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Old 12-24-2008, 11:00 AM   #1
Butt Dyno
Street's closed, pizza boy
 
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Join Date: Apr 2002
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2006 Evo #17 STU

Default ESP-The 2002 WRX Project

Starting this for Greg.

Go Greg!
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Old 12-24-2008, 12:07 PM   #2
mccanixx
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Location: San Diego, Ca.
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2005 XT 5sp, 02 WRX
01 Legacy 95 Impreza L

Default ESP-The 2002 WRX Project

Or, how to ruin a perfectly good STX car;

ej205 to ej255 < - for those doing searches in the conversions forum.

First I'd like to thank Billy Brooks and Jason Wong they've been helping me and have committed to helping me through next year. You guys rock!

This will be part swap, part set-up, part R&D, part how-to. I probably could have put this in conversions or motorsports but thought it best fit projects.

In the effort of free information and transparency, for fellow auto-x enthusiasts, I thought I'd begin a new thread. As many know the car in question has had a good and successful life as a STX car. Although I believe it would have performed admirably next year and beyond, in STX, I was bored with it and ready for a change. I have not worked on the car in over 2 years more than basic maintenance and really missed throwing wrenches so I dived into something different. And putting it in *SP will guaranty that I'll probably have something to constantly wrench on.

I had thought about selling it but I could not bear to part with my car! It has served me well for 7 years and at around 78,000 miles it goes under the knife.

What began as a thought or idea on the drive home from Topeka this September has became a full fledged obsession sitting in my garage. If you're prepping a 350+ ft-lb of tq. engine with a stock 5 speed transmission you must have some level of commitment to the side effects that are bound to come along.

I first laid out a basic cost/component structure. Then I laid out a schedule to start around the 1st of November 2008 and get it out of the garage by the end of March 2009. I know I have the advantage of it not being a DD.

All of this begins with owning the service manuals to each year. The internet is your friend. I may seem to go back and forth on some sequences with the project but it will probably be dictated by the availability at the time of funds/parts.

Hopefully this is all KC approved.

So follow along and have fun.

Greg

Last edited by mccanixx; 06-04-2009 at 08:11 AM.
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Old 12-24-2008, 12:11 PM   #3
mccanixx
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Join Date: Apr 2004
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Location: San Diego, Ca.
Vehicle:
2005 XT 5sp, 02 WRX
01 Legacy 95 Impreza L

Talking

It's hard to update once the season starts.

For those who didn't tune in when the thread was started: We put a 2.5 out of a 2007 wrx in it , along with the complete wiring harness. Worked through some issues. Threw some diffs in it and some big old tires on it and went racing.

Car's current stats.

Sponsors:
ModeRacing/PureTuning

Vehicle Weight at Lincoln in May was 2933lbs. With about 3/8 of a tank
Engine:
2007 WRX engine
APS intercooler
Perrinn turbo inlet
K&N Typhoon intake
TGV delete
Grimmspeed 8mm intale spacers
Grimmspeed 3port BCS
Cobb AP tuned by Keith @ PureTuning
~230hp ~300tq

Trans:
2002 wrx Transmission rebuilt w/used gears...... I do live dangerously
MFactory Helical front diff
Cusco 1.5 rs rear
Stock clutch PP and Flywheel

Suspension:
ZZYZX coilovers 12K fronts 6" 11K rears 6"
Stock front sway 17mm I think
24-27mm rear sway......may remove entirely
2006 WRX aluminium front LCA's
All suspension and chassis bushes have been changed.

Brakes:
328mm st 40 fronts w/endless pads
328mm st 20 rears w/hawk hp's

Wheels/Tires:
Rota grids 18x10 +35 bronze
Rota grids 18x9.5 +35 white
Enkei RPF-1'a 17x8 +45 orange
Hoosier A6's 285/30/18
Hoosier wets 245/40/17

Current pics



Last edited by mccanixx; 02-25-2010 at 09:44 AM.
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Old 12-24-2008, 12:11 PM   #4
mccanixx
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Join Date: Apr 2004
Chapter/Region: SCIC
Location: San Diego, Ca.
Vehicle:
2005 XT 5sp, 02 WRX
01 Legacy 95 Impreza L

Default Engine/Wiring Harness

2009 Results:

Local: I try not to get to hung up on local events. I usually use them to play or test-n-tune.
Event #1
Event #2
Detroit Memorial day event
Event #3
Event #4
Event #5
Event #6
Event #7
Event #8
Event #9
Event #10

National:
Lincoln Pro
DC Pro
Toledo Pro

Pro Finale

Solo Nationals


Ah the airport. I'm almost going fast, Jason hates the color of these wheels. IDK they're kinda growing on me.






Last edited by mccanixx; 10-23-2009 at 12:55 PM.
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Old 12-24-2008, 12:14 PM   #5
mccanixx
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Join Date: Apr 2004
Chapter/Region: SCIC
Location: San Diego, Ca.
Vehicle:
2005 XT 5sp, 02 WRX
01 Legacy 95 Impreza L

Default Drivetrain

I made the decision to go with a helical front and a 1.5 clutch rear. I will be currently leaving the factory center diff in. In conversations with others they did not necessarily like the performance of the 35/65. It will be using either the top street clutch/pressure plate or the low end H-D version. I see no need to put unneeded load on the gearsets and would rather go through clutches instead. I will also be replacing the flywheel with lighter a street version.

I will be performing these projects myself because no good ESP/WRX build would be complete without an extra transmission and a small shop press.

Update 2/16/09
Got around to installing the cusco rear. I pulled the drain plug and got:



I'd say I was very lucky last season to not have a failure. Probably even luckier that the pro-finale was rain. There were actually (2) whole teeth and a bunch of shards from the spider gears.

The swap was pretty straight forward. It took about 2 hours to pull it from the car, swap it, and re-install it in the car.

Last edited by mccanixx; 02-15-2009 at 12:09 PM.
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Old 12-24-2008, 12:15 PM   #6
mccanixx
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Join Date: Apr 2004
Chapter/Region: SCIC
Location: San Diego, Ca.
Vehicle:
2005 XT 5sp, 02 WRX
01 Legacy 95 Impreza L

Default Drivetrain

Installed the helical diff this morning.
I already had the trans split that we blew 1st gear in at the dc pro in 2007. It has a new mainshaft, 1st and 2nd.

I made this by buying 2 $10.00 sockets. (1) 50mm and (1) 2.25" cut the top off of the 50 and welded them together.


It's need for taking off and putting ~ 200 ft lbs on the pinion nut


Here's the internals of the trans with the new diff on left


I need to pull the bearings off of the old diff. You can use a bearing seperator on the right side one.


The left side one is kind of recessed so you need to improvise, they're not that tight.


Then transfer the bearings to the new diff. You could press or drive them on. An old T.O. bearing works great. Right side bearing should stay on the right, left on left.


Transfer the ring gear and the pieces will be ready to go back in the trans.


Drop them in......watch the alignment pins on the front mainshaft and pinion bearings.


Seal and bolt the cases together. No I didn't forget the counterweight thing that hangs on 5th.


Put the center and tail on and you have a it ready to go back in.


Diffy goodness, I can't wait.

Couple things. I did not check backlash or anything. I think 1st or 2nd gear will blow up before anything else would go wrong. I wasn't concerned about being anal with it. I did replace te front and rear seals, however.

Yeah for the autopsy table and home made trans stand

Now I can drop the trans that's in the car and install this one.........sadbanana - banana

Last edited by mccanixx; 02-28-2009 at 03:13 PM.
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Old 04-29-2019, 10:13 AM   #7
jax194
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Default tragic

Quote:
Originally Posted by mccanixx View Post
I made the decision to go with a helical front and a 1.5 clutch rear. I will be currently leaving the factory center diff in. In conversations with others they did not necessarily like the performance of the 35/65. It will be using either the top street clutch/pressure plate or the low end H-D version. I see no need to put unneeded load on the gearsets and would rather go through clutches instead. I will also be replacing the flywheel with lighter a street version.

I will be performing these projects myself because no good ESP/WRX build would be complete without an extra transmission and a small shop press.

Update 2/16/09
Got around to installing the cusco rear. I pulled the drain plug and got:



I'd say I was very lucky last season to not have a failure. Probably even luckier that the pro-finale was rain. There were actually (2) whole teeth and a bunch of shards from the spider gears.

The swap was pretty straight forward. It took about 2 hours to pull it from the car, swap it, and re-install it in the car.
i had the same thing happen to me and it was a painnnnn
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Old 03-13-2010, 10:46 PM   #8
sube-trex
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White

Default

Quote:
Originally Posted by mccanixx View Post
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Old 02-24-2015, 10:01 AM   #9
velgan_subaru
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Member#: 414346
Join Date: Feb 2015
Default looks perfect

Quote:
Originally Posted by mccanixx View Post
It's hard to update once the season starts.

For those who didn't tune in when the thread was started: We put a 2.5 out of a 2007 wrx in it , along with the complete wiring harness. Worked through some issues. Threw some diffs in it and some big old tires on it and went racing.

Car's current stats.

Sponsors:
ModeRacing/PureTuning

Vehicle Weight at Lincoln in May was 2933lbs. With about 3/8 of a tank
Engine:
2007 WRX engine
APS intercooler
Perrinn turbo inlet
K&N Typhoon intake
TGV delete
Grimmspeed 8mm intale spacers
Grimmspeed 3port BCS
Cobb AP tuned by Keith @ PureTuning
~230hp ~300tq

Trans:
2002 wrx Transmission rebuilt w/used gears...... I do live dangerously
MFactory Helical front diff
Cusco 1.5 rs rear
Stock clutch PP and Flywheel

Suspension:
ZZYZX coilovers 12K fronts 6" 11K rears 6"
Stock front sway 17mm I think
24-27mm rear sway......may remove entirely
2006 WRX aluminium front LCA's
All suspension and chassis bushes have been changed.

Brakes:
328mm st 40 fronts w/endless pads
328mm st 20 rears w/hawk hp's

Wheels/Tires:
Rota grids 18x10 +35 bronze
Rota grids 18x9.5 +35 white
Enkei RPF-1'a 17x8 +45 orange
Hoosier A6's 285/30/18
Hoosier wets 245/40/17

Current pics


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Old 02-23-2017, 01:17 AM   #10
Victormojica321
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Join Date: Feb 2017
Vehicle:
2002 Impreza wrx
World rally blue

Default

Excited to see it
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Old 03-16-2019, 05:02 PM   #11
C4epps
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Join Date: Mar 2019
Location: Orlando Florida
Vehicle:
2002 Impreza RS 2.5
Silver

Default

Any updates?
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Old 03-21-2019, 02:22 PM   #12
traininvain3eb
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Join Date: Jan 2016
Default

Looking forward to more -
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Old 12-24-2008, 02:40 PM   #13
Rasmusson14
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Join Date: Dec 2004
Chapter/Region: MWSOC
Location: Pemberville, Ohio
Vehicle:
2004 ej207, ppg dogs
3" green, ITS ALL 4 SALE!

Default

Ah, sweet sweet memories of the past......







Good Luck with the build Greg! You really should show the raftors of your garage, half of his car is stored right over head, haha.
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Old 01-03-2009, 10:09 PM   #14
Storm
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Join Date: Mar 2001
Chapter/Region: MWSOC
Location: SAUL'S Motorsports
Vehicle:
96L Most Over-
Developed Beater

Default

I'm so jealous Greg..........
















Your garage is friggin INSULATED!!!!!!

Looks like you're having fun! Keep up the good work and let me know if I can be of any help!

Jay
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Old 01-04-2009, 07:11 AM   #15
mccanixx
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Vehicle:
2005 XT 5sp, 02 WRX
01 Legacy 95 Impreza L

Default

Quote:
Originally Posted by Storm View Post
I'm so jealous Greg..........

Your garage is friggin INSULATED!!!!!!

Looks like you're having fun! Keep up the good work and let me know if I can be of any help!

Jay
Thanks Jay, I'll be in touch.

I've had to many years of laying in a driveway changing parts in freezing temps to ever go backwards. I have a good size electric unit heater that brings it up to 55* easily, even when it's 0* out. About $600.00 in insulation and a couple days work, the rafters are done as well.

Believe me I know I have it good.......... I've been out there since 5:00 am this morning cleaning/organizing <-----disturbes teh wifey less that way .

Cheers...Greg
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Old 01-04-2009, 10:22 AM   #16
Butt Dyno
Street's closed, pizza boy
 
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2018 Focus RS
2006 Evo #17 STU

Default

Specs on the heater?
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Old 01-04-2009, 01:35 PM   #17
Storm
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Developed Beater

Default

I can't wait to see the car in action!!!! Think it'll be done for the NWOR opener? If our Spinwerkes fit over your brakes, you're welcome to try them....Pat Lipsinic (PatrickL-Top_Dog) is trying to get something going with Rota for a 15x10.

Jay
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Old 01-04-2009, 04:33 PM   #18
mccanixx
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2005 XT 5sp, 02 WRX
01 Legacy 95 Impreza L

Default

Quote:
Originally Posted by Storm View Post
I can't wait to see the car in action!!!! Think it'll be done for the NWOR opener? If our Spinwerkes fit over your brakes, you're welcome to try them....Pat Lipsinic (PatrickL-Top_Dog) is trying to get something going with Rota for a 15x10.

Jay
It should be ready for tuning mid-march, so it should make the 1st event. How well it's sorted is gonna be another issue.

I saw the group buy and was tempted but there's no way 15's are gonna clear the stoptechs. The rotors are 13 inches as it is. I want to keep them for the potential reality of getting back into track days.

I did start it yesterday without a glitch and it's solid and smooth past redline. No bad noises or stumbles....... Which was a big fear of mine.

Quote:
Originally Posted by ButtDyno View Post
Specs on the heater?
ceiling mount 208 v on a 60 amp double pull putting out ~ 25,600 btu's The garage is 20x24 so that's right there for an insulated space of that size in my region.

Last edited by mccanixx; 01-04-2009 at 04:52 PM.
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Old 01-04-2009, 05:28 PM   #19
Rasmusson14
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3" green, ITS ALL 4 SALE!

Default

Quote:
Originally Posted by mccanixx View Post
I did start it yesterday without a glitch and it's solid and smooth past redline. No bad noises or stumbles....... Which was a big fear of mine.
Congrats! Glad to hear it fired up and without issue.
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Old 01-05-2009, 11:38 AM   #20
WRB_in_my_veins
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2005 Legacy GT wagon

Default

Wow. I had no idea what you were up to. I'm suprised the Body/Paint section even exists. I've seen your fender rolling job, I didn't think you even cared about appearance. Is this going widebody?
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Old 03-07-2009, 03:53 PM   #21
cquirki
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Built 2.5 6speed

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Quote:
Originally Posted by mccanixx View Post


ceiling mount 208 v on a 60 amp double pull putting out ~ 25,600 btu's The garage is 20x24 so that's right there for an insulated space of that size in my region.
its double POLE! haha not pull
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Old 03-07-2009, 11:37 PM   #22
Storm
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Quote:
Originally Posted by cquirki View Post
its double POLE! haha not pull
[awkward pause] ".....thanks Marv......now back to the game...."
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Old 03-13-2009, 08:01 AM   #23
mccanixx
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2005 XT 5sp, 02 WRX
01 Legacy 95 Impreza L

Default

Quote:
Originally Posted by cquirki View Post
its double POLE! haha not pull
I'll have to correct that......

Well I'll be putting in some updates this weekend. I think I'm to the point where I have enough components to be able to assemble and drive it.

I don't have every single component I'd wish to have but enough to make it workable and drive around any short comings.......

I've been in San Diego for the past few days so no real progress the past week or so. Ya, it's a rough life.

Cheers
Greg
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Old 03-13-2009, 03:45 PM   #24
Storm
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Vehicle:
96L Most Over-
Developed Beater

Default

See, I always thought the engineers called it a double pole, while the people who actually do the work call it a double pull....

Can't wait to see the car run Greg!!!!

Jay
Quote:
Originally Posted by mccanixx View Post
I'll have to correct that......

Well I'll be putting in some updates this weekend. I think I'm to the point where I have enough components to be able to assemble and drive it.

I don't have every single component I'd wish to have but enough to make it workable and drive around any short comings.......

I've been in San Diego for the past few days so no real progress the past week or so. Ya, it's a rough life.

Cheers
Greg
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Old 01-05-2009, 10:35 PM   #25
BlueSTI4Me
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WRB IG @got2boostit2

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Greg,

Looks like a nice winter project.

Darryl
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