2007 EUDM WRX Project (Warning Picture Heavy)
 

Ok, bits and bobs are all together now.

Had my 2007 WRX from almost new, 7500km on the ODO when i bought it, stock, in 2007.

Now, its got a few "basic" mods.

STi JDM v7 TMIC
3' DeCat TBE
A'Pexi intake kit
Uprated discs and pads all round
18x8.5' ROTA SVN's
AST Sportline II Suspension.
CDF Racin Droplinks front and rear.
Whiteline ALK
Whiteline 22mm adjustable ARB in the rear
Front and Rear Strutbrace
DEFi GeNome boost gauge
Odd carbon bits here and there.
Remap

http://www.flickr.com/photos/disodisp/4850265103/http://www.flickr.com/photos/disodisp/4850265103/ by http://www.flickr.com/people/disodisp/, on Flickr
http://www.flickr.com/photos/disodisp/4850883922/http://www.flickr.com/photos/disodisp/4850883922/ by http://www.flickr.com/people/disodisp/, on Flickr
http://www.flickr.com/photos/disodisp/4777472617/http://www.flickr.com/photos/disodisp/4777472617/ by http://www.flickr.com/people/disodisp/, on Flickr

Pushing 307bhp and 490Nm of torque, according to the dyno on straight v-power.

Been saving up for the past few years, and finally took the plunge.
2005 Type UK STi DCCD Box + gearlever + gearknob
Propshaft.
R180 diff.
Rear axles.
5x100 PCD STi rear hubs.
R180 handbrake shoe brake discs
DCCD Pro Controller
JDM STi gauge cluster
6speed starter motor
Excedy 6 speed clutch
Lightened flywheel
SC46 turbo, cermaic coated exhaust side.
Samco inlet pipe
RCMS manifold + uppipe
RCMS Bob Rawle 80mm intake trumpet with maf boss
RCMS "large" K&N cone
Frayz Engineering Wingsert
Carl Davey's Inlet Manifold Spacers
100mm Wiseco pistons
ARP Headstuds
PEC Automotive Conrods
Cosworth Sump Baffle
Cosworth Timing Belt
Cosworth 1.5mm headgaskets
Cosworth 12mm Oilpump
Walbro 255 Fuelpump
ACL bearings
850cc Bosch EV14 injectors
Hardrace Pitchstop + Engine and 6spd Gearbox Mounts

Can't thank Alan Jeffrey at Enginetuner enough for arranging most of the bits and bobs for me, going way above and beyond "normal" customer service, to make sure everything was absolutely spot on. Thank you Alan! :thumb:
(Although, I'm sure he and his staff were pulling their hair out from all of my nonsence :lol:)

Thanks also to Bren at Apex for sourcing some of the parts, and for their fantastic service.

Also a thanks to Frayz for his wingsert, lets hope I can make it work like I have planned in my head :P

Just waiting on getting my car to the builders to have the engine work done, run the engine in, swap turbo + injectors and get remapping! :P

A bucketload of pics to follow:

http://www.flickr.com/photos/disodisp/5147796369/http://www.flickr.com/photos/disodisp/5147796369/ by http://www.flickr.com/people/disodisp/, on Flickr

Wiseco 100mm EJ257 Pistons
http://www.flickr.com/photos/disodisp/5148400566/http://www.flickr.com/photos/disodisp/5148400566/ by http://www.flickr.com/people/disodisp/, on Flickr
http://www.flickr.com/photos/disodisp/5148400802/http://www.flickr.com/photos/disodisp/5148400802/ by http://www.flickr.com/people/disodisp/, on Flickr

PEC Automotive Conrods
http://www.flickr.com/photos/disodisp/5147796245/http://www.flickr.com/photos/disodisp/5147796245/ by http://www.flickr.com/people/disodisp/, on Flickr
http://www.flickr.com/photos/disodisp/5147795595/http://www.flickr.com/photos/disodisp/5147795595/ by http://www.flickr.com/people/disodisp/, on Flickr
http://www.flickr.com/photos/disodisp/5148399754/http://www.flickr.com/photos/disodisp/5148399754/ by http://www.flickr.com/people/disodisp/, on Flickr

Cosworth Baffled Sump Plate
http://www.flickr.com/photos/disodisp/5148399330/http://www.flickr.com/photos/disodisp/5148399330/ by http://www.flickr.com/people/disodisp/, on Flickr

Cosworth Kevlar Timing Belt
http://www.flickr.com/photos/disodisp/5148399588/http://www.flickr.com/photos/disodisp/5148399588/ by http://www.flickr.com/people/disodisp/, on Flickr

Cosworth 1.5mm Stopper HG's
http://www.flickr.com/photos/disodisp/5147796857/http://www.flickr.com/photos/disodisp/5147796857/ by http://www.flickr.com/people/disodisp/, on Flickr

ACL Bearings
http://www.flickr.com/photos/disodisp/5148400000/http://www.flickr.com/photos/disodisp/5148400000/ by http://www.flickr.com/people/disodisp/, on Flickr

ARP 11mm Headstuds
http://www.flickr.com/photos/disodisp/5148400414/http://www.flickr.com/photos/disodisp/5148400414/ by http://www.flickr.com/people/disodisp/, on Flickr

Bosch EV14 850cc injectors

http://www.flickr.com/photos/disodisp/5147863669/http://www.flickr.com/photos/disodisp/5147863669/ by http://www.flickr.com/people/disodisp/, on Flickr
http://www.flickr.com/photos/disodisp/5147864071/
Carl Davey Inlet Manifold Spacers

http://www.flickr.com/photos/disodisp/5179201694/http://www.flickr.com/photos/disodisp/5179201694/ by http://www.flickr.com/people/disodisp/, on Flickr

Hardrace bits and bobs.


http://www.flickr.com/photos/disodisp/5189413811/http://www.flickr.com/photos/disodisp/5189413811/ by http://www.flickr.com/people/disodisp/, on Flickr

http://www.flickr.com/photos/disodisp/5189411151/http://www.flickr.com/photos/disodisp/5189411151/ by http://www.flickr.com/people/disodisp/, on Flickr

http://www.flickr.com/photos/disodisp/5189408515/http://www.flickr.com/photos/disodisp/5189408515/ by http://www.flickr.com/people/disodisp/, on Flickr

http://www.flickr.com/photos/disodisp/5189405391/http://www.flickr.com/photos/disodisp/5189405391/ by http://www.flickr.com/people/disodisp/, on Flickr

RCMS Manifold

http://www.flickr.com/photos/disodisp/5349163437/http://www.flickr.com/photos/disodisp/5349163437/ by http://www.flickr.com/people/disodisp/, on Flickr

Cosworth 12mm Oilpump

http://www.flickr.com/photos/disodisp/5349778374/http://www.flickr.com/photos/disodisp/5349778374/ by http://www.flickr.com/people/disodisp/, on Flickr

http://www.flickr.com/photos/disodisp/5349172149/http://www.flickr.com/photos/disodisp/5349172149/ by http://www.flickr.com/people/disodisp/, on Flickr

Samco Inlet

http://www.flickr.com/photos/disodisp/5349788044/http://www.flickr.com/photos/disodisp/5349788044/ by http://www.flickr.com/people/disodisp/, on Flickr

Walbro 255 Kit

http://www.flickr.com/photos/disodisp/5349180877/http://www.flickr.com/photos/disodisp/5349180877/ by http://www.flickr.com/people/disodisp/, on Flickr

RCMS Intake

http://www.flickr.com/photos/disodisp/5349795494/http://www.flickr.com/photos/disodisp/5349795494/ by http://www.flickr.com/people/disodisp/, on Flickr

http://www.flickr.com/photos/disodisp/5349193531/http://www.flickr.com/photos/disodisp/5349193531/ by http://www.flickr.com/people/disodisp/, on Flickr

SC46 Billet Turbo

http://www.flickr.com/photos/disodisp/5349807844/http://www.flickr.com/photos/disodisp/5349807844/ by http://www.flickr.com/people/disodisp/, on Flickr

http://www.flickr.com/photos/disodisp/5349811270/http://www.flickr.com/photos/disodisp/5349811270/ by http://www.flickr.com/people/disodisp/, on Flickr

http://www.flickr.com/photos/disodisp/5349204355/http://www.flickr.com/photos/disodisp/5349204355/ by http://www.flickr.com/people/disodisp/, on Flickr

http://www.flickr.com/photos/disodisp/5349819344/http://www.flickr.com/photos/disodisp/5349819344/ by http://www.flickr.com/people/disodisp/, on Flickr

Frayz Newage Wingsert

http://www.flickr.com/photos/disodisp/5349822338/http://www.flickr.com/photos/disodisp/5349822338/ by http://www.flickr.com/people/disodisp/, on Flickr

Fantastic kit of parts you have there fella. Wingsert should work a treat with what you have planned. Keep us all updated.

Best of luck :thumb:

impressive lists!!

bet you're itching to get it done :)

I am, just got to make sure I have some surplus funds needed incase splitting the block has any "surprises" to deal with.

But should start early next month.

Jesse,

When you fitting the wingsert?? :)

Heh, I'll tackle the fitting round about when the engine gets pulled. Not to worry, I'll take pics and give you feedback regarding how it goes.

Interested to see how you get on with the wingsert. I have tha exact same 80mm RCM induction kit on my hawkeye, I fitted a cold air feed from the foglight area using some aluminium ducting fed through the inner wing and the maf sensor hated it which caused the car to keep stalling.
I have since bought an APS 70mm kit which I hope to fit once Ecutek release Racerom but the wingsert might have been a good alternative.

Without a maf rescale i doubt you can get it to idle properly with the 80mm maf housing.
Which is why the trumpet will be fitted just before the remap.

The maf was rescaled by one of the best mappers in the business. The problem was caused by the cold air feed causing too much turbulence as the maf housing is very close to the filter on that particular kit. I removed the ducting and the car has run perfectly ever since.

Looks like you're going to have some motor there when you've finished:thumb:

Oh, well lets hope it doesn't cause any problems.

Huoh, been a bit busy.. forgot about this.

Old gearbox is out, 2005 STi TypeUK box is in, along with R180 rear end, drive shafts and 2004 STi 5x100 PCD hubs: And new rear discs for the R180 handbrake shoe.
Was a bit of a job, but me and two mates (mates mostly :P) were able to pull it off in two days.

http://www.flickr.com/photos/disodisp/5717894997/http://www.flickr.com/photos/disodisp/5717894997/ by http://www.flickr.com/people/disodisp/, on Flickr

Wired up the DCCD-Pro and did the JDM STi 7 cluster swap (now with working ABS light :P)
Heres a quick video.

Relocated the heated seat switches to the centre console, OEM DCCD manual and auto controls in place of these.

http://www.flickr.com/photos/disodisp/5750747074/http://www.flickr.com/photos/disodisp/5750747074/ by http://www.flickr.com/people/disodisp/, on Flickr

Also, got some more bits and bobs. CDF Racing fuel rails and pulleys:

http://www.flickr.com/photos/disodisp/5740123392/http://www.flickr.com/photos/disodisp/5740123392/ by http://www.flickr.com/people/disodisp/, on Flickr

http://www.flickr.com/photos/disodisp/5739576445/http://www.flickr.com/photos/disodisp/5739576445/ by http://www.flickr.com/people/disodisp/, on Flickr

http://www.flickr.com/photos/disodisp/5740121162/http://www.flickr.com/photos/disodisp/5740121162/ by http://www.flickr.com/people/disodisp/, on Flickr

Had my exhaust manifold "ceramic coated", HHBK under ceramic and Black Satin topcoat, turned out really well.

http://www.flickr.com/photos/disodisp/5767436009/http://www.flickr.com/photos/disodisp/5767436009/ by http://www.flickr.com/people/disodisp/, on Flickr

Also, test fitting my new intake system:
Its a tight fit, but thanks to the wingsert from frayz, it does work.

http://www.flickr.com/photos/disodisp/5926650216/http://www.flickr.com/photos/disodisp/5926650216/ by http://www.flickr.com/people/disodisp/, on Flickr

Finally, after a bazillion false promises and people backing out, I've got a confirmed local company doing the engine build for me next month.

Great to see another crazy Wrx taking shape and going about it hardcore. Love it keep us updated

Looking good mate:cool: What power you aiming for?

As above nice to see WRX going for bigger power.Great project matey.



Jura

Im hoping for 450/480.
Possibly more on E85.

after reading this thread I had to take my car for a spin :thumb:

450 is a great level for the road. :thumb:

Some very tasty mods going on there indeed.

Great job mate. Glad the intake fits well. Looks like it's going to be a very potent WRX. Best of luck with it.

You need bigger injectors for e85 ;)

Lies. A friend tested it on 850CC injectors, it was fine to about 450bhp. Up the fuel pressure to 4 bar, and presto 1000CC injectors :)

No, probably right, but for now its going to be 99RON mapped only.

Speaking of, fuel system built up just now:
http://www.flickr.com/photos/disodisp/6024913728/http://www.flickr.com/photos/disodisp/6024913728/ by http://www.flickr.com/people/disodisp/, on Flickr

Now am about to pop in the car and drive it to the Engine Builder. o_O.

3 to 4 weeks without my car, how will I cope? :P

Subscribed! :thumb:

Some nice mods there love the gloss black headers!

I love the JDM cluster, that dial test on start up is awesome! I want it on my WRX!!

Still waiting on my car.. been nigh on 14 weeks now..

After far too long, the car is once again on the road, running it in ATM, so no word on power figures etc. It is however an eager bugger even with next to no boost, and low rpm, will be interesting to see what kind of power it puts down.
Possibly due to the 9.1 CR

Will post some pics of the "actual" car later on, once I have a chance of actually taking some :D

That said, here are a few of the Engine:

CDB Conversion:
http://www.flickr.com/photos/disodisp/6577558441/http://www.flickr.com/photos/disodisp/6577558441/ by http://www.flickr.com/people/disodisp/, on Flickr

Cosworth Baffle Plate:
http://www.flickr.com/photos/disodisp/6577554033/http://www.flickr.com/photos/disodisp/6577554033/ by http://www.flickr.com/people/disodisp/, on Flickr

TGV-Delete:
Before:
http://www.flickr.com/photos/disodisp/6577629745/http://www.flickr.com/photos/disodisp/6577629745/ by http://www.flickr.com/people/disodisp/, on Flickr
After:
http://www.flickr.com/photos/disodisp/6577635541/http://www.flickr.com/photos/disodisp/6577635541/ by http://www.flickr.com/people/disodisp/, on Flickr

Fuel rails were an absolute nightmare, haven't had a chat with Chris as of yet, but they just would not fit. The standard brackets were way off, and would catch the AVCS solenoid, i.e. new brackets had to be made.

http://www.flickr.com/photos/disodisp/6577632163/http://www.flickr.com/photos/disodisp/6577632163/ by http://www.flickr.com/people/disodisp/, on Flickr

Once that was sorted, they would not stop leaking, crush washers did not help either, so a groove was machined out of the thread for a O-ring after which they don't seem to be leaking any more.

http://www.flickr.com/photos/disodisp/6577650787/http://www.flickr.com/photos/disodisp/6577650787/ by http://www.flickr.com/people/disodisp/, on Flickr

http://www.flickr.com/photos/disodisp/6577654277/http://www.flickr.com/photos/disodisp/6577654277/ by http://www.flickr.com/people/disodisp/, on Flickr

Those of you with a Fuel Lab AFPR, have you noticed its got a slight "lag" to it, i.e. it seems to bleed off pressure slower than the OEM unit, and also builds pressure slightly slower. (Not significantly, but still noticeable on a Wideband)
Also, how well do yours generally maintain fuel pressure after turn off? By design, the ball and spring unit should lose pressure gradually, but is it a question of a day, a few hours, etc?

More to come:

Nice work on engine matey,similar problem we have with rails(same like you with CDF one) and our garage modified our WRX CDF fuel rails to fit Spec c manifold and AVCS


Jura

Looking good, just waiting for my welded tumblers to come back and I'll be grinding them out. Any reason why you didn't open up the elongated end? Does the taper help or hinder the airflow?

loving reading this mate. Very impressive shopping list and dedication. Looking forward to your updates.

I'm gonna be doing something similar to my WRX in a few weeks.

Good luck mate, it's gonna be a monster

Subscribed interesting read so far. Good luck with the project