Subaru Impreza GC8 & RS Forum & Community banner

61 - 80 of 439 Posts

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #61
What came next really epitomized how my last month or so have been going. Before even buying that WRX radiator, I wanted to get my GC8 Radiator connected to my upper tank the correct way, and I have been doing my reading, research. Found The Ultimate Radiator Solution thread, and really like that method of drilling and threading additional nipple into the bolt hole. So I did some more research, found the threaded nipple. When I made a decision to ditch the WRX radiator, and go back to RS one, I went ahead and got my drill out, go the nipple out, the tap. Then I look at the it the radiator... And the welded on bolt hole is just barely bigger diameter than the 1/8 NPT thread. If you drill and thread through it, you'll end up with tin foil walls.




From that last picture, you can see that the thickness of the walls on that welded on threaded spacer is much smaller that on the Koyo radiator that the guy had in that other thread. So I decided against doing that. But I still wanted to add the extra nipple some fancy way, instead of through the gutted cap. Back to McMaster.com I ended up ordering some 5/16th aluminum pipe, and the plan is to bend it with pipe bended, and weld it in, similar to how 90-94 Legacy Turbo radiators have them. This time I am just going to let one shop near me do the welding. I'll learn how to weld aluminum some other time.

 

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #62
Throughout the 2.5 years that the car has been stationary, I have been scouring ebay for some white face Greddy gauges to complement my 1.5 working ones. I had a working boost gauge, and an EGT one with broken sender unit. They have been long discontinued, but I liked the look of them, and I didn't want to spend $200 per on new gauges. So over time, I managed to collect all the gauges and sensors that I wanted. I got all the wiring and a sender for EGT, then got complete water temp, oil temp and oil pressure gauges. So being at the point of my build where I was, I decided it would be good time to look at possible locations for different sensors. I spend couple of weeks reading all of the debates of people saying that it should be here, or here, or you stupid if you are measuring you temperature there. I also spent a lot of time educating myself about the world of pipe threads, more specifically two worlds, American and British.

So for the EGT I had a PT fitting with that came with the sensor. After much research, and also the fact that my probe blew out originally, I looked at the replacement options, for future considerations. The most direct replacement is Defi probe, which cost around $200. Then I also read that people use this replacement probe on Defi gauges.
EGT Probe Exhaust Gas Temperature Sensor - 3/16" Diameter So I figured that for compatibility purposes I should switch the fitting from PT to NPT one, should I ever have to replace the fitting as well. I got this one, Defi 1/8 NPT Fitting for Exhaust Temperature Sensor PDF01109G at RallySportDirect.com I have to tap my new stock headers (Tommei headers can go to hell) and I will be good to go.

Next, oil pressure and temperature. Here is where the most arguments were in many threads. A lot of people say to install the pressure sensor in the front galley plug in place of the stock pressure sensor. They say why would you want to keep the stock unit as its useless because it only alerts you when the pressure is really low. And on top of that you will have your more accurate gauge. I went back and forth on that, but I thought that keeping stock sensor is still a good idea, because you don't look on you gauges at all times, but if a dash light comes on you will notice it the same instant. So after much deliberation I ended up installing the Greddy pressure sensor in the rear galley plug. I got the OEM plug with PT threads to match the Greddy/Defi sensors.

With oil temperature, there were also many different ways that I saw people do it. Some people put it in the rear galley plug, some in the front along with pressure one using some adapter similar to this one.

The problem for me was, that if I wanted to use this adapter, I needed all three threads to be BSPT, but all of the adapters that you can find have the side one with NPT. I looked all over the internet to find one with all BSPT threads, and right before completely loosing my mind, I found one on eBay UK. So I ordered it. When I received it, I realize that it really won't work with what I want to use it for. I would probably work for two pressure sensors as they don't protrude past the thread, but it certainly would not fir the temperature sensor, as that one sticks out and the fitting does not have enough room for it. On top of that it does add some height and I don't think it would fit in the front under the alternator, and in the back I wouldn't be able to use it because of what I described. It looks like these fitting adapters were really designed for oil bypass, or coolers anyways instead of multiple sensors. So after wasting couple of weeks getting that adapter from UK, I decided to just keep it simple, STUPID! I ended up getting oil pan drain plug adapter by Killer B, and putting the sensor there
Killer B Motorsport M20x1.5 to 1/8PT Adapter OEMPT at RallySportDirect.com



Water temperature debate was no different. It ranged from radiator hose adapter, to heater pipe, to in radiator fittings (on some Koyo radiators). However, I went a completely less common way. I saw only one person post about it, Patrick Olsen on Nabisco. I tapped the crossover coolant pipe and installed the sensor there. In fact right next to the stock sensor. Because I didn't know how well that would work, I bought another used crossover pipe on eBay for really cheap and decided to experiment with it, so that I would still have my stock one just in case.

This button looking thing looked like a perfect spot to drill and tap as it looked like there was a lot of meat, and almost looked like was there for some possible sensors on other models, I don't know.


I also checked to see if it would not interfere with anything else, and there was indeed a lot of space.


So I got out some smaller drill bits, as well as the final size of 8.4mm one, as specified for 1/8 BSPT tap and started drilling. There was really a lot of metal in that spot so that was good. Then I tapped it with 1/8 BSPT that I got from McMaster, and it was that easy. I used this thread sealant when threadng the sensors in the pipe


And the result was this





I don't know if that is the best way of doing it, and the best place to measure it but that's the way I did it.

The only thing was that because of my piss poor planning I ended up having to take the intake manifold back off.



I had previously purchase the new O rings for the water crossover pipe. When I compared the old ones and the new ones, the old one looked square, or maybe squished from years of sitting in that groove between the two surfaces. The new one was round and was taller, so I am sure it would seal just fine.

 

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #67
Since this thread got bumped couple of days ago, I just wanted to pop in here and assure everyone that I had not died.

I haven't really been able to make a much progress on the car as much I wanted to... sometimes life has other plans... but I have made some progress, and also am very close to getting back to the build more extensively.

I hope to have updates soon.
 

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #69
Alright, I am back for with some progress and updates.

A lot of things have happened in my life in the last few months but I will just keep going, trying to get this car to a triumphant return to the roads. One of these things is that I am going to be a daddy in 4 months. So if I die from old age before finishing the car, hopefully my kid will be able to take over this project :)

Onto the progress. I will need to catch up to some events going back to February. I have been doing few things here and there since then, but when I am making a very slow progress, or have long brakes in between working on the car, I generally have to stay away from this site so I don't get too depressed.

So after ditching Tomei Headers, I took a stock STI headers that I bought from another member that were in the very nice shape. They were from 2013 STI so everything was very shiny still and rust free. I went ahead and got all new gaskets for them. I also scored a very nice used GrimmSpeed uppipe, that I had ceramic coated over at BoneHead Performance.



Below are some pictures of me Installing the Defi EGT sensors that I had. One thing that I did after my extensive research and education on pipe thread standards, is that I went ahead and bought Defi 1/8 NPT Fitting to replace PT fitting that came with the kit. I got it at RSD. The reasoning behind it was if I ever need to get a replacement sender unit, I would just get one of these from This place which are a lot cheaper but are only come in NPT thread. So I would just tap out 1/8 NTP hole in my manifold and be done with it.

Here practicing on my old piece.



Finding a nice spot to tap



Tapped




Test Fitting the probe





 

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #70
Now fitting the heat shield with a hole for the sender.





Now onto the assembly of the headers/uppipe.








And installation
Along with new gaskets I went a head and got all new bolts, nuts and studs, because... why the hell not.




In these last pictures you can see the oil temperature sensor installed in the oil pan drain nut. I used KillerB nut for that that I got from RSD.
 

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #71
Next, I thought it would be a good time to finish with everything under the car and install the re-finished Cusco front sway bar. I also upgraded to RalliTek heavy duty links. Also previously I was using steel control arms that have slightly different angle to the sway bar link mounts. This was one of the reasons to upgrade to RalliTek links. Everything lined up very quite nicely.






Along the way during this build, I got a refresher course on fitment differences between Turbo vs NA sway bars on a turbo crossmember. Having forgotten all that I read up on it many years ago, I went out and gotten a new Whiteline sway bar that was designed for 98-01 NA Impreza. I ended up selling it after I learned my lesson, but I desided to take some pictures for comparison and to educate others using visual aid.

Here you see side by side comparison between Whiteline 22mm NA front sway bar and Cusco 22mm turbo wagon sway bar. White line is WHI BSF19XZ for anyone wondering. The one with bushings is the Whiteline.





And here is the reason why NA FSBs don't fit Turbo crossmembers. Whereas NA FSB has a those loops to clear above the NA headers that go under it, it in turn interferes with a dip in the crossmember that is there to clear space for the uppipe. In turn, turbo FSB clears the dip for the uppipe, but wont clear the NA headers.


 

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #72
Moving from under the car to under the hood, I installed the power steering tank. Using the OEM bracket, I simply drilled out the mount hole in it a little wider and mounted it on the bold that holds the front bumper.







In the last picture you see that I put a thick washer/spacer under the bracker, to make the bracket sit flat, with that rib that is under the bracket as well.



While I was at it, I slipped one of those hose heat sleeves onto the PS lines going to the rack. I got them at my favorite now store, McMasterCarr


 

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #73
Moving onto the radiator, for those who have been following last couple of pages, I went through some internal debate about the radiator setup, from considering WRX radiator ... other... Well I ended up staying with my GMS N/A radiator and having my go to local shop for precision welding, weld in a 1/8 NPT bung as you can see below. After a lot of test fitting, that seemed to be the best location to connect the hose going from the upper coolant tank. That whole area is really busy with main radiator hoses, PS hoses, and expansion coolant hose, but it seems to be fitting well.






I once again used Permatex Thread Sealant paste to seat the nipple on to help ensure the tight seal.
 

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #74
From this point on there were more "fun" stuff. The theme for the next few little projects is custom.

After I did the swap 10 years ago, I never gotten the AC to work. I looked into it, tried few things, but never gotten to the bottom of it. I decided to revisited it this time and try to get it working. I still suspect the issue is wiring related, but during this stage, I decided to address all of the possible mechanical things. One simple thing that came to mind that the AC line from RS that go in to WRX compressor have slightly smaller diameter ends so no matter how tight you bolt them in there I don't believe there can be a real tight seal. And since the AC pressure switch in WRX models is located in the compressor itself, I figured it would be extra sensitive to any leaks that close to compressor.

So I decided to have custom AC lines made. By that I mean that I decided to get WRX AC lines, and then take compressor ends from WRX lines, and the chassis (front condencer, cab cooling unit) end from RS lines, and then mate them together to create one frankenline. I went to a local hydraulics shop and the guy there gave me this suggestion. Take the aluminum ends that I need, have someone weld on aluminum AN male fitting, and he will then make me a rubber hose with female AN fittings to connect the two ends.

These are the fittings that I ended up getting, 8 AN and 10 AN. Earl's Performance Weld Fittings 997110ERL - Free Shipping on Orders Over $99 at Summit Racing

Here is what I ended up with.





Here are the scraps.



Due to the lack of foresight, one of the ends that you see in the pictures and one of the rubber lines had to be redone, but in the end things seemed to turn out quite nicely. With fresh O rings, and correct ends to match the compressor I can probably rule out lack of pressure, when I go to troubleshoot my AC issues.

Here is what they look like installed.







 

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #75
With installing new condenser and test fitting everything I need to test fit on the front of the car, and frankly running out of shelf space in my garage, I figured it would good time to reunite the front bumper with the car after 3 years apart. Well, it's not the same bumper, its new, painted white. But I sure gotten used to the bumperless look, so when I first put it on, it looked pretty different for a while.








 

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #76
This brings us to more or less current events, however, I got more updates and more pictures from the last few days. But I do need to sleep, so I will post more stuff tomorrow.
 

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #78
Next thing that I decided to tackle is build some kind of air box or a shield for my intake to help block the heat form the engine/turbo area.

This was my intake setup since I did the swap originally.
Circa 2005


Circa 2014


What also got me thinking about making an air box was this thread over on NASIOC. It's a really good write up and it seemed that the material that the guy was using, Kydex, was really easy to create things out of. So I got all of the materials that he was using, including the Kaydex, and couple of the heat insulating sheets.


I started making a template out of some cardboard.






I quickly realized that building an air box was going to be bit more difficult that what the guy did for his 2015 STI, because of the different engine bay layout. Where as his, was more or less a square box, mine did not seem to be able to have a single 90 angle egde. Furthermore, the brake line going to the ABS unit come out really close to the filter that caused me to make few more bends in the template. I also decided to make it a sheild, rather than a complete enclosed box. I figured it will still be better than having nothing at all.

Here I had to use some metal pieces to keep the correct shape while I was fitting the template.






 

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #79
Next I started cutting out shape out of Kydex sheet.






I took some scrap pieces of Kydex and practiced forming. For those who don't know its heat moldable. Its also often used to make gun or knife holsters. I used your standard heat gun to heat up the sheet. While practicing on scraps, I realized just how easily it bends while heated up. With how flexible it gets, you also have to make sure to keep it in the shape the you need it to be until it cools back down again. Given the fact I needed to make some non 90 degree angles, I made this form out some sheet of metal.




Then I simply placed the sheet of Kaydex and heated the area of bend up, and just let it take its shape.

 

·
Registered
99 Impreza RSTI
Joined
·
436 Posts
Discussion Starter #80
The first bend was the easy part, then after that things got a bit tricky, trying to bend areas that you need and keep others flat.
















 
61 - 80 of 439 Posts
Top