[Razlin]

Project "Aurora" Razlin's 2006 STI
LAST UPDATED: Feb 14th 2010




Plan: Transform a wrecked and abused STI into a all around part time Daily driven, track kitten!

Budget: $35k US/$40k Canadian

Time line: Goal to put it on the road in August 2009 Well I missed the first goal of getting Aurora completed by the summer. Now looking at assembly this fall and tune. Then park it for the winter.
Edit: Well life got busy! Its January now and the motor has been waiting for someone to bolt it together! Time to get to work!


NOTE: Opinions and suggestions are appreciated! hit me @ razlin_bw(at) hotmail.com

------------------------ TABLE OF CONTENTS ------------------------

For a quick list of the mods and stock equipment, sponsors, and other information, scroll down.

*Indicates pictures are included in the post

Photo Gallery #1 - Old Car 2006 WRX
Photo Gallery #2 - New car Stuff


1. Original Post Introduction, where I came from, the road here and the start of the project
2. Braking Overview - Initial setup
3. Drive-Train - Stuff that makes the wheels spin (motor back)
4. Wheels & Rubber - Rims, Tires, Lugs, spacers etc.


OTHER Posts of Interest:
1. Perrin Header & Moroso Oil Pan Clearance Problems
2.



--------------------------SPONSORS-------------------------

Wouldn't that be nice! Seriously if your interested in sponsoring me send me an email and lets chat! @ razlin_bw@hotmail.com

-------------------------- THE MODS & STOCK EQUIP-------------------------
Updated 2009/10/3

(2010/2/18: Edit this list in and reorganize... Engine, Fuel System, ECU and Electronics, Force Induction, Cooling, Intake and Exhaust System, Drivetrain, Suspension, Brakes and Wheels, Chassis And Reinforcements, Exterior, Interior, Other)


Brakes

• Calipers: Brembo Brake Calipers front and rear
• Front Rotors: Girodisc 2 pc Floating Rotor Set http://www.innovativetuning.com/ (Not listed but call / email good prices)
  
• Rear Rotors: DBA400 slotted
• Pads: Ferodo 2500
• Techna Fit Braided SS brake lines Touge Tuning
• Brake Ducts: DIY custom 06 fog bezels w/3” ducting to (Quantum Motor sport kit Quantum Motorsports - 2005 to 2007 Mustang Brake Cooling Kits)
• Fluid: something DOT5 Motul or ATE super blue
• Shims: TIC Titanium front Shims

Wheels and Rubber

• Street rims: Rota G-Force Gold 18x9 5x114.3/e30/73.1
• Street Rubber: Dunlop SP Sport 600 245/40/18 Tread wear 200, Traction and Temp A
• Fender Modifications
• ARP extended wheel studs
• Mutaki Open ended black lug nuts
• Track Rims: Enkie RPF1 Silver 17x9.5 5x114.3/e38/73mm
• Track Rubber: Undecided on exact size and brand
• Spacers – 5mm spacers x 2

Suspension

• JIC Coilovers FLT2 w/ front camber plates DD and Summer setup (January 2009)
• Stock Struts and Tanabe GF210 Max Agility Spring (winter setup)
• Vorshlag 02-07 Impreza rear camber plates
• Perrin Front & Rear Sway Bar’s 25mm and Stout Mount’s (November 2008)
• Ingalls engineering Camber bolts 2 degree adjustment (Rear) Manufacturer: INGALL'S Part Number: INGI-81260 (Nov 2007)
• Perrin PSRS kit
• Whiteline Roll Center Adjustment kit
• Perrin 25mm Sway bar kit, spherical endlinks and stout mounts
• Perrin PSRS Kit (ALK kit)
• Whiteline Front Anti Sway Bar
• TiC Giuyngmyo Fender Cowl Braces
• Subframe Locking Bolts

Drive-train

• Cusco Engine and Transmission Mounts
• Exedy Twin Plate Clutch (Cerametallic)
• TIC Super Shifter Kit - Kartboy Short shifter & Bushings
• Latheworks Copolymner shift knob in black
• Big heavy *** Stainless steel knob from Schnitz
• 6-speed Manual w/DCCD
• Driveshaft Shop Stage 2 SBR2 Rear axles rated to 600HP
• ACPT Carbon Fiber one piece Drife shaft
• Q-Rack - Quick 11.5:1 Steering rack
• TIC Transmission Cross member Bushings
• Techna Fit Braided SS Clutch Line Touge Tuning
• HTS Titanium wheel bearing shields TIC

Engine Setup

• Stock 2.5L 2006 WRX STI Block
• CP Pistions
• Supertech 1mm over Stainless steel intake and Inconel Exhaust Valves
• Brian Crower Springs and retainers BC0600 Kit
  
• Cosworth Cams PR7819
• Gates Racing timing belt
• ARP Head Studs
• NGK Copper LFR6A-11 Spark Plugs
• 08STI Oil Pump
• Morso Oil Pan
• Grimspeed TGV Deletes
• Grimspeed 8mm Phenolic intake manifold spacers w/ stock gaskets to sandwitch
• Power Enterprises 850cc Injectors (Start date)
• Walboro 255 Fuel pump (Feb 2008)
• Perrin Version 1 SS lines Fuel Rail and stock regulator
• Ultimate Racing GT3076R .82 A/R Kit
  • Oil Lines
  • Ultimate racing EWG up pipe Tial 44mm dump pipe
  • Down pipe
  • Intake piping
• Perrin Front Mount Intercooler (Polished) PSP-ENG-400
• Koyo Radiator w/ Samco silicone rad hoses
• Skunk 2 Radiator Caps x 2
• Crucial racing cool safe 160f thermostat
• IxizConcept Air Oil Separator w/ drain to oil fill
• Ixiz 3 port Electronic Boost Controller
• Perrin EL Headers
• GreddyTurbo Back 3” catless Exhaust
• Kartboy Exhaust Hangers
• Beatrush Pulley Cover
• SPT battery tie down
• Group A Performance Aluminum Pitch Mount (Bronze)
• Coatings: Fireball Performance Coatings - Home = Product coated with XMC on hotside of turbo, up pipe, headers, dump tube, down pipe & Crinkle red Ferrari Red on cold side turbine

ECU Tuning and Gauges

• AEM EMS plug-n-play ECU (1821 for 05-06STi)
• AEM 3.5 bar map sensor
• Defi triple gauge clock pod
• Defi 60mm EGT, Oil Temp, Oil Pressure + Controller
• Autometer Dual bezel Guage cluster
• AEM UGEO Wideband A/F ratio 52mm
• AEM Trueboost gauge and Electronic Boost Controller 52mm

Exterior

• Paint: Satin White Pearl 37J SUB9830
• 06 Trunk w/ STI spoiler w/ Two Perrin Wing Stiffies
• 05 Trunk wingless de-badged
• JDM Rear Spats
• Hella Horns (Aug 2007)
• DIY FMIC and Front Grill in black (Customgrills.com powder coated aluminum) (May 2008)
• Perrin front bumper plate eliminator (April 2008)
• Greddy Trust Gracier Front lip (May 2008)
• Subaru JDM Rain Guards (July 2008)

Interior

• Subaru all weather mats (Summer)
• Armrest extension center console
• 06 WRX Limited Leather Seating and door cards
• Ixiz Dead pedal

Stereo (Purchased in July 2007 and installed in 06WRX and installed in 06STI in October 2009)

• Headunit Pioneer DEH-P700BT
• Rockford Fosgate T162S 6.5” 2 Way component Front Door Speakers
• Rockford Fosgate T152C 5.25 Rear Door Speakers
• Kenwood Kenwood KAC 8402 4 channel 800watt Amp– Interior Speakers
• Re-wired to 12 gauge speaker wire to all door speakers
• 2 gauge power and ground lines

[Razlin]

------------------------ ORIGINAL POST ---------------------

First post!

Been lurking around here for years and I liked the amazing information i found following the members build Journals! Hopefully I will get some discussion on my build and during that help others.

Well… a little about me! Where I have come from and well… the plans!

I am a little nuts. a touch of undiagnosed A.D.D. (Attention Deficit Disorder) with some O.C.D. (Obsessive Compulsive Disorder) and a work ethic that is driven to succeed! = one wacky dude!

I was in sales for 9 years and drove a wonderfully reliable econo-box 2001 VW Golf TDI GLS! It served its purpose for getting me around 24/7/365 without any muss or fuss. I sometimes miss the mad torque of the diesel and 1000km/tank. Gladly it found a new home with a close friend that takes much better care of it than I ever did.



When I started a job where I hardly traveled I thought it was a good time for a “Toy”. I did a bit of research.. test drove a 06 WRX limited and fell in love! Picked it up from Vella Autosport in Concord, ON in April 2007.





Now, before this WRX, I had never owned a tuner, never done any wrenching on my own car at and it never thought of MODIFYING a car. Such a newb! I didn’t even change my own oil or air filters!

Unfortunately, my ignorance caused me to buy a car that was already violated! I had no clue that the Greddy exhaust would cause the problems I experienced.
Boost creep + WOT = CEL and a trip to the dealership.

I found out quickly the car had been modified, the stealership mechanic continued to explain that these parts are going to continue to cause CEL issues and would void my remaining warranty! Apparently the previous owner had installed a Perrin up pipe and turbo back Greddy exhaust system. Mechanic recommended replacing with stock off the shelf Subaru parts he just happened to have in stock!

I was lost.. didn’t know what to do. Drove out of the Stealership, looking for a second opinion and some time to think it over. Shortly after I found the solution! Cobb! Quickly ordered up a Accessport to tame the beast!. Phew. Things were all fixed.

I was a newbie’s newbie. When I found NASIOC, IWSTI and shortly after the TSC (Toronto Subaru Club) I was impressed with the “DIY guides” and the Technical Forums! I then got more and more interested in what potential the little 4 banger could do! I started reading and asking/posting questions. Thankfully questions were answered with great detail! Links to HOW TO’s with instructions and photos I was amazed at the friendly help. This sharing of information in the local scene and online forums was a great!

Well that was it for me once the COBB access port came in the mail, flashed ecu with stage 2 and I was hooked! The power, response and my god the torque!

I got infected with the “bug”

Well 07 was a blur between spending hours reading and chatting on the forums talking to local shops and spending time in Tim Horton’s parking lots hunched over engine bays!… the quest was on for that custom ride!

And it came in a flurry! Cobb CAI, Perrin Rad shroud, Tein Sways, Perrin Front and rear sways & endlinks, Tein SS Coilovers, Hawk pads Greddy lip, tint, tail light film.. phew! OOH grounding kit hehehe. I had a blast doing all the installs myself and enjoying every tweak of the setup along the way!

Winter 07/08 came and the quest for more power! I planned my turbo upgrade! Perrin FMIC, 18g, 740DW’s and a Wally fuel pump + protune! With the US and Canadian Dollar at part it was the right time to pull the trigger! I found the perfect shop! After doing some phone interviews with the local tuners and getting blown off… I found a thread on Innovative Tuning. Called up and spoke to the owner (Mr. Mike McGinnis) and ended up chatting for hours! He took the fear out of going to this next step and took the time to answer my questions and offer suggestions on things to avoid. Great hands on shop with great customer service

Innovative Tuning - Performance Parts, Service & Engine Tuning.

Engine bay at in the spring of 08! And Dyno @ Neetronics in Oakville, ON







Few pictures of the 06 WRX..

Won a small Show n Shine




My vision with the WRX was to go dark and mean looking and able to back it up! The WORK Rims, tinted tails, Greddy lip were the only real exterior mods! + piles of TLC and wax! I think the goal was archived!


Here was the details on its final setup as of July 22nd 2008

2006 Limited WRX (US Model Imported to Canada)

Stock:
2006 Impreza WRX Limited in Steel Grey Metallic
Limited (Full leather seating & door panels, Sunroof and Painted Mirrors)
5-speed Manual
Rear spoiler
Armrest extension
Security upgrade with Immobilizer
Auto-Dimming Mirror & Compass
3M Stone Shield Clear Bra
Factory Tint
Pillar Mounted Boost Gauge

Upgrades and Modifications

Brakes, Wheels and Rubber

• Stock Brakes Calipers 2+1 pots
• Goodrich Rotora SS break lines (Sept 2007)
• Hawk Street Pads front and back (Sept 2007)
• Winter: Stock wheels 17 x 7 with a +53mm offset and weighs 23.5 pounds. Lug Pattern: 5 x 100, + Dunlop Winter Sport M3 DSST 225/45 17 – Straightened & Painted Gun Metal (June 15th 2007)
• Summer: WORK CR KAI 18x8.5 225/40/18 +43 offset 5x100 Bolt Pattern w/ Fierce UHP 225/40/18
• Lug Nuts: BLACK McGard Spline Drive Lug Nuts 12mm x 1.25 LOCKS Lug Torque: 65 ft/lbs (April 2008)

Suspension

• TEIN Super Street Driving Master Damper Coil Over’s (August 2007)
• Perrin Front & Rear Sway Bar’s 25mm and Stout Mount’s (Aug 2007)
• Ingalls engineering Camber bolts 2 degree adjustment (Rear) Manufacturer: INGALL'S Part Number: INGI-81260 (Nov 2007)
• Kartboy Rear Subframe Outrigger Bushings - RACE KBU-053-RACE (July 2008)

Drivetrain

• Stock 5MT Transmission Clutch and Flywheel
• Cobb Short shifter and Bushings (June 19,2007)
• TiC Rear Diff Mount Bushings (July 2008)

Engine/Exhaust

• Stock 2.5L 2006 WRX Engine
• Perrin up pipe & Downpipe, (Unknown was purchased on the car April 19th 2007)
• GreddyTurbo Back 3” catless Exhaust (Unknown was purchased on the car April 19th 2007)
• Kartboy Exhaust Hangers 2 short 1 long (July 2008)
• Cobb Cold Air Intake (June 2007)
• Air resonator removed (June 2007)
• Perrin Front Mount Intercooler (Polished) PSP-ENG-400 (January 2008)
• Innovative Tuning Pro-Tune Cobb Accessport 2.0, 93 Octane 22peak Boost (Feb 2008)
• Perrin Blow-Through MAF Pipe for Perrin FMIC PSPENG410 (Feb 2008)
• Forced Performance TD06SL2-18G-7cm2 (Feb 2008)
• Detschwerks 750cc Injectors (Feb 2008)
• Walboro 255 Fuel pump (Feb 2008)
• Perrin Intake Tube PSPINT400 (Feb 2008)
• Cobb battery tie down (April 2008)
• Group A Performance Aluminum Pitch Mount (Bronze) (July 2008)
• SPT Oil filler Cap Billet Aluminum in Grey SOA3881010 (July 2008)

Exterior

• Impreza Cutout Tint Brake Light Cover Rear Light Tint 20% (May 10th 2007)
• Hella Horns (Aug 2007)
• DIY FMIC and Front Grill in black (Customgrills.com powder coated aluminum) (May 2008)
• Perrin front bumper plate eliminator (April 2008)
• Greddy Trust Gracier Front lip (May 2008)
• TSC Decal Rear Window (June 2008)
• SPT Blue “I” Front Grill emblem (TBA) DIY Black 93011FE000
• Subaru JDM Rain Guards (July 2008)

Interior

• Momo Shifter knob (April 20th 2007)
• Subaru all weather mats (Summer) (April 20th 2007)
• Redline Tuning Hood Gash Shocks (July 4 2007)
• Husky Liners (Winter) (Jan 08)

Stereo (July 2007)

• Kenwood DNX7100 NAV 7" LCD Screen Double Din
• Kenwood I-Pod adapter KACiP300V
• Kenwood Bluetooth KCA-BT100
• Rockford Fosgate T162S 6.5” 2 Way component Front Door Speakers
• Rockford Fosgate T152C 5.25 Rear Door Speakers
• 12" Rockford Fosgate P3 in a big rectangular box
• Kenwood Kenwood KAC 8402 4 channel 800watt Amp– Interior Speakers
• Kenwood 1800watt Amp– Mono driving the Sub
• Kenwood Sub Control Stealth Mounted in the Ashtray
• Polished Aluminum Checker plate Amp Rack
• Lightning Audio 2 gauge amp wiring Kit
• Re-wired to 12 gauge speaker wire to all door speakers

In short... the 340 ish whp/wtq was already making molten metal out of the stock clutch and the gears just wouldn't last to the heat, power, and abuse of lapping days. It was time to consider the new plans to get the car on the track... after some discussion with those much more experianced than I am on the track... the 5 speed trans wasnt going to hold up to the power, heat and general track abuse.



Introducing the Project car!

Some time during October 08 I was starting to investigate 6 speed swaps. When my buddy Matt/Polaren introduced me to a re builder in Oakville! Polaren knew I had a secrete love for white and the re builder just happened to have an 06 STI in white he just bought from auction in the states. We talked a bit about how the damage would be repaired and I snapped a pile of pictures.

I was excited but scared... "how would this thing become a rolling car again?!"

Here is one the rest will be in the gallery.





Did some digging based on the "O C C" decal on the rear window. Found him! Kevin : Dahellwidu on NASIOC





Then the previous owner Kevin was nice! gave me the inside scoop on the cars history. He had recently had the motor work completed a few thousand miles before the crash. Car hydroplaned and ... wrote off due to crack in the block casing from the FMIC hitting the idler pulley and the mount threads broke. (found that... )




He confirmed the 21,000 miles on the car. Even sent me some pictures of the car with the crazy green painted stock BBS rims!



Mod List:

Heads: 280 Cosworth Cams lightly Ported, Valve job 1mm over valves Supertech intake and inconel exhaust valves
cp coated pistons
Pe850s
Perrin EL header
Perrin FMIC
CoolingMist meth kit
UR Up-pip w/ Tial 44mm
HKS Carbon TI
HKS (POS) DP
Utec + SD
26-27psi
Burned no oil
Plans were for a t4 to4r
Broke motor in with a 35r Perrin kit
400 whp at 8500 rpm 14 psi

Previous owners youtube video's 1/4 Mile Video 11.9 @ 115miles/hr

I also found some posts on NASIOC related to the previous owner and the car:

1. Element GT52, Cams Pump + Meth - NASIOC
2. Who's car did i buy??? - NASIOC (This was started by the importer to Canada)

Then began the period of time where I started to seek advice, talk to people about building wrecks and trying to determine how far I was going to with the build. Lots of debate:

1. Daily Driven vs. track dedicated
2. Build a Wreck vs. Keep the WRX and swap trans etc
3. Buy a older car and build vs. newer model STI
4. Motor Build! all out crazy sleeved vs. forged pistons and a turbo

After much discussion and indecision, I was kind of pushed to sell the WRX... It must have been fate.

I called for a tow from Scott and we got the car in on the hoist, the motor needed to be pulled. Unfortunately found the compression test showed air was getting by.. at this point... it could be bent valves.



Turns out the idler pulley failed. See picture below. The idler pulley seal failed, grease came out + bearings all over! The belt slipped behind and viola! Swiss Belt. Replaced tensioner, all the pulleys on the front






The clutch was toast! time for replacement.




After tearing the motor down, I decided to take the opportunity with the car on the lift, to put the WRX back to stock and part out the WRX specific gear. The Coilovers, sways, endlinks, Turbo setup (minus the FMIC) injectors, Accessport, WORK Rims and a pile of other WRX specific stuff was sold off.. Replaced the Limited interior with a 06 RS interior in cloth with the intention of selling off the 06STI blue interior and installing the Limited Leather interior into Aurora. + $$$ for the build budget!

Took off both heads sent them out to Mississauga Engines for cleanup and to check the valves. Luckily there were no bent valves and the air leaking past the valves was from carbon buildup! While i was in there replaced the fluids and the toasty clutch returned the WRX back to stock and It then took 4 months to sell the car,... Winter + recession = no one was buying a sports car.

Finally got the car sold and I am currently driving the winter beater 1995 Golf CL... god i miss power <100hp



To be continued..... updates coming

[Razlin]

------------------------ GALLERY ------------------------

The 06 WRX days... now sold.

Back in 07 was running a set of Rota SDR's this color worked quite well on the SGM paint



Before paint on lip and custom upper and lower grills



Spring Fling meet with the local Toronto Subaru Club


Just some really nice light at the mail box


Playing around with long exposures for some action shots


Creative newb photography (I'm in the back)


Local popular Subaru Dealership held a show n shine! Turned out to be a great event!




Photo shoot at Angus Glenn Golf course at sunset!

[Razlin]

------------------------ GALLERY ------------------------

CRZYSTI the wreck car, the clay to be molded















Valve Cover splashed with Battery Acid in the accidnet WOW bad...

Just look at how clean the passenger side is.


Motor out!



Rims for Project Aurora



Sexy looking little battery



Moroso Oil Pan clearance problem.... Damn Headers!



Moroso Oil Pan - Modified for Perrin header clearance and covered with DEI Gold super duper reflective tape stuff! At least it looks neet!



Q- rack going in!


Q-rack, Whiteline RCA Kit, Perrin ALk/PSRS Kit, Perrrin front sway 25mm done! ready for motor mounting!






Well ARP 70mm studs are in! Forget all that grinding the ABS hole.. All ya need is a press!









Quantum motorsports front brake ducts and ARP extended lugs with Whiteline RCA Ball joint installed






Test fit wheels and rotors to roll it around the shop. I got a grin when i put the wheels on the suspension and all painted up!

Front Griodisk (These are on a temp front subframe and hubs) just for rollin


Rear - DBA4000 used. cleaned up, blasted and painted high temp black paint, on the ARP extended bolts.


Motor - 80% assembled. Waiting on a few front of motor parts from the dealer! Didnt want to risk slapping on a used tensioner and pullies! .... I already did that with the WRX....




X brace - in! Thanks Alex for the help... PITA to get these things in!

[Razlin]

Reserved

[Schnitz]

Great intro! I'll be keeping an eye on this build.

[jasv11]

Very Ambitious build!!

Your one crazy MoFo


oh and hurry it up

[KiR DieseL]

Nice build... Hope you enjoy... i still love white STis even though i dont have one anymore... still the best color to buy!

[vilar17]

good look. im doing the same wit my wrx

[Razlin]

Originally Posted by Schnitz

Great intro! I'll be keeping an eye on this build.

WoW PPC yakuza chimes in! I hope the thread becomes interesting and gets people thinking! I'm trying to DIY as much as I can!

Originally Posted by jasv11

Very Ambitious build!!

Your one crazy MoFo

oh and hurry it up

Yup Crazy project!! Sorry to hear about the last trans! Solid choice on the Andrewtech Dog box! and here come 9's
P.S. keep the grease off my Axles ").
P.S.S
Grats on the 10's and a solid showing at the battle event!

http://www.youtube.com/watch?v=2CcL2hFzPt0

Originally Posted by KiR DieseL

Nice build... Hope you enjoy... i still love white STis even though i dont have one anymore... still the best color to buy!

Kir! Love your car bro! exterior candy paint is just sexy! Its on my list of things i am considering.. But the build in 09 is go before show!

At some point i may do up some crazy widebody & GT wing action like my PPC bro WaynoSTI and the 600 hour wide body car.. Coolblue!

Only in a 06/07 body style!