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Old 12-07-2017, 08:55 AM   #1
TWDP
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WRB

Default 2.5 RS GC to to a V6 JDM STi swapped stage rally build

Hey everyone,

I've been a long time lurker on the forums not really into posting on threads but I've managed to learn a lot from on the site and figured I'd document my build on here as well as youtube for the ease of everything.

On to the build:
I've had the car for a few years as a daily driver/RallyX car on the weekends between my wife and I.

This is how the car was sitting last summer for events in it's completely stock form with around 238k on the clock running blown stock struts with my wife driving the car.



Fast forward to the last event of 2017 and the exhaust got ripped off and some misfiring developing under load, which leads me to begin this swap to a V6 EJ207 engine and drivetrain from an RA STI

Initially I was planning on only purchasing the drivetrain but the guy let it go for such a good deal I bought it as a package. I was still only planning on swapping the drivetrain and keep the car slow to get better at driving the car but as you can guess having that turbo engine sitting in my garage got tempting.
Aaaand that's how the swap started.

Future plans:
Over the winter of 2018 strip the car, cage it, logbook it, throw the rebuilt EJ251 back in it and run it in Sandblast Rally in SC or Rally in the 100 Acre woods in MO, and finally if those don't work due to falling behind schedule or work SOFR in ohio.


List of how the car is sitting now.
4/2 Pots w/ stainless lines.
Full RA V6 sti swap
V6 Ej207
4.44 Drivetrain
iWire harness
Feal 451 coilovers
Full bushings, endlinks ETC
Flocked dash

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Last edited by TWDP; 08-02-2018 at 09:39 AM.
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Old 12-07-2017, 09:01 AM   #2
TWDP
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Currently the car already has had the engine pulled and the entire drivetrain from the V6 In the car but It'll take me a bit to sort through stuff and get it all updated here
But if anyone is interested all of it is in these videos.

Video of the last Rallycross with my wife ripping the exhaust off
If anyone is interested I have some of my older progress in my crappy youtube videos.
Theres not much in them just pulling the engine and talking a bit about the swap and putting the rear end/brakes on.


I still need to work a lot on the editing and just making the videos in general but I figured it's an easier way to show progress on the car.
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Old 12-07-2017, 10:21 PM   #3
gjkrisa
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Subaru engines are called H 4 or H6 is that what you mean by v6?
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Old 12-07-2017, 10:24 PM   #4
gjkrisa
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Glad you got a race track you can use in Alaska we oddly don't have a rally track just a stupid oval even have a Nascar track being built
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Old 12-07-2017, 10:49 PM   #5
pakeharugger
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Quote:
Originally Posted by gjkrisa View Post
Subaru engines are called H 4 or H6 is that what you mean by v6?
He meant Version 6 (Subaru Impreza WRX STI Version 6, 1999-2000).
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Old 12-08-2017, 06:52 AM   #6
TWDP
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Yeah he got it right itís just in reference to the drivetrain going into the car since itís from a v6 WRX
Quote:
Originally Posted by gjkrisa View Post
Glad you got a race track you can use in Alaska we oddly don't have a rally track just a stupid oval even have a Nascar track being built


Thatís pretty crappy. In that video itís actually a parking lot of a local fair grounds that they let us use as a course. But Weíve got quite a few local businesses that let us do RallyXís
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Old 12-08-2017, 07:51 PM   #7
TWDP
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Well between work and everything haven't had any chance to work on the car all week so this is more of catch up on where the car is
So engine is currently in and bolted up but I can't do much more on the engine until I get the harness back next week from iWire.
almost looking like its coming together in this picture


I got new endlinks in and installed them since mine were completely shot with the front right actually broke during the last event
Old fronts pretty much destroyed



and new whiteline links


I really want to get the suspension finished but Feal is saying another two weeks for the coilovers so I'll have to rock the old stuff until they come in since I want to get this thing on a first drive next week if everything goes well with startup

The rear brake lines done since the ABS delete and ran up to the cabin to where the hydro will go


and ran new flexible Power steering lines with a braided High line and normal rubber low side, which I'm not too sure on how well it will work since the fittings I went with didn't feel that great getting tight so it may be exponential for leaks.

It would be great if they work on the first shot and I don't have to get more fittings but they're really soft AN fittings

I've got a huge list of stuff this weekend so I should have some better updates as things progress!
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Old 12-13-2017, 08:50 AM   #8
TWDP
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New video up with getting the engine ready to drop in

I did quite a bit over the weekend and haven't had time to post an update

First since I'm on a pretty small budget for stuff right now I modified the stock radiator to work with the cooling system on the JDM engine since it has the separate reservoir on top of the engine.






I took a 1/4 NPT brass fitting and tapped into my radiator and sealed it with thread sealer and some JB weld for now.




Eventually I will get a good radiator for it and this is purely to get the car on the road with keeping the cost low.

Then I modified the stock downpipe that came with the engine to use with an 02 WRX catback.



The JDM catbacks are about 5 inches too short to mate up to a USDM catback so I just extended it and made it compatible with a 3inch exhaust



I had to pretty much make my own Hydro Handbrake since the one I purchased fit terribly in the car..
so I chopped it up and welded it back together in a configuration that will work in the car without being in the way.

so before it was like this


where you pull towards the master and now its like this


The mount isn't done in that photo but now the master will tuck into the dash and only the handle will stick out.
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Old 12-13-2017, 09:14 PM   #9
PeteZ06
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Nice build!
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Old 12-14-2017, 06:29 AM   #10
RavensFan7
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I know it's just temporary, but you could've used the n/a radiator without those brass fittings.

You gut the radiator cap, the one on the actual radiator....carefully cut out the plunger and spring, leaving just the gasket. Run the hose from the radiator's radiator cap to the upper reservoir.....then from the upper reservoir's radiator cap to the overflow bottle.

There's also a way to "T" the 2 radiator cap lines together, then run to the overflow. I don't have experience with that way.

Nice work on the swap though!
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Old 12-14-2017, 07:11 AM   #11
TWDP
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It wasnít that much work to get it this to work and so far thereís no leaks with the car driving around.
I had seen people do it that way but tapping it and teeing off the overflow line made more sense to me.
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Old 12-16-2017, 01:44 PM   #12
TWDP
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I've gotten a lot done on the car so far currently it's running well and is almost completely back together

I got the harness in on Monday but before I started to put it into the car I needed to flock the dash still. So I recruited my wife to help out with the dash and we got it done





Some things I learned from that was make sure you put the glue on thick and evenly, we spread it evenly but on the actual dash section went too thin and it's lacking in areas.
Another thing is do it all in one go and not sections. We did the dash in two sections and ended up with a pretty noticeable line between the two. The smaller sections came out well since they were done in one attempt.
Eventually the dash will get redone but at this point I want it in the car and derivable.

Next up was the harness from iWire


First off they are a great business to deal with. Brian was very responsive to my questions even those completely unrelated to the harness since he knows a lot about JDM swaps.
The turn around time was very quick and the quality of the harness was great also.


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Old 12-16-2017, 01:44 PM   #13
TWDP
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Then I wasn't happy with how the hydro fit still in there and I would have to get rid of too much of the interior to get it to fit.
So I completely re made the bracket and got it to tuck pretty much completely into the dash and the only thing I had to get rid of was the cigarette lighter which I just relocated.




Thats not what it ended up looking like its just the best photo I took of it.
It only looked marginally better though with my poor tig welding skills lol.



I also got the proportioning valve routed through the center console and the knob comes out of the old dummy switch section of the console.



Currently I have some boost leaks I have to track down since it's only hitting about 10 PSI and running really rich because of the leaks, but this thing pulls really hard with the RA gears and this engine.
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Old 01-05-2018, 12:41 PM   #14
TWDP
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Not much to update on the car due to being busy with family stuff last few weeks and progress on the car will be slowing due to work stuff
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Old 01-06-2018, 12:07 PM   #15
TWDP
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Old 01-06-2018, 04:04 PM   #16
TWDP
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got the car running well enough to go play around in the snow for a bit.
Still have a boost leak I need to track down and a bunch of little stuff to get it back together
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Old 01-12-2018, 09:10 AM   #17
TWDP
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Got around to filming the driving of the car and messed around against my wife in her Focus ST to see how it compares.


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Old 01-14-2018, 02:17 PM   #18
TWDP
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Got my Feal 451 Rally coilovers in the mail and managed to get them on the car this week.
The car handles amazingly now on rough roads will without a doubt be great during rallycross.



The old suspension was looking a little rough possibly bent from a few quick glances. Needless to say it wasn't really meant for the abuse it's seen.




I need to play around with the ride height a little more and figure out what kind of preload they recommend for these.
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Old 01-15-2018, 06:40 AM   #19
TWDP
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Old 01-16-2018, 04:18 PM   #20
TWDP
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Made a video of messing around in the car on a deadend backroad.

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Old 03-07-2018, 11:01 AM   #21
Crazyced
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Have you had the chance to test the Feal 451 further?
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Old 03-07-2018, 04:02 PM   #22
TWDP
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Quote:
Originally Posted by Crazyced View Post
Have you had the chance to test the Feal 451 further?
I havenít had a chance to use them at any events just messing around on dirt roads, everything I can tell they are up to the task but until the car is out on stage Or a rallycross I wonít know.
They were discontinued by feal recently though which is odd and when I contacted them they said it was to explore other options.
Iím unsure if itís due to just poor sales or if it performed poorly but I have yet to see anything negative about them.
They did say they would continue to service them and may come out with another rally inspired set up.
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Old 03-08-2018, 10:37 AM   #23
Crazyced
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Quote:
Originally Posted by TWDP View Post
I havenít had a chance to use them at any events just messing around on dirt roads, everything I can tell they are up to the task but until the car is out on stage Or a rallycross I wonít know.
They were discontinued by feal recently though which is odd and when I contacted them they said it was to explore other options.
Iím unsure if itís due to just poor sales or if it performed poorly but I have yet to see anything negative about them.
They did say they would continue to service them and may come out with another rally inspired set up.
That's what I was afraid of after not seeing it on their website. Thanks for the info!
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Old 03-16-2018, 02:50 PM   #24
TWDP
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Quote:
Originally Posted by Crazyced View Post
That's what I was afraid of after not seeing it on their website. Thanks for the info!
No problem, though it's unfortunate they decided to get out of building the coilovers.
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Old 08-06-2018, 11:08 AM   #25
TWDP
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Been a long time since I've had time to do anything with this car due to work but finally did.



The parts have been stacking up so far..



Progress should be picking up fairly quickly now that I have time and plenty of parts



and a video if anyones interested
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