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Discussion Starter #1
Hi guys, though't you might like a read of my current ongoing project.

Shall start with a bit of background about the car.

It's a 1998 Version 5 WRX STI Type R. It was imported in dec 2010 by SVA imports with 63k miles on the clock.

It was sold in April 2011 and the new owner had a full 330mm AP 4 pot front kit fitted and rear new age brembo setup added.



Was sold on to Hurst performance over at Bedford in 2014 and i bought the car back end of October 2014. Was fairly cheap and was known to need a full service (inc cambelt)








After picking up the car i headed straight up to scoobyclinic for them to give it a once over and a dyno session

Few issues were found. Both rocker covers were starting to leak and the rear crank seal had developed a leak. So after coming to an agreement with hurst it was left with clinic for a couple of weeks to sort out the rocker covers, rear crank seal and do a full service.

The better news was that while the car had never been under-sealed, there was no signs of rust at all and the chassis was in near perfect condition. Arches were solid with no signs of rust.

The other disappointment was it was way down on power and down on boost, was running about 0.9 bar and about 240bhp. AFR was fine and no det was detected so was running ok in general.

When scoobyclinic dropped the gearbox to do the crank seal they also found the clutch was worn down to the botls, so it ended up having a new clutch as well.

Two weeks later i picked it up.





Hadn't planned to do much for a few months to let the bank balance recover but i got wind of a mate selling some of the bits from his car and was too good to miss. I managed to get,

Gt spec gen 2 headers
Harvey smith up pipe
Walbrough 300 fuel pump
Syvecs S6
Full race spec scr decat



spares anyone? lol



These were all fitted and car was strapped to the dyno and mapped.





As per before the power level was low, 290bhp even with the syvecs, headers and decat.

After some head scratching issue was put down as a possibly the turbo getting a bit tired after 104k miles. AFR was fine and no sign of det so was left at that. Drove allot better and sounded a whole let better.

Few weeks later was decided to try a new turbo and see what it did.

Dropped the car off sat ready for the upgrade during the week, but Monday morning comes and the dreaded phone call.

The mechanic had heard a rattle from the crank when he fired it up form cold, they gave it more of a look Monday and sure enough at 2k rpm you could hear it.

Over the next couple of weeks went through options and costs to decide best route. Was left with a few options depending on how bad the internal damage was.




Engine was stripped and report came back with mixed results,

Crank bearings worn down to copper
Crank slightly market (should polish out, if not crank scrap. never machine a subaru crank)
Valves work
Valve seats worn
3 thou Taper on cylinder 1 and 3, way outside tolerance

Block would be salvageable, but wall thickness would limit power/boost to about 350bhp so was decided to change that, new valves and then reface the valve seats will allow them to be reused with no issues.

Given the damage there were a whole heap of options,

1. machine the block, refresh the heads, fit and leave it under 350bhp.
2. supply a 2.0 block, refresh heads and rebuild for up to about 400bhp
3. supply a 2.0 block, add a 2.1 stroker kit for up to about 450bhp
4. supply a 2.0 semi closed deck block, 2.1 stroker for around 500bhp
5. supply a 2.0 closed deck block, 2.1 stroker kit for over 550-600bhp
6. supply a 2.5 block, forged pistons, uprated rods and limit it to about 450bhp
7. supply a 2.5 block, convert to closed deck and allow for 550-600bhp.

Most options were sacked off pretty quick, semi closed deck are hard to find unless you buy a full engine, don't wan't to limit power to under 400 so got rid of 1,2,4 straight away.

Originally i managed to source a 2.0cdb for decent money, but a slight mix up ment it was sold before i actualy got it.

This made me lean towards a forged 2.5. I'd had one in my old Hawk wrx and even on low boost it made a really quick car and the low down grunt of the 2.5 made it great on the road

My original goal had been 500+, but given the limits of the 2,5 i knew that wasn't going to be a safe working limit but i was happy with that. After a couple more weeks i changed my mind again (sorry kev up at clinic haha) and the final choice was made to go with a CDB converted 2.5.

The block is now back an its programmed in for building in the next 6 weeks or so



standard block on the right, mine on the left

 

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Discussion Starter #7
So things are progressing pretty quickly now, was back at garage today, bit of a mixed result.

The heads have been fully stripped and unfortunately the ware on them was found to be greater than previously thought, they are salvageable but need machining so they are going off next week. Engine builder is on hols week after next so gives him next week to sort the bottom end and then heads should be back ready for assembly when he returns.

But the good news is the bottom is was started today and will be built next week. Few pics of parts for the build,

cdb converted block,



crank, acl race bearings, manley rods



Mahl pistons



It will also get ARP head studs
 

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Is your CDB from an outfit in the States, i.e., Outfront or AIG? I've been reading really good reviews on CDB use and their reliability for high-output applications.
 

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Discussion Starter #9
No mate, scoobyclinic are doing the build and they get a company called SMG to do machining work.

Afraid i can't help with US companys, im in the UK so a bit of a postage bill i think if you did lol
 

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Discussion Starter #10
So big jump in progres last week. Bottom end is now complete and awaiting return of the heads and the engine builder next week to finish of ready to go back in the car :)





 

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Discussion Starter #11
And before anyone says anything, yes that is the mrs and she does know the cost hahahahahaha
 

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Discussion Starter #12 (Edited)
it's alive! it's alive!!!!!! :D

Not been plain sailing, seems that 17 years havn't been too kind to it mechanicly, or is that has been kind? After all the parts were checked as it was reassembled alot more wear and tears was found.

the exhaust valves were all fried so its had to have a full set of supertech valvse, the valve buckets were nackered, valve shims were nackered so it hjad to have a full set of supertech buckets and shims. The inlet pipe was torn, the radiator was very ropey so was decided to sack iot off for a new one.

but i can now say, it's alive! it's alive! o wait i already did hahaha

gets it mot tomorrow (english annual road worthy test) then its ready to pick up.

It's currently running 100bhp at the wheels :D (running in map so actuator disconnected lol)

 

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Discussion Starter #13
Couple of updates.

Car was run in, turbo swapped out (found to have leaking oil seal) for a billet GT2871R and loaded onto dyno for mapping. Had an issue with fuelling and not enough, so some nismo 740 injectors, perrin fuel pressure reg and a 400lph fuel pump, also a 4 bar map sensor was added.

Car was then mapped and the results,



330bhp, 380ftlb :D

Really pleased with the results. But it didnt last. The power levels were being held way back for fear of it spitting the gearbox out. So a few months later car was back up at the garage to have a Hawkeye STI 6 speed dccd gearbox, front mount intercooler, perrin induction kit, competition clutch twin plate clutch and the boost ramped up :D

The front mount was a reasonable size lol



went for the stealth look





and then finally the results,,,,,



398.2bhp (dam that 1.8 lol) and 465ftlb :eek:

Torques was always good but didnt expect it to climb as much as the bhp was going to, let alone even higher :eek:

Turbo is giving everything it has so top end it drops off a bit, but with the torque and nigh on 400bhp it goes like a stabbed rat lol

really pleased with how its turned out :D

Next step,,,,,, bigger turbo lol
 

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Discussion Starter #15
Congrats on the power gains! It's been quite some time since the last post, how's she runnin'?
Sorry long wait again lol

Well have to say i no longer have the car, my financial situation changed and I had to free up some of the cash i had in it. Garage that does all the work on my cars ended up having it and i did a deal and drove away in a very rare 1 of 25 RHD sti limited's.

It was returned to stock and repainted (same colour but sorted out the faded paint etc) and the good news is a guy i know through a friend has bought it so its gone to a good home :D

Other news is my financial situation sorted itself out so the Ltd is now in for an engine build :D engine spec is pretty much the same as was in this, but some slightly stronger rods :D

I'll get a thread going asap
 
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