My Engine build and maybe a bit more
 

Hi all

A little while ago I met a cool bunch of guys that regularly do track days. My first was Cadwell and to say I loved it was an understatement, totally got the track day bug. But then at Brands last December I suspected my headgaskets were on their way out.

It was decision time, do a simple fix/replace job or go the full hog rebuild the engine and make it bullet proof for the future. As we all know my pistons are known to go too if pushed much more so it seemed sensible to go for it.

This might be a bit of an odd build compared to most as it's gonna have to be done in stages. First stage is to get the engine solid and up and running so I can get my arse back on the track. Second, in a few months the 6speed will be fitted and then towards the end of the year the power will be coming, new turbo, better fuel system etc etc.

2006 WRX spec so far:
330/380 Duncan mapped
Engine
TD05 18g
Mishimoto FMIC
KSTec K&N cold air feed
Walbro fuel pump
3 port catch can
Custome baffle oil sump
Expansion system
Forge header tank
3.5" Fully decate milltek system
and a bit of ceramic coating here and there
Handling
BC Coilovers
8 pot 356mm K sport brakes
Tein front and rear strut braces

a few cosmetic bits and the usual gauges and knock sensor

I'm lucky enough to know an ace mechanic Tim (subbus) that is gonna do most of the work but actually do the final build at my place. I've always wanted to build my own engine but lacking the knowledge to do a top job. I'm hoping by end of this year with a little magic from duncan I'll have a 500bhp track monster

On the shopping list:
Cosworth 99.75 pistons
Cosworth rods
Cosworth headgaskets .7mm
Cosworth bearing set
Cosworth headstuds
Cosworth 12mm oil pump

As soon as all this arrives, I can get the engine out for boring and pinning and the magic can begin.

I've been reading a lot of the build threads and have been a real inspiration and hopefully mine will be up there

Cheers
Gez

Good luck with it Gez, gonna be awesome when it's done :thumb:

Good luck mate, I'll watch this as I can see myself going the same way with my 06 wrx. Costing things up now before engine goes pop. Lol.

Good luck matey and really looking on parts will be nice project...

I'm still not convinced with 2.5L and reliability at 500bhp level,maybe this prove i was wrong .

Jura

Duncan was running over 600 in his 2.5 which was still going strong when he changed it. Just couldn't get any more out of it so went 2.35 instead. Can be done, so will be interesting!

Yes i know this,but why people rather go with 2.1 or 2.35 instead with 2.5L which is still have more torque than 2.1 or 2.35.

2.35 is probably best option,not cheap,but proven by many people and many tuners


As i said before,this can prove i'm wrong :thumb:

Jura

Whoa, text size overload! odd. :wonder:

cheers guys

by all means chat away

In terms of what turbo, i'm not sure at the moment. At this stage I just wanna build an engine that can handle 500-600bhp. I might not even go anywhere near that. I still need to do loads of research etc into which turbo. 450ish might end up being the right sort of power, who knows. If it wasn't for having to get a 6 speed, I'd probably be doing this a lot quicker.

cheers

Know your pain mate, that’s exactly how I will be doing it! Doubt I can afford to do it all at once! 6 speed setup’s are not cheap at the moment, but it’s the right way to go in the long run.

Almost cheaper to sell up and buy and sti to mod instead! Lol

Good luck with everything.

Good luck mate, Tim is a top class engine builder. He does all my actual builds and rebuilds. In fact last week we just dropped in my latest 2.35 for my drag car.

Yeah but where's the fun in that :lol1: even if it was an STI I'd probably still do the engine build

Tim's the man. With him and Duncan I'm sure it will all work out, I need a CLUBCARD for these two though. He mentioned about your latest build the other day. Love the fact that I can just call these guys and they always help me out :thumb: Think mine's gonna be a bit smaller than yours mate :)

I went and got all the engine parts today, big thanks to James @ JW Racing

http://i1143.photobucket.com/albums/...d/P1020626.jpg
http://i1143.photobucket.com/albums/...d/P1020627.jpg

http://i1143.photobucket.com/albums/...d/P1020629.jpg

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http://i1143.photobucket.com/albums/...d/P1020630.jpg

http://i1143.photobucket.com/albums/...d/P1020633.jpg

I ended up getting the ultra high performance head studs

http://i1143.photobucket.com/albums/...d/P1020631.jpg

http://i1143.photobucket.com/albums/...d/P1020632.jpg

and this was a bargain mishimoto thermostat

http://i1143.photobucket.com/albums/...d/P1020634.jpg

Hopefully now, I'll be able to get the engine out in a couple of weeks time and get the machining started :luxhello:

Droolworthy! Very nice!

I had a spare set of TGV's lying around, so I thought I'd get them ready for the rebuild. Took me a while longer than I thought and I've still got the other one to do.

I know some people say they achieve nothing but its cost me virtually nothing

http://i1143.photobucket.com/albums/...d/P1020635.jpg

http://i1143.photobucket.com/albums/...d/P1020636.jpg

all cleaned up ready for my man Mike for welding :thumb: and then off to powder coating

http://i1143.photobucket.com/albums/...d/P1020637.jpg

Nice Job! :thumb:

Little update

Due to work being really quiet, I had to put the build on hold for a couple of weeks which has been killing me with all these sexy parts in my study :brickwall But now everything has picked up, its all systems go.

Tim is round on saturday :luxhello: and we're getting the engine out and stripped and then off to Finch Motorsport for boring, pinning and a little blasting.

Can't wait for saturday to come round, I'll get loads of picy's up

Cheers

Subscribed, looks like it will be a nice build mate:thumb:

Looking forward to seeing the pics! Good luck mate

Getting exciting now, I'd love to do a "pure cosworth" build. Cosworth Impreza has a real ring to it.

cheers guys

I'd love to do just pure cosworth but the block and crank gave me a heart attack when I found out the price. I will use cosworth as much as I can, total sucker for the name

black and gold impreza/cosworth FTW :luxhello:

The build really started today. Got up nice and early so first thing get the engine out, get all the necessary parts out and away so we can get the crane in.

http://i1143.photobucket.com/albums/...l/P1020794.jpg
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http://i1143.photobucket.com/albums/...l/P1020799.jpg

Gonna hopefully get SFS to make a custom pipe instead of all of this.
http://i1143.photobucket.com/albums/...l/P1020795.jpg

Tim showed me another way of telling if the head gaskets have gone. The sides of the rad bow. Mine has a little on the right-hand side.
http://i1143.photobucket.com/albums/...l/P1020796.jpg

Crane time
http://i1143.photobucket.com/albums/...l/P1020800.jpg
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http://i1143.photobucket.com/albums/...l/P1020805.jpg

Had a nasty little surprise, my clutch has virtually gone and I had no idea. Bit of a kick in nuts as I'm got changing to 6 speed for a few more months.
http://i1143.photobucket.com/albums/...l/P1020803.jpg

http://i1143.photobucket.com/albums/...l/P1020817.jpg

Had a call from a client and I had to disappear for a couple of hours. Gutted as I missed Tim breaking the block apart, sorry no pic's of this stage. When we actually build it, my phone is getting turned off.

http://i1143.photobucket.com/albums/...l/P1020818.jpg
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All the bolts, fixing etc went through the parts washer. I then get the great job of wiping all these lovelies down.
http://i1143.photobucket.com/albums/...l/P1020821.jpg
http://i1143.photobucket.com/albums/...l/P1020819.jpg

After cleaning the blocks down ready for Mr Finch we decided to get it skimmed. It's so slight but best to be on the safe side. There were a few clear signs that the gaskets were going.

There's still a load of jobs for me to do before we build the engine:

1. Clean a load of parts like the inlet manifold

2. Prep parts for powdercoating.
rocker covers
TGV's
Exp water tank
Header tank
Catch can - most of these were painted but have got a few scratched/chips that I wanna get sorted

3. Clean engine bay

4. Catch can needs welding - I'll explain in another post

5. Get a new push fit clutch

6. Clean K&N filter

Really enjoyed today and its good seeing it started. Hopefully things will start to happen very soon.

Looking forward to seeing this evolve.

Good progress. Looking good!

subscibed.

Small update. As all the main parts are with Finch, its was just a case of stripping paint of some parts and getting them ready for powder-coating.

http://i1143.photobucket.com/albums/...l/P1020825.jpg

Really enjoyed prepping the rocker cover, think they're gonna look top when coated
http://i1143.photobucket.com/albums/...l/P1020826.jpg

Had to swap the gaskets over as I later found that even though cosworth say the gaskets are for my age car they're wrong. Hawkeye gaskets need what they class as the 07 onwards.

The TGV's have gone off for welding (cheers Mike) and also we've come up with a mod for the catch can. My catch can is situated quite deep down in the bay and is a bit of a pig to get to, especially draining it. So we're gonna run a pipe from the drain plug down to the bottom of the bay with some sort of release so I can open it to drain - simples

This also arrived today. A bit w@nky I know, but I love it

http://i1143.photobucket.com/albums/...l/P1020824.jpg

Cheers

My flocked dash arrived yesterday. Top job from Phil (oh-flock), very impressed. Can't wait to get this in with a new steering wheel.

http://i1143.photobucket.com/albums/...l/P1020902.jpg

I had to get the passenger airbag cover out and gauge pod out for flocking too. The only issue was all the bloody snow and how cold it was.

http://i1143.photobucket.com/albums/...l/P1020903.jpg

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Hopefully get the block & heads back from finch mid/end of next week :luxhello:

Picked up the block and heads from Finch tonight. They look perfect and so so so clean. Had an interesting chat with Paul and given me a few ideas for the future.

Picked up a few other parts today. Mishimoto top rad hose from Amber. Not too keen on chrome so this will be going powder-coating.

http://i1143.photobucket.com/albums/...l/P1020908.jpg

popped down to sfs and my man Lee sorted me out as always. custom hose for the oe rec valve.

http://i1143.photobucket.com/albums/...l/P1020909.jpg

Just waiting for a few parts to come back and then off to powder-coating and then hopefully its build time.

Nice, any updates yet?

I'm just waiting for a few parts back that I've had welded. Hopefully getting them back early next week and then everything is off to powder-coating.

Soon as these are back the build can start, hopefully in a week's time. :)