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Discussion Starter #1 (Edited)
Starting a little something here to chronicle the evolution of my car from this point onwards.

To preface, it all began in 2004 when I picked up my DD for the next 10 years, a 2002 WRB WRX Wagon. The wagon ended up 10 years later with a version 8 swap, sedan front fenders, and taken about as far as I cared into an SM class racer. Life priorities changed, and in 2014 I needed a fullsize truck to build my business. I sold the wagon, and my 1997 Toyota Tacoma, and picked up a 2014 Toyota Tundra which has served me very well over the last two years.

Fast forward two years and the itch I could not scratch has come to the point I could not ignore it any longer, thankfully I had saved some money and was doing well at the time. I began to look for my next Subaru. I knew I wanted it to be Silver, Grey, or White, a Sedan, and either a 02-03 or 06-07. After about four months of searching, I came upon an add for a 2.5i which had a full Sti swap, semi built motor, and a rotated turbo all ready to go, or so I had thought, but the car was in Washington while I live in Hawaii.

I know what you're thinking, that sounds expensive! Well, sort of. For a similar car out here I would be looking to spend $20-24k, and I'm almost guaranteed that it has been trashed. I was looking at this 2.5i swap for $13k, it had an entire build thread, history, and after getting to know the owner better I knew she had been respected. I flew out, and after some minor issues which Pacific Import Auto helped diagnose and fix, I was on the road.

While the car was at PIA I exchanged the turbo for my choice of an EFR 6758, and had it tuned. Driving it felt great, and what I had been missing came flooding back all at once. The car was loud, raw, and I could FEEL the car. I was able to drive it for exactly 2 hours until I had to drop it off at the docks at Matson shipping and head home.

The car should arrive sometime around August 10th, at which point the suspension work and a few other minor things will be put in motion, all of which I will attempt to keep track of here.
 

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Discussion Starter #2
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

Event: Dyno Tune
Location: PIA Tacoma, WA
Ambient Temp: Washington Weather?
Elevation: sea level-ish
Weather: likely Raining
Conditions: Shop
Tires: 225/40/18

Car: 2007 STi
Tuner: Mike @ PIA
Dyno Info: Mustang Dyno
Transmission: Stock w/ LSD's
Gear: 3rd
Peak HP at RPM: Dyno 370whp ~6,070RPM
Peak Torque at RPM: Dyno 359 ~4500RPM
Baseline hp/tq for a stock on same Unknown
Target Boost: 20 psi ( Very conservative tune )
Fuel: Pump 92
Engine/Power Modifications: Engine work done by PIA in Tacoma WA.
New 09+ EJ257 bored 99.75 CP pistons / rings, ACL race bearings, New heads / new oem cams ARP head studs, Gates timing set, P&L FMIC, AEM 3.5bar MAP Sensor, Grimmspeed ECBS, Borg Warner EFR 6758 .64ar v-band, 3" CAI intake, TGV's deleted, 3mm phenolic spacers, Fluidampnr, secondary injection air pump delted, Evap sytem deleted, Garris rotated kit up /down pipe, Tial 38mm EWG @ 1 bar springs, Killer-B Holy Header, Q300 3" exhaust, ID1000cc injectors, Walbro 400 fuel pump Hard Wired, P&L fuel rail kit w/ regulator, SouthBend Stage 2 Clutch, EWG Rerouted to DP



Stoked with the results, and I'm thinking on the street it will be even better. Big thanks to Derek, and Andrew and Mike @ PIA for being awesome, couldn't have done any of this without you guys!


Phase two will involve fully wrapping header/up, and a turbo blanket. Addition of a Garrett Cored AWIC setup in the TMIC location, and probably a cutout with a turn down. Hoping to pick up a few hundred rpm of spool swapping the FMIC, and wrapping the pre-turbo exhaust. Might possibly run some higher octane if I can find it locally too.
 

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Discussion Starter #3 (Edited)
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

8-6-16
While the car is on the boat and should be arriving 8/10. I'm beginning to prep a few projects that I'm going to tackle before the my first race of the season on 8/14, namely:

- Replace all 4 rotors (Girodisc floating)
- Extended ARP studs if I have time
- New brake pads (hawk hp plus)
- Clearance Pads for Girodisc rotor hats
- New Goodridge Phantom lines
- Completely bleed brakes (ATE Blue)
- Replace all 4 endlinks (Whiteline adjustable)
- Redo Turbo Coolant lines (-an fittings)
- Shipped 8/5, hopefully will be here in time. Not happy with the way they are run now.







 

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Discussion Starter #4 (Edited)
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

8-6-16
Also, since it's constantly raining outside and I can't do yard work, I might as well get around to getting the Feal 441 coils ready to go also, this is my third set of Feal 441's and they never cease to please.

These were originally ordered from Odi for a GC I planned on building:

Feal 441 Road Race Specific
14k / 13k swift springs w/ helper springs in the rear to help droop

I need to:
- Change out all 4 tophats for GD Specific versions
- Mooresport Street version in the front
- Feal GD version adjustable rear
- Exchange the 5x100 perches for 5x114 perches

Notes:
- Getting the top nut off the front coils is a pita, but with an impact gun it comes off super easy. I don't see any other way these nuts come off honestly, the allen key size isn't big enough to get proper torque to break them with wrenches.

Rear coils with helper springs:


Rear tophats on and ready to go. I had to take the allen key bolts from the Feal adjustable front tophats and use them here, either the new tophats didn't come with bolts or I lost them. I probably lost them =)


Mooresport front tophats going on. #1:


#2:


Perches took some work to get off but nothing a 12" extension for leverage and a wrench on the end of the spanner won't take care of:


Ready to go:
 

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Discussion Starter #5 (Edited)
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

8-6-16
Between the 8/14 race and the 8/28 race I'm hoping to get my AWIC system setup, and battery relocated to the trunk. Most everything I need is here already, except for a few electrical components.

AWIC System
I have:
- AWIC ( Custom made, 1000hp Garret AWIC core, TMIC location )
- Reservoir ( 2.5 gal alumimum from frozenboost )
- Heat Exchanger ( type 101 from frozenboost )
- Pump ( Meziere WP136S 20gpm )

On the way:
- Fittings
- Lines
- Relay and Switches
- More gold reflective tape

Fab
- Panel to anchor pump and res
- Bracket to anchor pump to panel
- din sized panel to mount switches
- Bracket for heat exchanger
- Bracket for AWIC

Battery Relocation
I have:
- 4ga premium welding wire, 15' black / red ( for runs to trunk and misc grounding )
- wire ends

Local buy:
- Shorai lfx36l3-bs12 ( Battery Bills )

Need:
- Wire loom for pass-throughs and visible areas
- Distribution block for connections in engine compartment

Fab:
- Battery Bracket for trunk

Going to be a lot of work here but I think it's doable.

My inspiration for the AWIC placement, I think this IC piping is short enough for some good response.


AWIC, ran out of reflective tape in the second pic, more on the way:



Reservoir:


Pump. I need to comment that this thing feels solid as hell, glad I went with this brand. The other option was a Davies Craig pump but they were ABS construction:
 

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Discussion Starter #6
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

Boat is 103 nautical miles away traveling at roughly 21 knots, will arrive in 5 hours! Might actually get the car before the 10th, that would be nice!
 

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Discussion Starter #8 (Edited)
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

8-9-16
Went to pick up the car today, shes still it one piece! That's good news. It was still early so I started working on some state registration requirements since I was in town.

Before you can register a "modified" car in Hawaii, you need to get RECON ( Reconstructed Vehicle Permit ). This only applies to vehicles which have modified suspension, or heavily modified body. The suspension test involves a hand administered bounce test which most coilovers fail. Since I still have struts on the car I want to get this RECON done before coils go on. Another requirement to get RECON is that the car must have mad an alignment within the past 30 days to manufacturer specs. To me, this is very backwards, if the vehicles suspension is modified the alignment should be modified as well to make for a safe driving experience.

The end of this story is I went and got an alignment which destroyed driveability for the sole purpose of getting this permit. Almost $200 wasted. Yay.

Picking up at the docks:


I had a package waiting for me when I got home from getfast1.com with some goodies I had been awaiting.

Bunch of -12 AN fittings for the AWIC system:


A few -6 AN, and a banjo for the turbo coolant line from the block:


Got busy installing what I could.

Straight cut o-ring to -12 AN on the pump:


Made a -6 AN line for the block to turbo coolant feed, realized I need a proper braided hose cutter if I'm going to do much more of this:



Tomorrow, get the RECON inspection, then off to the Safety inspection, and finally Registration where I will get my Hawaii plates... Never been one for vanity plates but this would be the time.
 

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Discussion Starter #9 (Edited)
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

8-11-16
Had a good amount of time to put into the car today, not without some challenges though.

Swapped out the Invidia Q300 for my favorite exhaust of all time, Borla Hush. Just the right amount of noise I think, and I can still stealth around if I need to.

Swapped out pads and rotors all around in about an hour, felt like things were going to go swimmingly for the rest of the day. Decided not to embark on replacing the lines and bleeding everything today, I wasn't sure how much time I could dedicate and if I had to leave I didn't want to have the lines/bleeding part way done. I had never changed pads on Brembo's before, I gotta say these are a cakewalk compared to the 2 piece calipers that the early gen WRX's had, and I'm very happy that I get to work with these brakes from now on.

Fronts:


Rears:


Also, I have known that my front endlinks were bad for quite some time. Tackled this next, along with the rears. Didn't take long and I'm really happy with the new adjustable ones. However, the front adjustable links are not able to be adjusted while installed like the rears which really limits their usefulness, it's quite a bit of work to take all that apart just to take the links out a few turns when I eventually corner balance the car and set up the suspension.

Fronts, that lower collar is unable to move independently from the heim joint, so to adjust them I need to remove one end:


Rears:


Went on to tackling the water lines to the turbo......

My idea was I could simply remove the banjo on the head and slip my - 6 AN banjo on. Well, due to it's location I now feel this is something I would only tackle with either a majority of the crap in the vicinity removed, or even better, with the motor out of the car. My hands are toast from getting that one bolt out, and the new banjo in.

New Banjo with the - 8 AN fitting:


I inched my way into getting the stock banjo out for about an hour until I needed to head out for a while, in that hour I hadn't loosened it enough to release coolant so I just cleaned up and left it. Took a shot before I left:



Came back about three hours later, around 5pm, and began again. I removed the turbo oil drain to gain some more access, and dropped the nose of the car down on the jackstands a few spaces to get better visibility. After another two hours, I had it out! ( had I known it would take this long, I could have just removed the turbo and all that jazz ) Unfortunately, it was dark by now and I was in no shape to take pictures. After another hour I had the new banjo in, and by 8pm I had my water lines run and the top overflow tank jerry rigged in a stock-ish location, I will eventually make a bracket and put it on the wheel well I think.
 

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Discussion Starter #10 (Edited)
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

8-13-16
Yesterday I had a chance to get a baseline on my local dyno. Happy with the numbers, they are what I would expect. Both the original tune and my local dyno are Mustang dyno's, so they're very similar.

Local dyno, not sure why the TQ is down on this but I will figure it out:


And my chart overlaid on my EJ207 v8 wagon from 2013:
 

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Discussion Starter #11
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

First race of the season for me tomorrow, car is loaded up and I should get some decent footage.

I'm slightly bothered at the wheels I'm having to run, they are Evo 8 stock wheels. While they fit, this was all so last minute that I haven't had the chance to pick up some hub-centric spacers yet for them and for this race only I will be attempting with just the conical nuts holding them on. It's all sort of a moot point since its predicted to rain tomorrow in which case I will just run my junky Federal 595's and drift all day.
 

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Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

Got a chance to run my first rain AutoX this season... insanely fun. I actually was holding one of the top spots until it dried up.

Have fun out there!
 

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Discussion Starter #13 (Edited)
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

As to be expected after a 2.5 year hiatus, I did terribly! That said, I haven't had that much fun in a long time, and it was good to see familiar faces.

Still being on the Feal revalved struts is killing me on R-comps. The tires won't break free and it results in insane body roll. Hopefully before the next race on 8-28 I can do my suspension work and have the coils on, that should really help the times.

I'm also still getting used to the one way front diff, and when it kicks in. I could feel it catching really well though, and I can only imagine how the car will react once I get a proper rear diff also.

Some footage below for entertainment purposes, there were two slaloms which I tried to backside the cones as well as I could, I had it a few times but that needs some work. Also, I think slowing down more in the tight 180 degree turns at the start of the course would have helped.

Youtube is kicking my ass, I can't get it to embed right now but I will try again later.

https://youtu.be/vb6xZhrLZQA
 

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Discussion Starter #14 (Edited)
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

8-15-16
So I need to get rolling on the AWIC and get things wrapped up so I can get the car registered. I can't pass a safety inspection with the front mount so this is a priority at the moment.

Took a few minutes to try and layout the reservoir, and pump in my trunk. I knew I wanted to mount both the res and the pump on a platform so I could easily take them out if I needed to, also to isolate vibration and noise as much as possible.

This was my first shot, on the drivers side of the trunk.


Looking at it in there though gave me an idea. They looked like they both might fit well in the spare tire well, and that would serve double duty by lowering my CG. Gave that a shot.


Perfect! Even has space for my battery. Best part of all this is that the reservoir is the same height as the floor now, so I can cut out a hole in my spare tire cover and it will rest perfectly on the top of the reservoir. Nice clean install. I can even use the spare tire hold-down as my main fastening point for easy removal.

Fitted some cardboard to the area and laid everything out where I wanted, next step will be take the template and components over to my fabricator and see what we can accomplish. I think it should all be fairly straight forward. I'm hoping that I can also fit my circuit breaker for the battery and some other wiring neatly in this area so simplify install.
 

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Discussion Starter #15 (Edited)
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

Redid the template so everything was clear and dropped it off at my fabricator, hopefully in a few days I have something usable and can begin installing. In the meantime I will start putting together wiring for everything, and possibly mock up the heat exchanger and AWIC, although it would be much easier to do those two things once I have the FMIC out of the car completely.

Time will tell.

Update on things to do:

AWIC
- Fit Front Bumper Beam + Foam
- Confirm Fitment for Heat Exchanger
- Fit Heat Exchanger
- Fit AWIC
- Run water lines
- Wire up pump
- Confirm no leaks
Suspension
- Coilovers
- Lat Links
- Trailing Arms
- Diff Bushings
- Outrigger Bushings
- Subframe Lockdown
- Transmission carrier bushings
- Trailing link knuckle bushings
- Front control arms with bushings pre-installed
Drivetrain
- CF Driveshaft Install
- Change oil / Blackstone
Brakes
- Goodridge Lines
- Bleed
 

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Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

That's the .64 hot side? It seems to spool closer to my .85 hot side on my 6758.




It's nice looking build! Did you have to grind the rear pads to clear the rotor hats?
 

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Discussion Starter #17
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

Honestly it's possible that it isn't a .64 hotside, from what I've seen they look exactly the same. The few telltale items that I don't see are similar is that I have an exhaust temp bung directly before the intake. Have you found any imprints on the casting? Mine really doesn't have anything other than Borgwarner on the hotside. I will look closer when I take the turbo out and wrap my piping.

I did have to grind the pads down, really easy to do, but the clearances are very tight even after grinding.
 

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Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

Size is an indication. The .85 looks a good bit bigger. I might have found some part numbers, but at the time, I was one of the first to purchase the .85 hotside and couldn't match it to anything.

Do you have a picture of your turbo?
 

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Discussion Starter #19
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

Yeah I do have some pics, would be nice to get some info on it for sure!







 

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Discussion Starter #20
Re: Sti Swapped 2.5i in Paradise // SM Class Build EFR 6758

During my research I came across this thread that has an entire turbo with the .64 for sale, the flanges, and that egt sensor area all look the same to me which is why I was sold on it.

I only purchased the turbine, and then purchased a supercore separately from BW.

Borg Warner 6758 EFR Vband - No Longer Available
 
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