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Old 12-30-2016, 04:41 PM   #1
carnz-pj-410
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4 other Subarus

Default carnz Impreza LSTi thread

I've been planning on making a build thread for a long time now, but I've been lazy and haven't felt like typing up the details.....Here goes..

20G 6MT fun machine

Current Photo of car:


Updated Setup Here!




Current (virtual dyno) Power: 361hp/367tq

Directory:
Ortiz Custom Pods Triple Dash Pod Installed - Post #11
JDM GC Nardi Steering Wheel Installed - Post #12
22/02/2017 Road Tuning Results - Post #16
2005 STi Gauge Cluster Overhaul - Post #17
Pulled my SOHC turbo engine, broken #2 piston carnage
New engine is in and running!
- Post #31

I picked up a 95 Impreza Coupe (1.8L, FWD, automatic) for super cheap in May of 2015. The previous owner could not get the car to run and they decided they didn't want to attempt to repair and unloaded it on CL for a great price.

It's been very poorly repainted White by Maaco, but this car is going to be pretty much all business, so the condition of the paint didn't matter to me, I only cared that the body was 100% rust free and all original, never repaired, which it is!

First pic I took of the car (on blown OEM struts and Fedders? springs, after i swapped on silver 2.5RS wheels)


I put new KYB stock-replacement struts and oem springs on the car to make it driveable, and threw on a pair of Gold RS wheels i had laying around. Slight improvement in look, huge improvement in drivability.



The car was obviously boring as hell being a FWD auto 1.8L NA, so I slowly started collecting parts and making a plan for an engine swap.


I bought a donor 99RS from a good friend and got a jumpstart on my swap plans. His RS already had a full STi 6MT swap with DCCD, R180, Brembos, knuckles, etc. So i got all of my driveline stuff handled in one easy purchase, and also got the dash and wiring I wanted to use. 93-97 dashes are hideous, so i knew i wanted to switch up to the 98-01 dash.

Swap Details:
-Driveline-
2003 JDM STi 6MT with SURETRAC front LSD and DCCD
3.90 R180 (HX)
2004 Early-Style Female STi Axles
2004 STi Rear Axles (switching to 2005 soon)
2004 STi Rear Knuckles
2005 STi Aluminum Lateral Links (wider rear track version)
Full Solid Aluminati Engine Mounts, Transmission Mount, and trans crossmember "bushings"
Comp Steelback Stage 2 Clutch
New OEM STi Flywheel
STi "Group N" Short Shifter
Perrin Rear Shifter Bushing
Perrin Shifter Stabilizer Bushing
TiC 6MT Pivot Bushings
TiC 6MT Lever Bushings
DSS Carbon Fiber Driveshaft

-Misc-
Removed ALL sound deadening from the chassis
JDM Front/Rear Lightweight Bumper Beams

-Suspension-
Every Powerflex Suspension Bushing offered
Cusco rear frame brace
Cusco 99RS rear subframe brace
STi pink front Lower arm bar
Whiteline Steering Rack Bushings
STi pink 21mm front sway bar
OEM early-02 WRX 20mm rear sway bar
TEIN Flex Coilovers
Whiteline Subframe Lockdown Bushings
Kartboy T-Bar Bushings
SPC Rear Camber Bolts
TSSFAB Rear Subframe [Winter 2017]
TSSFAB T-Bar [Winter 2017]
TSSFAB Front Subframe [Winter 2017]


-Wheels/Tires-
APEX race parts ARC-8 17x9 ET42 Wheels
245/40/17 Bridgestone Potenza RE-71R Tires

-Engine/Power-
Perrin E4 Equal Length Header
HKS Downpipe
Arashi Dynamics TD05-20G-7cm turbocharger *old setup*
JDM V8 STi Intercooler
Grimmspeed 38mm EWG uppipe
Perrin GD Catback Exhaust
Code:
Blown Up!
2.5L Turbo "frankenstein" engine
 -2014 STi shortblock
 -2004 Legacy N/A SOHC Cyl heads
 -2002 WRX Intake Manifold
 -JDM OEM Top Feed TGV Deletes
 -2006 WRX Fuel Rails
 -Cobb Spec ID1000cc Injectors
 -AEM 3.5BAR Map Sensor
 -AEM IAT Sensor
New Engine!
-705 Block Casting
-Mildly Ported S20 Heads
-Crower 264 Cams
-Arias Pistons
-K1 Rods
-GSC Titanium Retainers
-GSC Valvesprings
-Cosworth Main/Rod Bearings
-2002 WRX Intake Manifold
-JDM OEM Top Feed TGV Deletes
-2006 WRX Fuel Rails
-Cobb Spec ID1000cc Injectors
-AEM 3.5BAR Map Sensor
-AEM IAT Sensor
Company23 Anti-Surge EBCS
NGK PFR7B Spark Plugs
Walbro 255lph Fuel Pump

-Interior/Electronics-
99RS Dash Conversion
99RS Power Window Conversion
98RS Door Cards
98RS Rear Quarter Panel interior panels
JDM STi V4 Front Seats
DEFI E.G.T. Gauge
DEFI Oil Pressure Gauge
DEFI Boost Gauge
DEFI Oil Temperature Gauge
Ortiz Custom Pods Triple Gauge Dashboard Pod
Ortiz Custom Pods Dual Gauge Cluster Trim
AEM UEGO Wideband
CarBerry Rom!!
02 WRX ECU
2005 STi Gauge Cluster
JDM STi Nardi Steering Wheel
2007 STi OEM Radio
Alpine Type-S Front Speakers

I'm sure i am forgetting some stuff for now...


100% of the work on this car was done by me, from the wiring, to the interior swap, to the engine assembly, fuel tank swap, awd conversion, auto to manual conversion, etc

Switch over pictures in next posts

Mike
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Last edited by carnz-pj-410; 04-14-2018 at 06:40 PM.
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Old 12-30-2016, 04:45 PM   #2
carnz-pj-410
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Join Date: Mar 2006
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Location: BALTIMORE
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1995 Turbo Impreza
4 other Subarus

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Beginning the interior teardown

I started with the rear of the car, fully gutted it, then swapped in the 1999RS wiring and panels, then reassembled, and just moved from the rear to the front of the car over the course of several hours. (never thought about how long it takes to fully remove and reinstall the interior of a car lol)

1995 Dash and most HVAC removed


Dash beam and Bulkhead harness removed!


1999RS with 02 WRX ECU merge(all done by me) going in car


1999RS HVAC boxes and dash beam installed in car


1999RS Dash installed!
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Old 12-30-2016, 04:48 PM   #3
carnz-pj-410
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LH door converted to power windows, 98RS door card installed, and LH V7 seat installed


Stripping the RH door, so simple with manual locks and roll-up windows


Finished product after converting to power windows and locks on RH side


Finally putting the tired, old EJ18 to rest
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Old 12-30-2016, 04:50 PM   #4
carnz-pj-410
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N/A Crossmember vs 04 STi Crossmember


Shot of the 6MT and front suspension before crossmember install


Frankenstein Turbo engine dropped in!


Slowly reassembling things in the engine bay


A STi intercooler appears


Shot of my TiAL wastegate screamer pipe, let's wake the dead haha


So close to being ready!
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Old 12-30-2016, 04:55 PM   #5
carnz-pj-410
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Video of my car running, one of the first videos I filmed

Car is running very well and I just put a super basic map on it to get it around but it's running about 14.8psi right now and very little timing, but it pulls great! I'm going to be working on street tuning over the next few weeks to get it all dialed in right.

This has been a super long project, but It's been fun and also a major pain in the ass haha. I really appreciate it more because i literally did every single part of this conversion myself, and anything that wouldn't fit, I modified as needed. Car drives like OEM but RIPS!

Did a test launch last night(hard to hold phone, and steering wheel, and shift at same time) so i only launched it then got off real quick.

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Old 12-30-2016, 05:05 PM   #6
carnz-pj-410
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Comparison of USDM 04 STi intercooler to JDM V8 intercooler, you can see the V8 is taller


2016 STi Power Steering fluid reservoir, had to figure out what tank I was going to use, and this came up cheap so i made it work!


DIY "X-Brace" using OEM seat reinforcements, saw the idea on RS25


This is the wiring chart I made and used when i was wiring the 02 WRX ECU into the 99RS harness. Not too bad, just tedious and time consuming!

Last edited by carnz-pj-410; 12-30-2016 at 05:10 PM.
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Old 12-30-2016, 05:14 PM   #7
carnz-pj-410
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Sorry this thread is kind of jumbled up, i'm just posting up various progress pictures as i find them.

Removal of automatic transmission


6MT shifter appears!


Random closeup of 6MT
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Old 01-02-2017, 09:07 AM   #8
winsor
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DGM

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Love reading through these threads. Glad to see everything is coming together. Any big plans for the LSTI?
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Old 01-02-2017, 10:14 AM   #9
carnz-pj-410
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I want to do some auto-x when it gets warm again. Really just made the car to be a fun backroads/twisties car
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Old 01-02-2017, 04:29 PM   #10
winsor
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Quote:
Originally Posted by carnz-pj-410 View Post
I want to do some auto-x when it gets warm again. Really just made the car to be a fun backroads/twisties car
I'll definitely be paying attention then! I've wanted to take autox abuse off of my wrx and find something else to play with. Good luck!!
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Old 02-07-2017, 06:59 PM   #11
carnz-pj-410
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Installed an Ortiz Custom Pods triple gauge pod today, happy with the fit and finish of the product.


Made a little review video
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Old 02-11-2017, 09:25 PM   #12
carnz-pj-410
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Installed a JDM STi Nardi Steering wheel today!

Got it from a friend for cheap, it's a little beat up but everything is an improvement over a stock usdm unit



Also got a video of my car using CarBerry Spark Cut Launch Control

the flamethrower effect is pretty cool


Last edited by carnz-pj-410; 02-11-2017 at 09:41 PM.
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Old 02-11-2017, 09:55 PM   #13
carnz-pj-410
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Also, ordered Ortiz Custom Pods 2-gauge cluster surround pod. I am going to run 2 DEFI gauges in there, one Boost, and move my Oil Pressure gauge there as well. My center triple gauge pod will have my E.G.T., AEM Wideband, and DEFI Oil Temperature.
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Old 02-17-2017, 05:26 PM   #14
carnz-pj-410
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Did some weight reduction today.

Installed front and rear JDM bumper beams

Rear USDM vs JDM


Front USDM vs JDM
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Old 02-18-2017, 07:46 AM   #15
carnz-pj-410
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Weighed my car last night at the truck scale: 2760lbs (rounds to nearest 20lbs)

The beams were about a 40lb drop over the previous weight
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Old 02-23-2017, 12:49 PM   #16
carnz-pj-410
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Did some more road tuning last night, made some pretty good gains and the car feels great.
I think this baby 20G is about maxed out, not bad for a SOHC turbo
Sorry for the potato photo lol



Blue run is first pull of night 282hp/347tq
Green run is final pull of night 361hp/367tq
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Old 02-24-2017, 01:10 PM   #17
carnz-pj-410
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Freshened up my 2005 STi gauge cluster today. New glass, new visor, and new 2007 STi "window plate". The 2007 STi got a darker background than 04-06 and, in my opinion, looks much nicer.
Heres a few shots of the process.
Before


Removed old Glass


Removed old Visor



Removed old Window Plate


2007 STi Window Plate and Visor installed


Finished product with new glass

Last edited by carnz-pj-410; 06-27-2017 at 10:09 PM.
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Old 03-02-2017, 04:21 PM   #18
carnz-pj-410
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Blew up my SOHC turbo frankenstein engine last night

hard knock event at 28psi at WOT = cracked piston.

Cyl 1 = 165psi, Cyl 2 = 60 psi, Cyl 3 = 185 psi, Cyl 4 = 185 psi

Virtual dyno for last night's tuning runs showed a new max peak torque of 410ft-lb too

Oh well i'll be pulling it down soon!
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Old 03-03-2017, 01:16 AM   #19
Smoke
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Very nice car. I can't wait to see more pictures, and videos when it gets moving again.
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Old 03-03-2017, 07:17 AM   #20
carnz-pj-410
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Thanks!

There will be plenty of pics and videos during the repairs and once it's running again

Going to be some delay as I am getting married in May, so i don't want to dump any extra money into this until that passes.

Version B of the Coupe will be faster and cooler!

Mike
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Old 03-14-2017, 04:01 PM   #21
carnz-pj-410
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I'm in the planning phase of my next engine and power setup, one thing for sure is I'm porting the heads.

I started working on my heads today, and got one of the intake ports roughed in, decided to take a few pics and compare ported to OEM ports. These are D25 heads BTW

LH Ported Intake vs RH OEM Intake


OEM RH Intake D25 Port (ugly casting marks, and so small)


Close up of my LH Ported Intake Port (not smoothed or polished yet)


Been using the "bottlecap" method for checking port size.


Going to smooth out and polish this port and move on to the rest! Haven't decided if i'm gonna work on the exhaust ports or not.
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Old 03-14-2017, 07:01 PM   #22
Patrick Olsen
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1996 Impreza coupe

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What tool(s) are you using for the porting?
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Old 03-14-2017, 07:09 PM   #23
carnz-pj-410
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I do the rough cuts with double-cut carbide bits, then smooth with various grit paper wheels and polish with flap wheels. Photos of cleaning up the rough cuts coming in a few days
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Old 03-14-2017, 07:22 PM   #24
SpicyPeaNut
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I clicked this thread fully expecting it to be an LS engine in a wrx.

Even though I was wrong this thread does not disappoint. Keep up the good work.
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Old 03-15-2017, 08:33 AM   #25
Patrick Olsen
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1996 Impreza coupe

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Quote:
Originally Posted by carnz-pj-410 View Post
I do the rough cuts with double-cut carbide bits, then smooth with various grit paper wheels and polish with flap wheels. Photos of cleaning up the rough cuts coming in a few days
Do you use an air grinder or something electric (drill or Dremel or whatever)?

I've got a spare set of EZ30 heads that I grabbed at the junkyard for cheap, figured I'd try my hand at porting some day.
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