Buildup finally in progress. 600+ hp or bust.

[Innovative Tuning]

I thought some of you might be interested in the buildup on one of my legacy turbos. I'll post updates as we go. I'm building the car for myself and the shop mainly, but I also have a friendly competition going with a buddy that has a 9 second galant vr4 since the cars are so similar. We'll see what happens.


I have almost all of the parts here now so we'll just peck away at it when we can stay late and work on it.

Basic list of parts:
2.2 bottom end (as long as mine is fine I'm rebuilding it. 190,000 miles on it)
Ross pistons w/Swain coating on dome
Eagle Rods
APS TGV housings w/custom secondary fuel system
STi v8 heads w/OEM COP
Cometic Head Gaskets
Hondata IM gaskets
Greddy Timing Belt
Perrin header (to be coated)
Ultimate Racing External Wastegate Uppipe (to be coated)
Tial 44mm WG
BB turbo from PTE
Custom turboback
STi v8 tranny (stock for now)
Legacy turbo rear end with welded diff (for now)
AEM EMS with JDM v7 harness

I have these parts minus the uppipe and APS TGV housings here at the moment so we should be able to move the project along. I have a couple clutches here that may work, but we've had mixed experience with them on other cars so I'm still undecided on that piece. I also have to decide on an ignition box and a few other odds and ends. I have an STi driveshaft here that I'll use if we want to get it on the road quick before it snows, but I plan to use a DSS one piece next year. The a/c was already out of the car and I plan to remove the ABS block this time.

I got a couple sets of Rotas for it. One will have Falkens RT615's and the other will have slicks. I'm going to drag race it a little because lets face it that's what gets the kiddies worked up, and I'll drive it on the street. Personally I'm looking to get it on some road courses.


Day 1:
We spent a little time on my car today. Pulled the engine and started tearing it down.




-Mike

[Innovative Tuning]

Oh yes. Here is what the car looks like at the moment.

[Innovative Tuning]

oops

[Splinter]

Not going to stroke+overbore for 2.4L?

[Innovative Tuning]

Nope. Just keeping it simple for now...to a point...

[douglas vincent]

How long since that thing ran?

What HP are you shooting for?

[Innovative Tuning]

It could have run until yesterday, but I took it off the road a year ago and haven't driven it since then. We've just been too busy at the shop to mess with it. I did take it down the 1/4 last spring to get a baseline. The stock setup ran 15.1 with 3" exhaust and the boost at 9-10 psi.

I want 625 whp on a dynojet or 500 whp on a mustang dyno without nitrous oxide and then I'm considering spraying 100 on it. I have a feeling I'll have to rev it to 8500 to get a lot out of the car at the track, but if I spray 100 on it I could probably run 6000-8000 rpm and still post the times I'm looking for. Spraying it is probably the safer option considering how other people's Subaru engines seem to fair at those speeds. Also, I'm not concerned with the engine holding the power.

-Mike

[Innovative Tuning]

This isn't the kind of thing you want to see...but my header was totally full of water and so was the engine.



The block is almost all the way torn down.

[Richard]

eeek. That thing needs a good bath!

[93forestpearl]

Sweet. She'll be a beast

What kind of comp. ratio are you running? I'm guessing those pistons are custom. I wish I had the option of going that big in power numbers, but won't untill I do something about the heads.

[scottzg]

I wish I had the option of going that big in power numbers, but won't untill I do something about the heads.

yeah, do something about the heads and 600whp should be no problem.

[Innovative Tuning]

Well it looks like I'll be able to get it to 8500 rpm safely if not 9000. We're plugging the oil squirters to help keep the oil pressure up at high rpm and I'm talking to Cosworth about their deshimmed legacy turbo oil pump which should get me the rest of the way without a dry sump system.

We finished the teardown on the legacy block today:


I decided on Exedy's new Triple Ceremetallic heavy duty version clutch/flywheel combo for my STi tranny and I'll have that tomorrow. I also ordered up coated main and rod bearings from Cobb so I can get the block to the machine shop ASAP.

Yes I did get custom pistons. They're from Ross. The compression ratio is supposed to be 8.5:1 with the sti heads and the Cometic gaskets I'm using. I also sent the pistons to Swain for ceramic coating on the dome.

-Mike

[evolutionmovement]

What are you doing about liners? Are those shot? I'd imagine they'd be quite pitted.

[Innovative Tuning]

Hopefully everything is ok aside from the bores. I have 20 over pistons so those should clean up. If there's an issue I have two other legacy turbos that I can pull an engine from.

-Mike

[Innovative Tuning]

We took a little time off to work on one of my other legacy turbos. Removing the A/C, installing another IAC, IM gaskets, simplifying the vac. lines and removing some of the emissions crap.

Waiting on two wrenches that cost $400 bucks to get the cam gears off the STi heads so we can work on them. Ugh....

-Mike

[evolutionmovement]

Buying them from the US government? Damn. You can't modify an existing wrench?

[wiscon_mark]

Sweet. I'd be interested to see who is making more power...you or PHATsuby (EZ30R build).

[Innovative Tuning]

lol. Have a look at the one that goes on the avcs gear and you can see what the other one would have to be like for the other gear. They're totally different and both rather goofy.



We could make them but it would be a pain in the ass and I don't want to waste the time on it.

I don't know what PHATsuby has planned but I do have a friendly competition going with my buddy's Galant VR4 since the cars are so similar. He has the second fastest GVR4 I know of. It has a best of 10.0 at 140 mph and he's going bigger this year so we'll see what happens.

[wiscon_mark]

PHATsuby has built (but not tuned yet) an EZ30 Twin Turbo with custom intake manifolds, etc...it's amazing. He did a ton of welding and custom fab work.

[Innovative Tuning]

Very interesting. It's always nice to see something different.

I'm supposed to have the special wrenches tomorrow so I can tear the STi heads down. In the meantime I put coilovers, a boost cut defender and some other little nonsense on my daily driver legacy turbo. The turbo is kinda shot. It's pushing lots of oil and boosting inconsistantly even with an MBC. I can also hear the wheels contacting the housings. I have a stock WRX turbo here that I may mod and jam in there. We'll see...I was trying to leave this one alone.

[Innovative Tuning]

Only one of the special wrenches showed up.

We threw a WRX turbo in my daily driver legacy last night as the stock turbo was totally shot. I'm running 10 psi until I feel like playing with it some more.

[jp233]

Keep it coming, glad to see an old turbo leggy getting a transplant so it can be a stalker and wail on some unsuspecting fools. (and some who suspect it )

[Splinter]

Can you get me a part number on the Eagle rods? I cant find them listed on their website.

[Innovative Tuning]

Sure the Eagle rods are part # CRS5137S3D

[azn2nr]

sweet project man. id like to get thoes numbers without a rebuild of teh sb. lol. we'll see how high we get. 29psi on pump baby