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remski 07-09-2014 09:20 PM

25DB Widebody Rsti
 
1 Attachment(s)
Lets get to the point.

Donor car: 2005 sti slightly modded.

http://citimail.us/journal/IMG_3614.jpg

Was fun while it lasted.

http://citimail.us/journal/IMG_4881.jpg

Fun in the snow.

http://citimail.us/journal/winter.jpg

And on the track.

http://citimail.us/journal/track.jpg

http://citimail.us/journal/seats.jpg


Then some water happened along with a crazy idea and this was purchased.

http://citimail.us/journal/buy1.jpg
http://citimail.us/journal/buy2.jpg
http://citimail.us/journal/buy3.jpg

and the FUN begins.

remski 07-09-2014 09:20 PM

New Longblock for the STI.
 
After 1 year, lots of unpleasant calls and a credit card to pay off.

This arrived.

A destroked 2.34, benson sleeved and bored out to 2.5

http://citimail.us/journal/block1.jpg

http://citimail.us/journal/block2.jpg

http://citimail.us/journal/block3.jpg

Had to be inspected on the spot.

http://citimail.us/journal/block4.jpg

With no room in the garage it took the main spot in the living room.

http://citimail.us/journal/block5.jpg

New 2.5 RS intake manifold was purchased and given a shave.

http://citimail.us/journal/mani1.jpg

Test fitted with 8mm Grimmspeed Phenolic spacers.

http://citimail.us/journal/block6.jpg

Heads came ported.

http://citimail.us/journal/head1.jpg

Taking no chances KillerBee oil pickup was installed.

http://citimail.us/journal/bee1.jpg

Ditching side feed, Top Feed Cosworth fuel rails came in but needed a custom bracket.

http://citimail.us/journal/rail1.jpg

From this.

http://citimail.us/journal/fu1.jpg

This was hacked.

http://citimail.us/journal/rail2.jpg

ID 1000's were the only choice.

http://citimail.us/journal/injector1.jpg

Test fit and all seemed to fit.

http://citimail.us/journal/rail3.jpg

After few more hacks the engine was in the STI.

http://citimail.us/journal/sti.jpg

Break in tuned few weeks later made ~370WHP @1bar.

http://citimail.us/journal/chart1.jpg

http://citimail.us/journal/tune1.jpg

Then water came...

remski 07-09-2014 09:22 PM

Engine story and more.
 
After a year of sitting it was time to disassemble the STI.

Took about 1/2 a day to get to this stage.

http://citimail.us/journal/diss1.jpg

Hoping that the engine have survived.

http://citimail.us/journal/diss2.jpg

http://citimail.us/journal/eng2.jpg

By next working day the car was stripped of most usable parts.

http://citimail.us/journal/diss4.jpg

http://citimail.us/journal/diss3.jpg

All wiring was ditched.

http://citimail.us/journal/sti1.jpg

and ready to get rolling again.

http://citimail.us/journal/diss5.jpg


Now was time for the GC.
Before

http://citimail.us/journal/gc1.jpg

http://citimail.us/journal/gc2.jpg

http://citimail.us/journal/gc3.jpg

After
(keeping my buddy anonymous for now)

http://citimail.us/journal/gc4.jpg

http://citimail.us/journal/gc5.jpg

http://citimail.us/journal/gc6.jpg

And a pile of unusable GC parts was created in the process.

http://citimail.us/journal/pile1.jpg

It was then time to lighten up the car and remove sound deadening.

http://citimail.us/journal/lite1.jpg

http://citimail.us/journal/lite2.jpg

While at it sti front end was bolted.

http://citimail.us/journal/n1.jpg

Few cans of brake cleaner and a small buzz later ...

http://citimail.us/journal/clean1.jpg

We decided to to take off the heads, since the exhaust manifold didnt look too healthy.

http://citimail.us/journal/bb1.jpg

Cylinder 4 was done for.

http://citimail.us/journal/bb2.jpg

There was damage in the pistion and pretty much all sleeves had a layer of rust.

http://citimail.us/journal/bb3.jpg

It was time for a tear down.

http://citimail.us/journal/bb4.jpg

Halves have been split since the block had to be re-sleeved.

http://citimail.us/journal/bb5.jpg

A quick chat with Benson and the halves were shipped for honing and re- sleeving.

http://citimail.us/journal/ben1.jpg

All packed and ready for ups.

http://citimail.us/journal/ben2.jpg

Permanent position for now.

http://citimail.us/journal/bb55.jpg

... Meanwhile battery tray was shaved.

http://citimail.us/journal/bat1.jpg

Rear was bolted up and them GC05F mounted.

http://citimail.us/journal/wheel1.jpg

And then finally after more than a year of aggravation this arrived.

http://citimail.us/journal/kit1.jpg

http://citimail.us/journal/kit2.jpg

http://citimail.us/journal/kit3.jpg

http://citimail.us/journal/kit4.jpg

http://citimail.us/journal/kit5.jpg

http://citimail.us/journal/kit6.jpg

This was really the deal breaker. If I couldnt get the kit, project would have been scrapped.


It was now time for some welding to be done.

But first....

http://citimail.us/journal/flip1.jpg

It really took 3 of us to get the car on its side.

http://citimail.us/journal/flip2.jpg

It was now time to prep for seam welding.

http://citimail.us/journal/seam1.jpg

Weld-meister doing the honors.

http://citimail.us/journal/seam2.jpg

And the finished product.

http://citimail.us/journal/co1.jpg

A pleasant surprise from Benson.

http://citimail.us/journal/ben4.jpg

o-ring-ed and shiny

http://citimail.us/journal/ben6.jpg

http://citimail.us/journal/ben7.jpg

With only one half re-sleeved.

http://citimail.us/journal/ben8.jpg

Moving along.. RS AL hood was finally picked up and installed.

http://citimail.us/journal/hood1.jpg

And in the parts department... A guy from nasioc had created a new fuel rail bracket. Making things lighter quite a bit.

http://citimail.us/journal/nrail1.jpg

The old and the new.

http://citimail.us/journal/nrail2.jpg

After a many days and nights I gave in to the thought of caging the car.

FIA cage has been ordered, and paint prep-work begun.

http://citimail.us/journal/scuff1.jpg

All scuffed-out before the cage install.

http://citimail.us/journal/scuff2.jpg

Seam welding traces

http://citimail.us/journal/seam5.jpg

And in the parts department those arrived.

http://citimail.us/journal/l1.jpg

And those as well.

http://citimail.us/journal/l2.jpg

Then came the roof time.

http://citimail.us/journal/r1.jpg

Cf should do just fine.

http://citimail.us/journal/r2.jpg

M0ar good news came from JE.
4 new custom pistons have been delivered.

http://citimail.us/journal/je1.jpg

Also Japanparts delivered as well.

http://citimail.us/journal/jp1.jpg

I know its early but the brains are here as well.

http://citimail.us/journal/v1.jpg

Time to make things neat.

http://citimail.us/journal/n2.jpg

And for those wondering here is the turbine housing of the turbo to come.

http://citimail.us/journal/t1.jpg

Cage prepping in progress.

http://citimail.us/journal/cage2.jpg

Some rust here and there got taken care of.

http://citimail.us/journal/rust1.jpg

Breaking power is ready.

http://citimail.us/journal/brake2.jpg

Few parts of the dieting process.

http://citimail.us/journal/diet.jpg




Update: Sep.07.2014
Finally some movement.

After a month of waiting and some struggles with shipping company...
This arrived.


http://citimail.us/journal/cage1.jpg

Unpacking the goodies.
http://citimail.us/journal/cage2.1.jpg

T45 FIA Certified straight from UK.
http://citimail.us/journal/cage3.jpg

Mounting plates.
http://citimail.us/journal/guss.jpg

Dash Bar test fit.
http://citimail.us/journal/cage4.jpg

Main hoop tests.
http://citimail.us/journal/cage5.jpg

Gave up testing when all of the bars fell apart.
http://citimail.us/journal/cage6.jpg

Now trying to find a decent welder that will TIG-it.


More goodies arrived.
Cossie oil baffle.
http://citimail.us/journal/cossie_baffle.jpg

1400' of mil spec tefzel wire.
http://citimail.us/journal/mil_wire.jpg

And a Motec PDM to suport it.
http://citimail.us/journal/motec.jpg

remski 07-09-2014 09:34 PM

Reserved 3

remski 07-09-2014 10:14 PM

Reserved 4

thegoldenfist 07-09-2014 10:40 PM

Nice built! Love the engine in the living room.

4ged207 07-10-2014 02:13 AM

kickazz seabazz!

salvi 07-10-2014 08:19 AM

Why was the RS intake manifold use instead of STI?

GeronimoRS 07-10-2014 08:59 AM

So the GC is getting the STi Drivetrain? Just confused cause you said the engine was put into the STi.

This is going to be a beast! What turbo?

remski 07-10-2014 09:07 AM

STI manifold has a small volume plenum due to the intercooler siting right on top of it. Thus limiting the hp @ high rpm.

Also having the long runners gets rid of tgvs.

Quote:

Originally Posted by salvi (Post 3221967)
Why was the RS intake manifold use instead of STI?



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