DIY 550bhp 2.5 STI V3 Type R
25 October 2008, 08:25 PM
#31
I stripped the heads the completely jet washed them and then put them on a heavy duty cycle on the old dishwasher i useas a parts washer.
The valve train is completely standard STI 5 with the exception of the springs which are RCMS WRC items. They are noticebly thicker to look at and much more difficult to compress.
The valves were reground with two types of valve grind paste harsh and then fine.
The heads were rebuilt but buckets and shims left off for the time being.
They were then bolted onto the head and torqued up inplace.
I did this in four stages 20ft/lbs, 40ft/lbs, 60ft/lbs, and finally 85ft/lbs.
They were left overnight and then re torqued in the morning.
Then all the valve clearances were measured with the heads in place and torqued down for greater accuracy. I was fairly meticulous with measurement and I even ground some shims down by hand on a wet stone. As a result the clearances weren't just within tolerance but they were all exactly spot on.
rechecked head stud torque after all tolerances were done.
Cams in place and caps bolted down.
Heat insulting manifold spacers placed onto heads.
Long block built
The valve train is completely standard STI 5 with the exception of the springs which are RCMS WRC items. They are noticebly thicker to look at and much more difficult to compress.
The valves were reground with two types of valve grind paste harsh and then fine.
The heads were rebuilt but buckets and shims left off for the time being.
They were then bolted onto the head and torqued up inplace.
I did this in four stages 20ft/lbs, 40ft/lbs, 60ft/lbs, and finally 85ft/lbs.
They were left overnight and then re torqued in the morning.
Then all the valve clearances were measured with the heads in place and torqued down for greater accuracy. I was fairly meticulous with measurement and I even ground some shims down by hand on a wet stone. As a result the clearances weren't just within tolerance but they were all exactly spot on.
rechecked head stud torque after all tolerances were done.
Cams in place and caps bolted down.
Heat insulting manifold spacers placed onto heads.
Long block built
25 October 2008, 08:42 PM
#32
The next job seemed quite tricky at first but after a fair bit of research the solution was quite simple.
I have a version 5 engine that was going into a version 4 car. That presented problems with the wiring loom and in partcular the Idle control valve which is completely different between both versions.
The version 4 manifold couldn't be put on as the bolts pattern on the heads is different. So I had to modify the version 5 manifold to accept the version 4 Idle control valve and version 4 throttle body.
I had to have a piece of billet aluminium machined to accept the valve itself and this in turn bolts onto the manifold.
A feed needed to come out of this into the manifold thus allowing air to bypass the butterfly valve on idle.
The manifold was drilled and tapped to allow ICV air to pass through.
.
It was then painted and all the fuel rails, injectors (740cc), braided fuel lines, goodridge fittings and SX fuel pressure regulator were assembled.
From the front.
From the rear with rotated turbo bolted on
Engine Built
I have a version 5 engine that was going into a version 4 car. That presented problems with the wiring loom and in partcular the Idle control valve which is completely different between both versions.
The version 4 manifold couldn't be put on as the bolts pattern on the heads is different. So I had to modify the version 5 manifold to accept the version 4 Idle control valve and version 4 throttle body.
I had to have a piece of billet aluminium machined to accept the valve itself and this in turn bolts onto the manifold.
A feed needed to come out of this into the manifold thus allowing air to bypass the butterfly valve on idle.
The manifold was drilled and tapped to allow ICV air to pass through.
.It was then painted and all the fuel rails, injectors (740cc), braided fuel lines, goodridge fittings and SX fuel pressure regulator were assembled.
From the front.
From the rear with rotated turbo bolted on
Engine Built
Last edited by dazdavies; 25 October 2008 at 08:53 PM.
25 October 2008, 09:04 PM
#33
Next to be looked at was the fueling system.
I already had an intank 255lph Walbro but with the power i'm intending to run this wouldn't have been enough on it's own so a more robust solution was needed.
I decided to still retain the walbro and use it as a lift pump to a swirl pot which fed an inline Bosch 044 Motorports fuel pump. This installation solved two problems 1 it would produce the amount of fuel needed two, will prevent the dreaded fuel surge on demanding right hand handers.
So, we have the swirl pot and bosch pump installed in the boot.
This leads to the fuel rails via a Sytec billet fuel filter.
That's about where I am with it at the moment. I'll update as and when any progress is made.
Cheers
Daz
I already had an intank 255lph Walbro but with the power i'm intending to run this wouldn't have been enough on it's own so a more robust solution was needed.
I decided to still retain the walbro and use it as a lift pump to a swirl pot which fed an inline Bosch 044 Motorports fuel pump. This installation solved two problems 1 it would produce the amount of fuel needed two, will prevent the dreaded fuel surge on demanding right hand handers.
So, we have the swirl pot and bosch pump installed in the boot.
This leads to the fuel rails via a Sytec billet fuel filter.
That's about where I am with it at the moment. I'll update as and when any progress is made.
Cheers
Daz
Last edited by dazdavies; 25 October 2008 at 09:07 PM.
06 November 2008, 11:44 PM
#45
I've been meaning to do this next job for years but never got round to it.
Heatwrap!!
OK first, the up pipe
Unwrapped
Wrapped
Headers Wrapped
Headers Wrapped and sprayed with DEI sealer.
Headers and down pipe wrapped an painted.
I'm going to go and get some wire lock tomorrow and just wrap that round the lot in a criss cross fashion. Should be secure enough!!
Heatwrap!!
OK first, the up pipe
Unwrapped
Wrapped
Headers Wrapped
Headers Wrapped and sprayed with DEI sealer.
Headers and down pipe wrapped an painted.
I'm going to go and get some wire lock tomorrow and just wrap that round the lot in a criss cross fashion. Should be secure enough!!
Last edited by dazdavies; 06 November 2008 at 11:52 PM.
11 November 2008, 12:50 AM
#51
Cheers Fellas.
2 cans cost me £25, from ebay and I got a free bag of Haribo when it was delivered.
They delivered the very next day too. Can highly recommend these guys.
eBay My World - camautodevelopments
2 cans cost me £25, from ebay and I got a free bag of Haribo when it was delivered.
They delivered the very next day too. Can highly recommend these guys.
eBay My World - camautodevelopments
13 November 2008, 08:07 PM
#52
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Cheers Fellas.
2 cans cost me £25, from ebay and I got a free bag of Haribo when it was delivered.
They delivered the very next day too. Can highly recommend these guys.
eBay My World - camautodevelopments
2 cans cost me £25, from ebay and I got a free bag of Haribo when it was delivered.
They delivered the very next day too. Can highly recommend these guys.
eBay My World - camautodevelopments
15 November 2008, 05:58 AM
#53
Hi Daz,
Big fan of your build and especially your fuel setup, and I'd like to do something similar on mine.
Would you mind telling me where you got the swirl pot and anodised fittings from please?
Many thanks
Ross
Big fan of your build and especially your fuel setup, and I'd like to do something similar on mine.
Would you mind telling me where you got the swirl pot and anodised fittings from please?
Many thanks
Ross
15 November 2008, 11:32 PM
#55
nice thread daz, nice surname too 
one for the davies clan lol.
£1000 was a bargin.
wish i could do something this technical. im finding it a ball ache and a wallet strain getting my 93 wrx back on the road and mint and its a runner.
one for the davies clan lol.£1000 was a bargin.
wish i could do something this technical. im finding it a ball ache and a wallet strain getting my 93 wrx back on the road and mint and its a runner.
16 November 2008, 02:30 PM
#56
Maybe not to everyone's taste but I needed to cover up some areas of the paint work that I wasn't happy with so I have had some graphics done.
I have to give a massive shout and a big thank you to Craig from CLM Signs who has put some stunning graphics on my scooby for me today.
He's done an awesome job the pictures speak for themselves, stunning.
Cheers
Daz
I have to give a massive shout and a big thank you to Craig from CLM Signs who has put some stunning graphics on my scooby for me today.
He's done an awesome job the pictures speak for themselves, stunning.
Cheers
Daz
