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Old 05-12-2020, 12:12 PM   #1
harryr34
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Default 07 UK STI 2.35 EJ22T Front Mount EFR9180 Build

Hi All,

I hope you are well, thought i'd share my STI build that is nearing completion over in the UK. It should be ready for mapping within the next 7-10 days.

- 2.35 engine, EJ22T block bored to 97.5mm, Mahle extreme pistons
RCM arrow extreme rods, mahle bearings, 79mm crank, rcm 14mm headstuds, RCM gaskets, Kevlar HKS belt and pulleys, AVCS JDM 2.0 fully ported and polished heads with Lateral Performance race cams and Supertech valves, titanium retainers, double valve springs and seats, Adjustable vernier cam pulleys.
- Dailey engineering dry sump kit.
- Custom front mount exhaust manifold and 3.5" downpipe/exhaust (Walton Motorsport UK).
- Borg Warner EFR9180 turbo, 0.92 twin scroll housing, 2x EWG.
- Cosworth Inlet Manifold with TGV Delete Housings and Fuel Rails.
- 2x external Bosch 044 Fuel pumps with a 3L swirl pot setup and ASNU 1500cc injectors, -8AN Teflon Braided lines throughout.
- Syvecs S6+ Including Toucan and associated sensors.
- Aquamist HFS3 water/meth injection kit.
- JDM Spec C Quick Steering Rack.
- Cosworth AP front brake kit.
- CAE Ultrashifter



















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Old 05-12-2020, 01:18 PM   #2
Gigs90
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Will be very interesting to see how that big EFR responds to your low mount setup , appears to be a wonderful all around build. If only you had access to the E85 we have in the states.

How do you like the quick jacks ?
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Old 05-12-2020, 03:05 PM   #3
harryr34
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Quote:
Originally Posted by Gigs90 View Post
Will be very interesting to see how that big EFR responds to your low mount setup , appears to be a wonderful all around build. If only you had access to the E85 we have in the states.

How do you like the quick jacks ?
Fingers crossed it will be worth the effort.

I love the quick jacks, have had them for almost 3 years, a pleasure to use.
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Old 05-13-2020, 12:05 PM   #4
Chooten
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Great looking build!!
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Old 05-13-2020, 05:33 PM   #5
Swift2
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Amazing build! I am also doing an EJ22 block into 2.35L, but going with a smaller turbo.

Who did the build and who is your tuner?

Also the heat wrap looks proper, is that bonded to the piping like for F1 cars?
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Old 05-14-2020, 07:29 PM   #6
technikhaus
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Wow what an epic looking machine.
With those specs I was expecting a fully caged race-car.
That's going to be an amazing road machine!
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Old 05-15-2020, 08:08 PM   #7
harryr34
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Quote:
Originally Posted by Chooten View Post
Great looking build!!
Thanks, it has been a long term, spare time build, looking forward to completing it now.

Quote:
Originally Posted by Swift2 View Post
Amazing build! I am also doing an EJ22 block into 2.35L, but going with a smaller turbo.

Who did the build and who is your tuner?

Also the heat wrap looks proper, is that bonded to the piping like for F1 cars?
Thanks, the engine was built by Area52 in the UK, the rest has been put together by myself bar the exhaust and intercooler/piping work. For mapping I usually use Martyn @ Enginetuner in the UK.

The exhaust lagging has been done by Thermo Met in the UK, their work is amazing!

Quote:
Originally Posted by technikhaus View Post
Wow what an epic looking machine.
With those specs I was expecting a fully caged race-car.
That's going to be an amazing road machine!
Thanks, I really want to keep this as a road car for a couple of years at least as my 4 year old son is quite hands on with this build, itd be nice to get some use out of it with the family before stripping it and caging it for track use.
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Old 05-17-2020, 11:54 AM   #8
OppositeLock
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Looks awesome! What heat wrap is that on the header and dp?
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Old 05-17-2020, 05:24 PM   #9
stu
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good job. love that wrap!
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Old 05-18-2020, 05:31 AM   #10
harryr34
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Quote:
Originally Posted by OppositeLock View Post
Looks awesome! What heat wrap is that on the header and dp?
Thanks, the manifold and downpipe heat lagging was completed by https://www.thermomet.co.uk/
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Old 05-18-2020, 08:02 AM   #11
Smurftastic
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Epic build! Out of sheer curiosity, how to you handle the routine MOT requirements?
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Old 05-18-2020, 12:23 PM   #12
OppositeLock
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Quote:
Originally Posted by harryr34 View Post
Thanks, the manifold and downpipe heat lagging was completed by https://www.thermomet.co.uk/
Cool stuff, thank you!
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Old 06-01-2020, 05:32 PM   #13
harryr34
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In between life getting in the way I***8217;ve managed to make some progress;

- Dry sump lines have all been covered in fire sleeve, fitted up and the whole system has been primed.
- ASNU 1500cc injectors fitted.
- Breather pipework fitted.
- Turbowerx Exa turbo scavenge pump fitted.

Outstanding tasks:
- Turbo oil drain pipework
- Fuel pump carrier AN fittings and pipework to swirl pot
- Wire in the the rest of the sensors to the Syvecs ECU, load a basemap, tweak IO and get it running.

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Old 06-11-2020, 04:12 PM   #14
Barge
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Is that a custom radiator? It looks kind of like a subaru radiator but kind of not.
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Old 06-11-2020, 05:52 PM   #15
harryr34
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Quote:
Originally Posted by Barge View Post
Is that a custom radiator? It looks kind of like a subaru radiator but kind of not.
It is an off the shelve Mishimoto Universal Radiator, 25.51" x 16.3" x 2.55".
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Old 08-01-2020, 04:16 PM   #16
harryr34
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Last edited by harryr34; 08-01-2020 at 04:29 PM.
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Old 08-01-2020, 05:27 PM   #17
2slofouru
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My BOV goes
COVFEFE!

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Quote:
Originally Posted by harryr34 View Post
It is an off the shelve Mishimoto Universal Radiator, 25.51" x 16.3" x 2.55".
If you want the radiator to actually work correctly and not waste time dealing with overheating, get a proper shroud and not something like Mishimoto offers. You need two shrouds, one for each fan, and both shrouds should seal to the edge all the way around the shroud. Aftermarket slim fans already aren't up to par with oem for flow, using aftermarket shrouds is a disaster waiting to happen. I constantly see people chasing high temperature situations and they are usually running aftermarket garbage shrouds and fans. Do yourself a favor and avoid all of that.


And yeah, that looks like some serious power will be had. Will definitely be paying attention. Have fun!
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Old 08-01-2020, 06:03 PM   #18
harryr34
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Quote:
Originally Posted by 2slofouru View Post
If you want the radiator to actually work correctly and not waste time dealing with overheating, get a proper shroud and not something like Mishimoto offers. You need two shrouds, one for each fan, and both shrouds should seal to the edge all the way around the shroud. Aftermarket slim fans already aren't up to par with oem for flow, using aftermarket shrouds is a disaster waiting to happen. I constantly see people chasing high temperature situations and they are usually running aftermarket garbage shrouds and fans. Do yourself a favor and avoid all of that.

And yeah, that looks like some serious power will be had. Will definitely be paying attention. Have fun!
The advice is much appreciated, Ill be monitoring temps and changing parts if required. Space is at a premium with the turbo positioned where it is, on the first pass I managed to squeeze in a pair of 9 Davies Craig fans, if theyre not up to the task Ill have to cut away some of the front panel and implement a better solution.

https://daviescraig.com.au/product/9...c-fan-12v-0160
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Old 08-01-2020, 06:23 PM   #19
2slofouru
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Quote:
Originally Posted by harryr34 View Post
The advice is much appreciated, I***8217;ll be monitoring temps and changing parts if required. Space is at a premium with the turbo positioned where it is, on the first pass I managed to squeeze in a pair of 9***8221; Davies Craig fans, if they***8217;re not up to the task I***8217;ll have to cut away some of the front panel and implement a better solution.

https://daviescraig.com.au/product/9...c-fan-12v-0160
Don't mention it, anything to help a fellow enthusiast. It pains me seeing so many high power subies with coolant setups that are lower capacity than the original oem, yet demanding much more cooling capacity. Aftermarket fans simply aren't designed to move as much air and dropping fan size and blade pitch further lowers their efficiency. They are designed primarily for setups that have less than oem room for fans.

Keep in mind, a fan is only as good as the shroud it's attached to. If you don't have much depth, you need to get the largest fans possible and design your shroud to fit and seal well.

The subject of fan and radiator setups isn't discussed nearly enough here. We need a thread dedicated solely for radiator and fan shroud design, discussion always seems to splinter off into nonsense. I'd start a thread, but don't have enough proof of my knowledge to keep people participating in the thread. People here expect a racing pedigree or degree thermodynamics before they will actively engage in a thread on something this controversial. I just stick with trying to help when the opportunity arises.

Last edited by 2slofouru; 08-01-2020 at 06:29 PM.
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