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Amazing history on a car that has really been used the way it should. I bought a 350z back in 04 instead of an STi and ended up trading it for an 07 STi and now an 11. Your planned build is exactly what I'm considering.
 

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Discussion Starter #22
lidrew: Glad you enjoy. I catch myself reviewing it as well-quite a few experiences a car offers. I've been very fortunate to have it just at the right time for career/family it seems. Additionally, I had more than a couple folks tell me the car wouldn't be reliable back in 2003-glad Subaru proved them wrong or it would have been a short relationship.

Coworker had a 350Z Track Pack (2004?) as well. We did Snetterton track event together in the UK...similar brakes, but vastly different powerplants/chassis. Great fun to sample his car (passenger) and then jump into mine. Loved its exhaust note and seating arrangement (felt like a race car as low slung sports cars do).

I hope my engine update pans out-lots of folks with assembly/tune issues with these engines and I'm not exactly an experienced builder. :)
 

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What is hiding under the car cover with the little mag-lite wheels?

Have been enjoying reading your car history, really fun seeing your car brand new too! I also love seeing these cars as practical family cars that allow for fun time. I didn't gather, did your engine fail, or are you just upgrading as a project?
 

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Discussion Starter #24 (Edited)
The original Smart car...1972 Mini 1000 (38 HP / 45 MPG!). Benefit of being in UK for 3 years.

No I'm not a giant! Checking the oil prior to its 'first' trip on the British Motorway (highway)...seriously. Car had 12,282 miles on it and never left the suburb in London.



Original engine is going strong and do hate to pull it, but more power is required and instead of failing the mill at the track and being down extended period (daily drive it 250 miles a week), I've got the opportunity to freshen it up on my schedule.

I'm impressed with Subaru reliability, but nearing 170,000 miles...I expect something has got to give as I hope to add another 100 HP.
 

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^^ I knew it was a Mini! Short hood, fender mirrors, maglites.

I have an '70 MGB GT that I love, so it's nice seeing other subie owners with the British bug too.

Yeah my motor just blew in my 04. I guess the previous owner didn't replace the pulleys when he did the timing belt (cheapo!), and a bearing exploded in my timing assembly. So I'm doing an engine swap now at 165k, but just going with a stock ej207. It is the twinscroll version tho, so it should be pretty nice.
Look forward to your progress...
 

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Discussion Starter #27
QuailEyes: I should clarify on the condition of the original engine. It does have an issue-overheats/pushes coolant on a road course. I don't do track events much now, but last two trips to Sebring the car filled the overflow tank and began to run hot (within last 18 months). That ended my day earlier than liked. Between the events, I confirmed I had a good fill/bleed of coolant and new OEM caps. I then had it tested a week after the event for combustion gases in the coolant-no telltale.

Outside of track events-absolutely no issues with the cooling.

It also leaks oil...oil pump / oil pan area and possibly the cam seals.

I can't eliminate track events from the fun, oil leaks are unpleasant, and possibility the car may go overseas again...time to assemble a new powerplant.

Mini: I enjoy the engineering of it...engine/trans share the same lube oil, rubber biscuits for suspension springs, and 10 inch wheels with 7.5 inch brake rotors. Impressive packaging. Besides UK, these cars are dime a dozen like a Cobalt/Cavalier here. It is a clown car. I began driving in a $600 1971 MG Midget with chrome wire wheels. Forced me to work on cars...
 

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Discussion Starter #28
Dropped one of the Cosworth heads off to be flowed...may prove to be more difficult. They are used to domestic 2 valve layouts... They want a cam to actuate both valves simultaneously...hadn't planned on that.

I would like some third party flow numbers to justify the cost.
 

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QuailEyes: I should clarify on the condition of the original engine. It does have an issue-overheats/pushes coolant on a road course. I don't do track events much now, but last two trips to Sebring the car filled the overflow tank and began to run hot (within last 18 months). That ended my day earlier than liked. Between the events, I confirmed I had a good fill/bleed of coolant and new OEM caps. I then had it tested a week after the event for combustion gases in the coolant-no telltale.

Outside of track events-absolutely no issues with the cooling.
TimM- If you are only experiencing coolant going into the overflow tank at track events there is a good chance you'll need new head gaskets. I just had them replaced on my car due to the coolant system purging the coolant into the overflow tank only under boost. If I drove around without any boost the system would perform perfectly. The issue is that the increased pressure under boost lifts the heads and introduces air to the system, thus creating air bubbles in the coolant and making your system overflow into that tank.
 

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Discussion Starter #30 (Edited)
sti2relaxxin: I hear you and agree after reviewing the forums. It has just shy of 1000 track miles and only started doing this within the last 160. I may have done it myself considering how critical the tune is-Cobb OTS Stage II Tune with their approved parts except the K+N Typhoon air intake. I've now added the Perrin 2.4 inch turbo inlet too. Who knows...

A gasket rebuild would likely make the engine solid again, but what is the fun in that?!

I do want to update it, add ~100 HP, and be able to rack up another 50K+ miles to it before additional work.

Thanks for the input!
 

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Discussion Starter #31
I've got an autocross tomorrow...runway site-read just a big slalom, unfortunately.

Only change since last event was adding lightweight bumper beams from Oswald.

Expensive, but appear to be quality and few things don't cut weight that result in quite a few compromises. I suppose if I avoid an accident...no compromises with these aluminum jobs.

I've never pulled the bumper covers off this car...so took my time. I also bought all new plastic clips for all connections-there are many! I will say it had the positive effect of tightening up the body panels...each old clip had some play...not the new ones.







This brings the car to 3090 pounds with no fuel, spare tire, or people. Pretty impressive.
 

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Discussion Starter #32
Autocross was a success...I drove home! 15th of 97 cars and third in class. Another Subie got me by .9 of a second on a 50 second course...have to work a bit harder.

New Z06 (650 HP) and Z28 (505 HP) showed along with a real Skyline GTR (RWD only) although none were a threat as they were not experienced drivers. The Corvette reved amazingly quick-OEM.

Didn't notice the lightweight bumper reinforcements...didn't expect to either-no worries 40 pounds is 40 pounds.

Grid:



First turn (1st Gear):



Finish-hard in third gear with a drift (Car still has lots of lean...):



Great fun in 55 degree weather-first run was a thrill with chilled concrete and Rivals...several 4 wheel drifts-yeehaw.
 

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Didn't notice the lightweight bumper reinforcements...didn't expect to either-no worries 40 pounds is 40 pounds.
Are you sure... I mean, you spent so much money on them. :lol:

I've seen people say how much they could feel the difference when adding these and what the car now did differently/better, but I felt NOTHING. I was under the same consensus, take off some weight (thought it was closer to 50lbs). I never actually expected to feel a difference, which I did not.
 

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What class are you racing in? I just moved from Florida this year, what groups are you racing with?

The build looks fun, curious on the cossie flow figures.
 

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Discussion Starter #35
yamahaSHO: I also pull the spare for an event even though it is weight from the wrong end of the car...I need all the help I can get with my driving... Less weight only helps, I figure. I still think it was a worthy purchase.

T3h_Clap: I'm not building the car for any particular class-just for fun. I've stuck with a group call FAST-not SCCA affiliated just because many co-workers are part of the group. Their classing puts me in a full modified class without race tires. I would have to research and figure out how that translates to SCCA. I may try the Martin Sports Car Club in the future although their site is 2 hours away...

So where in Iowa did you relocate?
 

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Discussion Starter #37
Here is a video of three of the runs with different angles. Yawn for most, but I found it interesting with the tire deflection and suspension compression.

Need to close up the spacing to the cones in almost every case other than the 'fishbone' section.

https://www.youtube.com/watch?v=skH4UTEgYzU&feature=youtu.be
 

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yamahaSHO: I also pull the spare for an event even though it is weight from the wrong end of the car...I need all the help I can get with my driving... Less weight only helps, I figure. I still think it was a worthy purchase.

T3h_Clap: I'm not building the car for any particular class-just for fun. I've stuck with a group call FAST-not SCCA affiliated just because many co-workers are part of the group. Their classing puts me in a full modified class without race tires. I would have to research and figure out how that translates to SCCA. I may try the Martin Sports Car Club in the future although their site is 2 hours away...

So where in Iowa did you relocate?
I can help with the transition, it's not going to be "ideal". Although Martin is a bit looser with their rules, more of gentleman's agreement where you may have 1 or 2 mods that are illegal but they don't help much.

Martin and SCCA both do events down in Sebring, where abouts in FL are you? If you want to bounce over to PM feel free.

I ran with Martin and Central Florida SCCA when I lived in Orlando. Ran with equip Rapid and PCA while I was in Ft. Lauderdale and we liked to hit up the Ft. Myers Gulf Coast autoxers events on occasion.

Currently living in the Iowa City area. Trying to get more involved with the local autox groups and hit up some track days this summer.

Yazel, shoot me a pm I can help ya.
 

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Discussion Starter #39 (Edited)
Picked up the ported head from the flow guy. Still have a bit of translation / clarification on the resulting numbers, but here is what I have:

Lift Intake Flow Exhaust Flow
0.050.......33..........23
0.100.......86..........87
0.150.......137........144
0.200.......182........186
0.250.......224........215
0.300.......256........227
0.350.......275........237
0.400.......285........241
0.450.......292........242
0.500.......297........244

Superflow Bench @ 28 inches.

Cylinder number 2 using clay to ease the transition-no tubes were used.

End result is this isn't much use until I put the OEM original head on the same bench in a couple of months. I will say the flow guy was impressed although he is used to domestic engines.

I will be using the original OEM cams (hopefully they don't wear out after 170K of use!) so valve max valve lift is .378 / .385 according to NASIOC posting.

I also picked up my wrinkle red powder coated valve covers...to match the OEM intake manifold. Bummer it will be hardly noticeable once installed-calls out the unique heads a bit at least. Images to follow.

Edit: Updated numbers after getting the final copy from the head flower guy...bad news the intake numbers decreased, but good news the exhaust was higher than originally reported-better scenario with a turbo car!
 

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Discussion Starter #40
T3h_Clap: I know Iowa City well. Wish I had pursued autocross back in the day-would have lessened my thirst for street hell rides... I'm located in Tampa area.
 
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