Aijii's EJ207 JDM V10, EFR7163, Flex Fuel 2008 STI

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Aijii's EJ207 JDM V10, EFR7163, Flex Fuel 2008 STI

Postby aijii » Wed Jun 17, 2015 8:10 pm

So this is my attempt at a build thread, documented almost two years after I bought the car. Let's see how we go....
Car: 2008 WRB STI
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Current Modifications (February 2016)
So once I got over the new car feels, I realised there was so much about the car I didn't like, and didn't realise was the way it was before I bought it. I probably would not have bought the car knowing what I know now. However it has been an interesting, somewhat frustrating, and perhaps expensive journey over the last year and a bit. I thank my wife for her patience...
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------------------------
NEW SETUP (As of August 2017)

Engine Build (August 2017)
JDM EJ207 W20/V10 (came out of 2009 or 2010 JDM Subaru STI)
Wossner EJ207 8:1 Pistons
Cosworth Rods
ARP 625 Head Studs
New 75mm double crossed drilled nitrated crank
King .005 o/d main bearing shells
ACL race big end bearings
Kelford KVS109 valve springs
RCM head-gaskets *ej207 v10*
Full head recondition (needed a few valve seats cut)
Killer B Oil Pan, Pickup and Windage Tray
Competition Stage 2 Clutch and Lightweight Flywheel
Full rotating assembly balance
Line-honed to get the tunnel nice and true again *the mains were out some*

Engine Ancilliaries
Crawford Air Oil Separator, with PCV hooked in to return (August 2017)
Koyorad Double Pass Aluminum Radiator (February 2016)

Intake/Exhaust
Borg Warner EFR 7163 .85AR Single Scroll V-Band Turbo
Custom 3.0" Alloy Inlet
Custom Air-Water Intercooler (Frozenboost Type 14 Core, Modified Frozenboost Radiator, Davies Craig EWP115 Pump, Custom Charge Pipe Work, 3/4" Lines and Lots of Insultherm Sleeving) (December 2015)
Turbosmart Kompakt Shortie BPV
Turbosmart IWG-75 Dual Port Wastegate Actuator
Hitech Mufflers 3.0” Catback Exhaust (modified to mate with stock location 3.0” flange) (May 2015)
Active Exhaust Systems 3.0" Inline Butterfly Valve
Custom CANBus controller for butterfly valve, integrated with SI drive and loud pedal
SSI Equal Length Headers (PSR), Wrapped with DEI Titanium and eBay Titanium Wrap (July 2015)
Modified SSI Up-Pipe (August 2017) Hyperflow Single Cat Down Pipe (Wrapped with Thermotec Wrap, Sprayed with Silicone Spray) (November 2014) Modified in August 2017 for Twist setup
Custom 3.0" Intake (Modified KS-Tech) (August 2017)
Turbosmart (MAC) 4-Port EBCS (August 2017)
Busted Finger Motorsports Ported TGV-Deletes (September 2014)
KsTech 3mm Phenolic Spacers (September 2014)

Tuning
98RON Road Tune, E85 Road Tune (rough tune whilst testing Flex Fuel Merpmod Build) by Shadow Tuned, the Magical Wizard of Blowhard
Custom build of 32-bit Merpmod patch with SD, LC, ****, Flex Fuel, CEL Flashing and more (ongoing development project but first loaded onto the car in November 2015)

Fueling
ID1300 Injectors (November 2015)
Cosworth Fuel Rails (January 2015)
Serial Pro-Flow/Aeroflow Braided Fuel Line and Fittings (January 2015)
MY09 WRX Return Fuel Dampener (July 2015)
Turbosmart FPR-1200 (September 2014)
Electronic Fuel Pressure sensor, hooked into ECU (2016)
Continental Flex Fuel Sensor (January 2015)
Flexconverter Ethanol Content Analyzer (September 2015)
Custom-Built Arduino Gauge (January 2015)
Walbro 460 Fuel Pump (January 2015) Hardwired in January 2016, 58PSI base rail pressure
CJ Motorsports Billet Fuel Pump Holder (January 2015)
Customised MRA - relocated fuel filter to engine bay (Early 2017)

Stopping
DBA4000 2-Piece Rotors (Front)
DBA T2 Slotted Rotors (Rear)
Akebono Rear Pads (July 2015)
Winmax W3 Front Pads (July 2016)

Wheels/Tyres
Bridgestone RE003 Tyres

Suspension/Handling/Bushings/Mounts/Other
Group-N Engine Mounts
Group-N Tranny Mount
Perrin Pitch-Stop
Whiteline Anti-Lift Kit
Whiteline Front 24mm Adjustable, Rear 22mm Adjustable Sway Bars (2016/2017?)
AVO (I think) End-Links

Asthetics Brah
Front-end Face Lift (2011+ WRX/STI), blanked out fog covers, new wheel arch liners (October 2016)
Perrin Radiator Shroud
Perrin Alternator Shroud
Never-ending Gobstopper Intake Manifold paintjob with red, blue and black
Ultrex side skirts
Ultrex rear Diffuser
Custom Tail-Light Overlays
White LEDs where required

------------------------
OLD SETUP

Engine Build
Engine just had minor rebuild by Phil Lowe to fix original HG issue (July 2015)
Cosworth Pistons (99.75)
Cosworth Rods
ACL Race Bearings
ARP Case Bolts
ARP CA625+ Head Studs (July 2015)
Cosworth Head Gaskets (July 2015)
Killer-B Windage Tray (October 2015)
Cosworth High Flow Oil Pump
Killer-B Pickup (Customised by Phil Lowe to fit with Cosworth Baffle Plate) (July 2015)
Air-Pump Delete (Two bolts in the head ports, retained rear valve for atmospheric pressure sensor) (July 2015)
SG Motorsports 2 Port AOS (changed so that it is in-line with rocker cover breathers only) (July 2015)
Catch-can (borrowed from Kristian) running in-line with Crankcase vent (July 2015 - temporary till I can find a good dual can setup, thinking Saiko Michi)
Perrin Alternator and Radiator Shrouds (August 2015)
Evan's High Performance Waterless Coolant (July 2015)
Koyorad Double Pass Aluminum Radiator (February 2016)

Intake/Exhaust
Blouch Dominator 2.5XTR (8cm Hotside) Stock Location Turbo (September 2014)
Perrin 2.4” Silicon Turbo Inlet (September 2014)
Custom Air-Water Intercooler (Frozenboost Type 14 Core, Modified Frozenboost Radiator, Davies Craig EWP115 Pump, Bunnings Spec Reservoir, Custom Charge Pipe Work, PWR Filler Neck, 3/4" Lines and Lots of Insultherm Sleeving) (December 2015)
Turbosmart Dual-Port BOV/BPV (VTA Blocked)
Hitech Mufflers 3.0” Catback Exhaust (modified to mate with stock location 3.0” flange) (May 2015)
SSI Equal Length Headers (PSR), Wrapped with DEI Titanium and eBay Titanium Wrap (July 2015)
Hyperflow Single Cat Down Pipe (Wrapped with Thermotec Wrap, Sprayed with Silicone Spray) (November 2014)
Mishimoto 3.0” Race Intake (November 2014)
Cobb 3-Port EBCS (June 2014)
Busted Finger Motorsports Ported TGV-Deletes (September 2014)
KsTech 3mm Phenolic Spacers (September 2014)

Tuning
98RON Road Tune, E85 Road Tune (rough tune whilst testing Flex Fuel Merpmod Build) by Shadow Tuned, the Magical Wizard of Blowhard
Custom build of 32-bit Merpmod patch with SD, LC, ****, Flex Fuel, CEL Flashing and more (ongoing development project but first loaded onto the car in November 2015)

Fueling
ID1300 Injectors (November 2015)
Cosworth Fuel Rails (January 2015)
Parallel Pro-Flow/Aeroflow Braided Fuel Line and Fittings (January 2015)
MY09 WRX Send/Return Fuel Dampeners (July 2015)
Turbosmart FPR-1200 and Fuel Pressure Gauge (September 2014)
Continental Flex Fuel Sensor (January 2015)
Flexconverter Ethanol Content Analyzer (September 2015)
Custom-Built Arduino Gauge (January 2015)
Walbro 460 Fuel Pump (January 2015) Hardwired in January 2016, 58PSI base rail pressure
CJ Motorsports Billet Fuel Pump Holder (January 2015)

Stopping
DBA5000 2-Piece Rotors (Front)
DBA T2 Slotted Rotors (Rear)
Akebono Rear Pads (July 2015)
Race Brakes Australia Front Pads (July 2015)

Wheels/Tyres
Bridgestone RE003 Tyres

Suspension/Handling/Bushings/Mounts/Other
Group-N Engine Mounts
Group-N Tranny Mount
Perrin Pitch-Stop
Whiteline Anti-Lift Kit

Acquired but to be installed
Whiteline Front Strut Brace (Not Installed at the moment, rubs on AWIC)

Asthetics Brah
Front-end Face Lift (2011+ WRX/STI), blanked out fog covers, new wheel arch liners (October 2016)
Perrin Radiator Shroud
Perrin Alternator Shroud
Never-ending Gobstopper Intake Manifold paintjob with red, blue and black
Some other black bits.

Wish List
New bushings throughout
Wheels
MCA Coilovers
2015 STI Steering Rack
New Paint/less stone chips
Yellow Callipers, yellow pinstripe.
R205 fender garnish.
Bottomline kit
Jegs Power Steering Cooler
Oil Cooler (if I can find a setup that doesn't leak at the sandwich plate)
Last edited by aijii on Sun Aug 20, 2017 10:57 pm, edited 16 times in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Wed Jun 17, 2015 8:10 pm

For the sake of the build thread (so I'm not starting it at the end of my build), I'll go into the history of the car that i've gleaned through chats with the original builder, the previous owner, and the huge stack of invoices I got with the car.


I bought this car back in April 2013. I used to own an MY11 WRX, TP "stage 3" tuned, it made about 195KW at one of the docklands dyno days and was a fun car to drive. But I wanted more, and came across this built STI for a decent price, and jumped on it.
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It was nice having both cars in the driveway for a bit...
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I bought this second hand from an old WRX club member (who shall remain nameless) and the car had seen a fair bit of track work. The previous owner was unfortunate enough to have experienced dual piston ringland failure (#2 and #4, surprise surprise) at Phillip Island back in 2011. At the time, he was running an MRT Stage 2 (XB) kit, so basically TBE and tune. For varying reasons, the MRT warranty was not honoured by MRT and he eventually took the car to TMR (Team Mitsubishi Ralliart) to be rebuilt. Interestingly enough, he put it down to lack of oiling on the sweeping right hand at Phillip Island causing the pistons to overheat. I’m not sure I agree with that diagnosis 100%, however who knows.


Mods when I bought the car
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Engine Build
Original build done by TMR
Cosworth Pistons
Cosworth Rods
ACL Race Bearings
ARP Case Bolts
ARP 2000 Head Studs
Cosworth Oil Control/Baffle Plate
Cosworth High Flow Oil Pump
SG Motorsports 2 Port AOS (tee'd off rocker covers and crankcase)

Intake/Exhaust
ATPTurbo GTX3076R IWG Stock Location Turbo
Process West TMIC
Pierburg 3-Port EBCS
Cosworth Cold Air Intake (really just a rebadged K+N Typhoon)
Turbosmart Dual-Port BOV/BPV (VTA Blocked)
MRT Turboback Exhaust
Perrin 3.0" Inlet

Fueling
ID750 Injectors
Stock FPR
Stock Fuel Pump ?!?!
Stock Rails

Other
DBA5000 Front Rotors
Stock Rear Rotors
Ferodo Pads (all round)
Yokohama Advan AD08R/AD08 Tyres

Tune
Tune by RE Customs, original dyno sheet shows 238KW on 98. More on this later..

At the time I bought the car, I didn't really know enough to know that it was an odd choice of bolt-on parts. I mean, why the relatively large turbo, but stock fuel pump, regulators, lines, small injectors, lack of cylinder reinforcement etc. I got excited at the time thinking this car had the potential to make way more power with just a tune, not understanding the shortfalls of the stock EJ257 cylinder walls or the other limitations in the car as it stood. I guess that was one reason I looked past the very "linear" feel of the car (compared to my previous MY11 WRX - that thing rocked with a TP stage 3 tune) as I believed a simple tune tweak could fix it up.

I got subaru docklands to do a full compression/leakdown test. I have the results somewhere, but they were good. One of the Cylinders leakdown was a little worse than the others. More on this later. I bought the car. Yay. Two Subies in the driveway. ****. I need to sell the old one now.

Anyway - after getting a few different local tuners to look at the tune, all pretty much agreed. The tune was very wierd, and probably dangerous. Aggressive timing curve, very lean, no MAF tuning (my table compare showed it was changed from stock, but only ONE cell was changed) and ridiculous amounts of MAF EL compensations. It was almost as though the tuner didn't really know how to tune Subies, but somehow managed to limp his way through it. I was pissed at this point, as I had sent the tune to my previous e-tuner (TP) who actually commented and said it looked good "looks like they spent a lot of time dialling in the EL compensations". I probably wouldn't have bought the car if I'd known how bad the tune really was.

The other thing I noticed at this time was that the car had a audible low-load knock, and got the GR fuel stumble like a mother **** just cruising around town. And it was now that I learnt about the GR stumble/fuel system resonance. It was at this time I decided it would be a good idea to get it re-tuned.

Around this time I was hanging out at some local meets, and met a bunch of the local WRX club members (hi Kristian, Pottsy and Ben).

These boys all talked up this wierdo from Ballarat called Warwick who knows a thing or two about tuning, but at the time I couldn't be **** driving all the way to Kryal Castle for a tune given I was a new Dad at the time. So I settled on tuning with Graham from Boosted Performance in USA. He had a handful of good reports, and I was pissed off at Eric from TP for not spotting the dodgy tune so why not.

$250 USD later we had started. Fast forward about 6 weeks, 20+ revisions later, a TurboSmart IWG75, and we're still having trouble getting boost under control. Graham was targeting higher boost (around 24PSI). But I was regularly seeing boost spikes (especially in lower gears) up to and over 28PSI. ****. The car did feel **** great, much faster. The stumble was largely cleaned up, with the help of 1 metre of rubber hose. But it wasn't perfect. He was trying to tune per gear boost, but this takes lots of revisions, and my main point of contention with Graham was the 3+ days in between receiving revisions from him, having a car that boost spiked that was a DD.

i’ll also mention that on one of these 28PSI e-tune log runs, that the car pushed coolant. Lots of it. I knew just enough at that point to know it wasn’t a great sign about the health of the engine however I have this amazing ability to disassociate from bad things and just keep going… and so I did. I was scared that I had just lifted heads e-tuning the car, but in reality I just uncovered a symptom of a head gasket issue that was present prior to me even laying eyes on the car. More on that later
Last edited by aijii on Sun Feb 28, 2016 5:20 pm, edited 5 times in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Wed Jun 17, 2015 8:10 pm

Brake Woes/Drive Shaft Woes/LCA Bushing Woes/Mechanic Woes

I’ve learnt a lot about Subarus, and cars in general since I’ve owned this one. Expensive lessons at that.

The car came with pretty heavy duty Ferodo racing pads. These squealed like no tomorrow about 100% of the time. Fairly irritating after a while. So I bought some Akebono front pads from Race Brakes and set about replacing the fronts. Ahhhh.. silent stopping. For about a week. Then I got all sort of clunks as I was stopping the car, and changing from forwards to reverse or vice versa.

Initially I thought it might me the LCAs clunking, as the LCA bushes were due to be replaced. So I set out looking for replacements. It just so happened that Super-Pro had pillow balls listed and their site (and guy on phone) both said they would fit the GR STI. Which I found a little odd, as the pillow balls didn’t come out till the 2011. Maybe they made them a bit smaller to fit the older LCA. Who knows. I ordered some through Tuspeed, and the mechanic tried to fit them and rang me telling me they wouldn’t fit, way too big. Adam at Tuspeed organised a set of Whiteline ALK bushes for my car (that would definitely fit) and a simple bushing replacement took a day too long. Dunno if SuperPro have fixed their site since. Anyway I reversed the car out of the mechanic shop and the clunk was still there. Damnit.

My mechanic then got the car up on the hoist trying to work out what was causing the noise and wobbled the front axles around a bit and they made a similar noise. Bam, he said. Thats the problem he said. You need new drive shafts, he said. At least $400 or so later, reconditioned drive shafts in, I go to reverse out of the mechanics workshop and clunk. Same **** noise. By this point I was getting a little over it.

After a couple of minutes inspection on the hoist (again), "Oh - it’s your brake pads wobbling around" the mechanic says. To say I was frustrated would be understatement.

He did some magic with a welder to stop the pads moving around so much. Again, the clunk/noise stopped for a bit, but was back after a fortnight. I haven’t been back to that guy.
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This time I went back to Race Brakes Australia. Lets just say it took them a few weeks to rectify things, with multiple visits. They eventually refunded the Akebono fronts, sold me Akebono rears, modified RB24 front pads (that were a little larger) as apparently all my callipers had seen a lot of heat and thus there was a bit of room for the pads to move around. The rear discs were toast, so they put DBAs slotted rotors in whilst they were there.

Car still squeals, not as bad though, and the front pads didn't instill a great degree of confidence when I was hurtling around Sandown last Rexmas. Watch this space..


Steering Column Woes

A niggling issue that got progressively worse during the first few months of owning the car was that I could “hear” the engine from the drivers seat. That might sound silly, but it was as though I was on the wrong side of the firewall when I was driving the car. I could hear all sorts of wonderful valve train noises, noises that sounded like marbles rattling around in a tin can, and other things that I shouldn’t be able to hear from the drivers seat. I couldn’t work out where it was coming from, quite obviously there was a hole in the firewall somewhere but where oh where was it ? One 4 degree morning I was driving on the freeway, and I could feel ice cold air hitting my legs whilst on the freeway. Ahah… so there definitely was a hole there… right around where the steering column “grommet” is. Oh. The grommet had dislodged from around the steering column.

Easy fix. I’ll just get a mate to help undo the steering knuckle, support the steering wheel from inside the car, pull it through, reseat the steering column retainer, and grommet, put the whole thing back through the firewall and reconnect the steering knuckle. Bobs ya mum. Should be easy.

Wrong. This has to have been the most anxiety inducing, pain in the anus job my mate and I have ever undertaken. Sunday night, car on the wrong side of Melbourne, it’s late, cold, we’re tired, stuck under the car learning all about how difficult it is to support a steering column and slide align the master spline on the column/knuckle whilst your arms are shaking due to lactic acid buildup. We eventually got the steering column back together. That was a very weird issue, but I was glad it was fixed. Car sounded normal again. No wind chill between my legs either whilst driving on the freeway.

TMIC woes
One thing that irritated me about the car was the PW TMIC. When you have a stock location turbo the size of a GTX3076, you need to get creative about how you fit a TMIC over the top of it. TMR used spacers. Big ones, like 1 inch thick, under the TMIC bolts, putting the whole thing on a slant. It looked cool, and probably resulted in a better seal with the splitter, but meant it the paint at the top of the TMIC was worn down due to rubbing on the underside of the bonnet and the big fat dual port BPV fouled on the intake manifold.

I am just a little OCD, and this pissed me off. So I decided to “upgrade” my large intercooler with a smaller one - a Grimmspeed. $1000 later, and I had resolved my bonnet fouling issue, and had more black stuff in my engine bay.

In hindsight, this was a silly upgrade. Should have left the PW TMIC there. Waste of time, and lost money on a perfectly good intercooler that I would rip out later on anyway….
Last edited by aijii on Sun Feb 28, 2016 8:08 am, edited 4 times in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Wed Jun 17, 2015 8:10 pm

Turbo, Turbo Inlet, Fuel Injector, HG Woes
So I started tuning with Shadow Tuned just before Docklands Dyno Day 2014. We had just started e-tuning the car, and were having issues getting timing into it up top, clearly obvious from the initial dyno graph.
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After chatting to the guys at ATP Turbo (america) about the GTX3076R I had on the car, it was apparent that it really needed a good kick in the arse boost wise to get up and dance, anything below 25 PSI was basically wasting time.

Turbo Swapsies
So I decided I was going to go with a smaller turbo. Mikes was looking for something bigger than his dom2.5 8cm, so it was a match made in heaven.

We set about to do the swap on a warm Saturday in September 2014 in Mike's driveway. I had purchased a standard size PSR inlet, FIC 1100 injectors and 3mm KS-Tech Phenolic spacers to go along with it.

It took about 3 hours to get the dump pipe off all thanks to one nut, underneath the bell mouth. Through some stroke of sheer luck we eventually managed to find a socket that was skinny enough to fit over the top of the nut but not foul on the bottom of the casting.

Next off was the manifold - and then a struggle to try and get the "universal" PSR inlet to fit. It clearly looked to me like a direct copy of an AVO WRX inlet, and the WRX and STI inlets are completely different. I'm sure one could try hard enough and move a bunch of sheet to get the PSR inlet to fit, but we clearly didn't have time nor the inclination, so I dug out my old sti stock inlet and used that for the moment. Yuck. Got the FIC1100s on, then went up to Warwick's the next day for a tune.

Issue we had was that at idle, the short term corrections were -25%. Playing with latencies made the trims better but the idle quality got unbearable. 3 hours of dicking around and Warwick sent me on my way to put my old ID750s back in. I got the FICs flow tested, one was WAY out of spec. So they eventually swapped me for a set of much better matched injectors.

Got the car tuned again by Waz before Rexmas and had a fair bit of fun. Car pushed lots of coolant at Rexmas again. Everyone was suggested I needed to pull the engine out. With a 5 month old non sleeping child it was the last thing I needed or wanted to hear.
Last edited by aijii on Mon Feb 29, 2016 9:38 pm, edited 3 times in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Wed Jun 17, 2015 8:10 pm

Fueling

Sick of the GR Stumble, I decided at the end of 2014 to do FPR, rails, parallel lines and fuel pump.

Here are some piccies:
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Last edited by aijii on Sun Feb 28, 2016 8:27 am, edited 2 times in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Wed Jun 17, 2015 8:10 pm

IMG_20141230_205756 1.jpg
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Last edited by aijii on Sun Feb 28, 2016 8:30 am, edited 1 time in total.

ryano
Impreza WRX Driver
Posts: 271
Joined: Thu Aug 19, 2010 9:12 pm

Re: My 2008 STI Build Thread

Postby ryano » Thu Jun 18, 2015 10:26 am

nice colour and i like the wheels

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 8:32 am

dirty.
IMG_20141230_214712 1.jpg
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Never played with braided line before... this stuff isn't the best hose to work with. Soft braid (as i've since found out) is so much nicer.
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Last edited by aijii on Sun Feb 28, 2016 8:50 am, edited 1 time in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 8:33 am

Pulling things apart
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Lots of car bits.
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Obligatory pussy shot.
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Last edited by aijii on Sun Feb 28, 2016 8:51 am, edited 1 time in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 8:34 am

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aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 8:36 am

Black all the things
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Last edited by aijii on Sun Feb 28, 2016 8:52 am, edited 1 time in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 8:38 am

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****. Fouls on the manifold. I used a 1" -6AN extension to give a bit of clearance. No pics unfortunately. I think I made about 20 trips to and from VPW through the course of these few days.
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Last edited by aijii on Sun Feb 28, 2016 8:53 am, edited 1 time in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 8:42 am

IMG_20150101_125040 1.jpg
version 1 of routing.. not ideal but fixed with
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aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 8:46 am

getting there. **** braided hose.
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time for a sip of nice tassie whisky...
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Last edited by aijii on Sun Feb 28, 2016 8:49 am, edited 1 time in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 8:47 am

Testing for leaks ...
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IMG_20150103_144354 1.jpg
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aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 9:00 am

Finally got it back together...

2015-01-04 20.00.35.jpg
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Learnings: Hard braided hose is difficult to route, work with and time consuming to get right. The routing here is far from perfect, but i needed to get the car back together. It would all be redone in the middle of 2015 anyway..

I now get a bit of FLKC in neutral when revving, plus also the hardlines down the car rattle at idle. Not ideal, don't know if it's proximity of the drivers side feed/return lines to the knock sensor or what...

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 9:09 am

15th Jan, 2015: MRT system back on the car, to see if we could get any more timing in up top. I previously had a tsudo 3" midpipe, that mated to the stock muffler. Quiet, but probably pretty restrictive.

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Even with the addition of another mid muffler, I quickly remembered why I took the MRT off in the first place. Wow this thing was obnoxiously loud and droned like piss.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 9:38 am

Ben found a Hitech exhaust for sale in May2015, second hand for $200. Couldn't go wrong. Got it fitted up with a resonator (the guy removed it for some silly reason) and YES - it was much better than the MRT.

Quiet at cruise, screamed at WOT. Perfect. I got to enjoy it for about 1.5 days. At that point it became pretty apparent that something was up with the motor. I got tuned in February 2015 for e85. I started to have the odd overheat in addition to regular coolant pushing episodes. Teekay test over the header tank showed nothing amiss at idle, but did show combustion gases over the coolant overflow as it'd sit there bubbling after a hard drive.

Time to pull the engine out, head gasket shot. I decided to wait for a while until things were bad enough to warrant the effort. Timing was interesting - I had the car blow the bottom hose on me on the way to work one day - just a pinprick hole but wow it was quite an amazing show of steam, hot spray and green sheet all over the road. Car towed to the folks place and sat in their garage for the next month and half while we fixed it.

Here we go...

2015-05-30 19.58.27.jpg
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Last edited by aijii on Sun Feb 28, 2016 7:08 pm, edited 1 time in total.

aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 9:40 am

2015-05-30 20.46.41.jpg
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Leaky seal around sump. Turns out the cosworth baffle plate I had in there was a bit warped.
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This is what happens when you use hose not rated for carrying fuel vapour to carry fuel vapour. This one section of hose installed by workshop from previous owner was weeping oil, but others it was connected to weren't.

2015-06-06 17.29.42.jpg
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aijii
Impreza RS Driver
Posts: 116
Joined: Fri Mar 04, 2011 2:23 pm

Re: My 2008 STI Build Thread

Postby aijii » Sun Feb 28, 2016 9:43 am

Missing about 5 days worth of photos. Whoops.

Engine out:
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Clutch disk. Seems okay.
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