20G wagon project started at last!
 

Been a long time coming, my wagon started off a 220ps auto, i converted to a sti v2, (my mates v2 saloon was the donor, just the front wishbones and alloy bonnet left to do), last winter, running around 300+ bhp on a td05 16g.

Just bought a 20g from Andy Forrest, ss headers from API, 550cc nismo injectors, Aeromotive fuel reg, parallel fuel rails, Clutch coming next week, with 4 new oe coil packs, i have two gearboxes, (will prob need them).
Will do a manifold refurb while its off.
Well anyway it started today, will be a long time before its finished, but it will be in Bob Rawles hands on the 29th Nov!
A couple of pics,
the car(ignore the wrx sticker, its gone now:norty: )
http://i41.photobucket.com/albums/e2...4/IMG_0264.jpg
http://i41.photobucket.com/albums/e2...4/IMG_0249.jpg
Original state!
http://i41.photobucket.com/albums/e2...234/before.jpg
These headers do look loveley in the flesh, and are ported and flowed loveley too!
http://i41.photobucket.com/albums/e2...34/headers.jpg
http://i41.photobucket.com/albums/e2...alfwrapped.jpg
On!
http://i41.photobucket.com/albums/e2.../headerson.jpg
car stripped
http://i41.photobucket.com/albums/e2...234/midway.jpg
20G!
http://i41.photobucket.com/albums/e2...ginplace-1.jpg
http://i41.photobucket.com/albums/e2...20ginplace.jpg

I am going to do an induction heat shield, (let me know if anyone wants a basic one cut out that you will have to modify specifically for your car, as i have a few spare!), ABS removal, carbon canister removal, lightened flywheel, inlet manifold insulators, quality clutch, new gapped 7b plugs, 4 new proxes T1-R's, tracking, sorting the 90 degree inlet to the front entry 20g, the list is longer, but as you lot know its hard to remember, so i have just started to write it all down!

Stripped the inlet manifold last night and put it in the dishwasher tonight with the ok from the missus!, spray time tomorrow and parallel fuel mod.

Top quality, i'm in the middle of doing this very thing (minus the 20g unfortunately).

What are you doing the parallel fuel rails setup with?

I'll take one of your air filter boxes if your wanting rid?

cheers, Dave

Looks good, you keeping the ABS ?

I don't miss it in mine and it weighs a tonne.:)

It does look good, is the 20g going on the standard bottom end while you are building your 2.1? I'm running similar spec on a standard bottom end with an AFP 18g...its fun :D

There's a project thread here which my be of interest...I must update it though :sleep: https://www.scoobynet.com/projects-4...-fettle-9.html

Hi bigdaveallen, i am waiting for my aeromtive fpr kit to turn up, will see what parts come in the kit, too see if i will go full out for the braided parallel setup, or the other cheaper alternative which i already have all the parts for.
Which air box are you after?, i already had a fmic and an HKS SPF induction kit, so the oe air stuff went ages ago, but i might have what you want laying around?

53WRX, my ABS is going, luckily the father inlaw has all the brake line working kit, so can do a proper job, i have the master cylinder and servo off the sti2 donor which i will use in favour of the old abs stuff.

Trails, the 20g is going on the standard open deck sti2 full engine for the time being, i thought i would have this tinker before my 2.1 is complete, time to money to fun ratio, bolting this 20g to my sti2 engine is more fun at the moment than watching the money pit of a forged engine being built, i do have another sti2 ra cdb engine in my garage as a back up, plus a spare gearbox!

A couple of pics
v2 inlet manifold waiting for stripping
http://i41.photobucket.com/albums/e2...2112008096.jpg
v2 inlet manifold, fresh from the dishwasher!
http://i41.photobucket.com/albums/e2...2112008101.jpg
And the start of my induction shield, need to get rid of the abs first!
http://i41.photobucket.com/albums/e2...2112008094.jpg

Hey trails, can you give me a run down of removing the roof rails please? i really want to remove them!

Of course Sam; there are two bolts to each rail leg, you willwill need to remove the inner trim that runs around the edge of the roof lining to access. Its a bit of a pita but worth taking it all off rather than putting stretch marks in the plastic from stressing it. You then need to pop the remaining external trim off, by gently sliding it off the fasteners. You should be able to remove them and reuse all the fasteners. The rail delete trim just pops back onto the fasteners. There are some pics in my thread that will help. The hardest part is sourcing the trim delete, new they are ridiculous money...I got mine from JGM when he broke his old wagon but all non-turbo variants (with the exception of the Sport), came without roof bars.

I'll be watching how you get on with your induction shield, its on my list of outstanding jobs...its a long list :brickwall

Ian

cheers mate, just read your thread, awesome, i dont think i could stretch to the cost of doing that to my car as much as i would love too! (she wouldnt love it though!)
With regards to the trim deletes for the roof, i will get searching.
I am doing this car as a hobby, i have been working on it two years now and there is a group of us tinkering with our scoobs which is helpful, although my mate is opting for the 700bhp route at the moment and that is stupid money will be a serious car at santa pod next year though!

Another great wagon project thread :thumb:

Thanks Sam, I will updtae it a little later today:) My wagon is totally DIY with the exception of mapping and geometry by Mocom...if you are lucky\careful you can pick up most stuff second hand so it can (like mine), be carried out on a budget :thumb:

700bhp...thats gonna take a serious chunk of money to build and maintain :eek:

Oooh, just spotted this thread, will be watching with interest. :thumb:

Just masked off the inlet, etched and sprayed it, bright red!, looks good, cant get good pics of it for some reason!, will pick up the new gaskets from subaru tomorrow.

Would anyone give me a quick run down of the abs removal?, the servo on my car has got two pipes out, could i use this one to tee into the brake lines for front and rear, with a bias controller on the rears?, or is it easier/better to use the servo off the sti2 with four pipes coming out of it?, if i need to remove the servo from the master cylinder is there anything to watch out for? etc etc
cheers

TB back on, fuel rails back on, put some adapted ends on the rails ready for the parallel lines tomorrow.

Here's a photo of what i've done mine this week. I wouldn't have went this route but as dad sent me over the fuel line most of the fittings i thought why not.

http://www.bergsport.co.uk/images/su.../031108_10.jpg

I have a K&N induction kit and still have my abs . If you had anything that would make a rough suround then i'd be happy to pay whatever you think its worth (within reason :norty: ).

That looks really nice dave!, i do have like i said, some basic shields that need to be trimmed for the specific car, the template of them does fit facelift and pre facelift classics.

Could anyone help me out with advice or pics on the abs removal please?, do i need to change my servo with 2 lines out for one with the 4 lines out? is that a hard job taking it off the master cylinder? I do do have the stuff off an sti2, but just wondering if its possible or good enough to retain the braking gear that is already on my car?

sorry keeping my ABS so no idea Sam :(

Thank god for that the way you drive :p

bleedin' cheeky beggar :hjtwofing:D

The IM is sort of getting there now, it is bloody time consuming all this work!
a few pics to follow..

Hopefully this FPR will be up to the job!
http://i41.photobucket.com/albums/e2...ng1234/fpr.jpg
masking is a bit tedious!
http://i41.photobucket.com/albums/e2...1234/mask1.jpg
3k etch primer
http://i41.photobucket.com/albums/e2.../justprime.jpg

this paint is just not photogenic for some reason, must be the flourescant lighting methinks?
http://i41.photobucket.com/albums/e2...34/sprayed.jpg
rails and hoses half done
http://i41.photobucket.com/albums/e2...34/halfpar.jpg
took me a while to get to this stage, was just not happy with the original hose clips, settled for these crimp ones instead on the t's
http://i41.photobucket.com/albums/e2...g1234/para.jpg
http://i41.photobucket.com/albums/e2...4/paratop2.jpg
http://i41.photobucket.com/albums/e2...34/paratop.jpg
what this valve type thing just under the tb screwed into the IM?,
http://i41.photobucket.com/albums/e2...4/wotsthis.jpg
seems to be part of the breather system, i am fitting a catch can and ridding of as many breather pipes etc with little filters etc, i have seen some people take this valve out and bung it, what are my options, and what is the best thing to do?
cheers

good thread mate WAGONS RULE !!! i just done my inlet looks nice .

That's looking good so far - keep up the good work! The valve there under the TB is the PCV valve. Allows crankcase gases to be drawn directly into the inlet manifold to be burnt off while the car is off boost. Soon as you get a boost condition, the valve shuts tight so you don't lose any boost and the gases are diverted into the inlet pipe instead to be drawn through the turbo and intercooler.

I still run a closed, 'green' breather system, in basic terms I have a sealed catch tank intercepting the crankcase breather outlet which then tees off to both the standard breather inlets. The system works the same as usual, but cleans the oil vapours out of the gas.

thanks silent, i will do the same green breather system, does that mean you leave the PCV as it is? i dont necessarily need to connect anything to it if i am using a catch can?, or is it easier to blank it off completely?
Note the carl davey coolant header tank insulators on the IM!

I just blanked mine off completely.

i will be blanking mine off.
I have still not had any luck on the abs removal advice front!

On hold at the moment, waiting for a few bits to arrive, should be back on it tomorrow hopefully, and saturday is the big day putting the car back together with fpr, manifold insulators, new coilpacks and catch can.

ps, wagons rule!

:thumb::D