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Old 12-01-2020, 01:50 AM   #1
alexmartynyuk
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Join Date: Oct 2008
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2005 EVO VIII
open source tuning subaru

Default 2015 STI build

Hello everyone! Not sure if this is the right place to start a build thread or the power proven section(mods move if needed but I felt the built motor discussion section would be more appropriate).

Anyway, a while ago my brother ended up acquiring a 2015 sti that was mostly stock with the exception of an Invidia catless downpipe. A long time before him getting this car I got into tuning and Subaru was my learning platform, doing it as a hobby over time my tuning experience has advanced and because of that my brother was looking out for an sti as it would allow us to do a good amount in mods while saving a bit in tuning costs.

After getting this car I quickly checked the map and found it was stock, so after getting a wideband I did a quick stage2 tune on it and it didn't make super high numbers but it was a safe tune. After owning the car for a while and getting bored of low power he ended up getting more mods which included an FP Red turbo(older cast compressor wheel with the antisurge cover) and other supporting mods with full 3" exhaust and an external wastegate and enough fuel system to support 500whp on pump gas. So we installed everything and started getting the car dialed in and on the third revision it spun a bearing after letting off. So we were really upset about the whole situation as that last pull was super conservative, running about 17psi with very conservative timing and afr being on the rich side. Got the car towed and parked it.

After about a year of the car being parked we finally yanked the block out and to our surprise we found out it was an outfront grocery getter series block, both of us were really upset that it spun a bearing being that it was already built and the fact that in my brothers ownership the vehicle was always regularly maintained and always used good oil. The car was regularly logged and never encountered detonation. After splitting the block we found out that it obviously spun a rod bearing, and all bearing wear looked really bad and uneven on the main bearings to the point that one of the main bearings lost tension. Its hard to say why it had that kinda bearing wear, but at this point we were bummed out because the block was already bored out to 99.75 and our hope was that it was a stock block so we can get 99.75 pistons and decent rods and have the case halves closed decked. However if we were to do that with the block we have we would have to bore it out to the next size up which is 100mm and both of us felt like its sketchy to run that size because cracking a liner is something we were trying to avoid. So anyway my brother considered getting a whole new closed deck short block from outfront but that didn't work out, he also considered the IAG route as well but we figured why not be different and sleeve the block.

A friend of mine who I regularly tune has been working with a local machine shop who has experience with darton sleeves on the ej engines as well as other platforms so after getting in touch with the machine shop and having him inspect the case halves we decided to proceed and start gathering a parts list. So this brings us to today, since RealStreet was having a black friday sale my brother made a huge purchase, parts list and part numbers as follows:

Bottom end

Pistons
JE Ultra series pistons 99.5mm 8.5:1cr 361327

Rods
Brian Crower forged I beam rods 130.5mm with 625 fasteners BC6606

Crank
OEM subaru 79mm ej257 crank shaft 12200AA430

Sleeves
Darton dry sleeves 300-031-3

Heads

Cams
GSC S2 Dual AVCS cams 7026S2

Intake valves
GSC Chrome polished stainless steel +1mm 2014-1

Exhaust valves
GSC Super alloy exhaust valves +1mm 2017-1

Valve springs and retainers
GSC Beehive valve springs and retainers 5043

Head studs
IAG performance ARP2000 14MM head studs IAG-ENG-1711

Head Gasket
Currently thinking of using a JE Proseal with copper orings

Update on newest parts list, the sleeve install and line bore was extremely botched by the local machine shop, in the end everything related to the heads stays the same, now as for the bottom end:

IAG 1150 series closed deck case halves are now being used(arp main bolts, pinned mains, 14mm head studs, fire lock grooves)
Still JE ultra pistons although had to buy 99.75mm ones due to IAG requiring next size up to get the bores round after closed decking
Still stock sti nitrited crank
Still BC I beam rods with arp 625 fasteners
IAG CNC oil pump
IAG oil pan and baffle
Head gasket is now IAG firelock
Killer B oil pickup
ACL main bearings
King rod bearings
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Last edited by alexmartynyuk; 03-04-2024 at 04:51 AM.
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Old 12-01-2020, 01:50 AM   #2
alexmartynyuk
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open source tuning subaru

Default

iag case halves





Last edited by alexmartynyuk; 01-29-2024 at 09:59 PM.
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Old 12-01-2020, 01:56 AM   #3
alexmartynyuk
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open source tuning subaru

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pics of blueprinting, unfortunately I didn't take pics of me setting bearing clearances on the rods or mains but I did have to buy two sets of main bearing sizes and two sets of rod bearing sizes(sunnen and mitutoyo tools were used to check clearances not plastigauge), for now I will not disclose the clearances but once I put this thing through some hard abuse and if it holds up I will update the clearances for bearings and ring gaps.












Last edited by alexmartynyuk; 01-29-2024 at 03:20 PM.
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Old 12-01-2020, 01:58 AM   #4
alexmartynyuk
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To set ring gaps, I did have to invest in my own tq plates and a spare set of fire lock gaskets. I checked how much the bores distorted with and without tq plates as well as with and without the firelock rings in place, and let me tell you, on the firelock grooved blocks YOU WANT TO USE THE GASKETS IN PLACE WITH TQ PLATES T TORQUED TO THE FINAL TQ VALUE! Things move A LOT, enough to butcher your ring gaps by a good amount.



I had to modify the piston ring compressor to be able to go flush in the firelock groove otherwise the rings would pop out






Last edited by alexmartynyuk; 01-29-2024 at 03:34 PM.
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Old 12-01-2020, 06:10 AM   #5
Zak6182
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Click on "Images" at the top of this page. Once you have everything setup and your pictures uploaded, select the images you want by clicking the box in the right corner of the picture (see #1 below). Then action (#2) and get embeded codes (#3) and then click copy. Then paste into the forum and the images will show up without having to click the link. At least that's the way I do it.
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Old 03-06-2021, 03:15 AM   #6
alexmartynyuk
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Other IAG stuff

oil pump




Pan and baffle stuff




Heads and cams (new buckets installed not pictured)






Last edited by alexmartynyuk; 01-29-2024 at 11:25 PM.
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Old 04-27-2021, 02:22 AM   #7
alexmartynyuk
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Sorry, this is out of order but before assembly I touched up the oil galley on the case halves where the outlet of the pump is and also the oil pickup area and oil filter housing area.

before


after


different side after


oil pump outlet side before


after


oil filter housing area after

Last edited by alexmartynyuk; 01-29-2024 at 10:04 PM.
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Old 04-27-2021, 02:24 AM   #8
alexmartynyuk
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open source tuning subaru

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I did the cylinder head porting on these w25 heads, I did tons of research before doing any kind of porting and had a decent amount of tutoring from Dave at headgames. Nasioc image hosting killed all of my original uploads so Ill re upload some of the ones I have still

taking some measurements before cutting






time to grind


Cleaning up the combustion chamber area








baking in the sun after pressure washing before going to machine shop

Last edited by alexmartynyuk; 03-04-2024 at 03:49 AM. Reason: more pictures
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Old 04-27-2021, 11:05 PM   #9
alexmartynyuk
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Heads after visiting machine shop





Valve covers powdercoated neon green to match the newer caliper swap




The beautiful bigger factory calipers! sorry for the bad picture


Last edited by alexmartynyuk; 03-04-2024 at 03:51 AM.
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Old 05-20-2021, 01:57 AM   #10
alexmartynyuk
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sort of coming together






Decided to touch up the entry on the runners for the exhaust manifold(forgot to take a picture after i was done)

Last edited by alexmartynyuk; 03-04-2024 at 03:56 AM.
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Old 05-20-2021, 02:08 AM   #11
alexmartynyuk
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ready to get dropped in


getting dropped off at work


and its in



Last edited by alexmartynyuk; 03-04-2024 at 04:08 AM.
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Old 05-31-2021, 04:53 AM   #12
alexmartynyuk
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basemap before first start


Running after first start

https://youtube.com/shorts/QQ6rcsOsXM0?feature=share

3 am everyone is tired and even driving is hard lol


Last edited by alexmartynyuk; 03-04-2024 at 04:41 AM. Reason: added videos
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Old 06-09-2021, 02:22 AM   #13
alexmartynyuk
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First drive after cam break in


Some more videos

Some basic street driving
https://www.youtube.com/shorts/-GJI-wByaUE

All three brothers in the car for the first time
https://www.youtube.com/shorts/trrBrhU17k8

And some easing into it at wastegate pressure
https://www.youtube.com/shorts/R0BmzlgfE3I

Last edited by alexmartynyuk; 04-30-2024 at 04:21 AM.
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Old 06-09-2021, 08:51 AM   #14
Karlot
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nice. what are the plans for the entire build? still plan on the fp turbo or going with something else?
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Old 06-09-2021, 02:07 PM   #15
alexmartynyuk
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Quote:
Originally Posted by Karlot View Post
nice. what are the plans for the entire build? still plan on the fp turbo or going with something else?
Fp red will be used until its broken in, two choices for turbos on hand after break in which are precision 6466 or 6870.

Last edited by alexmartynyuk; 03-04-2024 at 04:43 AM.
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Old 06-09-2021, 03:10 PM   #16
Karlot
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Quote:
Originally Posted by alexmartynyuk View Post
Fp red will be used until its broken in then we will build our own twin scroll kit for an EFR series or maybe one of the precision offerings.
very nice. be sure to keep this thread updated. i'm subscribed and very interested to see where it goes lol. love being able to see other people's builds
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Old 06-10-2021, 03:23 AM   #17
alexmartynyuk
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open source tuning subaru

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Quote:
Originally Posted by Karlot View Post
very nice. be sure to keep this thread updated. i'm subscribed and very interested to see where it goes lol. love being able to see other people's builds
Yeah now that we finally got the ball rolling on this project I will update the thread as we make progress. I need to rip the guts out of the heads so that the guides can be pressed out before I start porting it.
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Old 06-10-2021, 05:18 PM   #18
Ebradley
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Quote:
Originally Posted by alexmartynyuk View Post
Hello everyone! Not sure if this is the right place to start a build thread or the power proven section(mods move if needed but I felt the built motor discussion section would be more appropriate). Anyway, a while ago my brother ended up acquiring a 2015 sti that was mostly stock with the exception of an Invidia catless downpipe. A long time before him getting this car I got into tuning and subaru was my learning platform, doing it as a hobby over time my tuning experience has advanced and because of that my brother was looking out for an sti. After getting this car I quickly checked the map and found it was stock, so after getting a wideband I did a quick stage2 tune on it and it didn't make super high numbers but it was a safe tune. After owning the car for a while and getting bored of low power he ended up getting more mods which included an FP Red turbo(older 35r compressor wheel with the antisurge cover) and other supporting mods with full 3" exhaust and an external wastegate and enough fuel system to support 500whp on pump gas. So we installed everything and started getting the car dialed in and on the third revision it spun a bearing after letting off. So we were really upset about the whole situation as that last pull was super conservative, running about 17psi with not very much timing and flat 11 afr. Got the car towed and parked it for A LONG time, honestly I don't remember the last time it ran. After about a year of the car being parked we finally yanked the block out and to our surprise we found out it was an outfront grocery getter series block, both of us were really upset that it spun a bearing being that it was already built and the fact that in my brothers ownership the vehicle was always regularly maintained and always used good oil. After splitting the block we found out that it obviously spun a rod bearing, and all bearing wear looked really bad and uneven on the main bearings to the point that one of the main bearings lost tension hard to say why it had that kinda bearing wear but at this point we were bummed out because the block was already bored out to 99.75 and our hope was that it was a stock block so we can get 99.75 pistons and decent rods and have the case halves closed decked. However if we were to do that with the block we have we would have to bore it out to the next size up which is 100mm and both of us felt like its sketchy to run that size because cracking a liner is something we were trying to avoid. So anyway my brother considered getting a whole new closed deck short block from outfront but that didn't work out, he also considered the IAG route as well but we figured why not be different and sleeve the block. A friend of mine who I regularly tune has been working with a local machine shop who has experience with darton sleeves on the ej engines as well as other platforms so after getting in touch with the machine shop and having him inspect the case halves we decided to proceed and start gathering a parts list. So this brings us to today, since RealStreet was having a black friday sale my brother made a huge purchase, parts list and part numbers as follows:

Bottom end

Pistons
JE Ultra series pistons 99.5mm 8.5:1cr 361327

Rods
Brian Crower forged I beam rods 130.5mm with 625 fasteners BC6606

Crank
OEM subaru 79mm ej257 crank shaft 12200AA430

Sleeves
Darton dry sleeves 300-031-3

Heads

Cams
GSC S2 Dual AVCS cams 7026S2

Intake valves
GSC Chrome polished stainless steel +1mm 2014-1

Exhaust valves
GSC Super alloy exhaust valves +1mm 2017-1

Valve springs and retainers
GSC Beehive valve springs and retainers 5043

Head studs
IAG performance ARP2000 14MM head studs IAG-ENG-1711

Head Gasket
Currently thinking of using a JE Proseal with copper orings
Following
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Old 07-23-2021, 03:07 AM   #19
alexmartynyuk
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reserved

Last edited by alexmartynyuk; 01-29-2024 at 11:47 PM.
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Old 07-23-2021, 09:03 AM   #20
Tampa_Wagonman
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Following. Looks like one hell of a project! Props to you!!
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Old 07-23-2021, 01:27 PM   #21
benflynn
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Well, I was wondering, what worse than a 900 word essay with no breaks, and now I see, it’s some one who quotes the entire damn thing to say ‘fallowing’
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Old 07-23-2021, 03:47 PM   #22
Dave D.
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Quote:
Originally Posted by benflynn View Post
Well, I was wondering, what worse than a 900 word essay with no breaks, and now I see, it’s some one who quotes the entire damn thing to say ‘fallowing’
Better than multi-quoting the entire thread. GL with the ongoing build, OP!
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Old 07-23-2021, 10:55 PM   #23
undyjr
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Quote:
Originally Posted by benflynn View Post
Well, I was wondering, what worse than a 900 word essay with no breaks, and now I see, it’s some one who quotes the entire damn thing to say ‘fallowing’
That

was

a

tough

read.
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Old 08-10-2021, 01:35 AM   #24
alexmartynyuk
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2005 EVO VIII
open source tuning subaru

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Quote:
Originally Posted by undyjr View Post
That

was

a

tough

read.
I apologize to everyone about the run on sentence and poor writing lol. I wasn’t in the best state of mind as I wrote the first post at like 2am. I did a quick edit on the first post, that said I’m no writer so if you feel like it needs further work give me some pointers.
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Old 08-10-2021, 02:48 AM   #25
alexmartynyuk
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open source tuning subaru

Default

Wanted to mention that because we decided to keep avcs, ended up replacing all 4 of the cam gears with new factory units. Since the previous engine spun a bearing didn't wanna take any chances with trapped shavings working their way out and causing another failure just to save a couple hundred bucks.

AVCS solenoids were reused after extensive cleaning (avcs filters caught all of the shavings).

Oil cooler was replaced with a new factory genuine unit.

Last edited by alexmartynyuk; 01-29-2024 at 11:54 PM.
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