Bolt-on 360 bhp x 330lbft: Phase one started.
26 December 2004, 05:07 PM
#1
Bolt-on 360 bhp x 330lbft: Phase one started.
Edited:
It is now early November 2005, and this crazy long thread continues!
The next phase is really a look at what the engine is like after a very hard (and successful) season of hill climbs and road driving.
If you are interested, pop across to Page 42 and scroll down to November the 5th!
Graham.
Christmas is over and time to get the bits on the garage floor into my Sti V3 hill climb/road going Impreza.
The Plan is to fit:
Andy F TD 20g turbo
GruppeS v2 headers/helix uppipe
3'' sport cat downpipe to my current Magnex decat 3''
Walbro / 550cc injectors
SX FPR
Apexi FC/Commander (well, Andy will)
3 port boost solenoid
Sti8 TMIC
I hope to tweek a '360x330' engine by March or before ready for the first of the 2005 Hill climb events in Spring.
The engine has been RR'd @ 314 bhp/280 lbft in current stock trim.
First time I've done a full blooded thread so bear with me...
The Car:
<img src="http://tinypic.com/zpppk">
TMIC off, Sti8 verses the StiV3:
Stock turbo coming out, not a single stud sheared!
The turbo is on the bench about 30 mins ago, but there is something good on the TV so enough for today.
The stock turbo next to the 20g is tiny! More pics tomorrow.
911
It is now early November 2005, and this crazy long thread continues!
The next phase is really a look at what the engine is like after a very hard (and successful) season of hill climbs and road driving.
If you are interested, pop across to Page 42 and scroll down to November the 5th!
Graham.
Christmas is over and time to get the bits on the garage floor into my Sti V3 hill climb/road going Impreza.
The Plan is to fit:
Andy F TD 20g turbo
GruppeS v2 headers/helix uppipe
3'' sport cat downpipe to my current Magnex decat 3''
Walbro / 550cc injectors
SX FPR
Apexi FC/Commander (well, Andy will)
3 port boost solenoid
Sti8 TMIC
I hope to tweek a '360x330' engine by March or before ready for the first of the 2005 Hill climb events in Spring.
The engine has been RR'd @ 314 bhp/280 lbft in current stock trim.
First time I've done a full blooded thread so bear with me...
The Car:
<img src="http://tinypic.com/zpppk">
TMIC off, Sti8 verses the StiV3:
Stock turbo coming out, not a single stud sheared!
The turbo is on the bench about 30 mins ago, but there is something good on the TV so enough for today.
The stock turbo next to the 20g is tiny! More pics tomorrow.
911
Last edited by 911; 05 November 2005 at 04:38 PM. Reason: No picture
27 December 2004, 11:02 AM
#3
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Tdo5/06 20g vs VF24
Alot bigger, and you may have to do a bit of jiggery pokkery on your header tank to clear the actuator, once it's up and running you'll not be disapointed.
Andy.
Alot bigger, and you may have to do a bit of jiggery pokkery on your header tank to clear the actuator, once it's up and running you'll not be disapointed.
Andy.
27 December 2004, 06:05 PM
#4
Been in the garage today, freezing cold!
The 2 turbos:
Will start to fit it tomorrow as the up pipe and the headers are all wrapped, what a tedious job, but it all took 3 hours! The special clips were a bit naf so suplemented stainless wire ties as well. don't want to have to do this job again for some time.
Next jobs will be the Sports cat d/p to be fettled/wrapped and the bottom of the engine finished off.
This pc is frustrating me now, tea's ready!
911
The 2 turbos:
Will start to fit it tomorrow as the up pipe and the headers are all wrapped, what a tedious job, but it all took 3 hours! The special clips were a bit naf so suplemented stainless wire ties as well. don't want to have to do this job again for some time.
Next jobs will be the Sports cat d/p to be fettled/wrapped and the bottom of the engine finished off.
This pc is frustrating me now, tea's ready!
911
27 December 2004, 07:58 PM
#5
Graham - are you going to paint the header wrapping with high heat paint, to stop it soaking up water? Worth doing, about £5 a tin IIRC.
Looking good!
Ohh yeah
don't forget to remove that bar between the two exhaust heads!
Erm, seriously though, are you going to clean up the weld in the flange to pipe joint, as it looks a bit rough ( mine did, although mine were OBX headers ).
That looks a big M/F turbo, esp. compared to your old one ... any idea how much bigger than a std TD05 it is ? Me thinking to the future perhaps....
Neil
Looking good!
Ohh yeah
don't forget to remove that bar between the two exhaust heads!Erm, seriously though, are you going to clean up the weld in the flange to pipe joint, as it looks a bit rough ( mine did, although mine were OBX headers ).
That looks a big M/F turbo, esp. compared to your old one ... any idea how much bigger than a std TD05 it is ? Me thinking to the future perhaps....
Neil
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27 December 2004, 10:52 PM
#8
You can't believe how cold it was do the wrapping just standing still...
I think you are right about the spray, best do it right from the start.
There is pleanty to press-on with, also forgot to buy the threaded bungs for the up-pipe/manifolds....
So, probably do the Sti8 TMIC tomorrow.
Found that there is a big split in the intake to the turbo, so need to get a Samco pipe, where from? Want a black one so the engine isn't too tarty.
Thanks for the interest, takes ages fooling about with the pc to do pic etc, but I enjoyed Carl's and Flat4's very much, so thought I would tell my version.
Sure hope that Turbo delivers...bloody huge isn't it!
Remember, a fast Impreza is a modified one.
911
I think you are right about the spray, best do it right from the start.
There is pleanty to press-on with, also forgot to buy the threaded bungs for the up-pipe/manifolds....
So, probably do the Sti8 TMIC tomorrow.
Found that there is a big split in the intake to the turbo, so need to get a Samco pipe, where from? Want a black one so the engine isn't too tarty.
Thanks for the interest, takes ages fooling about with the pc to do pic etc, but I enjoyed Carl's and Flat4's very much, so thought I would tell my version.
Sure hope that Turbo delivers...bloody huge isn't it!
Remember, a fast Impreza is a modified one.
911
27 December 2004, 11:00 PM
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Graham, what's all this headers and heat-wrap malarky? 
You mean you're doing it properly first time around?
Looking good mate, i'm especially interested to see how you're going to get the '8 top mount on there. Having flirted with a 6 on my own 1.5 manifold i can't see it being straight forward...
Top tip for keeping warm in the garage whilst standing still: wooly hat. Just come in after far too many hours standing over the lathe and i never really felt the cold.
Star-jumps whilst on screw-feed are also good.
You mean you're doing it properly first time around? Looking good mate, i'm especially interested to see how you're going to get the '8 top mount on there. Having flirted with a 6 on my own 1.5 manifold i can't see it being straight forward...
Top tip for keeping warm in the garage whilst standing still: wooly hat. Just come in after far too many hours standing over the lathe and i never really felt the cold.
Star-jumps whilst on screw-feed are also good.
28 December 2004, 01:49 AM
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Originally Posted by vulnax999
That looks a big M/F turbo, esp. compared to your old one ... any idea how much bigger than a std TD05 it is ? Me thinking to the future perhaps....
Neil
Neil
90 degree or front entry TD05's can be rebuilt to this spec for very reasonable cost.Andy
28 December 2004, 07:47 AM
#11
Andy, you suddenly have a shop window! 20g's everywhere on view.
Having spent 25 years in cold winter garages I always wear The Red Wooly Hat, it's just standing still forever threading the tape, and I mean forever.
Thinking of buying a turbo blanket, but £80 is a lot, so maybe simply lag the scooby tin turbo cover.
Peanuts says the TMIC will install with a good use of the Hammer, but I cant see how you can get the stock cross-brace back on as the IC is so much bigger.
Hammering gets you warm!
Don't think I will get this all installed this week!
This is the first Xmas since getting this car I havn't taken the gearbox/rear diff out...
911
Having spent 25 years in cold winter garages I always wear The Red Wooly Hat, it's just standing still forever threading the tape, and I mean forever.
Thinking of buying a turbo blanket, but £80 is a lot, so maybe simply lag the scooby tin turbo cover.
Peanuts says the TMIC will install with a good use of the Hammer, but I cant see how you can get the stock cross-brace back on as the IC is so much bigger.
Hammering gets you warm!
Don't think I will get this all installed this week!
This is the first Xmas since getting this car I havn't taken the gearbox/rear diff out...
911
28 December 2004, 08:57 AM
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Peanuts has a MY99 or 2000 car which, to me, seems to have a much-friendlier-for-STi8-intercooler-fitting Phase 2 manifold. Size-wise i'm sure it'll go in, it's the dump valve i would be most concerned about as there is a hell of a lot more space in that area on the MY99/00 cars than there is on ours. See the pic below for what i'm trying to say lol...
Don't get me wrong, it's challenge i'd love to have a go at myself and the part of your project i'm most interested in.
Don't get me wrong, it's challenge i'd love to have a go at myself and the part of your project i'm most interested in.
28 December 2004, 09:17 AM
#13
Carl, understand and I looked hard at your solution for the '8 unit. Getting it all to fit/link-up is the fun part!
I am ready to weld the stock DV area and weld in a tube to pick-up the stock Sti v3 tube, that is weld a tube into the end instead of the side where you have your custom flange.
I have a thread somewhere in the folder of an 8 welded shut and a tube let into the corner, all very neat and with a bit of prepping it all looks nearly stock (22B thread I think)
The Xmas hols is a bad time as everyone is shut, but I want to be mapping the car in late Feb so 6 weeks to get it done.
Trouble is the 911 needs some work too
911
I am ready to weld the stock DV area and weld in a tube to pick-up the stock Sti v3 tube, that is weld a tube into the end instead of the side where you have your custom flange.
I have a thread somewhere in the folder of an 8 welded shut and a tube let into the corner, all very neat and with a bit of prepping it all looks nearly stock (22B thread I think)
The Xmas hols is a bad time as everyone is shut, but I want to be mapping the car in late Feb so 6 weeks to get it done.
Trouble is the 911 needs some work too
911
28 December 2004, 09:20 AM
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Last chance to get rid of that horrible twin dump d/p with cat and fit an open necked d/p with hi-flow cat'ed centre (I see H&S sell one now)?
I second painting the wrap - saves clouds of steam at traffic lights in winter, and reduces smell too.
Richard
I second painting the wrap - saves clouds of steam at traffic lights in winter, and reduces smell too.
Richard
28 December 2004, 11:07 AM
#15
Originally Posted by 911
Found that there is a big split in the intake to the turbo, so need to get a Samco pipe, where from? Want a black one so the engine isn't too tarty.
Alternatively, make your own! I did
28 December 2004, 01:56 PM
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Originally Posted by dowser
Last chance to get rid of that horrible twin dump d/p with cat and fit an open necked d/p with hi-flow cat'ed centre (I see H&S sell one now)?
Richard
Richard
Andy
28 December 2004, 04:56 PM
#18
Where have yopu lot come from suddenly? Thought you all must have gone abroad while some of us are 'busy'
If I could I would keep to the stock V3 inlet; maybe no 'shunting'/no turbo porting and no hassle, but I think I'll follow the Samco route for now. Got enough going on: see below.
As to the D/P: I already have a 3'' Magnex open neck, but want to go 'legal' hence the sport cat D/P off David at API. This will be wrapped (and sprayed).
My focus has been the Sti8 TMIC, just spent the day attacking it.
911
If I could I would keep to the stock V3 inlet; maybe no 'shunting'/no turbo porting and no hassle, but I think I'll follow the Samco route for now. Got enough going on: see below.
As to the D/P: I already have a 3'' Magnex open neck, but want to go 'legal' hence the sport cat D/P off David at API. This will be wrapped (and sprayed).
My focus has been the Sti8 TMIC, just spent the day attacking it.
911
28 December 2004, 05:02 PM
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The Prodrive pipe doesn't have the take-offs - you are correct... I'm running one on my 98 (mapped 'again' by AndyF just before Christmas).....
Mark
PS - I just ditched the D/V....
Mark
PS - I just ditched the D/V....
28 December 2004, 05:24 PM
#20
Been sweating it out for 6 hours today getting the TMIC basically in place.
It sure is tight!
Took a few measurements first and noted several similarities but there is a 45mm difference in the turbo outlet-to-TMIC elbow which will need a custom Samco pipe to fix. That is the least of the issues.
First drop of the Sti8 unit in the hole:
Note that it sits on the clutch master, the inlet and about 3 other unseen places underneath.
Fixed the clutch first by cutting the tube down by 15mm (thanks to a Snet tip)
I had to take the top suspension strut off (do they actually DO anything noticeable?) and the 'thing' off the inlet manifold that is opposite the d/v location. the TMIC then settled nicely and the brackets needed to be done next. There is a MAXIMUM of abot 10mm clearance to several parts, best order some very stiff engine/box mountings..
You can see the real problem here. I hope i can 'cut n weld' the TMIC header tank to get out of jail, weld a closing plate over the stock hole, and let-in a 32mm tube for the existing DV.
Note the pricision jig to set the TMIC at a height about 10mm too high. It also shows the shortened clutch master cylinder. I have made/adjusted/butchered the stock Sti v3 brackets to have a 10mm gap to allow the insertion of packers to get the level just so.
At this position I doubt that the bonnet will close...
There is no chance of putting the Sti strut brace back.
These are the finished brackets, don't laugh at my crude approach!
Bonnet clearance/scoop plate and that sort of thing comes next. If you are reading this Andy F is your scoop an Sti 7 unit in a classic bonnet? I have to make a custom air deflector (see thread on 22B) to maximise the benefit of the v8 TMIC.
Then there is the dv issue...ouch!
Off now to watch the 'Build a Hot Rod' program, such memories; (bloody sight harder than this lot though.)
Graham (911)
It sure is tight!
Took a few measurements first and noted several similarities but there is a 45mm difference in the turbo outlet-to-TMIC elbow which will need a custom Samco pipe to fix. That is the least of the issues.
First drop of the Sti8 unit in the hole:
Note that it sits on the clutch master, the inlet and about 3 other unseen places underneath.
Fixed the clutch first by cutting the tube down by 15mm (thanks to a Snet tip)
I had to take the top suspension strut off (do they actually DO anything noticeable?) and the 'thing' off the inlet manifold that is opposite the d/v location. the TMIC then settled nicely and the brackets needed to be done next. There is a MAXIMUM of abot 10mm clearance to several parts, best order some very stiff engine/box mountings..
You can see the real problem here. I hope i can 'cut n weld' the TMIC header tank to get out of jail, weld a closing plate over the stock hole, and let-in a 32mm tube for the existing DV.
Note the pricision jig to set the TMIC at a height about 10mm too high. It also shows the shortened clutch master cylinder. I have made/adjusted/butchered the stock Sti v3 brackets to have a 10mm gap to allow the insertion of packers to get the level just so.
At this position I doubt that the bonnet will close...
There is no chance of putting the Sti strut brace back.
These are the finished brackets, don't laugh at my crude approach!
Bonnet clearance/scoop plate and that sort of thing comes next. If you are reading this Andy F is your scoop an Sti 7 unit in a classic bonnet? I have to make a custom air deflector (see thread on 22B) to maximise the benefit of the v8 TMIC.
Then there is the dv issue...ouch!
Off now to watch the 'Build a Hot Rod' program, such memories; (bloody sight harder than this lot though.)
Graham (911)
Last edited by 911; 28 December 2004 at 05:29 PM. Reason: missed a picture out
28 December 2004, 07:11 PM
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Yes, the top scoop is the same, It is a taller version of the original V5/6 scoop. Looks quite subtle I think.
Underneath I didn't have time to make a proper deflector and ended up with some flexy foam filling the gaps to stop the air escaping ......rough ! but it worked so I have not improved on it yet
Regarding the DP cat, just a bit curious regarding its flow potential ? Have there been any other 350+bhp engines running this particular set up ?
Andy
Underneath I didn't have time to make a proper deflector and ended up with some flexy foam filling the gaps to stop the air escaping ......rough ! but it worked so I have not improved on it yet
Regarding the DP cat, just a bit curious regarding its flow potential ? Have there been any other 350+bhp engines running this particular set up ?
Andy
28 December 2004, 08:29 PM
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Using the Prodrive PPP Downpipe CAT can flow upto 350bhp.... What downpipe is that out of interest?
Looking good Graham. Not the only one in the garage either mate
Cheers
Jon.
Looking good Graham. Not the only one in the garage either mate
Cheers
Jon.
28 December 2004, 11:15 PM
#27
David at API told me it came over from Japan with some other stock, so don't know it's origins. The main tube dia is 3'', but the centre section connection is flanged for a 3'' but was sleeved for a 2.5'' (ie stock system). I'm removing the sleeve and matching the flange dia with the rest of my Magnex tubing. The dp was wrapped once as the tell-tale marks are there. I will freshly wrap this one.
Jon, I bet only you and I are out there!
Thanks for the scoop info, will follow it up later. Got to get the brackets on and the bonnet closed tomorrow and a fit that will blow the doors off AndyF!!
Then there is the 'thingy' to get back onto the manifold. What is it? Some kind of water temp sensor? Bloody silly place to put it ....
Hot Rod programs were great, V8's into old 1930's Fords...... Graham
Jon, I bet only you and I are out there!
Thanks for the scoop info, will follow it up later. Got to get the brackets on and the bonnet closed tomorrow and a fit that will blow the doors off AndyF!!
Then there is the 'thingy' to get back onto the manifold. What is it? Some kind of water temp sensor? Bloody silly place to put it ....
Hot Rod programs were great, V8's into old 1930's Fords...... Graham
28 December 2004, 11:34 PM
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Hi Graham
DR motorsport also do do the large STI 7 style scoops for the classic shape, and i believe they are also still doing free painting of all their products too which could save you quite a bit.
The 'thingy' as you put it is the idle control solenid i believe and it is in a bl00dy awkward position on the phase one manifolds!
Happy modding and i can't wait to get mine back from scoobyclinic so i can carry on too!
Dan.
DR motorsport also do do the large STI 7 style scoops for the classic shape, and i believe they are also still doing free painting of all their products too which could save you quite a bit.
The 'thingy' as you put it is the idle control solenid i believe and it is in a bl00dy awkward position on the phase one manifolds!
Happy modding and i can't wait to get mine back from scoobyclinic so i can carry on too!
Dan.
29 December 2004, 08:25 AM
#29
Just found the thred that solves the Idle solenoid (thanks Dan!)
http://img.photobucket.com/albums/10...t%20stuff/Pipe
All the answers are on Snet!
Thanks to Dyney.
Time for breakfast and a morning in the garage.
911
http://img.photobucket.com/albums/10...t%20stuff/Pipe
All the answers are on Snet!
Thanks to Dyney.
Time for breakfast and a morning in the garage.
911
Last edited by 911; 29 December 2004 at 08:28 AM. Reason: spelling
29 December 2004, 08:56 AM
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Looking good G 
Carl is indeed correct, I have a ph.2 99 car and the DV malarky is already covered for conversions.
Im also with the "ditch the DP cat" crowd and would suggest getting maybe a twin cat centre section welded up
Im also fettling over the holidays, so far though, its gone as far as respraying the grille badge and today I might even grip-fill it in place!
Andy(.F), have you got pricing in place for 18g conversions on existing F/E 16g's yet?
Seems I was wrong to rest on my laurels at 330/305, took my oppo out in the car to compare to his evo6 and he said it felt too smooth, no turbo shove, not quick!! wtf, I could have got out and walked past his own car. I explained that a smooth MAP was letting me make far better progress but he said the illusion of speed was greater in his 6 because the turbo came in late but with a bit of a kidney squeeze.
Hence, phase 2 modding begins with either an 18g or a 20g, a set of tubular headers and a new intercooler.
Carl is indeed correct, I have a ph.2 99 car and the DV malarky is already covered for conversions.
Im also with the "ditch the DP cat" crowd and would suggest getting maybe a twin cat centre section welded up
Im also fettling over the holidays, so far though, its gone as far as respraying the grille badge and today I might even grip-fill it in place!
Andy(.F), have you got pricing in place for 18g conversions on existing F/E 16g's yet?
Seems I was wrong to rest on my laurels at 330/305, took my oppo out in the car to compare to his evo6 and he said it felt too smooth, no turbo shove, not quick!! wtf, I could have got out and walked past his own car. I explained that a smooth MAP was letting me make far better progress but he said the illusion of speed was greater in his 6 because the turbo came in late but with a bit of a kidney squeeze.
Hence, phase 2 modding begins with either an 18g or a 20g, a set of tubular headers and a new intercooler.