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Old 02-19-2017, 07:49 AM   #1
methaddict
Scooby Specialist
 
Member#: 159738
Join Date: Sep 2007
Chapter/Region: SCIC
Location: SGV
Vehicle:
2004 WRB STi 620awhp
OFCD V3, FR TS, BW8374EFR

Default 04 WRB STI Catastrophic engine failure May 13, 2017, 3rd build Outfront V3 CD

2004 WRB STI, purchased June 2004 .

Original motor spun a rod bearing due to cracked oil pickup @ 43K
1st engine build (never trust John Edwards @ Costa Mesa R & D machine shop), motor builder was a Subaru Master technician.
2nd engine builder Prolific Autosports had my car for 2 years. Had a partner falling out so some parts where missing but got replaced by Frank. Very bad on updating the customer and I only asked monthly (acted like I was harassing him and got teste several times), till he couldn't give me an estimated time of completion (kept on taking other jobs though) I decided that was enough so I towed the car home incomplete although the motor was built and assembled. I've been wrenching on my car till October 2015 since I towed it home in June.
Over all the car has been down since 2008. 53K on odometer.

Car down again, Prolific auto motor didn't last a year and never ran right. Picked up my car in Oct 2016 from Outfront motorsports after being down since May 2016, from a seized motor, spun rod bearing after tear down.

Build #3, all work done by Outfront including R&R: V3 closed deck, 1/2" head studs, replaced 1 Manley TT rod and balanced to the remaining rods. Replaced nitrided crank with a new OEM induction hardened crankshaft 12200AA330, reused case halves as there were new from the previous build, bore to 99.75mm as required for the V3 closed deck, extra clearance Kings racing bearings, JE FSR 99.75mm pistons, replaced stock windage tray with KB tray, JE Proseal head gasket. Will be replacing the discontinued Koyo R2704 (R core 53mm) with the newer Koyo VH091672 (Hyper V core 36mm) which I purchased at from Jeremy of Outfront today. Replacing due to a leak that developed today in the Koyo R2704 which actually expanded from over pressure from the previous build. The replacement VH091672 as slimmed back down to oem thickness.
Engine:
  • Case halves from last build for Outfront V3 CD block
  • new OEM induction hardened crankshaft 12200AA330
  • Manley Turbo Tuff Rods replaced one from spun bearing damage
  • JE Billet FSR standard size pistons 8.8:1 99.75 for OFCD block with JE Pro Seal Piston Rings
  • ATI dampener
  • JE Pro Seal head gasket
  • 1/2" Outfront custom ARP head studs previously ARP 2000 head studs
  • jdm 12mm oil pump
  • Cosworth timing belt guide
  • Gates Racing timing, alternator, a/c belts
  • Canton oil sandwich adapter
  • Canton billet oil filter nixed due to unreliability of collapsing so went back to factory Subaru filters
  • -4AN steel braided turbo oil feed/avcs oil feed (forgot who makes these)
  • Covert performance -12AN fitting to block turbo oil return adapter
  • Killer B billet oil pan, KB oil pickup, KB windage tray
  • Motul beak in oil with Redline break in additive
  • previously under hood scoop mounted external 38 row TRU cool oil cooler moved to passenger side front of wheel well with dedicated oil cooler fan which turns on when rad fans kick on
  • Cusco engine / transmission mounts
  • DC Power Engineering 270 amp alternator 200amps @ idle
  • Started with AEM 3.5 bar stainless steel map sensor but just upgraded to 5 bar ss map sensor

Heads, work by Tom @ Portflow:
  • blending of bowl area
  • 5 angle valve job
  • Supertech std size inconel exhaust valves, std size black nitride intake valves to retain velocity and didn't want to move the power band too far to the right, Super tech springs
  • Brian Crower 272 avcs cams

Turbo/exhaust system:
  • Full Race twinscroll header, up pipe, down pipe, vta dump tubes
  • BW8374 twinscroll EFR ext wg
  • dual Tial MVS 38mm wg, originally ordered with 1.1 bar springs but changing to .3 bar springs
  • Mac 4 port boost solenoid
  • Turbosmart Kompact shortie plumb back bpv replaces the plastic bpv assembly
  • JIC Spartan DE type 2 ti 3" catback with revised 3" thoughout ti piping (no bottle neck at flange or no resonator), Kart Boy long exhaust hangers

Intake/Intercooler/cooling system:
  • JDM V9 Spec C long runner tgvless manifold reverse mount
  • 4" diameter 8" length K&N universal cone filter directly on turbo inlet
  • Borg Warner EFR built in FR billet cover changed to Turbo Smart plumb back BPV
  • AMR 04-07 FMIC 5" thick core 3" inlet and outlet
  • Full Race reverse mount 2.5" aluminum ic piping modified by Jason Noren Fabrications to clear stock fans, retains A/C
  • Mikalor W2 Stainless Supra heavy duty hose clamps throughout
  • KS Tech 19mm phenolic spacers
  • KS Tech custom dbw to dbc throttle body spacer
  • replaced discontinued Koyo R2704 (R core 53mm) and cheap slim fans with the newer Koyo VH091672 (Hyper V core 36mm) with oem 2 speed radiator fans, Samco radiator hoses
  • Relocated custom Covert Performance turbo reservoir
  • Mishimoto 60 deg racing thermostat, Redline water wetter, 20% coolant, Subaru coolant additive, the rest is deionized water, recently added a higher percentage of Subaru coolant due to too much water causing mix to boil and causing over pressurizing the cooling system

Fuel:
  • Full Blown billet dual pump hanger, removed bottom half to accommodate wider bases of Walbro 450lph pumps
  • Added Holly Performance Hydromat to primary in tank pump to address fuel starvation on turns and works great
  • dual Walbro 450lph in tank pumps, (one dedicated, 2nd as auxilary to be activated by AEM S2 @ 14psi of boost), 8 gauge wired to power pumps and Fuel Pro fpc
  • -8 Fragola black covered ptfe lined feed fuel line, -6 Fragola black covered ptfe lined fuel return line, Fragola/Aeromotive hose ends and fittings configured in reverse series order (4231)
  • Radium JDM long runner top feed fuel rail adapters
  • IAG top feed fuel rails/ rail mounted fuel dampeners
  • Fuel Injector Development 2000cc Bosch Ev14 based High Impedance injectors
  • Continental long pipe flow through flex fuel sensor on return line
  • AEM series 2 Engine management (supports Flex Fuel)
  • Aeromotive FPR, Aeromotive shut off valve fuel filter
  • Fuel pro fpc with computer fan mounted on circuit box turns on with ignition
  • Auminati o-ringed fuel injector seal buckets

Clutch:
ACT Xtreme clutch with high performance organic disc rated to 550 hp and still holding since I don't do launches from a dig, just rolling starts.

PVC, purge valve deleted, pvc solenoid retained dedicated crank case (3/4"hose) and (5/8" hose) T'd valve cover Radium catch cans with outlets Y'd to a hose routed near the exhaust exit vta.

Last tune was 620 awhp/612 ft lbs which I forgot to get a copy of the graph but same profile as the previous tune by Shawn of Church Automotive




AMR 5" thick core


pass side wheel well mounted oil cooler with dedicated fan

Turbosmart Kompact shortie plumb back bpv

Full Race reverse mount ic piping modified by Jason Noren Fabrications to clear and run stock fans.

JIC Magic Spartan DE II ti full titanium 3" catback no neck down at mid pipe

Factory Subaru Recaro option / Schroth 4 point harness


Latest mod, DSS carbon fiber shaft:
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Last edited by methaddict; 05-15-2017 at 01:40 AM.
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Old 02-19-2017, 11:21 AM   #2
Squirtledasuby
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Member#: 463182
Join Date: Feb 2017
Default Squirtledasuby

How is the car running?
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Old 02-19-2017, 11:33 AM   #3
sc00ter
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Member#: 117767
Join Date: Jun 2006
Chapter/Region: RMIC
Location: Denver, CO
Vehicle:
2015 WRX (CWP)
Flex Fuel + Things

Default

Quote:
Originally Posted by methaddict View Post
2nd engine builder Prolific Autosports had my car for 2 years.
Wow!
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Old 02-19-2017, 09:11 PM   #4
methaddict
Scooby Specialist
 
Member#: 159738
Join Date: Sep 2007
Chapter/Region: SCIC
Location: SGV
Vehicle:
2004 WRB STi 620awhp
OFCD V3, FR TS, BW8374EFR

Default

Quote:
Originally Posted by Squirtledasuby View Post
How is the car running?
Drives like stock around town. Organic disc with Extreme clutch engages like stock although works out my left leg in traffic. Smooth power curve with early spool up like stock with vertually no lag, early torque on tap, accelerates very quick, no misfires, no backfiring. Boost is easy to regulate off the throttle, but when I drop the hammer things get intense but still manageable. Some wheel spin @ full boost but I installed an AEM 12 position trim pot to incrimentally set my boost which Shawn setup in the AEM S2.

Last edited by methaddict; 02-19-2017 at 09:24 PM.
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Old 02-20-2017, 05:10 PM   #5
wantsti
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Member#: 134764
Join Date: Dec 2006
Chapter/Region: RMIC
Location: Lindon, Utah
Vehicle:
04 sti
java black pearl

Default

Do you have any info on your holly hydromat install?
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Old 02-20-2017, 09:09 PM   #6
stu
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Member#: 25768
Join Date: Oct 2002
Chapter/Region: RMIC
Location: CO springs
Vehicle:
35RR OFCDV3 Bugeye
Slowbaru

Default

Love your build. Glad you stuck with it.
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Old 02-20-2017, 09:31 PM   #7
methaddict
Scooby Specialist
 
Member#: 159738
Join Date: Sep 2007
Chapter/Region: SCIC
Location: SGV
Vehicle:
2004 WRB STi 620awhp
OFCD V3, FR TS, BW8374EFR

Default

Quote:
Originally Posted by stu View Post
Love your build. Glad you stuck with it.
Thanks, this one better last because I don't think I have another build in me. If it does I'll be upgrading to the 9174 EFR with the lighter aluminum chra.

Quote:
Originally Posted by wantsti View Post
Do you have any info on your holly hydromat install?
More info is in Fuel systems thread. Very easy to install it just slips on the inlet of the primary 450lph Walbro and can be orientated in several incremental positions 360 degrees . I sits on top of the slosh tray longer side hanging over the tray on the left side under the filler neck. The second 450lph Walbro has the original sock filter but sits on top of the Hydromat siphoning off of it. The pumps are diagonally staggered on the hanger legs to accommodate the wide bottoms of these pumps and held on by stainless worm gear clamps. I had to remove the Fullblown hanger fuel pump clamps to fit the wide bottom 450s. The 1st pump is controlled by a relay with 8 gauge power and ground to the Fuelpro fuel pump controller, second pump is hard wired with 8 gauge power and ground. AEM S2 sends a ground signal to a relay to turn on @ 14psi. The Full blow hanger has two barb fittings under the base and internally Ys the fuel output to one -8AN male fitting.


Last edited by methaddict; 02-20-2017 at 10:07 PM.
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Old 02-20-2017, 10:52 PM   #8
wantsti
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Member#: 134764
Join Date: Dec 2006
Chapter/Region: RMIC
Location: Lindon, Utah
Vehicle:
04 sti
java black pearl

Default

Thanks did you attach the mat using magnates in the tank or is it just sit in there connected to the pump?

What size is the mat?
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Old 02-20-2017, 10:59 PM   #9
methaddict
Scooby Specialist
 
Member#: 159738
Join Date: Sep 2007
Chapter/Region: SCIC
Location: SGV
Vehicle:
2004 WRB STi 620awhp
OFCD V3, FR TS, BW8374EFR

Default

Quote:
Originally Posted by wantsti View Post
Thanks did you attach the mat using magnates in the tank or is it just sit in there connected to the pump?

What size is the mat?
For now there is only one Hydromat 11mm outlet with 6 lock pin position that connects directly to The TI 450 LPH (F90000267), 400 LPH (F90000262) & GSS342. It's literally sandwiched between the slosh tray and the fuel pump so it's not going to move. 3" X 15" off set.
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Old 05-04-2017, 12:08 AM   #10
methaddict
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Member#: 159738
Join Date: Sep 2007
Chapter/Region: SCIC
Location: SGV
Vehicle:
2004 WRB STi 620awhp
OFCD V3, FR TS, BW8374EFR

Default

Fuelpro fuel controller was removed due to a circuit board failure so I just hardwired the primary Walbro 450lph pump. Change all rubber hoses, which will eventually expand and crack, to Flex tech reinforced heater hoses. I had a small leak with the turbo return line that I used 90 degree -10 an fittings, steel braided hose, and the Tigwerks -10AN male to o-ringed fitting into the block so I bought a 45 degree -10AN to barb for the return from a flange fitting with a gasket to the chra and a 90 degree -10AN to barb to the Tigwerks fitting and Flex tech silicone hose with some ss worm gear clamps.

To move the K&N filter away from direct heat soak from the turbo I added a 45 degree elbow and I cut up the stock air intake duct to get air to the filter. Also covered the ic piping with some aluminum 2.5" sleeves. I also had to get a new 4 port boost solenoid due to the original one failing.
I also extended the fuel pressure sensor to keep it away from heat soak and engine vibration.

Still using the Radium catch cans which I have to empty after doing any wot pulls on the freeway onramps. I still don't trust air oil separators. This also keeps my regiment of checking the oil levels frequently.

Last edited by methaddict; 05-04-2017 at 03:51 AM.
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Old 05-04-2017, 08:59 AM   #11
STiSomeday
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Member#: 265430
Join Date: Nov 2010
Chapter/Region: MWSOC
Location: Cleveland
Vehicle:
2005 OBP WRX STi
IG - seriousblacksti

Default

Glad you've stuck with it, love the build man. Sucks that you've had so many bad experiences but the current setup should treat you well. My 05 was down for about 3 years due to issues with a shop similar to the second one you worked with.

I'm going to regret asking for this but, do you have any sound clips (especially under load) of the Spartan? I sold the one I snagged without ever running it and will always regret it.
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Old 05-11-2017, 02:40 AM   #12
methaddict
Scooby Specialist
 
Member#: 159738
Join Date: Sep 2007
Chapter/Region: SCIC
Location: SGV
Vehicle:
2004 WRB STi 620awhp
OFCD V3, FR TS, BW8374EFR

Default

Quote:
Originally Posted by STiSomeday View Post
Glad you've stuck with it, love the build man. Sucks that you've had so many bad experiences but the current setup should treat you well. My 05 was down for about 3 years due to issues with a shop similar to the second one you worked with.

I'm going to regret asking for this but, do you have any sound clips (especially under load) of the Spartan? I sold the one I snagged without ever running it and will always regret it.
Thanks, when I get a chance I'll record a sound clip. I can do it from my iphone 6 from inside the cabin with the windows down. Something like a wot on the fwy onramp?
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Old 05-11-2017, 10:23 AM   #13
STiSomeday
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Member#: 265430
Join Date: Nov 2010
Chapter/Region: MWSOC
Location: Cleveland
Vehicle:
2005 OBP WRX STi
IG - seriousblacksti

Default

Quote:
Originally Posted by methaddict View Post
Thanks, when I get a chance I'll record a sound clip. I can do it from my iphone 6 from inside the cabin with the windows down. Something like a wot on the fwy onramp?
Whatever you can come up with, no biggie. Just want to hear what I could have had haha.
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Old 05-11-2017, 10:40 PM   #14
oh.pig
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Very nice, can't wait to get myself an STI
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Old 05-15-2017, 01:35 AM   #15
methaddict
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Member#: 159738
Join Date: Sep 2007
Chapter/Region: SCIC
Location: SGV
Vehicle:
2004 WRB STi 620awhp
OFCD V3, FR TS, BW8374EFR

Default

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Last edited by methaddict; 05-15-2017 at 02:55 AM.
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Old 05-15-2017, 06:19 AM   #16
A-man07
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Member#: 271525
Join Date: Jan 2011
Location: BagEnd
Vehicle:
7/2 STi/WRX wagon
SWP/AW

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Sorry to hear about your continued troubles mate. That wild fuel set up looks complicated enough to give you troubles maybe? Also you'll need to go back and change the header on your thread.
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Old 05-15-2017, 07:48 PM   #17
methaddict
Scooby Specialist
 
Member#: 159738
Join Date: Sep 2007
Chapter/Region: SCIC
Location: SGV
Vehicle:
2004 WRB STi 620awhp
OFCD V3, FR TS, BW8374EFR

Default

Quote:
Originally Posted by A-man07 View Post
Sorry to hear about your continued troubles mate. That wild fuel set up looks complicated enough to give you troubles maybe? Also you'll need to go back and change the header on your thread.
Fuel setup has worked great. It's now @ Outfront and tear down will determine the failure and hopefully under warranty. It's only been a little over six months. Tune from Shawn Church has been solid, last time he checked the tune I went to adjust the idle he said it was on the rich safer side throughout the boost rpm range. I had to agree to $1500 for tear down and if under warranty they should waive that.
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Old 05-18-2017, 11:38 PM   #18
methaddict
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Member#: 159738
Join Date: Sep 2007
Chapter/Region: SCIC
Location: SGV
Vehicle:
2004 WRB STi 620awhp
OFCD V3, FR TS, BW8374EFR

Default

I gave them a call yesterday and Ozzy told me a valve broke off into one of the combustion chambers possibly taking out the block and one of the heads. That's all the info they gave me. Other than that I'm waiting for a more detailed report. They still need to tear the short block down. OF sent the heads out for an inspection and came back as good to go, obviously they were not. If they recommended new valves I would have purchased them. Supertech inconel exhaust valves and black nitride intake valves are what were in the heads.

Last edited by methaddict; 05-18-2017 at 11:43 PM.
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Old 05-20-2017, 12:09 PM   #19
181stLeader
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Member#: 184183
Join Date: Jul 2008
Chapter/Region: SCIC
Location: The OC
Vehicle:
1996 Impreza RSTi
V8 EJ207 Aerosim Carbon

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I have seen quite a few threads on here regarding the heads snapping off super tech valves in EJ applications.
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