Subaru Impreza GC8 & RS Forum & Community banner

81 - 100 of 134 Posts

·
Registered
Joined
·
134 Posts
Discussion Starter #81 (Edited)
Originally posted 5/13/19
The upper manifold is now welded to the tgv housings. It went okay, but it was a little rough in some spots. I ended up grinding all of the welds smooth and I'm going to keep practicing and eventually make a final pass over it again. The hardest part was welding in between the runners where it's difficult to get a #17 torch in there. I switched over to a stubby gas lens on the torch which made it much smaller and I was able to get in there and get it all sealed up. Also, preheating the part to around 220* in the powder coat oven before welding seemed to help it puddle easier too. It's a lot of mass (and being aluminum) it dissipates heat quickly so it can be hard to even get a puddle going at times.

I used a 1/2 pipe to -8AN compression fitting adapter on the hard coolant pipe that goes from the water pump, under the intake manifold and to the coolant expansion tank. I wanted this hard line out of the way to make more room for the turbo inlet and also relocating the expansion tank since I didn't want to mount it to the intake manifold. To get the compression fitting to go on, I had to cut the flare on the very end of the hard pipe. It should work nicely.
[IMG]

[IMG]


It's not the greatest picture and it's still a work in progress, but I began modifying my Moroso coolant expansion tank that so that it can be relocated to to the passenger fender. I cut the bracket off that formerly mounted it to the stock intake manifold and welded it back on so it will mount to the fender. The coolant hose that was adapted with the compression fitting that I previously mentioned will connect to the expansion tank using a -8AN 90* on the back side of the tank (between the tank and the strut tower). After cutting the stock barb fitting off and plugging the hole for the coolant feed from the AOS, I drilled a new hole where I'll weld a -8AN fitting on. I'll need a new/longer hose for my AOS (which I can order through IAG), but I'll use a -8AN to 1/2 hose push on fitting for that connection. Should be fairly clean and work well as long as the welds seal
:D

[IMG]
 

·
Registered
Joined
·
134 Posts
Discussion Starter #82 (Edited)
Originally posted 5/14/19
I had a couple of hours to play around in the garage last night and got my expansion tank finished up. It just needs blasted and coated now. I welded on two -8AN fittings. I had to move the tank about an inch forward from where I had it mounted previously to allow enough room for the 90* fitting, but no biggie. I'm loving rivnuts for the ease of mounting stuff on firewall/fenders.
:D


Meh, I've seen worse welds lol
[IMG]

[IMG]


Again, the 90* fitting is connected to the compression adapter fitting that I previously put on the coolant pipe off the water pump. The barbed fitting will connect to the AOS coolant hose, but I need to order a new one because this one is cut too short for where the tank is now. The tank is a little rough looking, but hoping some powder coat will clean it up a bit. As long as it doesn't leak I'll be happy.
[IMG]

[IMG]


It's a bit of a mess right now, but it's getting there.
[IMG]
 

·
Registered
Joined
·
134 Posts
Discussion Starter #83 (Edited)
Originally posted 5/20/19
Small update...Finished expansion tank
[IMG]

[IMG]


Last night I pulled the power steering and looped the hard lines from the rack where they come up through the subframe. Conveniently, I had two -6AN hose ends and 8" of hose laying around so I made a quick line and looped the feed and return together. I'm going to see how much I hate not having power steering. If I can't stand it, I'll look into going the electric/hydro power steering pump direction.

Very rough mockup of turbo inlet and IC piping. 3" hard inlet and 2.5" intercooler piping coming off a 90* coupler from the turbo will both fit under the intake manifold. This is the main reason why I wanted to ditch the pump...to make room for the IC piping. It will go right where the pump used to live, 90* down under the radiator hose, along the timing cover, and then connect to the intercooler right below the headlight (in theory). More to come on that once I get materials.
[IMG]

[IMG]


Last night I welded a 50mm Tial BOV flange onto a charge pipe for a buddy. The welds are a little lumpy, but it didn't turn out too terrible. This was the thinnest aluminum I've welded yet and I learned a lot. It's not going to win any beauty contests, but will hold all the boost! Got it recoated in some Desert Wrinkle Black too.
[IMG]

[IMG]

[IMG]

[IMG]
 

·
Registered
Joined
·
134 Posts
Discussion Starter #85 (Edited)
Originally posted 5/27/19
Continued working on the intake manifold...
Upper manifold to TGV welds are basically finished. Trimmed the plenum a bit more.
[IMG]

[IMG]


Started some plenum mockup...
[IMG]


Plans for intercooler piping routing. This is roughly mocked up, but will sneak it under the headlight:
[IMG]

[IMG]


Trying to decide on an intercooler core. I'm trying to keep in mind the level of difficulty I will be encountering when fabbing end tanks. I've narrowed it down to basically 3 different options:
Treadstone 28" x 10.5" x 4.5"
Garrett 24" x 10.5" x 3.5"
Several brands (CSF, Treadstone, Vibrant) for a 24 or 25" x 12" x 3.5"

I made two cardboard templates.

First one was the 28" x 10.5" x 4.5"...it's huge. Probably a little too big, especially for just an FP black. But being 28" long would make for the easiest end tank fab up because it would be a straight shot below the headlight into the end tank. No 90's and 45's to work out to mate it to the end tank. It also fills the entire opening in the bumper which would make it look nicer IMO (and hide my welds
:D
). I would more than likely need to trim the bumper a little bit more, but not much. I would also have to cut out more of the "bucket" that's built into the bumper for the fog light mounting...which wouldn't bother me.
[IMG]

[IMG]

End tank mockup
[IMG]


The second one was the 25" x 12" x 3.5". Looks tiny compared to the previous one. The end tanks could a be a little more complex with the shorter length, but should still be doable. Just need to make a decision.
[IMG]

[IMG]

[IMG]


Anywho, more to come, just an update out of boredom at work
:D
 

·
Registered
Joined
·
134 Posts
Discussion Starter #86
Originally posted 4/5/19
#ANFittingsOnAllTheThings

AN hoses for the EBCS, wastegate, boost reference on the turbo compressor, and also replaced the "sweaty" coolant lines that come with the IAG AOS with AN hoses (they have always permeated pretty badly). I had to make a new hose to reach my relocated coolant expansion tank anyway, so figured I'd replace both. I used a 1/2 pipe to AN compression adapter on the turbo hard coolant line. TBD if it leaks...

[IMG]

[IMG]

[IMG]

[IMG]
 

·
Registered
Joined
·
134 Posts
Discussion Starter #87
Originally posted 4/9/19
Drove 9 hrs round trip this past Saturday to pick up some new wheeeelz (again)...I plan on getting another set of drag radials (again) and hopefully keep them this time
:D


These might be the cleanest set of 05-07 BBS wheels I've seen as far as road rash goes - there is none. They were also freshly powder coated, but the clear is a little orange-peely in some spots, but I can get over that. This pic is kind of washed out, but I'm digging the gold.
[IMG]
 

·
Registered
Joined
·
134 Posts
Discussion Starter #88
Originally posted 4/10/19
I got my hot side charge piping all routed and welded up except for where it needs to connect to the IC core. I should have the core tomorrow. Turns out I'm going to need thicker phenolic spacers to make clearance for the 2.5" pipe to route under the manifold after all. I have 3mm currently and it needs maybe another 5mm of clearance. It shouldn't be a big deal because I've yet to design the manifold plenum so if I need to shorten it more, I can do that...but with the bracing cut out of the hood I think I'll still have plenty of hood clearance.

90 coupler right off the turbo...I'll be making or buying a 3" hard inlet instead of using the FP silicon inlet. It's just there for mockup.
[IMG]


Many pie cuts to snake the pipe between the timing cover and the fan...
[IMG]

[IMG]


Making the turn to where the IC end tank will be...
[IMG]


I got to the point where I had everything welded up (except for the 90 to the IC core) and realize I'd never be able to take this pipe back off without first pulling the intake manifold. So I'll put a coupler on the straight section of the piping so I can remove it in a couple pieces.
[IMG]

[IMG]

[IMG]


Getting there. My aluminum welding is getting better...still not the prettiest, but it will do. Pipe is much more difficult to weld than a flat surface, I've found. The cold side charge piping should be cake compared to what needed to be done on the hot side, but won't be able to start on that until I at least get started on the manifold.
 

·
Registered
Joined
·
134 Posts
Discussion Starter #89
Originally posted 4/12/19
Starting mockup on this huge Treadstone core. The bumper will need some additional trimming, but it's not too far off. I installed Quiklatches last week on the sides of the bumper (where it would normally bolt to the fender) so it will make fitting and removing the bumper super fast and easy.

[IMG]

[IMG]

[IMG]
 

·
Registered
Joined
·
134 Posts
Discussion Starter #90
Originally posted 4/25/19
Finally got started on end tank fab. Picked up a 3x4' sheet of 1/8" aluminum and have now realized I bought way too big of a sheet! But that's ok...better than not enough I suppose.

[IMG]

[IMG]

[IMG]

[IMG]

[IMG]


Got the second one done and it actually turned out the same size!
[IMG]

[IMG]

[IMG]


Getting there...next need to cut holes and start mocking the cold side piping up!
 

·
Registered
Joined
·
134 Posts
Discussion Starter #91
Originally posted 4/30/19
I feel like a lot of these update posts are fairly redundant, but they are updates nonetheless...

I got holes cut in both end tanks for the piping entry and then fully welded inside and out. The driver side is welded onto the intercooler core and that process went pretty smoothly. So far so good. I'm waiting on a 30* coupler to try on the passenger side end tank before I weld that side on, just in case I need to make changes to the inlet design a bit.

Next challenge will be beginning on that plenum...I don't think it's going to be much fun

[IMG]

[IMG]

[IMG]

[IMG]

[IMG]

[IMG]

[IMG]

[IMG]

[IMG]
 

·
Registered
Joined
·
134 Posts
Discussion Starter #92
Originally posted 5/8/19
Intercooler is done!
[IMG]


One of my better beads. I feel like I get a litter better every time.
[IMG]


The 30* coupler was a perfect fit. I was able to use a straight coupler on the other side with the way the piping is oriented.
[IMG]


I got the "hot side" intercooler piping coated last night
[IMG]


I had to make a tight radius 90 for the throttle body as the radius on a standard off the shelf 90 isn't tight enough. This will allow me to have the throttle body a little bit more forward. I bought an Alpha Loc coupler to connect this piece to the throttle body, but the way it's designed I'm not able to get the coupler around the tighter radius...so I sent that back and went with a Vibrant vanjen HD style clamp instead since it can be complete removed from the piping. More on that later when I get that far.
[IMG]

[IMG]

[IMG]


After some more cutting to the fog light mounts, the bumper fits nicely
[IMG]

[IMG]


Obligatory picture of doggo for Sheen
:D

Yawn.
[IMG]


Probably have said this a couple times, but next thing to tackle is the plenum design. I can't finish the piping on the "cold side" of the intercooler until I get the plenum and throttle body into it's home then build off of that to connect to the pipe that comes off the intercooler.
 

·
Registered
Joined
·
134 Posts
Discussion Starter #93 (Edited)
Originally posted 5/9/19
Vibrant vanjen clamp came in yesterday and I got it welded to the throttle body then began some mock up for the plenum. I have the throttle body basically where I want it, now just trying to figure out the best way to make the plenum while trying to make it at least half way ascetically pleasing and not just an ugly square.
[IMG]

[IMG]

[IMG]

[IMG]
 

·
Registered
Joined
·
134 Posts
Discussion Starter #94
Originally posted 5/13/19
I made some major progress on the plenum this weekend. It would actually be done if I didn't run out of argon Saturday night! Oops. I'll get a refill after work today and get back at it...

Not gunna lie...I completely winged this...

Started with the top and bent it by hand to get the right contour and length. Then placed the bottom at the correct angle so I could have 4.5" and the correct slope between the top and bottom for the TB plate.
[IMG]


From here, I didn't hate it, so I continued on...
[IMG]

[IMG]


Welded and smoothed the inside...
[IMG]


Mocking up side pieces...
[IMG]

[IMG]


Sides on and I ran 3 beads around every outside seam
[IMG]


Welded the inside of the sides and smoothed it out. Sides distorted a bit from the heat, but I'll spread that back out once I weld the throttle body plate on.
[IMG]


aaaaaaaand I ran out of argon as I was welding the TB flange onto the front plate. Mocking up the TB and piping to the plenum though, everything looks pretty good. The piping sits just where I wanted it to in correlation to the radiator.
[IMG]

[IMG]

[IMG]

[IMG]


New meat...
[IMG]
 

·
Registered
Joined
·
134 Posts
Discussion Starter #95
Originally posted 5/15/19
I think all the fab stuff is done now with an exception of adding a IAT bung to the charge pipe. It's coming together nicely. Nothing much about it is perfect, but I'm super happy with how it turned out especially considering how I jumped into it without really knowing what I was doing in regards to metal fab and welding. Learned a LOT!

...now if it will just hold up without blowing apart
:D


[IMG]

[IMG]

[IMG]
 

·
Registered
Joined
·
134 Posts
Discussion Starter #96
Originally posted 5/21/19

Oh so wrong on the almost done with fab part...

I opened this can of worms over the weekend thanks to my self-diagnosed case of OCD...

Ran bead after bead to fill in the recessed areas of the manifold. I didn't like how "built up" the welds were around the edges and I didn't want to grind them smooth due to potentially weakening the weld and/or making it more susceptible to cracking. So I began building up material to grind it flush.
[IMG]

[IMG]

[IMG]


Kind of regretting going this route, but I think it will look cleaner once it's been completed. It's just going to take some time. Ideally, I would have made the fitment of my pieces much tighter so I wouldn't have had to fill gaps and build up some welds a bit excessively - oh well. I still have the passenger side to build up and then grind/smooth out then also tidy up the welds around the throttle body plate.

[IMG]


I welded my IAT sensor onto the charge pipe and got that powder coated, BOV installed
[IMG]

[IMG]


There will also be other fab work with making a turbo inlet that I forgot about.

Slowly, but surely...
 

·
Registered
Joined
·
134 Posts
Discussion Starter #97
Originally posted 5/29/19
That look when the motor is out of the RS yet again...
[IMG]


But this time for a good cause. Competition Clutch twin disc installed
[IMG]


The twin come with a pull-to-push conversion that includes a new TOB, fork, and slave. I was able to use my braided stainless steel clutch line instead of the provided hard line that comes with the kit.
[IMG]


I found some damage on the TOB (presumably) from shipping. The packaging is not adequate considering it's a 50lb flywheel/clutch in a cardboard box with some foam around it and all of the other components are just loose in the box. Luckily this is the rearward facing part of the TOB and is stationary. The inside of it has no burrs or gouges, so it shouldn't be an issue. The vendor I bought it from is aware and is going to try to get me a spare just in case something comes up later down the road related to it, which I don't think is likely.
[IMG]


Old flywheel, clutch disc, and pressure plate. This setup has about 6k miles on it and had definitely seen a bit of abuse.
[IMG]

[IMG]

[IMG]
 

·
Registered
Joined
·
134 Posts
Discussion Starter #98
Originally posted 5/29/19
Manifold is done...ish. Still have some small finishing touches and then powder coating to do, but I wanted to bolt it up and check for leaks/other issues before I do that.
[IMG]


I got the motor back in, everything hooked up, fluids all topped off and ready to fire, only to find out I have no fuel pumps. No priming when turning the key. Spent some time troubleshooting that, looking at the pump relays, playing with the wiring...found that I don't have a switched signal triggering the relays for some reason. Then I notice I don't have any power to OBDII/Accessport. Lights still working, car cranks, no spark or injectors...now realize I've got something else going on. Checking fuses, I find this one blown...
SBF No 5
[IMG]

30A "FMX" fuse, better known as a J case fuse. Never blown one of these before. They are $5 a piece...
[IMG]


I bought 4 at AutoZone, came back to the garage to do some more trouble shooting and popped all of those. Went to Advanced Auto and they only had one left...tried something else and popped that one too. At this point I have it pinned down to something in the main engine harness. If I unplug that connector and switch the key on, I don't blow the fuse.

The only thing I had done in the harness over this past winter was hardwire the injector connectors to get rid of the ID injector adapters (I think those were attributing to my intermittent cyl roughness issues). I had also reloomed the entire engine harness and rerouted the throttle body wiring to make it longer for the reverse manifold.

As I pulled the intake manifold off to further investigate the harness I noticed that one of the wires had been pulled out of the injector plugs that I put on on cyl 3. Fixed that, went to Oreily and bought the last two 30A J case fuses in Austin (LOL), came back and viola...that was it. It must have been arcing off the cyl head or intake manifold or something...whew.

It runs again! It runs good. No issues other than my turbo coolant feed line that I used the hard line to AN adapter on weeps a little coolant. I had issues installing that adapter and I think I buggered up the collet when I was crimping it down. It's just enough to hear it hissing a little after you shut the car down and everything is hot. Hardly any coolant actually coming out. Will have to probably redo that adapter.
[IMG]

[IMG]

[IMG]


P.S. no power steering kinda sucks. Not so much just cruising around, but if the car gets a little out of line around a corner (theoretically speaking of course
:unsure:
) it can make it difficult to correct it. I think because it still has fluid in the rack and the lines are just looped, it's kind of fighting itself/you as you turn. It really makes quick corrections difficult. I think I'll look into the MR2 pump option a little more seriously now.
 

·
Registered
Joined
·
134 Posts
Discussion Starter #99
Originally posted 6/6/19
A couple of very amateur-esk iPhone photos from when I had the car running for a few days before pulling it apart again lol
[IMG]

[IMG]


Plugging leaks and fabbing a turbo inlet are next on the docket. Tuning will now have to wait until sometime in July as Jr skipped scheduling at Off the Line in June too
:(
 

·
Registered
Joined
·
134 Posts
Discussion Starter #100
Originally posted 6/17/19
Intake manifold is finally done and powder coated! Soooo many hours into this thing with cutting, shaving, grinding welding, blasting and coating...it's a bit depressing to think about honestly. I was able to plug several pin holes last week, then I blasted it and got it coated this weekend. I decided to go with wrinkle red....I'm not really in love with it (it's a lot of red), but it's done and it's functional so it'll stay that way for a while
:D


[IMG]

[IMG]


I started on the turbo inlet, welding a small straight section of 3" to the 3" to 3.5" transition piece. The 3" would clamp into the silicon coupler to the turbo and the rest of the intake would be 3.5"
[IMG]


Well, that was the plan anyway until I talked with someone much smarter than I am on Facebook (it's good for some things) about how the transition could actually hinder performance. My scenario would be similar to #4 in the example below
[IMG]


Imagine this wall being the wall of the transition...the air would naturally follow the angle of the transition and once it gets to the end of the transition, it would essentially choke down the flow even smaller than 3".
[IMG]


So, I'm just going to stick with a standard 3" which will take out some complexity in making the piping fit and will be much easier to fab. I'm waiting on a 45 degree bend before I can finish the intake/inlet and then it will be done.
[IMG]
 
81 - 100 of 134 Posts
Top