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Old 12-27-2020, 04:21 AM   #1
BSPS
Scooby Newbie
 
Member#: 521018
Join Date: Dec 2020
Default SAS RALLY EDITION Build - S401 EZ30R Turbo

So for the last 12 months I have been modifying a 142 of 400 2002 S401 STI BES5 Legacy with a EZ30R from a 2005 with an GTX3582R G4 Link Custom headers and 3.5" exhaust amongst other modifications , I've had a few questions about the car and adding a turbo to the EZ30R H6 so thought it was time to do a build thread and talk bit how I approached it with the help of Specialised Auto Services https://www.facebook.com/SASworkshop and Vinny fabrication https://www.facebook.com/vinnyfabnz and how it all went with some pictures and whats to come.

https://ibb.co/FBC0MPc
https://ibb.co/bRDP6Lk
https://ibb.co/6D3bydM

I approached SAS in February for a full wiring of the EZ30R and to supply a good engine which they did with 120ish kms on the engine and over the following three weeks got the g4link extreme 4bar map sensor mac valve iat etc i supplied wired in to get it driving as NA form first and foremost due to the lockdown that eventually came and not the best year to start modifying a car but once started had no choice but to finish.
Week of lockdown car was done just in time from awesome bunch of guys and got to drive it doing over 2000km pretty quickly and didn't miss a beat. Decided to tackle this project in three stages once i realized i didn't wanna do it cheaply with non-branded or under preforming parts. Stage 1 wire in the link and get the engine in and running with a daily driver tune, stage 2 turbo the NA engine at safe level and stage 3 build a fully forged ez30 to see what one of New Zealand's best tuners and best workshops can really do when handed a rare collectable S401 STI.

While it was driving good in NA form approached AVS and got a 5 star alarm and gps tracking installed and is good peace of mind and will be looking at adding more in the near future as i am big believer if your spending money on your car you should be looking at tracking from your cell phone as one of your first round of mods.

Over april/may approached vinny fabrication and paid for some headers to be me made up that will bolt the first of two turbos the smaller GTX3582r Gen 2 T3 0.82AR and a turbosmart gen-v hypergate 45mm wastegate i supplied to the H6 engine and they done some amazing work the headers come out really well. I asked for a 2" vband in the up pipe about 15-20cm from the turbo above steering rack so i can at a later point do a 2" vband to T4 for the bigger turbo once the T3 reaches its limits.

https://ibb.co/ySVqQZ7
https://ibb.co/PcwVK53
https://ibb.co/Syspbfn
https://ibb.co/J7fT71Q
https://ibb.co/hZn75XM

While the headers were getting made up I modified the factory rails with AN8 steel weld on fittings then powder coated black. Installed flex fuel sensor then done the split fuel rail mod with a AEM high capacity fuel regulator and -8 Teflon braided line from engine bay fuel rails to the 2litre surge tank in boot with dw300 intank pump with bosch 044 external pump, Picked up 6x Raceworks EV14 1000cc top feed injectors from nzefi and installed them also installed a AEM water injection kit with 1000cc nozzle in the intercooler piping and tank in the boot. Full alloy radiator and fans aeroflow oil sandwiche plate and oil cooler aeroflow pod filter and turbo blanket, 2 fire extinguishers and first aid kit 1kw powertech inverter and 50w solar panel and battery relocated to boot. Installed a Ryzen pc below passenger seat and a 8.9" screen on drivers sun visor to talk to the link ecu with JVC 7" touch screen head unit to bluetooth to pc, 2 amps and a 6x9 sub in parcel tray .

https://ibb.co/NrSNVwf
https://ibb.co/fxK36MM
https://ibb.co/QjgQKBW
https://ibb.co/kgTVSRF
https://ibb.co/44cVRhp
https://ibb.co/jTvkCsB

Approached few places about a exhaust and got a good price so decided to go full 3.5" stainless with the 3.5" perforated resonator and exhaust from Adrenalin-R mufflers good to flow decent amount. Got a vband welded 30cm down off the back of the turbo so i can change turbos and down pipe very easily at later stage.

Got it on the dyno December after all the hard work at SAS through the year and got 400lb/ft on torque and 350hp or 260kw atw on 7.8 psi safe daily drive tune on the Factory NA engine with plenty more to come while i build the second engine up.

https://streamable.com/fzi22h
https://streamable.com/eyzovh
https://streamable.com/y8yizh

Ordered a EZ30 closed deck from pbms and supplied them with a spare block also grabbed spare set of heads off SAS and turn around was about a month on the block getting closed decked with everything else in the catalogue ordered at the same time custom je pistons ppm I-beam rods arp head bolts kelford springs etc. Next years goal building up the forged closed deck block and dropping it in and doing a 2" vband to T4 then looking at next step up with clutch injectors front mount amongst other needed upgrades. Looking at another 6-12months to finish the build with maybe the eventual goal letting SAS get four figures at the engine out of the S401.
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Last edited by BSPS; 12-27-2020 at 05:59 AM. Reason: .
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Old 12-27-2020, 06:09 AM   #2
07imprezRS
Scooby Specialist
 
Member#: 164302
Join Date: Nov 2007
Location: Arizona
Vehicle:
11 20 STi, 11 STi
07 WRX, 02 WRX

Default

Cool build, try using the NASIOC photo sharing website for posting your photos. Makes it easier to see what you’ve got to share with us.

https://img.nasioc.com/?lang=en
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Old 01-05-2021, 01:21 AM   #3
BSPS
Scooby Newbie
 
Member#: 521018
Join Date: Dec 2020
Default

Quote:
Originally Posted by 07imprezRS View Post
Cool build, try using the NASIOC photo sharing website for posting your photos. Makes it easier to see what you’ve got to share with us.

https://img.nasioc.com/?lang=en
appreciated i will do that. Getting ready to put the fully forged ez30 closed deck together and wind up the boost to 25-28 and see what it can do.
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Old 01-07-2021, 09:45 AM   #4
mandkens
Scooby Newbie
 
Member#: 516724
Join Date: Jul 2020
Default

Awesome build. Would love to see more pictures of it.
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