Turbine Wheell, 71mm XT Compressor wheel, 49lbs per min, and Ceramic Coated. Power Rating: 490HP



Last edited by RIBahler; 12-29-2014 at 04:14 PM.
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Old 12-05-2014, 02:45 PM   #15
RIBahler
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Join Date: Jul 2012
Chapter/Region: NWIC
Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

Default

If anyone wondered about the benefits of D25 Heads

http://forums.nasioc.com/forums/show....php?t=1856856

"You can see how on the D25 heads the coolant passages have been redesigned to allow more flow through the head because after comparing the cross sections you can see that the inner cooling passages are now smaller to allow for bigger exhaust ports (I'll take a picture of this). Also much more importantly you can see the different style combustion chambers! IMO the D25 has the best design because of its hemispherical based design and the lack of valve shrouding. The STi's b25 however has a very squared off combustion chamber." - fateo66
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Old 12-05-2014, 03:18 PM   #16
RIBahler
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Join Date: Jul 2012
Chapter/Region: NWIC
Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

Default

Anyone experienced with and can chime in on this subject?

My goals are to maximize AVCS, Flow, Spool and Torque.

I was thinking about getting GSC 264 Intake and 272 Exhaust Cams. This supposedly gives full AVCS range, great spool, great gas mileage and very flat torque curve with great power potential up top.

Information derived from the conversation between MAXWELL and others, here:
http://forums.nasioc.com/forums/show...2443615&page=2

Last edited by RIBahler; 12-05-2014 at 03:55 PM. Reason: spelling error
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Old 12-05-2014, 03:54 PM   #17
RIBahler
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Join Date: Jul 2012
Chapter/Region: NWIC
Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

Default

Quote:
Originally Posted by RIBahler View Post
Anyone experienced with and can chime in on this subject?

My goals are to maximize AVCS, Flow, Spool and Torque.

I was thinking about getting GSC 264 Intake and 272 Exhaust Cams. This supposedly gives full AVCS range, great spool, great gas mileage and very flat torque curve with great power potential up top.

Information derived from the conversation between MAXWELL and others, here:
http://forums.nasioc.com/forums/show...2443615&page=2
Answering my own question:

GSC S1 Camshafts- These will not drop any low end power, but actually cause faster spool of the turbo, creating more power and torque across the entire rpm range. Good for stock turbo or up to 500WHP(GT35R) upgrades. 268/266 duration.

Maybe this is the way to go. Feel free to chime in!
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Old 12-08-2014, 07:51 PM   #18
RIBahler
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Join Date: Jul 2012
Chapter/Region: NWIC
Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

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Question by me RIBahler -
I am having a reputable shop build my motor, but I was doing some research on GSC cams and springs which I order, and it has come to my attention that the cams are failing. As you can imagine I am scared of this happening and cannot afford failure.

How true is this, how can it be prevented, or should I stay with my stock cams?

My Build Thread w/ Tomei Poncams (I returned the GSC S1 Cams) and GSC Single Valve Springs with titanium retainer Kit:
http://forums.nasioc.com/forums/show....php?t=2683310

Failing Cam info derived from here:
http://forums.nasioc.com/forums/show....php?t=2642831

Answer from "Trusted Source" -
"It's very true and extremely common. I wouldn't run the GSC cams. I made that thread for a reason. The chance of them failing is greater than the chance of them not failing.
The Tomei cams are a much better made camshaft. They have the correct lobe offset, better finished lobes and journals etc. They are a quality piece that I haven't had any issues with and I would trust in my own engine.

I wouldn't run GSC cams unless they paid me 5k dollars to cover the cost of tearing it down again and replacing the parts that received excessive wear from all the metal particulate circulating through the engine.

I know that sounds harsh, but it's the sad reality."

Answer from Greg @ GSC -
"Any EJ Camshaft is susceptible to the type of failures talked about in the thread that you posted. The root of the cause of failure is inadequate supply of oil to the cylinder heads. Oil volume will always follow the path of least resistance. The oil supply of the EJ cylinder head, AVCS components, and Turbo feed are all shared. The internal head components are on one side of a 1mm restrictor the other side will feed the AVCS and the turbo feed. If you are having a reputable shop perform the work on your engine request thorough cleaning of the cylinder head oil galleys. When reassembling the AVCS request the use of NEW OEM AVCS screens and thorough cleaning of the lines. If you are using an aftermarket turbo oil feed line it is suggest to reroute the turbo feed line to the one of the cylinder block ports. If these items are paid special close attention you will not have an issue with our product or any aftermarket cam set and you can enjoy modding your Subaru EJ engine."

Answer from Travis Brodie @ GSC-
"The main consistency we see with that type of failure is a lack of lubrication during the break in time(usually with in 500 miles). This can be caused by many different things, but to help combat them the shop that is building your engine needs to have all of the oil galley plugs out and completely clean the cylinder head. There is also a very small restrictor pressed into the head that needs special attention when cleaning. It has a 1mm orifice, so any piece of small debris can cause a flow problem. That 1mm hole is all the feeds oil to the cam journals and buckets. The other things to check are the oil screens for the AVCS and turbo feed. We recommend new screens in the AVCS and Turbo feed( do not remove them if your car has them) and keeping with a stock size turbo feed line. Oversized turbo feed and removal of AVCS screens add a lof of volume to those areas, which can take away from the cam journals and buckets. Add that with opened up bearing clearances in the bottom end and there is very little to no oil left for the heads.
If you can run a larger oil pump we also recommend that, the more oil volume the better.
Ever single cam manufacture, including OEM has had identical lobe and bucket damage. Its not a cam profile or blank issue, its an installation and parts compatibility issue(outlines above). Every manufacture of cams uses different blanks, materials and profile specs, yet according to that thread they are all wrong and no one knows how to make a cam….
I also recommend raising the idle to over 1,000 RPM to help keep the oil flow in the head a little higher, Subarus in my experience like to drop down to 4 and 500 rpm, then slowly climb back up, there is basically no oil pressure to the head at that low of an RPM( I owned a WRX for several years with an STi motor)
I hope this helps, if you have any other questions feel free to ask."

Answer from Engine Builder and Master Tuner at FTW Tuning-
"We are doing everything GSC has mentioned. I'm sure "Trusted Source" and the GSC guy's all have a lot of experience. However, the "Trusted Source" has more first hand experience on Subaru cars. Let's go with what he said."

Last edited by RIBahler; 12-15-2014 at 01:12 PM.
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Old 12-11-2014, 10:00 PM   #19
RIBahler
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Join Date: Jul 2012
Chapter/Region: NWIC
Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

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***Updated 12/11/14: Added Killer B and Tomei Pics***

• Tomei Poncam:
- 252 Intake Durration, 252 Exhaust Duration
- Peak Lift: 10.2mm Intake, 10.2mm Exhaust


Last edited by RIBahler; 12-29-2014 at 04:16 PM.
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Old 12-19-2014, 06:27 PM   #20
RIBahler
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Location: Oregon
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2005 WRX STi Wagon
Crystal Grey Metallic

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***Updated 12/19/2014: Added Fortune Auto 500 Coilover Pics***

Fortune Auto 500 Coilovers w/ Swift Springs and Radial Bearing Upgrade

Last edited by RIBahler; 12-29-2014 at 04:17 PM.
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Old 12-24-2014, 06:50 PM   #21
RIBahler
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Location: Oregon
Vehicle:
2005 WRX STi Wagon
Crystal Grey Metallic

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***Uptaded 12/24/14: Added Picture of heads in the beginning process of Porting, Matching and Knife Edging***

Begining of heads being ported, matched and knife edged

Last edited by RIBahler; 12-29-2014 at 04:18 PM.
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Old 12-31-2014, 01:39 PM   #22
RIBahler
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2005 WRX STi Wagon
Crystal Grey Metallic

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***Updated 12/31/14: Added Picture of the +1 valves seated and installed***

Valves seated and installed

Last edited by RIBahler; 12-31-2014 at 01:47 PM.
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Old 12-31-2014, 02:37 PM   #23
Delphi
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Interest in seeing how the Poncams do with this turbo.

Great build thread!
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Old 12-31-2014, 04:45 PM   #24
RIBahler
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2005 WRX STi Wagon
Crystal Grey Metallic

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***Updated 12/31/14: Stage 2 Heads Complete with +1 Valves, Porting, Matching, Knife Edging, and Tomei Poncams.***

Stage 2 Heads Complete with +1 Valves, Porting, Matching, Knife Edging, and Tomei Poncams


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Old 12-31-2014, 04:54 PM   #25
RIBahler
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Crystal Grey Metallic

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Quote:
Originally Posted by Delphi View Post
Interest in seeing how the Poncams do with this turbo.

Great build thread!
Thank you! I hope it gives me what im predicting. Time will tell.
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