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578 Posts
Discussion Starter #1 (Edited)
Lets get to the point.

Donor car: 2005 sti slightly modded.

Was fun while it lasted.

Fun in the snow.

And on the track.

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

and the FUN begins.


578 Posts
Discussion Starter #2 (Edited)
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

Had to be inspected on the spot.

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

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

Test fitted with 8mm Grimmspeed Phenolic spacers.

Heads came ported.

Taking no chances KillerBee oil pickup was installed.

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

From this.

This was hacked.

ID 1000's were the only choice.

Test fit and all seemed to fit.

After few more hacks the engine was in the STI.

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

Then water came...

578 Posts
Discussion Starter #3 (Edited)
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.

Hoping that the engine have survived.

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

All wiring was ditched.

and ready to get rolling again.

Now was time for the GC.

(keeping my buddy anonymous for now)

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

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

While at it sti front end was bolted.

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

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

Cylinder 4 was done for.

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

It was time for a tear down.

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

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

All packed and ready for ups.

Permanent position for now.

... Meanwhile battery tray was shaved.

Rear was bolted up and them GC05F mounted.

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

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....

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

It was now time to prep for seam welding.

Weld-meister doing the honors.

And the finished product.

A pleasant surprise from Benson.

o-ring-ed and shiny

With only one half re-sleeved.

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

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

The old and the new.

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.

All scuffed-out before the cage install.

Seam welding traces

And in the parts department those arrived.

And those as well.

Then came the roof time.

Cf should do just fine.

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

Also Japanparts delivered as well.

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

Time to make things neat.

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

Cage prepping in progress.

Some rust here and there got taken care of.

Breaking power is ready.

Few parts of the dieting process.

Update: Sep.07.2014
Finally some movement.

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

Unpacking the goodies.

T45 FIA Certified straight from UK.

Mounting plates.

Dash Bar test fit.

Main hoop tests.

Gave up testing when all of the bars fell apart.

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

More goodies arrived.
Cossie oil baffle.

1400' of mil spec tefzel wire.

And a Motec PDM to suport it.

2001 D2 A8L
929 Posts
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?

578 Posts
Discussion Starter #10
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.

Why was the RS intake manifold use instead of STI?

578 Posts
Discussion Starter #11 (Edited)
Yes.. brand new engine was put in the STI.

Then the STI became the donor car for the swap.

and yes.. the GC is getting all its guts from STI.

For now i am pretty much set on gtx30 since i already have the tial turbine housing.

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?

The subaru of many acronyms
1,918 Posts
destroked bored over ej25? thats crazy oversquare. what rpm is the motor intended for?
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