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Old 06-02-2016, 04:13 PM   #501
morrocco88
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Member#: 104098
Join Date: Jan 2006
Chapter/Region: NWIC
Location: Eastern WA
Vehicle:
97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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Small update......finally getting my heads ready to go.


I pulled all the hex plugs on the oil galleries, and removed the restrictors, so I could go all OCD on the cleaning. Finally got my solvent tank set up that I bought 3 years ago




Here is my parts cleaning station. After the solvent tank, I run them through a hot dishwasher cycle. I picked up the dishwasher for $50




Custom Piper Cams all clean and ready!




Here is my buddies valve spring pressure gauge. I measured the installed height of the Kelford springs, and then compress the springs to that height on the gauge, and verify what the actual seat pressure will be. Confirmed 85 lbs on the seat at 36mm just like what the specs of the kelford springs called for! Now I'm ready to assemble
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Old 07-25-2016, 04:42 AM   #502
morrocco88
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Member#: 104098
Join Date: Jan 2006
Chapter/Region: NWIC
Location: Eastern WA
Vehicle:
97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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project is moving really slow thanks to working 70hrs per week at the day job.

Finally got the heads assembled, and ready to bolt them on




Heads on




Killer B pickup




almost there. I keep finding more parts I'm missing, and have to order, and then get very few opportunities to work on her


Hoping to at least have it driveable and tuned before I put it away for the winter, then enjoy next spring and summer

Oh, and my buddy machined a custom JDM L7 badge for my custom grill project





I'm going to power coat and paint and try a few different looks
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Old 09-26-2016, 06:00 PM   #503
morrocco88
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Member#: 104098
Join Date: Jan 2006
Chapter/Region: NWIC
Location: Eastern WA
Vehicle:
97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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She Lives!!!!

I finally took a vacation from work so I could just keep my head down and get her running again.



Motor going back in.....Finally after almost 3 years!
[IMG][/IMG]

[IMG][/IMG]



Wrapped my Killer B Header
[IMG][/IMG]



Tons of factory wiring diagrams for 05' wrx (that's the harness my car is swapped with), 07' STI (that's the engine harness I used to get the AVCS solenoid plugs and cam sensor plugs from), and of course 97' Legacy diagrams haha!
[IMG][/IMG]



Lots of wiring fun trying to add the AVCS
[IMG][/IMG]



All buttoned up and ready for the first start!
[IMG][/IMG]

[IMG][/IMG]



[IMG][/IMG]
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Old 09-26-2016, 06:55 PM   #504
morrocco88
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Member#: 104098
Join Date: Jan 2006
Chapter/Region: NWIC
Location: Eastern WA
Vehicle:
97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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So I wanted to give a huge shout out to Dom Acia (GET a DOM tune). He gave me all the info and guidance to successfully add AVCS, and get all the wiring sorted out. With his hand drawn wiring diagram of what I needed to do, and all the factory wiring diagrams to give me the wire colors and pin locations, I was able to get the wiring mostly done. He then drove 3 hrs all the way from the Spokane WA area to help me. He helped me finish the wiring, re-pin a few wires at the ECU, and lastly reconfigure the software setup in the Link G4 to make it all work. He then built a custom map from for my particular setup, and it fired right up! We broke the cams in, checked for leaks and then changed the oil. Next we took it out for a drive and he road tuned it to make sure everything was happy for the break-in. The car runs so freakin smooth!!! I will break it in and then drive over to Tier 1 Imports in Liberty Lake near Spokane WA to have it dyno tuned!

Motor specs:

Block:
2.34 De-stroker
99.75 Manley Pistons
Stock 2.0L crank
+2 H-beam rods with ARP L19 bolts
Killer B pickup
Fuly blueprinted and balanced with the crank pulley and clutch

Heads:
D25 heads from 08' wrx, single AVCS
Stock ports
Stock valves
Kelford single valve springs
BC Titanium Retainers
Custom Piper Cams - Dom's custom specs for a de-stroker

Exhaust:
Killer B equal length header 2-bolt connection
Custom rotated kit built by me
Borg Warner Airwerks S200-56 (58 Lb/min)
Turbosmart CompGate 40 external wastegate - VTA at the moment
Custom 3" exhaust with no cats

Intake:
Custom 3" Intake (speed density setup on the Link G4)
Custom IC piping and FMIC
Stock 05' wrx intake manifold - ceramic coated
Grimmspeed phenolic spacers
TGV's deleted
Synapse Synchronic BOV
ID1000 injectors
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Old 10-17-2016, 11:06 PM   #505
nasiocjunkie
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Member#: 80864
Join Date: Feb 2005
Chapter/Region: AKIC
Vehicle:
I'll have the tuna.
No crust.

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subbed!
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Old 10-23-2016, 11:10 AM   #506
abomination
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Member#: 456880
Join Date: Oct 2016
Location: Iowa
Vehicle:
2003 Ourback
Red

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Super clean build. Fab work and wiring was top notch.
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Old 10-29-2016, 10:42 PM   #507
Michelle L
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Join Date: Feb 2015
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This was awesome to read through! Your car gives me so much inspiration for my white postal wagon.
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Old 12-08-2016, 06:38 PM   #508
morrocco88
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Member#: 104098
Join Date: Jan 2006
Chapter/Region: NWIC
Location: Eastern WA
Vehicle:
97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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Quote:
Originally Posted by nasiocjunkie View Post
subbed!
Thanks!

Quote:
Originally Posted by abomination View Post
Super clean build. Fab work and wiring was top notch.
Thank you! I'm still learning, and try to hone my craft a little more each day

Quote:
Originally Posted by Michelle L View Post
This was awesome to read through! Your car gives me so much inspiration for my white postal wagon.
Thanks! Postal wagons are legit



Small update:

I have about 400 miles on the motor and it's running like a top! No oil consumption, and runs really smooth. It doesn't look like I will get it tuned until spring, because the snow is definitely here now. If I get a break in the weather, I might bomb over to Spokane real quick.

I might be going with a TWIN SCROLL EFR7670 though. I would like to get a single scroll Treadstone housing for it, and do a back to back comparo......drive it over single scroll for the tune, then swap it over to twin scroll and re-tune. It would be awesome to have the back to back test with everything being the same.....same car, same motor, same dyno, same day and see what the difference is. More to come on that in the future.



For now I've been working on some smaller odds and ends......

adding fuel pulse dampers on feed and return lines
adding fuel pressure and temp sensors to ECU
built a coolant overflow tank
building a custom Air Oil Separator
extending wastegate dump to rear diff area, or recirculating (can't decide)
installed my stereo
installed MOMO steering wheel with NRG quick release
installed new PLX wideband with Bosch 4.9 sensor (faster acting)


coolant overflow tank I built real quick. Not sure if I like it, but it works for now.



It's just laying there, and not bolted down yet






Powder coated it satin black




I ditched the factory fuel filter and added this
Aeromotive filter. I built some small aluminum manifolds that go inline with the rubber feed and return lines. Each manifold has a fuel pulse damper and the temp or pressure sensor. pics of those to come. This is just temporary until I build the whole fuel system for E85 (depends on if a station pops up closer to me)





new MOMO wheel






I was able to keep the cruise control by mounting the switch in the column. The only thing I lost was self canceling blinkers, but no big deal








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Old 12-14-2016, 04:06 PM   #509
morrocco88
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Member#: 104098
Join Date: Jan 2006
Chapter/Region: NWIC
Location: Eastern WA
Vehicle:
97' LGT 2.3 Dstroke
Rotated BW S256 6speed

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EFR7670 twin scroll external gate.














Going to develop a twin scroll turbo kit for this, and might just install this on my car. As I said before, I would love to get a Treadstone single scroll housing for it and install it on my current kit. Then I could have Dom tune it single scroll, and then switch it over to twin scroll and have a back to back comparo on the same car, same everything, same day, same dyno to see how twin scroll power band compares to single scroll.
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Old 12-14-2016, 09:04 PM   #510
Titter
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Member#: 416107
Join Date: Mar 2015
Chapter/Region: International
Location: Ontario, Canada
Vehicle:
2002 WRX Wagon
EJ207 Spec C 4EAT

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Quote:
Originally Posted by morrocco88 View Post
Then I could have Dom tune it single scroll, and then switch it over to twin scroll and have a back to back comparo on the same car, same everything, same day, same dyno to see how twin scroll power band compares to single scroll.

that would be awesome of you to do this and share the info.
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Old 12-15-2016, 02:56 AM   #511
bugwgn
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this build is perfect! my eyes have been glued to my phone for hours now going through the entire thread!
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Old 12-15-2016, 07:59 PM   #512
morrocco88
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Member#: 104098
Join Date: Jan 2006
Chapter/Region: NWIC
Location: Eastern WA
Vehicle:
97' LGT 2.3 Dstroke
Rotated BW S256 6speed

Default

Quote:
Originally Posted by Titter View Post
that would be awesome of you to do this and share the info.
It will be a fair amount of extra work and money, but I will try my best. I really don't want to have to buy a Treadstone single scroll housing for $500 just to test, because I will keep it twin scroll in the end. I'm going to see if I can borrow one from someone, or maybe Dom has one. And, I would have to pay for the extra dyno time most likely. I'm just too curious and want to see a good comparison for myself!

Quote:
Originally Posted by bugwgn View Post
this build is perfect! my eyes have been glued to my phone for hours now going through the entire thread!
Glad you're enjoying it! Too bad a bunch of pics are missing because Imageshack had a problem, and now I have no way to recover the photos
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Old 12-15-2016, 11:05 PM   #513
bugwgn
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page 17 was heartbreaking, but now I'm looking forward to see what you do with that 7670 😈
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Old 12-17-2016, 11:01 PM   #514
motorbykemike
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your cars looking great and coming along most awesomely garris !

I have the same cams!

unfortunately my 2.34 had to come back out and I have an iag cd shorty in there with a 61lb turbo , for now at least .

2.34 will be back and with a giant friggin turbo as the 61lb fp jobbie was nowhere near enough for it up top . thinking 40r or super 94/99

I use a tial 44mm ewg that is plumbed to the back of the car and uses a straight through motorcycle muffler . stepped from 1-3/4 , 1-7/8 , 2 , 2-1/8" then a taper into the muffs 2-1/2 inlet . it's hung off of the main exhaust so it can move with it , and the muffler itself at the back of the car has it's own oem rubber hanger . super quiet and no change in power/tune so if must flow just fine .

pm me your number again and i'll send pics . also want to run some ideas / fab questions by you and see if you're game for tackling it .



oh and - I have another muffler too if you entertain the idea of doing the same or similar on yours

vta ewg sounds like a lawnmower falling out of it's ass imho

plumb back was a compromise I was not willing to accept



what wrap is that on the header ?

how high are you spinning it ?

feels real linear huh ?



damn I miss mine !


not to be a killjoy , but the single scroll may work better for the destroker ?
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Old 12-19-2016, 08:38 PM   #515
morrocco88
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Member#: 104098
Join Date: Jan 2006
Chapter/Region: NWIC
Location: Eastern WA
Vehicle:
97' LGT 2.3 Dstroke
Rotated BW S256 6speed

Default

Hey man, thanks!

I hear you on these motors loving a big turbo, but......they also shine with any size turbo if what you're after is a silky smooth feeling engine, and a more linear power delivery. Dom had a customer way back in the day that put a tiny 18G on one, and it was a pleasure to drive. I just love how smooth and refined these motors run, and always felt a 2.5 was clunky. I also love how the linear power band feels compared to the peaky 2.5

On the twin scroll, I'm curious more than anything, and if the single scroll power band suits me better, I will swap it back and sell the twin scroll kit. I'm not after absolute all out power, but whichever power band feels better and suits my driving style best, that's what I'll go with. It's just a fun street car/hobby for me.

I want to see pics of the motorcycle muffler on your wastegate! That's the same idea I had, and I have been looking at sport bike mufflers on ebay, but most are around $400 or more for a good one, so I haven't pulled the trigger. I've actually started the fab work to extend my dump tube and stopped at the end of the down-pipe to decide if I want to just re-circ it there, or continue on back to the rear of the car with a "Two Brothers Racing" muffler

The wrap I used is DEI Titanium, and then I covered it with high temp foil tape to keep the wrap clean. All the adhesive burned off in the first few minutes, but the tape hasn't peeled up at all. It was more an experiment, but so far it's working haha!

Sending you a PM
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