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Discussion Starter #1 (Edited)
Owned this car for nearly 12 years and with the decision to install a new engine this year...likely means an investment for another 12 years...

Bought new in Omaha, Nebraska...3rd STI in the city at the time.



It became our 'family car' for next 8 years...much of the time with multiple baby seats in the back seat. :)

Wonderful day picking it up...12.5 miles on the odometer.

Look how fresh it is!













Changed oil at 500 miles with Pennzoil 5W-30 conventional oil, then again at 1000 miles to Mobil 1 5W-30 which we used for the life of the car until just recently (0W-40 M1).

As the odometer passed 1000 miles-break in was complete...we were hitting the redline! Prior to that we were religious to not exceed 4000 rpm and most of the time 3000 rpm and always a light throttle. I do wonder if this is key to a long, healthy engine as we had nil oil consumption even to its replacement...still counting at 169,000 miles (except track events-.5 quart consumed).

First top speed run @ 2,170 miles...153 mile indicated...hard into limiter.

First drag visit (@ 3,120 miles / 13.57 @ 100 MPH / Scribner, NE):



First autocross (@ 9,500 miles / Lincoln, NE / 5th of 100 cars):



Transfer to United Kingdom (via Baltimore Port):



Only one minor scratch!

Nurburgring Visits (3):







Snetterton Track Visit (UK / Lotus Test Track):







Bedford Autodrome Visit (UK):



Donington Park Track Visit (UK):

http://www.iwsti.com/forums/video-collection/105254-lap-donington-park-uk-o4-sti.html

Cadwell Park ("UK Nurburgring") Track Visit:







Autobahn Run:

http://www.iwsti.com/forums/video-collection/61231-150-mph-speed-limiter-autobahn.html
 

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Discussion Starter #2 (Edited)
Transition from Family Car to Fun Car...

Added a Cobb TBE, Cobb Sway Bars, Sparco Pro-2000 seat, and update to Cobb Stage II setting.



Had my 100,000 mile Ohlins Fixed Perch Struts rebuilt by Feal along with set of RCE Yellow springs and offset front camber mounts.



Nice .75 inch drop:



Nifty Offset Camber Strut Mounts (-1.5 negative)



Added BFG Rivals in 245/40-17 size (OEM is 225/45-17):



Sebring Track Visit:





Autocrosses (20 so far):



Drag Visit #2 at Bradenton Dragway, Florida (153,250 miles / Stage II / 12.84 @ 105 MPH):





Updated to Perrin 2.4 inch Turbo Inlet (OEM was damaged at the turbo):



 

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Discussion Starter #4 (Edited)
Fresh Bullet Project (New Engine)

OEM Subaru Shortblock:



Cosworth Cylinder Heads:











 

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I am dying looking over the photos of the car when it was brand new! I never had the chance to see a brand new/perfectly clean GD chassis. I really am sad I never got the chance!
 

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I've owned an '04, '06, and currently have an '07, and now I'm kicking myself for never taking chassis/engine photos of ANY of them when I first brought them home. I LOVE those photos you posted!
I'm officially jealous of you too, as you fulfilled one of my current fantasies; you got to drive your STi on the Nurburgring. I took 4 laps on the Nurburgring in our Diesel Audi A6 which we rented when I went to Germany with my family and that was just a big tease. The automatic gearbox made it feel like I had an arm tied behind my back.

Lastly, the photo of the sod in your trunk is upsetting : )
 

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Discussion Starter #10 (Edited)
I have a few more of the car new (I think 2 days old). I recall at the time I felt a bit odd as magazines had all the imagery already...but the detail that now comes out for an aged car is striking. Every metal surface is bright and shiny, etc.

sti2relaxxin: Nurburgring-great track. I actually had more fun renting a Ring car...the cheapest, but semi-race prepped Suzuki Swift (cage, tires, suspension, and an extra .4 hp from the air filter). As they say, the best handling car in the world is a rental car...

In the Subaru, was ~8 hours from home (and 4 countries) during those trips so driving was kept at the 7/10 level).

I tried to find some images of the Christmas tree sticking out the trunk each year (4 years), but no dice. It has hauled plenty of sod (typically 18 squares at a time) always with plenty of plastic and thorough vacuuming following!

:)
 

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Discussion Starter #12 (Edited)
Previous Chassis Updates:

Carbon Fiber Driveshaft @ 141,116 miles (The Driveshaft Shop):



High HP Rear Axle Shafts (new OEM front as well) @ 160,000 miles (The Driveshaft Shop / 800HP):

 

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Discussion Starter #13 (Edited)
Placed an order for a Blouch 1.5 XTR turbo with 3 inch inlet and 10 CM outlet.

I'd love to make some decent power, but the street manners and autocross response kept me from going any larger. Although this is my first foray into modifying a turbocharged car. We will see if I'm too conservative or will be disappointed removing the original VF39 turbo (it does have a slight crack in the waste-gate area, but sure runs very well).

Plan to chassis dyno the car as it sits-wish it was completely stock, but it is not.
Current:
Cobb AP Stage II
K+N Typhoon
Perrin 2.4 Turbo Inlet
Cobb TBE

169,000 miles and 22.5 mpg average on a tank

Next, same chassis dyno shop tune with (23 psi? / 93 octane):
Blouch 1.5 XTR 3 inch inlet/10 cm outlet
Perrin 3 inch Turbo Inlet
Process West TMIC
850 cc Injectors (Top Feed Conversion)
Grimmspeed Electronic Boost Control Solenoid
TVG Deletes
Walbro Fuel Pump

Finally, same chassis dyno shop tune with (23 psi? / 93 octane):
New Long Block with Cosworth Cylinder Heads
Cobb Up Pipe
Ported Exhaust Manifolds

Any comments? Thanks.
 

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I built my 05' for road course use primarily. It had an FP Red turbo when I acquired it. I changed it to a Blouch 18g XTR. Some thought it would be too small. If you check out my dyno sheet Although have 14 HP MAX less, I gained 22 HP average. From my perspective I moved 20 HP from over 6K rpm into the power curve under 6K rpm where I have more opportunity to use it. I love the responsiveness, its much better coming out of slow corners.

I LOVE your history with the car! Good luck with the new engine!
 

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Discussion Starter #15
bossdog: Thanks. Honestly, figured I would keep the car for quite a bit as it fits my requirements so kept a bit of a log as I went. It has been thru 12 countries as well-used to have a flag of each on the side window (small decals) as we checked off each one.

I hear you on the turbo response. Autocross it is even more evident, but likely can be minimized with a good driver, I suppose.

This video alone shows me shifting 8 times...not counting the initial accel:

https://www.youtube.com/watch?v=3eVP_0d597k

I was surprised, but the gearing is relatively short. I recall a course that had a 'pin' turn...I took FTD by over a second on entire field, all because the car would come out in second and once the boost hit (very early) it accelerated far better than any other car. The organizers haven't used a pin turn since... :)

I've reviewed your journal...lots of useful info-thanks.
 

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Discussion Starter #16
Finally moving to the next stage...prepare the new shortblock for disassembly!

It really is a box motor...:



Even fits on my previously Chevy only stand:



Amazing I just picked the little powerhouse up and stuck it on the stand...so much easier than a 150 pound block of iron-I like these little engines. Amazing it supports 300 + HP stock.

Hate to take it apart, but new rods seem like an easy deal for ~$400 update along with the Cosworth Pistons.
 

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Yep, they're not heavy at all. I think the bare block on my SHO weight much as an STi long block. The SHO crank was also something like 50lbs (long block with intake and exhaust manifolds was nearly 500lbs).

Building motors can be fun!

Been meaning to ask you... Where in Omaha/Bellevue did you live?
 

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I resided in La Vista off of 96th Street.

Your suggestion on the rods makes sense...I would like a few more RPMs out of the engine.

I will say the cylinder heads are fairly substantial in weight and size compared to the shortblock.
 

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Discussion Starter #20
Turbo arrived...Blouch 1.5 XTR with 3 inch inlet and 10 CM outlet (coated hot section):



Billet compressor wheel close up:



Turbine:



Exhaust Inlet:



Hope it all works!

 
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