The Widow Maker (Newage 2.5 cdb build)
 

A few people have mentioned posting a tread on my build over the next few weeks to share my learning (including mistakes, I’m sure there will be many) and get other peoples advise (who’ve already done similar work). Here we go!

Car is a 05 sti type uk, running on standard internals at the moment, made 410/340 when mapped a couple of months ago with the following mods:

MD321t, 650’s, hybrid fmic, 255 pump, NGK 7’s, solaris ecu, K&N filter, Miltek Exhaust.

I thought this was enough (for a couple of weeks at least ;))

The 321t and 650’s were put on with the intension of bumping power to the 450/450 mark with a new short block when I’d saved enough (original budget was £5k). A lot of emails, a few visits and a couple of months later (and the budget out the window :lol1:) she’s now booked in at Pennine for a lined 2.5 cdb.

A summary of the spec is listed below, items shown in red are still to fit (will update progress as I go). Most parts have been supplied by Mark at Lateral (think I've paid for your next 3 years holidays over the last 6 months Mark). Pat fitted and mapped the Solaris and will be doing the final map hopefully by the end of July (as long as I get the engine run-in in time and he can fit me in).

Over the next few weeks I’m going to asking a lot of daft questions so bare with me. I’m no expert and am learning as I go (part of the fun/torment of messing around with cars :thumb:, lol). If I start talking rubbish correct me I don't mind as I've probably picked the rubish up from someone else.


Engine Details:
EJ20 closed deck block
Vapour blasted, crack tested, chemically and ultrasonically cleaned block
Block Machined and fitted with Pennine custom liners,
Machining for with rear thrust main bearing
Modification for oil squiters
14mm Stud Conversion
14mm Studs (Pennine custom made high tensile rolled threads)
Standard EJ 257 79mm Crank
ACL Race Series Bearings
Lateral/Crower Custom Rods
Lateral/Wiseco Custom Stroker Pistons and rings
Dowels Modification for 14mm Studs
Standard Oil Pump
CDF Lightened Aux Pulley Wheels
Modified Head Gaskets (for 14mm studs)
Air Con Stripped Out

Reworked Standard Sti 2.0l VVTType Uk Heads (Small Port)
Heads modified for 14mm Studs and dowels
Cleaned ports, remove casting marks etc.
Fit new 1 piece Inlet Valves
Fit new 1 piece Inconel Exhaust valves
Re-machined valve guides to take oversize valve stems
Oil Catch can return to head modification (as opposed to return to sump)
NGK 8’s (Plugs)
Standard Cams
Oil Cooler with -10 Earls Lines and Fittings (mounted behind front grill, remote filter)
Lateral Baffled Sump

Fuel System/Cooling
Spec C inlet Manifold (main reason is to give a little extra room for the 76mm intake pipe)
Carl Davey Billet Parallel Fuel Rails (with Earls -6 hose and fittings)
Custom rail adaptors
Carl Davey Tufnol Inlet Manifold Spacers/Insulators
PE 800cc Injectors (Flow matched by Lateral)
Fuellab Fuel Pressure Reg (Mini)
Bosch 044 Pump (Mounted in-tank)
‘Big’ K&N Filter in the wing (Hyperflow Cold air feed piped to inner wing)
Hyperflow Monster Front Mount Intercooler[/i]
Hyperflow Oil Catch Can (Now relocated to back right of engine bay)

ECU:
Solaris (Syvecs) S6GP Generic ECU (with Cal switch)
Inovate Wideband and Controller
3 Port Boost Solenoid
Lateral 3 Bar Map Sensor
Odessey 680 Battery


Turbo/Exhaust/Induction:
MD321V turbo with ceramic coated exhaust housing
RCM 76mm intake pipe
Lateral GT Spec Headers (heat Wrapped)
Miltek Decat downpipe (3")
Miltek centre section (3")
Blitz Backbox (modified to give 3” right through)


Suspension:
AST Sport-Line Suspension Kit
Whiteline Anti Roll Bars (front and rear
Whiteline Anti-Lift Kit
CDF Solid Alu drop links
4-Wheel Alignment etc by Power Station

Interior:
Defi BF Gauges (Oil Temp, Oil Pressure, Boost, Exhaust Gas Temp, Fuel Pressure)
Innovate Air Fuel Ratio Gauge (on A pillar)
S204 Dask Kit (Red Hazard Button)

Drivetrain:
Standard 6 Speed Gearbox/diffs etc
Excedy Twin Plate Clutch/Fly Wheel

Wheels:
18 x 8.5 Rota Force ET48 (Time Attack) with 235/40 toyo tr1's

The car:
http://i615.photobucket.com/albums/t...t/DSC00426.jpg
http://i615.photobucket.com/albums/t...t/DSC00425.jpg
http://i615.photobucket.com/albums/t...t/DSC00436.jpg
http://i615.photobucket.com/albums/t...t/DSC00427.jpg
http://i615.photobucket.com/albums/t...t/DSC00435.jpg

Bits are arriving daily so will post pics when I get chance.

No going back now! :lol1:

First up what have I missed of the list?

:thumb:

Spec c manifold, supplied by Scoobyclinic :thumb:. As abve main reason was for extra room around intake pipe (didn't want the expence of going rotated):

http://i615.photobucket.com/albums/t...t/DSC00416.jpg

http://i615.photobucket.com/albums/t...t/DSC00415.jpg

http://i615.photobucket.com/albums/t...t/DSC00420.jpg

Nice looking car Dave, I would look at upgrading the fuel pump as 450bhp seems to be about the limit for a walbro 255.

Banny

Also arrived some very sexy Carl Davey Fuel rails, cheers Carl, look fantastic. Was orginally going to fit Perrins until I saw the pics Duncan posted of these.

http://i615.photobucket.com/albums/t...t/DSC00417.jpg

http://i615.photobucket.com/albums/t...t/DSC00418.jpg

Rails are meant for standard sti intake manifold with tumbler 'deletes' so I need to machine some billet adapters for the fit (waiting for injectors from Mark so that I can take some measurements :D.

http://i615.photobucket.com/albums/t...t/DSC00424.jpg

http://i615.photobucket.com/albums/t...t/DSC00422.jpg

Cheers Banny, was under the impression the 255 would be good for 550 ish, is this not the case?

Dave

Definitely not, you could run two intank walbro for that power but a single will let you down. If you you want to stay single pump how about a Bosch 044?

Banny

I would look at more than one fuel pump and I would go for bigger inejectors. I'm on a single 044 bosch and that isn't good enough for me :(

Not expectimg 550, lol, just read my post and it sounds like that, sorry. Picked the 550 up from Andy Forest's site. Expecting upper 400's so will look into this :thumb:.

While I'm on with this here's my first question (you'll wish you hadn't posted after this;)). I have three fuel lines under the bonnet:

One to the filter (then onto the injectors)
A return line from the regulator
A thrid line

Whats the third line?

http://i615.photobucket.com/albums/t...t/DSC00408.jpg

Can you help, just currious? And whats the small plastc in-line fitting

Cheers,

Dave

not sure about the inline fitting but pretty sure the third is the tank breather pipe which cant vent to atmos because of emissions

the 3rd one goes to the carbon canester i think

Carl Davey tufnol spacers/insulators arrived, excellent quality :thumb:!

Cheers Carl

http://i615.photobucket.com/albums/t...t/DSC00438.jpg

Right, managed to get a couple of hours work in on the car today, stuck for bits at moment, injectors should land tomorrow, will be able to make a start on the adapters for the rails.

Spent today making up the lines, took me about 2 hours to do the first one then 10min for each fitting after that :thumb:. Carl sent me a Earls guide on how to assemble the fittings which helped but what ever you do don't use a hacksaw to cut the braided hose (it just makes a mess of the braid then you can't get the braid through the fittings) this took me two hours to figure out :cry:. I eventually used a drimel with a small cutting disk which cut through the braiding like butter and didn't upset the braid at all (super neat). The fittings are still quite fiddly tho (cursed Carl a few times, sorry Carl if you felt your ears burning a bit today), but end result is fantastic, lets hope the rest of the bits arrive from Mark tomorrow so that I can finish off the mainfold.

8 days to go until I drop her off! :luxhello:

http://i615.photobucket.com/albums/t...t/DSC00440.jpg

http://i615.photobucket.com/albums/t...t/DSC00439.jpg

http://i615.photobucket.com/albums/t...t/DSC00441.jpg

http://i615.photobucket.com/albums/t...t/DSC00442.jpg

http://i615.photobucket.com/albums/t...t/DSC00443.jpg

Pillar pod also arrived today for new innovate Air/Fuel ratio gauge (runs from wideband which is already in, plugs into a serial out on the controller so no soldering etc) and red hazard light button should arrive tomorrow as well. Part fittied pod and removed swicth in preparation.

http://i615.photobucket.com/albums/t...t/DSC00444.jpg

http://i615.photobucket.com/albums/t...t/DSC00445.jpg

Back to fuel pumps, can you run a Bosch in line with the 255 without a swirl tank? It could be mounted under the car.

Probably easier running the higher flow Walbro I'd imagine mate.

The pod looks neat! I wasn't expecting you were getting that one for some reason. Good choice though.

You should have got the local pro in (me) to help with the braided lines :norty: Not really, I wouldn't have a clue.



PS. You still need a knob on the map switch ;)

You going to take your car back and forth to work to get the running in done on it? As it will take you ages otherwise!! :lol1:

If your about on the 27th I'll pop round and see her, as I'll be back then as well.

Dave - welcome to the Chy/Pennine Subaru world!! Nice list of parts and pics too. :thumb:

The wr1 in the right side of Chy's workshop is mine! Like you I've used Mark @ Lateral for most of my parts and Pat had already installed my Solaris last year in Aug - yep the full works of calibration switch with als and launch control. Like you I was running 422/400 but decided that was not enough! Ask Chy about his special "rings" set up for the future. :)

You may want to consider getting your down pipe and headers coated by Zircotec, speak to Chy about it - see below link to my post:

https://www.scoobynet.com/members-ga...same-time.html

Cheers JP4, saw this link when you first put it up, they look fantastic :thumb:, do you know it they can coat 'used headers'. I assume they must media blast the headers before they coat them?

Dave

Chris, how long you going for again? Are you back for the rolling road day in Leeds (if it goes ahead)?

Hi Dave,

will watch this one with interest.

The braided hose is easy if you bind it with PVC tape before the hacksaw comes out.

Too late I know, but if a "mod" is needed it may help.

Good luck with the project.

dunx

P.S. RS Tuning meet in Leeds was last Saturday ?

Cheers Dunx, I did wrap the braid in PVC but was still a nightmare, as soon as you take the tape off to fit the 'fitting' the bloody braid starts to expand :cry: (as if its spring loaded). Got the knack of it by the end tho and there isn't a braid out of place or scatch on any of the fittings at the moment (famous last words as I still have one more to do :lol1:).

I need to get pics up of the bits I've made and more detail up rather than just pics of new bits.

Last I heard the RS day was going to be August?

Maybe another one then ?

I dunno, but stupidly I was double booked for RS and Thoresby car show, DOH !

dunx

P.S. did you slide the "nut" on before cutting the hose tho'. ?

I'm back on the 26th Dave, so you'll have around a week to do a 1000 odd miles and get a full on remap ready for my return :lol1: Think you should aim to max out the turbo with how ever much boost is needed! lol.

We Could go to TRL for a RR day with Murf, Mark etc maybe......although I'll have the weakest powered car there.......so maybe not!! :lol1:

Hi Dave...i'm running a Chy built block too:thumb:

My build is currently getting to the finishing stages now and my build should be good for 600+;)

So 450/450 should be easy on your build:cool:

Hi Fai,

What turbo etc you going to run with yours, what other goddies you putting on ;), what kind of power you hoping for?

Dave

Made a little more progress over the past few days on the adaptors for the spec c manifold.

For those that haven't seen yet I'm going to fit a spec c inlet manifold which is a 1 piece item without the 'tumbler deletes'.

- The benefit of this is the extra room it provides where the intake pipe fits onto the turbo (the standard type uk manifold can 'nip' a 76mm pipe, caused by the bolts whcih hold the intake to the tumbler deletes, this can reduce flow). This isn't a problem if you go rotated but my budget wouldn't stretch to this :cry:.

- The drawback of the spec c inlet is that the rail fixing points on the spec c manfold sit lower down and I couldnt find and any aftermarket spec c rails.

Injectors landed on Saturday so was able to offer them up and measure what I need for the adapters. See pics of rails and injectors fitted:

http://i615.photobucket.com/albums/t...t/DSC00446.jpg
http://i615.photobucket.com/albums/t...t/DSC00447.jpg
http://i615.photobucket.com/albums/t...t/DSC00451.jpg

See copy of sketch for adaptors:

http://i615.photobucket.com/albums/t...t/DSC00452.jpg

Adaptors were started today, should get them tomorrow to test fit before we carryout the final machining. I'll put a better copy up of the drawing once I know they fit in case anyone else goes the same route :thumb:.

Remaining parts also landed from Mark at Lateral on Saturday :luxhello:, will put some pics up later this week for those people like me that like looking at shiny new bits :D:

http://i615.photobucket.com/albums/t...t/DSC00448.jpg

Excedy twin plate
md321V
76mm intake
Set of 8's
PE 800's
Fuel lab mini

Can you not turn the fuel rails the opposite way so the bolt holes are underneath the rail?

That way I'm sure one of the holes lines up (albeit with a spacer) and the other hole is about half hole out, which would need the lug cutting off and re-welding in the right place..?

Looking good though, and the 2.5/MD321V will make a great road car. ;)

Hello E_M_B,

The injector 'ports' aren't symmetrical so you cant turn them round (is difficult to expain) have tried the rails every-which-way :freak3: they will go but this will be the easiest and neatest way of doing it. I'm machining the adaptors from alu billet so they will match Carl's rails and should look neat.