Welcome to the North American Subaru Impreza Owners Club Monday May 30, 2016
Home Forums WikiNASIOC Products Store Modifications Upgrade Garage
NASIOC
Go Back   NASIOC > NASIOC Technical > Built Motor Discussion

Welcome to NASIOC - The world's largest online community for Subaru enthusiasts!
Welcome to the NASIOC.com Subaru forum.

You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, free of charge, you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, so please join our community today!

If you have any problems with the registration process or your account login, please contact us.
* Registered users of the site do not see these ads. 
Reply
 
Thread Tools Display Modes
Old 05-09-2016, 02:07 PM   #1
Stags4
Scooby Newbie
 
Member#: 423480
Join Date: Jun 2015
Location: Baltimore, MD
Default Built 500AWHP STI. Detailed List, Steps, and Prices (and all the small things)

NOT READY YET... STILL MESSING WITH FORMAT AND SPELLING!
Pics to come!
TL;DR $25,000 from stock



So I know there is A LOT of posts about how to make 500awhp but I wanted to post what I have done and learned throughout the process. I also wanted to have a few write-ups on the big items I had to do a lot of research on.

Overall Goals: 500AWHP "daily" toy that it is NOT a ghetto built nor is all done by someone else. That being said, there was some thought of saving money and I like to do as much as I can on my own. Where I wasn't comfortable (or didnít have the time) to do things, I had IAG Performance (in Westminster, MD) to do the work. I DEFINITELY RECOMMEND IAG PERFORMANCE. Quality work, with great people.

The start:
I bought an Aspen White bone stock 2006 STI with 150,000 miles for $11,000. Everything checked out great and was a great ride. I then bought a used Stage 2 Kit (Perrin intake, Invida Catless Downpipe, HKS Carbon Catback Exhaust, V2 AP) for $800. Also in that $800 came with a EBay lip, and APR Carbon Splitter (which was a nice touch). I was super happy with it. Unfortunately for me, the OEM pickup broke, lost oil pressure and destroyed my shortblock (as well as a lot of long block pieces that had oil go through them). So it was time to build the monster I wanted. I recommend to all, stay stage 2, or just above. Easily the best bang for buck.

And so it begins:
I decided to go with a rotated setup
I decided to go with speed density
I wanted to buy the best parts
I wanted to do as much labor as I could
I used the forums and the IAG Techs A LOT

Below is the list of all the parts I used. The total comes out to $22,600 (before tax for just the performance mods) and it is still climbing. Now, this is retail prices. I did not pay retail. A lot of parts I bought new but second hand, so they were ďusedĒ. I also was able to talk to companies and buy in bulk to save some $$. Now, I didnít save much, but anything helps.

To Date (5/9/16), I have spent $19,000 in performance parts and labor and $2400 in suspension, wheels, tires, and exterior mods. I have also sold about $3500 in stock STI parts.

Total......$23,954
Tax 6%....$1,356
Sub.......$22,598

Short Block
IAG Stage 3 Short Block (Open Deck).................3700 (at the time their Closed Decks where Stage 4 and $4500... Now I wish I waited for Closed Deck)
-OEM Case Halves
-OEM Heat Treated Crankshaft
-Manley Turbo Tuff Pistons
-Manley Steel Pro Series I Beam Connecting Rods
-ACL Race Main and Rod Bearings
-Wrist Pin Seal Kit ($100 Add on).......................100

Long Block
OEM 11mm Oil Pump.......................................190
Killer B Oil Pickup...........................................1 70
OEM Oil Cooler............................................ ...286 had to get new due to too much metal in oil
OEM Intake Cam Gear Sprocket (Driver)............191 had to get new due to too much metal in oil
OEM Intake Cam Gear Sprocket (Passenger).......191 had to get new due to too much metal in oil
Oil Feed Line Fittings (3)...................................40 had to get new due to too much metal in oil
Timing Belt Kit............................................... 367
-OEM Timing Belt Tensioner
-Gates Timging Belt Idler Smooth
-Gates Timing Belt Idler Gear
-Gates Racing Timing Belt
-OEM NA 2.5i Water Pump (oil-only Turbo)
NGK Iridium IX One Step Colder........................36
OEM STI Oil Pan.............................................12 0

Long Block Labor
Intall timing/water/oil components....................255

Head
JE Pro Seal 100mm Head Gaskets (Pair)............96
ARP Head Studs............................................. 222
Brian Crower Stage 2 272 Cams.......................767
IAG Half Moon Seals.......................................50
GSC 6mm Valve Stem Seal..............................15
Manley Valve Springs......................................272
Manley Race Exhaust Valves (33mm; +1mm)......175
Manley Race Intake Valves (37mm; +1mm)........175
AVCS Oil Plate Gaskets....................................5

Head Labor
Flush and Clean............................................. .100
Cam Journal Cleanup.......................................85
Resurface Heads............................................1 00
Set Valve Lash.............................................. .250
Multi Angle Valve Job.....................................300
Build and Install Heads..................................340

Turbo & Wastegates
Borg Warner S200-SX (Heat Coated)................930
Twin Tail MVS Waste Gates (38mm) (Pair).........480
IAG Rotated AVCS Oil Feed Line.......................110
Home Built Up Pipe Bracket.............................0

Exhaust
Full Race EL Headers (Heat Coated)..................1400
Full Race Up Pipe (Heat Coated).......................900
Full Race V-Band Down Pipe.............................750
Full Race Dump Tubes.....................................215
HKS Carbon Ti Cat Back..................................860

Intercooler, BOV, & Intake
Reverse Intake Manifold Intercooler Kit............1660
Black Intercooler Anodizing............................150
Weld Speed Density Bung...............................50
Tial Q BOV (Red)...........................................26 0
IAT Speed Density Kit.....................................57
IAG Street AOS (Red).....................................400
IAG TGV Deletes - Top Feed (Black)..................320
IAG Phenolic Spacer (8mm).............................50
AEM 3.5 Bar MAP Sensor.................................150

Fuel
AEM 320 Pump.............................................. 120
Walbro Fuel Pump Kit.....................................31
Injector Dynamics 1300 cc (Top Feed)...............1000
IAG v2 Top Feed Fuel Rails (Red).....................180
IAG Braided Race Fuel Lines & Fittings..............230
Fuel Pressure Dampers...................................60
AEM Fuel Pressure Regulator...........................120
FPR Guage............................................. ......30

Drivetrain
Resurface Fly wheel......................................75
ACT Heavy Duty Clutch (SB10-HDSS)...............592

Mounts
Perrin Pitch Stop (Red).................................105
Group N Engine Mount (Driver).......................75
Group N Engine Mount (Passenger)..................75
Group N Transmission Mount..........................87

Engine Management
Cobb V3 AP................................................ ..650
Grimmspeed EBC..........................................110

Gauges
SMY Dual Cluster Guage Pod...........................95
AEM Wideband.......................................... ...190
AEM Boost............................................. ......160
ATI Triple Guage Clock Pod.............................141
Defi Oil Pressure.......................................... .254
Defi Water Temp...........................................173
Defi EGT............................................... .......254
Defi Controller........................................ ......170

Cooling
Nothing Extra Yet

Fluids
IAG Motul Engine Break In Package..................62
IAG Motul Engine Package..............................62
Motul DOT 5.1 Brake Fluid..............................11
Motul Gear 75w90 Diff Fluid............................15
Motul Gear 75w90 Diff Fluid............................75
Subaru Coolant........................................... ..50
Subaru Engine Coolant Conditioner...................3
Distilled Water............................................. .3

Pro Tune
IAG Tune.............................................. .......500

Misc
Upgr8 Universal Boost/Vacuum Tubes..............40
Dorman Vacuum Connector Pack.....................8
Oetiker Stepless 1-Ear Clamp Kit....................43
100 pack of Zip-Ties.....................................8


More To Come!!!
* Registered users of the site do not see these ads.

Last edited by Stags4; 05-10-2016 at 09:01 AM.
Stags4 is offline   Reply With Quote
Sponsored Links
* Registered users of the site do not see these ads.
Old 05-09-2016, 02:07 PM   #2
Stags4
Scooby Newbie
 
Member#: 423480
Join Date: Jun 2015
Location: Baltimore, MD
Default

Non-Performance Things Bought

Again, These are retail prices.
To date (5/9/16) I have spent $2400 on all of this.

Suspension
BC BR Coilovers (8K/6K).........................1000
4 Point Ladder Brace..............................200

Wheels
Rota Grid 18x9.5 Flat Black (With Tires)......1500
Perrin Wheel spacers (15mm) (2 sets)........302

Brakes
Nothing Yet (probably SS lines soon)

Exterior
Ebay Lip............................................... .50
APR Carbon Splitter.................................320

Tools
Company 23 AVCS Cam Sprocket Tool........50
Company 23 Exhaust Cam Sprocket Tool.....50
Company 23 Valve Spring Compressor........85
Habor Freight Engine Stand......................65
Habor Freight Engine Crane......................180

Last edited by Stags4; 05-09-2016 at 03:19 PM.
Stags4 is offline   Reply With Quote
Old 05-09-2016, 02:07 PM   #3
Stags4
Scooby Newbie
 
Member#: 423480
Join Date: Jun 2015
Location: Baltimore, MD
Default

Not Done Yet; Still need to add Data

Cleaning Up the Engine Bay:

Upper Coolant Reservoir Delete (Oil-Only Turbo)
Why: Upper Res isn't needed anymore when you switch to an oil-only turbo. Cleans up engine bay.
Goal: Clean up engine bay.
Price: Price: $20 in hoses, a $5 Plug (plus new NA 2.5i Water Pump, but I already bought this)
Forums that helped:
http://www.iwsti.com/forums/2-5-lite...es-delete.html
http://forums.nasioc.com/forums/show....php?t=2278409
http://www.i-club.com/forums/engine-...ir-tank-71369/

Note: Didn't cost much, but was a pain to get right and there isn't an exact "how-to" out there. Also I bought a NA 2.5i Water Pump so I could delete this and have less coolant lines. I also plugged the passenger side coolant hole in the head.

Material:
TBD

Steps/Pics:
1. Remove all Hoses
2. Plug Head (use teflon tape?)
3.TBD

Last edited by Stags4; 05-10-2016 at 10:27 AM.
Stags4 is offline   Reply With Quote
Old 05-09-2016, 02:08 PM   #4
Stags4
Scooby Newbie
 
Member#: 423480
Join Date: Jun 2015
Location: Baltimore, MD
Default

Not Done Yet; Still need to add Data

Cleaning Up the Engine Bay:
Custom SS Power Steering Lines

Why: These are in the way of the rotated kit. Cleans up engine bay.
Goal: Route the PS Lines along the passenger fender, move the PS Res location, change all hoses to SS.
Price: $150
Things That Helped:
http://forums.nasioc.com/forums/show....php?t=2722535
http://www.rs25.com/forums/f105/t185...ing-lines.html
http://www.technafitstore.com/produc...-06-custom.htm

Notes: So much garbage out there when it comes to this... DON'T USE FRAGOLA FITTINGS!!! Second link is full of junk.

Materials:
TBD - still buring through all the crappy write-ups.

Steps/Pics:
1. Remove all PS lines (there are 3)
High Pressure from Pump to Rack
Low Pressure from Pump to Res
Low Pressure from Res to Rack

2. Build Hoses
3. Re-mount the PS Res to X
4. route and connect lines
5. Fill and turn wheel 10 times. Refill

Last edited by Stags4; 05-10-2016 at 10:27 AM.
Stags4 is offline   Reply With Quote
Old 05-09-2016, 02:08 PM   #5
Stags4
Scooby Newbie
 
Member#: 423480
Join Date: Jun 2015
Location: Baltimore, MD
Default

Not Done Yet; Still need to add Data

Cleaning Up the Engine Bay:
Purge System Delete (Purge Control Solenoid Valve, Purple Valve, and all associated hoses)
Why: Because Racecar and I don't mind killing baby animals. And I like a clean engine bay.
Goal: Clean up engine bay
Price: $10 in Vacuum hoses and Zip-Ties
Forums that helped:
http://forums.nasioc.com/forums/show....php?t=1831000
http://forums.nasioc.com/forums/show...1#post44381906
http://www.iwsti.com/forums/2-5-lite...id-delete.html
http://i115.photobucket.com/albums/n...bypass_JDM.jpg
http://legacygt.com/forums/attachmen...7&d=1281402450

Note: Didn't cost much, but was a pain to get right...

Material:


Steps:
1. Remove all Hoses

Last edited by Stags4; 05-10-2016 at 10:27 AM.
Stags4 is offline   Reply With Quote
Old 05-09-2016, 02:08 PM   #6
Stags4
Scooby Newbie
 
Member#: 423480
Join Date: Jun 2015
Location: Baltimore, MD
Default

Saved 5
Stags4 is offline   Reply With Quote
Old 05-09-2016, 02:38 PM   #7
user1029
Scooby Specialist
 
Member#: 57064
Join Date: Mar 2004
Vehicle:
2008 STi IAG built
HTA86, Meth, 272s, Cos IM

Default

Saved 6
user1029 is offline   Reply With Quote
Old 05-09-2016, 03:07 PM   #8
Stags4
Scooby Newbie
 
Member#: 423480
Join Date: Jun 2015
Location: Baltimore, MD
Default

Saved 6 (cold man cold)
Stags4 is offline   Reply With Quote
Old 05-09-2016, 06:30 PM   #9
wrxhard
Scooby Specialist
 
Member#: 108091
Join Date: Feb 2006
Location: Fargo, ND
Vehicle:
2002 WRX

Default

Daaaamn. Love this thread already!!!













Saved 7?
wrxhard is online now   Reply With Quote
Old 05-09-2016, 07:00 PM   #10
user1029
Scooby Specialist
 
Member#: 57064
Join Date: Mar 2004
Vehicle:
2008 STi IAG built
HTA86, Meth, 272s, Cos IM

Default

Saved 8

I just beat a GT3 with my completed setup I like to thank everyone involved in this project, my life is complete.

-future self
user1029 is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump

All times are GMT -4. The time now is 10:07 AM.


Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2016, Jelsoft Enterprises Ltd.
Powered by Searchlight © 2016 Axivo Inc.
Copyright ©1999 - 2016, North American Subaru Impreza Owners Club, Inc.