very impressive!!

the rears are pretty tight to the arches there!!

 

Great little project!!!

Can't wait to get a project for myself in the future

 

Very impresive dude. Hats off...

 

A great thread fella, keep up the good work...

 

Last week me and several friends rented a track for half a day. Being a working day it was not expensive.

The cars were:

1. My Impreza
2. Almost Stock MY07 EUDM Sti with Cosworth pistons and very large water radiator
3. Toyota Glanza - 275 whp
4. Stock Toyota Celica GT4
5. Honda del sol

The weather was extremely hot - over 40 C under shadow.

The MY07 Impreza STi running on stock maps had knock and overheating issues.

I covered almost 200km without problems but after I took a glance at the logs I was a little bit surprised:

- perfect boost control
- perfect (a little rich) AFR - 11-11.5 under full throttle at 1.4bar boost
- terrible intake air temperature - from 85 to 105C under full throttle with MY98 intercooler.

Now I have to decide whether I should stick with TMIC from my MY04 donor or I should go FMIC - probably with a Hybrid intercooler.

Additionally, I have lots of body roll. The 22mm Whiteline rear ASB is not helping too much - I'll consider buying 24mm rear and 22mm front one.

Some photos:

 

Several days ago I disassembled the EJ257 unit. To my surprise there was no internal damage. Next step is to buy forged pistons and put it together, but first I have to decide:
- what pistons should I use - CP vs Cosworth? CR 8.2:1 or 9.0:1?
- should I replace OEM rods for 400-450bhp? OEM vs Carrillo Pro-H vs Pauter? However if OEM is good enough I'd rather not spend that money.
- What turbo should I use - I'll start with VF39 and then probably will move to ATP GT3076R Hybrid - http://www.atpturbo.com/mm5/merchant...egory_Code=BCS - or something similar. I'm tempted to go twinscroll, but I've never seen OEM twin scroll manifold for sale .

The other thing I did was installing the Apexi catback system along with a new 2.75" downpipe.

I ordered the downpipe at a local shop because I wanted to have heat shielding and I hate exhaust wrap. It cost me only 150 euro and I'm more than happy with the result.

Sound - very deep and powerful but too noisy for my taste.

Pics:

 

Today I ordered:

- CP pistons
Part Number: SC7425
Bore Size: 99.5mm
Compression Ratio: 9.0:1

- ACL Race bearings (5M8309H + 4B8296H)

- OEM Overhaul Gasket set + Cam gear + Timing Belt cover + Timing belt pulleys and tensioner

- Gates Race Timing Belt

I decided to stick to OEM rods for now. I guess that I'll have to resleeve the block long before snapping a rod.

 

cracking project and very cool cars but *pedant mode on*that's a MY98...MY99\00 had different grills *pedant mode off*

 

LOL

The car is MY99. There are lots of other minor differences - cristal headlights, instrument panel (although the front is almost the same), wiring, etc.
Maybe the previous owner simply changed the grill, maybe 1.6's received the less aggressive one - I have no idea...

 

I'll get back in my box then

Nice Glanza btw, one of my friends had a 250 Starlet and once the wheels stopped sinning it was insane

 

Last week I finally had enough time to put together the engine.

And here comes the next dilemma - which intake manifold to use:
1. V5-V6 Phase II manifold - I found a very cheep one on ebay and bought it;

2. V8 WRX non-DBW manifold - I bought one from US for $70 including everything except injectors;

3. V8 DBW manifold with changes to fit non-DBW trottle;

I would have used MY99 manifold, because the wiring is pretty similar to my MY98. However I realized that I need 4 (!!!!) outputs to run the idle and that means to loose the VVT control.

That's why, after considering STi DBW manifold modification I bought USDM WRX manifold. It is exactly the same as JDM one from the same year except for the TGVs. The idle is controlled by only one output. The plan is to use that manifold fitted with the V8 STi side-feed rails and injectors, to remove the Purge/Evap parts and to run some wires for the two additional coil packs, second cam sensor and AVCS solenoids.

I bought Dremel 300-30 and and have almost finished my DIY TGV deletes .

Next dilemma would be whether to go rotated or stick with stock location...

 

EJ257 + Hybrid FMIC:


It was a fairly easy swap. I used everything from EJ257 except upper manifold and TB. They came from MY03 EJ205 WRX and are exactly the same as EJ207 STi from the same year. I had to do a little bit of wiring and soldering but the engine started from the first try and working nice since then.

The pistons ARE noisy. Especially early in the morning.

I had to change the front bumper when I fitted the FMIC and since the scoop was no longer needed I swapped the hood. One of the pipes is scrubbing the hood while it did not with EJ20K.