Calishere's USDM 08 STI ... 700+BHP Flat mount turbo setup !!

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07 January 2015, 10:25 PM

Calishere

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Calishere's USDM 08 STI ... 700+BHP Flat mount turbo setup !!

So here begins the start of a project that has taken me forever to complete...

I'd like to thank

Moore Performance
No Limit Motorsports
MA Performance
Flat 4 motorsports
DCCD PRO

It first started back in 2012 when i bought a used 2008 Aspen white STI from a guy located in new york... Im originally from new york but im stationed in Arkansas so it was a bit of a travel but i snagged it for a good deal and with 42k miles on the motor... She was then named " Riley "

When i bought her she had basically a stage 2 setup , Aem Intake, Invidia down pipe, invidia n1 exhaust, Tein S tech springs ( crap ) Cobb AP ... After driving it from new york and around Arkansas for a while June 2012- Dec- 2012... i spun a rod bearing .... total loss on the motor / turbo ect.... locked up on the high way and couldn't even crank it over... towed it home ... started spinning the crank by hand and ended up turning it over to hear the sound of rod knock ... with 55k miles on the motor and basically 2 weeks left on the 6 year power train warranty... Subaru decided to warranty the entire motor... i ended up with a brand new SB ... re worked heads / brand new turbo ect..... got it back Jan 2013.... I drove Riley around for about 2 months while talking to a shop ( one that shall not be named but will be known as "****" ) We had come up with a plan to build a 500whp car for a decent price... originally it would of been a BW 8375 w/ supporting mods...

Fast forward to march 2013... my car is shipped of to the **** shop in IL where it is taken apart... deposit put that ( $7000 ) and work is started.. with a lead time of about may to have it completed and ready for Scoobapalooza .... The next few months are dedicated to multiple calls... run arounds and lack of progress on their end... I decide to randomly take a visit to said shop... The guy ive been talking to up there is beyond shocked that i showed up randomly... He proceeds to tell me that my motor is being worked at by their " engine builder " i again ask whats going on and around what time should i expect my car back to me ... he says " 2 weeks " .... i press on to new york to visit my family and take some well deserved vacation... two weeks comes and goes... and he starts avoiding my calls all together... I eventually have a friend call him ... he picks up first ring... lol... i immediately there after.... no pick up at all... at this point im on my way back to IL to meet up with a friend that had a job interview at a shop in IL .... I call **** shop and ask to meet up with them the next day... fed up with lack of progress / no proof of anything being done.. i meet up and tell them im pulling my car and either want my money back + a new long block or my motor and my car.... they decided to give me the motor they've worked on and my car back... the shop that my friend ended up getting a job at decides to help out and hold my car for me until i figure things out...

so basically my car was at **** shop from Mar 2013 - Aug 2013 with no progress... I finally get the motor and all my parts from them to find out that ... they had gave me the wrong cams / Rod bolts / and a few other parts... furious i threaten legal recourse and they fix what they've jacked up ........ I have the second shop fix the heads and send my car back to me in Feb 2014... still long block out of the car and SB assembled ...

So out of curiousty i have the engine shop that did the work send me a copy of the build specs.... they're absolute crap... to give you an idea of what my clearances where....

Mains looked .0024 - .0029

i decide to take the SB apart and get everything where i want them ... after this painful ordeal i've finally gotten my motor together ... installed in my car and running.... Now waiting on time to get it to the Dyno and final tuning....

Sleeved EJ257

Wiseco pistons std bore 8:5:1
Manley Turbo Tuff I Beams w/ ARP 625 rod bolts
Balanced Heat treated crank
king main bearings / acl rod bearings
oem 11mm oil pump with 2 shims
ARP case bolts
ARP 625 head studs

Built DAVCS heads

Supertech + 1 mm Intake +.5mm Exhaust valves
Supertech titanium retainers
supertech dual springs
Kelford 220-D cams with heads notched for them
porting and polishing 5 angle intake and exhaust ( i believe )

Turbo components + misc

Comp CT43 6765 oil-less turbo flat mounted Billet wheel/ Triple BB
Moore Performance Equal length headers/ Uppipe
Turbosmart 40mm wastegate
Tial Q BOV
motivewerks EBCS
AEM IAT sensor relocated to right before TB
upstream o2 sensor relocated to down stream location secondary removed
AEM Uego Wideband in down pipe
4" Downpipe merging to a 3" midpipe exiting a invidia n1
Motivewerks TGV deletes
Air Pump delete

Fueling

F4M Fuel rails + -6 AN lines from the firewall to the rail
Aeromotive FPR
Full blown dual pump hangar with 2 340 full blown pumps
ID 2000 CC injectors
AWD tuning fuel lines from tank to fire wall
Drivetrain

Exedy Hyper Twin disk

Suspension/ enhancement

kW variant 3 coil overs
Beatrush engine mounts
Beatrush pitch stop
Beatrush trans mount
Beatrush prop bushings
Beatrush x member bushings
White line control arm bushings

Engine assembly part 1

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07 January 2015, 10:52 PM

thenewgalaxy

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Looks impressive.

What kind of lifespan do you expect from that engine and what kind of maintenance does it require?

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07 January 2015, 11:01 PM

Calishere

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thank you ! well it all depends on what an oil analysis says, but i built it to handle 1k hp so it should be fine.. the only issue i ran into was a head gasket going because of high boost ( 35 psi) ( 2.3 bar) .... but it didnt leak oil into the combustion chamber .. just pushed coolant at high boost

as far as maintenance, i usually change the oil every 2k miles, and regrease the turbo @ the same time... eventually going to change the intake manifold to a processwest reverse mount and go for more power as the stock manifold is holding me back.... if i swapped manifolds i could drop the boost 5 psi and make another 30 hp or so with less boost.... hoping to go for a lot more power if i can !

Last edited by Calishere; 07 January 2015 at 11:02 PM.

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07 January 2015, 11:05 PM

thenewgalaxy

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Quote:

Originally Posted by Damian Maya

I occasionally skim through the American forums and have to say I'm amazed at what they push out of 2.5 blocks. In fact, you even have companies like Crawford and Cosworth pushing the displacement further!

Over here the general consensus is that it's a poor place to start for big power, yet you lot get these incredible figures out of them quite regularly.

Over here if it's not a 2.35 then there are a few 3.3 twin turbos.

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07 January 2015, 11:15 PM

Calishere

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could have to do with availability of parts / tuners and a community that supports each other? Could also be fuel availability as im running e85 and not pump gas ... on pump gas + meth or running race fuel i could potentially make more .. but not entirely sure

I thought about doing a 22t stroker motor at one point but decided against it ... I might even change my setup to a rotated borg warner s300sx or stick with everything i have right now and continue to squeeze as much power as i can haha ... i think a kaps sequential is in my future though ......... i do plan on drag racing eventually

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