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Old 05-13-2020, 11:23 PM   #76
Patrick Olsen
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What intake manifold did the EJ204 have on it? I've seen pics of some of those that have a variable runner manifold.
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Old 05-13-2020, 11:36 PM   #77
Kostamojen
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Quote:
Originally Posted by Patrick Olsen View Post
What intake manifold did the EJ204 have on it? I've seen pics of some of those that have a variable runner manifold.
Crap that was a typo on multiple fronts... Ej203! I was researching EJ204's last night and I guess it got stuck in my brain
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Old 05-14-2020, 01:40 AM   #78
Kostamojen
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Final update video before race weekend in two weeks:

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Old 05-14-2020, 06:25 PM   #79
Kostamojen
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Alright, did a couple test drives now that the car has a good alignment and non-leaking engine

This engine is NOT BAD AT ALL! I'm quite happy with it. Its certainly putting out more power than with the 1.8l block but not so much as to make the FWD become a torque steer monster. 1rst through 3rd feels plenty quick, should be just fine for Autocross.

Tweaked the Bilsteins a little to make them softer and it rides nice enough. Obviously without the sound deadening and how little there is to the car its rather loud, but thats good because racecar Most of its coming from the trunk area and the stiffer mounts since I don't have a loud pipe yet.

The handling... WOW this thing sticks! You can IMMEDIATELY feel the lack of weight and the huge sticky tires. It doesn't feel like any other car I've owned, not even the 3 other first gen Imprezas. The FWD tugs at the steering wheel but not too much, it doesn't feel like the AWD cars at all.

Turn in is immediate but not as tight as I would like, probably due to the lack of rear swaybar and still not-replaced rear bushings. The car is twitchy on the freeway as well because of no rear sway. I noticed this with my wagon as well, as soon as a rear sway was on it was significantly less twitchy at 70mph+.

Couple pics from today and the alignment specs... The alignment shop couldn't figure out the rear toe bolts with the FWD subframe Its ok though, like I said, still need to work out the rear end.


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Old 05-15-2020, 02:35 PM   #80
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New custom exhaust made today!


So nice to have a Subaru that sounds like a Subaru again

Magnaflow muffler and Magnaflow resonator installed at West Coast Muffler with 2.25" piping and a tip I had laying around. Didn't want it loud because of potential track noise restrictions, plus the fact the car has ZERO sound deadening and I need to drive it long distances. Sounds pretty good though I'm happy.




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Old 05-16-2020, 01:18 PM   #81
Patrick Olsen
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I'd say that sounds pretty darn good. Got part numbers for the Magnaflow muffler and resonator, or were they just the "generic" parts the muffler shop had on hand?
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Old 05-16-2020, 03:02 PM   #82
Kostamojen
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Just the generic 2.25" Magnaflow stuff nothing special.
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Old 05-16-2020, 08:08 PM   #83
Kostamojen
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Took the car on its first long spirited drive to make sure everything is working well for the Autocross next weekend...


Good news: Car drives great in the twisties! SUPER grippy and pulls pretty well out of corners.

Bad news: Small leak from the oil filler tube, not a big issue though since its just the O-ring. The transmission is leaking for sure which is a bigger issue... I think its fine for the race but I'm not sure where its coming from, its either the passenger side diff seal, the front shaft seal, the case itself, or a combination of those. I need to pull the trans to find out, but I probably won't until after the race.
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Old 05-17-2020, 07:14 PM   #84
Pakin
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Awesome build man, enjoyed this thread. Look forward to your first event in the new class!
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Old 05-25-2020, 12:11 AM   #85
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Ran the car in its first events this weekend, here is my first vid:


Car ran pretty good speed wise, I was about a second off the fast GS guys I used to race in the mk7 GTI I had for s year.

It has issues though, REALLY needs a rear sway bar and the adjustable rear lateral links I have on the wagon so I can fix the rear end a big. Also have some serious leaks from the transmission, possibly from the front shaft seal and certainly from the pass side diff seal. The shifter also rattles badly and on Saturday there was another external rotational rattle of some kind.

Biggest issue was the drives back home... No AC in 95 degree weather is no bueno Also the car is rather rough at 75mph and the wheels might be out of balance.

A lot of stuff to work on...
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Old 05-25-2020, 06:28 PM   #86
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Old 05-27-2020, 02:54 PM   #87
Kostamojen
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Dyno day today! I'm happy with the results too, considering this is just EJ18 heads on an EJ203 block and stock intake/header/cat section (just a catback really).




[email protected] [email protected]

It was a hot day today too... Its interesting though that the torque was higher on the first run, but the HP was higher on the last two runs. The motor actually likes to be hot.

For reference, here is my old Impreza 13 years ago with a comparison run for the EJ25 with a custom header setup versus stock header/cat section.



I know its hard to compare numbers from so long ago and different dynos, but only being down about 10whp and 20wftlbs to an EJ25 feels about right considering how strong the car feels right now and running just FWD instead of AWD. Might be worth doing a drag run just for ****s and giggles
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Old 05-27-2020, 03:25 PM   #88
nygbrc
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I love every minute of this. I used to have a 96 wagon bare bones that I loved and wish I did something like this. Miss that car
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Old 05-28-2020, 02:24 AM   #89
Kostamojen
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Some photos from Saturday by www.gorillatornado.com Photography. Car looks pretty good, not much body roll, just need to get that rear swaybar in to help rotate the car.






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Old 05-28-2020, 05:32 AM   #90
archer1.8
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Such as awesome project. What are the next upgrades
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Old 06-19-2020, 05:43 PM   #91
Kostamojen
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Been busy since the last post...

Pulled the transmission due to the leaks. Had to buy a seal kit and a couple seals to do the job, but it did go fairly well.

Its a small transmission, and I believe it shares more in common with transmission from EA motors rather than EJ motors. Very interesting:







No longer leaks btw, so all the leaks on the car are now sorted and it no longer smells like burnt oil after a drive LOL!

Also took the time while the car was up on jacks to redo the rear suspension...

Installed SPC rear control links so I could bring the wheels in more and have better bushings of course. Installed Superpro bushings on the trailing arms as well to stiffen those up, along with adding a 22mm rear sway bar.





The car handles MUCH better now! The sway bar made a big difference with high speed stability along with better turn in. Going to find out tomorrow how well it works for autocross
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Old 06-19-2020, 05:45 PM   #92
Kostamojen
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Also going to start towing the car to events due to the lack of A/C and 100+ degree temps in this area...



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Old 06-22-2020, 02:23 AM   #93
Kostamojen
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Video from the second race weekend!

Had an interesting time with the car, seeing as it handles completely different with the new rear end and sway bar. Started out with some snap oversteer that had to be dialed out, but it was running well by the end.


REALLY need to up my redline though... And get the header/intake on the car for a little more umph.
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Old 07-16-2020, 05:13 PM   #94
Kostamojen
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Few updates.

I've been working on trying to raise the redline the past month or so. What I learned that could be done is swapping out the Clock Crystal in the ECU, which basically overlocks the ECU and causes the redline to raise. Note: I went this route in order to try something cheap and easy with an OBD-I car. A stand alone would be idea, but SUPER expensive and very difficult to setup. This is a stop gap for now.

With some help from Jay Storm, I learned the stock crystal is an 8mhz crystal, and I shouldn't go any more than 10-15% above stock. I started with a 9.2mhz crystal (15%) which raised the redline to 7000rpm, but causes a bit of engine knocking. Tried it with the new intake setup too and it knocked still, so I tried a few different crystals and wound up with an 8.66mhz crystal plus running some octane booster and it works now without engine knock plus with a ~6600rpm redline.






I also installed the old school COBB/PRM intake, which sounded AMAZING at 7000rpms when I tried that, but ya will just be running 6600rpms. Still sounds great at that point and pulls strong. I'm also trying out a plug in the vacuum lines for the smog pump to keep it from running while using this intake.



Finally, I installed a protective grill behind the front bumper to protect the fancy new radiator. It took a big hit on its first long trip, so I had to run SOMETHING especially with running it on the track and what not. Pretty simple setup, have it securred with some zip ties, a couple bolts, and a couple poppers.


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Old 07-31-2020, 02:56 PM   #95
Kostamojen
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Couple of videos and photos from last weekends autocross:







The extra 600rpms made ALL the difference in allowing to keep the car in 2nd gear and not have to shift to third during the course. There still seems to be some engine pinging or something, I'm not sure what else to do about it... Maybe try different injectors and fuel pump, maybe Iridium spark plugs? Not sure at this point.

Also, the front right keeps locking up under hard breaking. Yes it doesn't have ABS, but I had a non-ABS Impreza before and it didn't do this. I'm wondering if its an issue with the 4-pot caliper.

The car looks slow in the exterior video, but really it isn't that slow! It rotates really nicely now. Might have to add some rear camber bolts though to get a little more rear camber. I think the tire wear in the back is a bit much. The rear tire is lifting with the new sway bar though, which is what I expected. Doesn't lift a ton due to the stiff front suspension keeping the car planted. My GTI used to lift the rear a TON more than this.

Next event is an actual track day next month Hopefully the brakes aren't a big issue, but I shouldn't be braking as hard on the track versus autox especially since I won't be competing or anything like that.
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Old 07-31-2020, 03:19 PM   #96
WhiteZombie
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Very cool!

What track are you going to be running?
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Old 07-31-2020, 04:45 PM   #97
Kostamojen
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Quote:
Originally Posted by WhiteZombie View Post
Very cool!

What track are you going to be running?
Thunderhill West with SCCA Track Night in America. Only $105 with a coupon and I don't have to wake up so damn early to attend
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Old 07-31-2020, 11:42 PM   #98
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Thunderhill West will be a blast with that car! Just a larger Auto-X course .
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