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01-04-2013, 05:58 PM | #1 |
Scooby Newbie
Member#: 143982
Join Date: Mar 2007
Chapter/Region:
South East
Location: NC
Vehicle:2004 Impreza WRX STi Java Black Pearl |
Setaro's 2004 STi- losing the bolt on's
It is long overdue that I make this. This is my 2004 Java Black STi. I bought it July 7th 2007. Bone stock. Over the last 5 and a half years, it has become a huge part of who I am. Over the years I’ve done quite a few basic mods, but in October of 2011, I decided to dig in and do something that I have wanted to do for a very long time; rotated turbo, reversed intake manifold.
The very first day I met my STi. July 7 2007 absolutely bone stock. First day home. Sometime in 2009 one of my favorite shots before pulling apart. The last day I drove it before beginning the build. Here is the mod list as the car stands today: Cobb AccessPORT (42 Autosports tune) Braille lightweight battery - 15 lb. Mounted with braille aluminum battery mount kit Powerslot slotted brake rotors front and rear Project Mu H12 street/track compound brake pads front and rear Motul RBF 600 DOT4 brake fluid ACT 6 puck sprung hub clutch with HD pressure plate and ACT streetlite flywheel Whiteline Steering rack bushings Kartboy front and rear shifter stay bushings Turbo: Borg warner/ Bullseye power S259 Batmowheel Billet compressor wheel. Compressor: 59mm Inducer / 80mm Exducer BatMoWheel Turbine: 64mm Inducer / 74mm exducer 70a/r Oil source same as factory location: banjo bolted from head to a 'T' fitting, running -4 lines from 'T' to turbo and to passenger side avcs Reverse intake manifold Aluminum 10mm tgv spacers (between tgv and head) Aluminum 10mm Throttle body spacer Tgv deletes Custom routed intercooler piping - 2.25 from turbo to I/c - 2.75 from I/c to tb Perrin Fmic Tial 50 mm BOV Relocated brake booster barb fitting 3.5" maf housing NGK 1 step colder plugs LFR7AIX Separate breather and catch can systems (keeping the pcv system and valve cover breathers separate) Deatschwerks 850cc side feed injectors (flow balanced within 1%) Walbro 255 fuel pump Gruppe-s unequal length header Perrin rotated up pipe- modified to accommodate tial mvs wg. Custom rotated 3" down pipe with wastegate dump plumbed back in. Tial MVS wastegate (water cooled) -6 water lines from head to wg and wg to coolant tank Gm 3 port boost controller Invidia N1 race cat-back Aps coolant overflow tank. Fluidyne aluminum racing radiator Drivers side radiator fan changed to slim fan to make room to I/c piping Setrab oil cooler (vertically mounted behind intercooler; mounted on rubber) Mocal thermostatic sandwich adapter -8 lines from cooler to sandwich plate Stainless steel braided high pressure power steering line Extended throttle body harness to accommodate intake manifold reversal, and to allow tb to open horizontally Debadged trunk (kept the STi emblem) Pillarless grille mod Spec-c front lip Rota Grid 18x8.5 Hyper-black Defi BF series 60mm gauges, white numbers with red needle, metric reading, boost, exhaust gas temperature, and oil temperature, all inside an ATi abs plastic clock replacement gauge pod. AEM Uego wideband. Alpine CDA-9856 head unit with iPod cable Factory option embroidered STi floor-mats - black. OEM leather STi owners manual case 118 db Hella horns I decided to go though all this before building the engine so that I could have everything running and shaken down prior to going all out for everything the turbo/fuel system will do. That, and my wallet can only take so much of a beating at a time.
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01-04-2013, 05:58 PM | #2 |
Scooby Newbie
Member#: 143982
Join Date: Mar 2007
Chapter/Region:
South East
Location: NC
Vehicle:2004 Impreza WRX STi Java Black Pearl |
And so it begins.
Remove intake manifold and reverse. Install TGV deletes, 850cc injectors, TGV spacers, and throttle body spacers. Relocate brake booster line on intake manifold. TGV spacers Originally, this was the only orientation I could mount the throttle body due to the lack of clearance from the TB motor. I didn't like this orientation. I felt that under part throttle, the blade opening would favor the drivers side cylinders. So I made clearance. That's more like it! |
01-04-2013, 05:58 PM | #3 |
Scooby Newbie
Member#: 143982
Join Date: Mar 2007
Chapter/Region:
South East
Location: NC
Vehicle:2004 Impreza WRX STi Java Black Pearl |
Perrin FMIC core mounted
That means its time to cut this up. I believe it fits. The very finest paperweights money can buy Factory vf39 next to BW/bullseye power S259 Ok, now for the fun part. The turbo is mounted on a Perrin rotated up pipe. This is one of very few pre made parts on the car. We decided to run the charge piping the way we wanted, we would need to weld a 90* elbow on the compressor housing. So the turbo comes apart. This is the batmowheel. It truly is an interesting looking compressor wheel. Elbow tacked on. |
01-04-2013, 05:59 PM | #4 |
Scooby Newbie
Member#: 143982
Join Date: Mar 2007
Chapter/Region:
South East
Location: NC
Vehicle:2004 Impreza WRX STi Java Black Pearl |
Starting on the cold side piping. I decided to keep my A/C. It made life pretty difficult, but worth the extra headaches in the long run.
One side down. Hot side piping. The bov can bee seen here on the cold side piping. Mocal thermostatic sandwich plate. -8 lines heading to a Setrab cooler. Jumping ahead a bit, but here’s the oil cooler mounted. Catch can system: one can for PCV system, the other for the valve cover breathers. To the exhaust. I am running an Tial MVS (38mm). For those of you who don’t know, the Perrin rotated up pipe is only made for a 44mm WG. More modification! We added a soft 90* bend to pull the WG away from the trans, and allow the WG out to flow more smoothly into the downpipe. In the first shot you can also see the water lines to and from the WG. I was able to easily run water lines here since the new turbo only has provisions for oil. WG out merging back into the downpipe. |
01-04-2013, 06:00 PM | #5 |
Scooby Newbie
Member#: 143982
Join Date: Mar 2007
Chapter/Region:
South East
Location: NC
Vehicle:2004 Impreza WRX STi Java Black Pearl |
Built the intake using 3.5" piping and the same sized maf. Yes the maf is huge, yes its definitely too big, yes im considering a smaller one. Also in this shot you can see where we relocated the coolant reservoir tank off of the passenger side strut tower.
putting the final touches on the car before getting it tuned. At 42autosports. Since this is a stock motor for the time being, the goal was no more than 400whp. Steven and all of his guys at the shop were more than accommodating. It's easy to tell that these people love their job. They were excited to see an uncommon build, and excited to make future plans. The car made just shy of 400 on spring pressure (19lbs). The inaugural drive home! Brought it up to Ocean City for Cruisin OC. As it sits today. |
01-04-2013, 06:14 PM | #6 |
Scooby Specialist
Member#: 77200
Join Date: Dec 2004
Chapter/Region:
NESIC
Location: Woodinville, WA
Vehicle:2002 WRX WRB w/BoBo trunk monkey |
Looks like crap what a n00b! JK! Looks good bud now get it the hell out of the garage and drive it a bit!
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01-04-2013, 06:35 PM | #7 |
Scooby Specialist
Member#: 198179
Join Date: Dec 2008
Chapter/Region:
MWSOC
Location: Cleveland,ohio
Vehicle:2009 GTR Red |
Are u going break the motor open and run different cams?
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01-04-2013, 06:41 PM | #8 |
Scooby Newbie
Member#: 143982
Join Date: Mar 2007
Chapter/Region:
South East
Location: NC
Vehicle:2004 Impreza WRX STi Java Black Pearl |
Definitely. I wanted to get all of the fabrication out of the way first, since it is the more difficult part, then drop a built motor in after. I'm hoping to sleeve the block, upgraded pistons, rods, cams and go from there.
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01-16-2013, 10:48 PM | #9 |
Scooby Newbie
Member#: 143982
Join Date: Mar 2007
Chapter/Region:
South East
Location: NC
Vehicle:2004 Impreza WRX STi Java Black Pearl |
No love?
No, but really, what gives? |
01-16-2013, 10:58 PM | #10 |
Scooby Specialist
Member#: 156877
Join Date: Aug 2007
Chapter/Region:
MAIC
Location: Montgomery Village, MD
Vehicle:04 sti |
Looking good! do you have the dyno plot?
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01-16-2013, 11:03 PM | #11 |
Scooby Guru
Member#: 219492
Join Date: Aug 2009
Chapter/Region:
Tri-State
Location: Soviet Russia
Vehicle:17' 5mt XV & 02 WRX @comrad |
gonna go scoop less soon? maybe an RS hood?
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01-16-2013, 11:04 PM | #12 |
Scooby Specialist
Member#: 156877
Join Date: Aug 2007
Chapter/Region:
MAIC
Location: Montgomery Village, MD
Vehicle:04 sti |
also what brand and size coolant line did you use for your ewg? are the fittings on the wastegate -an or did you need some special fitting?
nm: they're -4 on the wastegate Last edited by Ballistic1350; 01-16-2013 at 11:06 PM. Reason: looked it up myself... |
01-16-2013, 11:05 PM | #13 |
Scooby Newbie
Member#: 143982
Join Date: Mar 2007
Chapter/Region:
South East
Location: NC
Vehicle:2004 Impreza WRX STi Java Black Pearl |
i do! bear in mind, its on spring pressure (19lbs). Not too bad for a stock motor. With any luck, it wont be that way much longer.
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01-16-2013, 11:08 PM | #14 |
Scooby Newbie
Member#: 143982
Join Date: Mar 2007
Chapter/Region:
South East
Location: NC
Vehicle:2004 Impreza WRX STi Java Black Pearl |
Coolant lines are -6, fittings are an. We took the supplied -4an fittings and modified them to support -6 instead (cut and weld to make a hybrid fitting).
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01-16-2013, 11:14 PM | #15 |
Scooby Specialist
Member#: 267343
Join Date: Dec 2010
Location: Southern California
Vehicle:2006 STI White |
how many miles have you put on the stock internals with that kind of power?
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01-16-2013, 11:18 PM | #16 |
Scooby Newbie
Member#: 143982
Join Date: Mar 2007
Chapter/Region:
South East
Location: NC
Vehicle:2004 Impreza WRX STi Java Black Pearl |
Just over 86k. However, I'll be lucky if I put 2,000 miles on the car all year. Partially due to my job keeping me on the road quite a bit, and the other part a perpetual fear of breaking it before its properly assembled
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01-16-2013, 11:42 PM | #17 |
Scooby Specialist
Member#: 156877
Join Date: Aug 2007
Chapter/Region:
MAIC
Location: Montgomery Village, MD
Vehicle:04 sti |
wow seems really really laggy
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01-16-2013, 11:54 PM | #18 |
Scooby Newbie
Member#: 143982
Join Date: Mar 2007
Chapter/Region:
South East
Location: NC
Vehicle:2004 Impreza WRX STi Java Black Pearl |
It is a bit. We played with the boost controller a little and had it reaching full spool much more quickly, but I really don't want to push my luck with the stock internals.
Also, I'm having some temperature issues since nothing is coated or wrapped yet. So there is also some timing being pulled. All in the plans for the future. |
01-17-2013, 01:26 AM | #19 |
Scooby Newbie
Member#: 242932
Join Date: Apr 2010
Chapter/Region:
South East
Location: New Orleans, La
Vehicle:2004 WRX STi WRB |
Love it
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01-17-2013, 07:12 AM | #20 |
Scooby Newbie
Member#: 143982
Join Date: Mar 2007
Chapter/Region:
South East
Location: NC
Vehicle:2004 Impreza WRX STi Java Black Pearl |
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04-19-2013, 01:01 PM | #21 |
Scooby Specialist
Member#: 77200
Join Date: Dec 2004
Chapter/Region:
NESIC
Location: Woodinville, WA
Vehicle:2002 WRX WRB w/BoBo trunk monkey |
Sick build, cant wait to see how it does once you finish everything up!
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