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Old 08-20-2019, 06:34 PM   #1
tipsymechanic
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Default 08 Legacy 2.5i turbo build

I know a lot of these posts come around, but never follow through. But I will follow through with this for sure. I've got my parts list complete, and have begun ordering bits & pieces.

Background: I've had the car for several years and have had the itch for a new car lately. I can't justify it, mine has been paid off and there's nothing wrong with it. So instead of spending 20k+ on a new(er) car, I'm going to spend less than $2500 and make this one a lot more fun and "new" to me again.

Car: 2008 Subaru Legacy 2.5i 4EAT 86k miles

Mods:
-H&R springs w/ Koni struts
-Damn near every suspension bushing is Whiteline/Energy
-Whiteline rear sway bar
-LGT brakes w/ DBA rotors
-Delta 1000 cams
-Grimmspeed LW crank pulley
-Grimmspeed phenolic intake spacers
-AEM dry-flow filter
-hybrid intake system
-WRX injectors
-e85 fuel
-Infernofab 4-2-1 header
-Infernofab high-flow cat
-stock GT midpipe
-HKS Silent Hi-Power axleback

Turbo build list in next post --->
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Old 08-20-2019, 06:35 PM   #2
tipsymechanic
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I'd like to say I'm doing this the "right" way. But I suppose there isn't a perfect way to do it, aside from either swapping a factory turbo motor in or selling the car and buying a factory turbo car. (I'm sure I'll hear that a million times during this)

I'm not buying the AVO kit, I'm not cutting my crossmember or making a funky up pipe. I'm going to use as many stock turbo parts I can to make this appear like it came from the factory. I feel that is the right way to do it.

I won't type out the entire parts list, there's too many small things that most of you won't care about. But here's the main pieces:

-Kinugawa TD04HL-20T
-OEM turbo header/UP
-CNT catless downpipe
-LGT airbox lid/MAF
-OEM turbo inlet
-OEM BPV
-Water to air intercooler
-LGT front crossmember
-OEM turbo swaybar

I will have more parts and much more detail in future posts as I begin work.
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Old 08-20-2019, 06:35 PM   #3
tipsymechanic
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My friend has talked me into creating a youtube channel to document the progress of this build. This is my daily driver, so I will be doing a little at a time on weekends.
I will edit this post with videos as they become available.
Channel: tipsymechanics

First video is up!!
Our camera had some focus issues, we'll figure it out by the next video.


Part 1.5 is up!


Part 2 is up!


Last edited by tipsymechanic; 09-14-2019 at 08:55 PM.
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Old 08-20-2019, 06:37 PM   #4
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All parts have been ordered! Getting excited!
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Old 08-20-2019, 07:08 PM   #5
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Hell yea do the youtube channel!

How are you going to tune it? I'd almost not bother with the 1000 cams, go straight for the 1500s or nothing at all. Especially if turbo'ing.

EDIT: Whoops, didnt realise you already had the cams installed. How have you found them? Noisy? Make much difference?
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Old 08-20-2019, 07:19 PM   #6
tipsymechanic
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Quote:
Originally Posted by nvmylh View Post
Hell yea do the youtube channel!

How are you going to tune it? I'd almost not bother with the 1000 cams, go straight for the 1500s or nothing at all. Especially if turbo'ing.

EDIT: Whoops, didnt realise you already had the cams installed. How have you found them? Noisy? Make much difference?
Unfortunately they only offer the 1000 grind for the 06+ AVLS engines. Theyre definitely more noisy than stock, but not too bad. I feel like they made a difference, I never drive the car that hard, so them helping the lower rpms is great for my driving style. Light/moderate acceleration seems easier Vs the stock cams.

As for tuning.. I had my ecu defined by the folks on the romraider forums many years ago. Im doing a lot of research and will slowly tune this setup myself.
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Old 08-20-2019, 08:33 PM   #7
Boxcar80
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How much boost do you have planned?
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Old 08-20-2019, 08:42 PM   #8
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just subbed to you youtube channel. I've been wanting to do this to my 09 forester but haven't committed due to the same reasons you mentioned. cool to see someone go for it

goodluck with the build
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Old 08-20-2019, 09:03 PM   #9
tipsymechanic
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Originally Posted by Boxcar80 View Post
How much boost do you have planned?
I plan on starting at 5psi, running e85. I will go up from there, as far as my injectors will allow. Im guessing 8psi max.
I want to stay with e85 for safety
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Old 08-20-2019, 09:03 PM   #10
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Quote:
Originally Posted by Subie_Doo View Post
just subbed to you youtube channel. I've been wanting to do this to my 09 forester but haven't committed due to the same reasons you mentioned. cool to see someone go for it

goodluck with the build
Thanks!
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Old 08-20-2019, 09:14 PM   #11
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what's your plan for fuel setup?

I read that returnless fuel setups on the newer vehicles are PITA to tune so I was planning to swap an STI or equivalent tank and matching upgraded fuel pump and route a return that way. disregard if your vehicle has a fuel return still.
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Old 08-20-2019, 09:21 PM   #12
tipsymechanic
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Quote:
Originally Posted by Subie_Doo View Post
what's your plan for fuel setup?

I read that returnless fuel setups on the newer vehicles are PITA to tune so I was planning to swap an STI or equivalent tank and matching upgraded fuel pump and route a return that way. disregard if your vehicle has a fuel return still.
Mine still has a return line, fortunately.
I've got a Deatschwerks 65c pump with WRX 565 injectors (they flow tested @ 590cc)
I'd rather not push them to their absolute limit, so if I have to stop at 6psi.. thats fine. 6psi on e85 should make ~210whp
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Old 08-20-2019, 09:27 PM   #13
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Originally Posted by tipsymechanic View Post
Mine still has a return line, fortunately.
lucky duck.
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Old 08-20-2019, 09:29 PM   #14
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why'd you choose awic vs tmic or even fmic? just wondering because I went through the same issue: deciding awic vs tmic or fmic.
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Old 08-20-2019, 09:31 PM   #15
tipsymechanic
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Quote:
Originally Posted by Subie_Doo View Post
why'd you choose awic vs tmic or even fmic?
I've used awic in supercharger setups in the past.. they're simple and work very well. Very low pressure drop and doesn't require 10ft+ of extra pipe.
TMIC would be easy but with the big NA intake, you can't really fit one in there...and I'd have to get a hood with a scoop.
I felt awic was the best value.

Last edited by tipsymechanic; 08-26-2019 at 08:10 PM. Reason: I can't type
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Old 08-20-2019, 09:32 PM   #16
tipsymechanic
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lucky duck.
yours doesn't? You're only one year newer than mine. Same ej253
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Old 08-20-2019, 09:49 PM   #17
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Quote:
Originally Posted by tipsymechanic View Post
yours doesn't? You're only one year newer than mine. Same ej253
not to be a kill joy but I would double check your car does indeed have the fuel return line.

your engine bay looks exactly like mine tbh
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Old 08-20-2019, 10:01 PM   #18
tipsymechanic
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Quote:
Originally Posted by Subie_Doo View Post
not to be a kill joy but I would double check your car does indeed have the fuel return line.

your engine bay looks exactly like mine tbh
She's dirty, don't judge

pic links, they're large and I don't wanna fubar this post

https://i.imgur.com/RlhqADi.jpg
https://i.imgur.com/kICLIdp.jpg
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Old 08-20-2019, 10:25 PM   #19
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Quote:
Originally Posted by tipsymechanic View Post
She's dirty, don't judge

pic links, they're large and I don't wanna fubar this post

https://i.imgur.com/RlhqADi.jpg
https://i.imgur.com/kICLIdp.jpg
I've read that 09 NA foresters definitely have returnless fuel setups but that might not apply to legacy's. but I do think the lower hose in the first pic is a vacuum line and not fuel.
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Old 08-20-2019, 10:28 PM   #20
tipsymechanic
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Quote:
Originally Posted by Subie_Doo View Post
I've read that 09 NA foresters definitely have returnless fuel setups but that might not apply to legacy's. but I do think the lower hose in the first pic is a vacuum line and not fuel.
I've had it off before and its definitely fuel. Maybe the Legacy is different *shrug*

Its been tuned before and never had an issue with fueling. Hopefully you won't have any trouble!
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Old 08-20-2019, 10:41 PM   #21
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Quote:
Originally Posted by tipsymechanic View Post
I've had it off before and its definitely fuel. Maybe the Legacy is different *shrug*

Its been tuned before and never had an issue with fueling. Hopefully you won't have any trouble!
well if you dont have any issues with tuning with low boost I'm definitely gonna be doing this exact setup to my forester
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Old 08-20-2019, 10:44 PM   #22
tipsymechanic
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Quote:
Originally Posted by Subie_Doo View Post
well if you dont have any issues with tuning with low boost I'm definitely gonna be doing this exact setup to my forester
Awesome! I should be filming the first video next week. Hopefully all done within a few months. I don't have another car (that runs), so I have to do this in strategic stages on the weekends.
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Old 08-26-2019, 08:06 PM   #23
tipsymechanic
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Its raining and I'm still waiting on some parts, so here's some crappy drawings of the intercooler setup and a dual catch can setup.





Last edited by tipsymechanic; 08-26-2019 at 08:45 PM. Reason: updated pcv pic
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Old 08-30-2019, 07:53 PM   #24
tipsymechanic
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Its here! Its also tiny...but beautiful



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Old 09-03-2019, 12:13 AM   #25
tipsymechanic
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First video is up!!
Our camera had some focus issues, we'll figure it out by the next video.


Last edited by tipsymechanic; 09-03-2019 at 08:39 PM.
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