May be interested in this let me know a price.
Cheers.

 

Hey Frayz, you lucky so and so. Is that a open deck block you got there???

Rich

 

Hey Frayz.

Bought a Black prodrive Bug a couple of months back and have to say I'm getting loads of great Ideas from this trade.

As soon as I have cash in hand I'll start modding myself.

Your car is unreal and the bumper skirt from a WRC car was somthing I was thinking about myself but looking at your mock ups I'm now not sure as they do make it look front heavey.

Eveything else that you have done is unreal.

She really is a credit to you. Keep up the great work man.

Eric.

 

99% of things are done by myself on the driveway. Obviously any mapping or geometry changes are done at Mocom Racing as i dont have the 4 wheel alignment stuff at home etc.

My engine will be built by me at Mocom though

 

you make me sick!!!!

 

what i want to know is when you're going to start fabricating and selling the fire extinguisher mounts? could help to pay for all those braided hoses and AN fittings

 

Ericsti, Mrtheedge2u2 cheer bud

Rich, its a stock STI EJ257 block thats semi closed deck, same as my V7 block.

Stoneface, unsure as to a price yet buddy. I'll get back to you when i know more.

Lol, Matt you know i dont have time to make em. Billet machined brackets just consume too much time lol.

Got about an hour spare today and measured up my bigend bearing thickness and free spreads. Then i weighed and balanced my bearing sets along with my pistons and rod assemblies.

Once i set them up the weights were as follows.

Cyl #1 = 1083.8g
Cyl #2 = 1084.2g
Cyl #3 = 1083.2g
Cyl #4 = 1083.8g

So only 1 grams between the heaviest and lightest set... thats pretty damn good so im happy with that.

Also managed to track down a JDM Spec C long runner intake manifold today which will delete a load of unwanted sh1te out of the engine bay and give me more room to run the large intake pipe to the turbocharger.

So all in some nice progress

 

lol. well what about if you make one more to fit a classic

 

Newage/classic, its all the same fitment mate

 

frayz you said your a proto type engine builder.. did you go to uni to gain qualifications for this? reason i ask is that i am going to do uni in september to do motorsport engineering, but i still am not 100% on whether to do motorsport engineering, or a course focused more on engien design. just wanted to see if you had an opinion if you did go to uni

 

when you have 5 mins at work then................... got to make something up for the push button start and fia battery isolater i'm about to order too. any ideas? interior is strip so very little dash left.

 

Nice one.

 

Subaruturbo 18 :


No mate, i left school at 16 and managed to get a Ford apprenticeship.

I started at 16 and trained for 5 years, 1st year being a broard spectrum of engineering. Turning, milling, electronics, CNC, CAD, welding etc etc.

The next 2 years i was trained as a Ford mechanic and did everything you would normally find in a dealers etc.
My next 2 years i was trained purely as a prototype engine builder... now i do exactly that i dont do anything other than engines. All of my training was by Ford themselves, not at a dealers or garage.

Ive been an engine builder for 6 years now and the whole way through my training i had lecturers and exams borght to me in house. This enabled me to do my accademic work etc. A level maths, science GNVQ L3s, Advanced modern apprenticships etc etc etc.

So in answer to your question, no i do not have a degree in engineering, i do not feel i need one if im honest nor to i have the time to undertake one.

Personally judging from some of the engineers ive seen that are coming into the business have years at uni with degrees and im glad i dont have one lol.

They are qualified up to the hills but have no experience with anything that relates to the job that they are in charge off and most dont know their **** from their elbow.

Its a shame as the likes of the proper old school machinists and engineering craftsmen that i cut my teeth under are dying out and IMO will never be replaced

God i feel like im writing a CV ha ha, so i hope that helps you out a little.

 

Frayz
the cars bloody awesome. after a 4 month break god time flies. mega problems with the finance company would make a good hours read alone.i can know get back on track with my 05 STI. i have been in the motor trade a long time. problem is not on cars so you make mistakes and learn from them. i think you pointed out the problems with the many colours under the car. a while ago that hopefully putting that right soon. keeping the blue flock though.
the APS cooler is so nice, i went for the hyperflow. anyway the motors a credit to you. hope to meet one day no doubt at a show etc
cheers mick

 

You have had a very interesting few years there, I can see how you manage to do so much to yours now and quality when your at it

 

Props to you for getting into Ford Motor Co at 16, its a very difficult place to get into, especially without experience or a 1st class honours degree...my dad started as an apprentice draughtsman at 16 and retired as the Brakes\Chassis Supervisor at 57

 

Micky, Si and Trails.

Cheers guys. Im still a pup at only 24 but im always trying my best. I really like to think the car reflects my passion to get things right.

Thanks for all your comments, i'll do my best to keep things updated as i go.

 

hats off to you frayz, it's coming along nicely. just wish i had a tenth of the knowledge you do around an engine.

 

If you spent less time posting on here, you could have had that engine built.

Built not bought, just the way it should be. Top work.

 

Lol, theres only so much i can do at a time guys lol,

The car is doing one last outing on on the 8th then its coming off the road and the engine will come out. My heads will be stripped from my old motor and they will be machined. Thats when the new motor will be built

 

Yee God's it this sort of thing that makes me feel old..... I'm just about in Dad territory for you young Jedi

 

Ha ha, dont feel old mate.

Ive an old head on my shoulders so im told... i think that means im ugly?

 

cheers for the advice frayz, looks like youve done it the way i wish i could. originally i was going to get an apprenticeship at porsche, but they basically told me that when you qualify as a mechanic, you cant go on to do other things as a technician/mechanic is too valueble to them. so to do what i want to do im going to have to get degrees etcetc. but no doubt without the experience i will be one of those people who dont know there **** from there elbow i guess ill just have to go to uni then work my way up after.


p.s. i love your car

 

Just try and get as much experience along the way as posible mate. Get your hands dirty and get stuck in on a few projects of your own.

Also something i did at the weekends is to shadow a local race team at events etc. Chances are you wont get paid but you learn so much more actually being in the thick of it. Which in turn will really help your understanding and your study will become easier.

Get as many books etc as you can on mechanical engineering and learn the actual workings of engines, vehicle dynamics etc etc.

Best of luck my friend, keep us posted on your progress

 

oh my god!!! just sat here for like an hour and a half reading everything in the whole thread! amazed, i've always been in to modifing the exterior more than anything, but now im starting to grow up i really want to learn the engine side of things and get into that! i work as an architectural technician and it bores the hell out of me, the fact there is no work around doesnt help!

im not a computer person, i have always been one to work with my hands! wish id left school and gone into either something like what you done or areonautical engineering, i may only be 22 but i still feel i have missed my chance!

As for the car love it! perfect choice of colour on the cooler, i was shouting at the screen to anthracite when i was reading about what to do it in! lol

only thing i would change at all on this car would be the exhaust tip. i liked the style of the old one, but everything else is stunning, and the fitment on that bumper is insane!

Great work, extremely jealous of the car and career!

 

Cheers Tez, nice words buddy

Also to add to the ever growing list of parts ive ordered a full Hardrace engine/gearbox mounting kit today.

I figured id fit new mounts in when the new engine goes in. I want it to all be as new looking as possible

 

So today saw another few little bits towards the build.

I managed to grab some time today to get my big end bearings fitted up in my rods and measured the big end bearings with the liners installed. From here i can measure my crank and work out the running clearances. Unfortunately we're still waiting on my crank from Mark @ Lateral Performance. Once i have the crank, things can really start to move forward.

Edit: Mark @ Lateral Performance is not to blame for any delays on this build and never was.

Another thing ive been hunting high and low for recently is a genuine JDM long runner Spec C intake manifold. These are like rocking horse sh1te, and if you are lucky enough to find one, generally people are not willing to sell them.

Whats wrong with my stock manifold you ask?

Well essentially... nothing. However, all the newage STI's (with exception of the later JDM V8s) came with TGV's (Tumbler generator valves). These are a set of risers that sit in between the manifold and the head.
As their name suggests they have a butterfly valve that sits in them that is controlled by the ECU to close in varying degrees during startup and low throttle angles in order to tumble the intake charge into the cylinders. This is designed to help with emissions. However due to their design they can become a restriction when going for big bhp but more to the point they are a cumbersome item, and generally add to the mess that is a subaru engine lol.

Almost all of the big stock location turbochargers have a larger 3" inlet as opposed to the stock 2.4" item. This means the use of a big bore inlet pipe to feed the turbo. The TGV's just add to this tight squeeze in getting it all in so deleteing the TGVs is a worthwhile idea.

Some people remove the motors and guts from the stock TGVs and weld up the holes that remain.

Here is a pic of a deleted setup


Here is a pic of a stock manifold from the underside with the TGVs, you can see just how fussy they make the manifold setup.




But i wanted a cleaner job than that. So the only answer was a Spec C intake manifold.

Here you can see the long runners on the Spec C intake that are much smoother and cleaner than one with TGVs. There are one or two marks on it so im going to either paint it or have it powdercoated, but overall im really chuffed at finding one of these.






So all in, and apart from me being absolutely skinted by the whole project...

its coming together nicely.

 

Any thoughts on a price for the short engine yet?

 

Its still in the car at the moment fella.

I need to wait until its out and all okay and then i will put it up for sale.

What are your plans for it then mate?

 

Thats cool i'm not in a rush like that I just wana sort out what i'm gonna do.
It would be going into my wagon which is a bit of a project at the moment (never actually driven it yet!) i've just been collecting parts for it lately-not quite as many as you though