Ken Ross

I've always wanted to do one of these threads, so here goes.

Nothing to spectatcular, just simple things people can do at home, with a little time.

Starts off looking like this


Remove the strut brace and then intercooler, might get it changed for an STI 5 model




Remove Inlet hoses



A few bolts later it looks like this




the original throttle body



This is what the underneath of the manifold looks like as standard

Ken Ross

Carl had a few spacers made up, so offered to by the tester


A trial fit of Carl's spacers


Close up


Spacers on the head



During this I discovered a large part of metal (about 3" by 1" by 1/4") inside the inlet, seem to be a fault in the casting, how STi let it out of the factory, I'll never know !

A hour or so with a Dremel soon cured the problem

Ken Ross

A little work to remove the edge of the throttle body, knife edged the butterfly and fit countersunk screws



Parallel fuel rail modification done, used a fuel pipe from a scrapped legacy instead of a FSE adapter. Decided to use y connectors for better flow, and to send the feed to the rear injectors just to make sure they get the most fuel.

Also the throttle and idle valve water supply bypassed hopefully Scotland is warm enought to get away with it.

Ken Ross

SX fuel reg ready to go. Regulator,gauge and fittings from Carl, yet again.



Having got rid of the aircon compress and pipework the manifold is back on the spacers and in the car.

ScoobyDoo555

looking good so far - what to you hope to achieve once completed?

Dan

Ken Ross

It's just a few mods before I go and stick a APEXi Power Fc on to it. More doing it to see what can be done rather than anything else.

Ken Ross

Fuel pressure regulator fitted behind the fuel filter, where the Air con acumulator was before.

Jolly Green Monster

iTrader: (4)

Not keen on the plastic Y pieces myself.. would swap to metal.. otherwise looks nice.

Simon

Ken Ross

Why ?

I Checked that they are fuel and up to 6 bar pressure rated. But will be keeping an eye on them for heat damage/going brittle.

rossyboy

iTrader: (8)

You'll need to give the engine bay a good clean now Ken, that freshly painted manifold is showing it up!

911

Wish I had thought of fitting my SX there!
I agree with Monster, metal Tees are the best, not just the pressure side, but batter against vibration and the clamping pressure/twisting of the hose clips over time.
Factory used metal.

Great thread, you are now Done For and on a very very slippy slope.....

Graham.

Mark A

iTrader: (1)

Come on Ken we want complicated mods!!

Mark A

Jolly Green Monster

iTrader: (4)

for the same reasons Graham said really.. heat, clamping force etc..

Ken Ross

Sti 5 Intercooler fitted with a little help from an Angle Grinder and a big hammer.
Next stage is to get someone at work to weld up the old intercooler hole and to make a new one on the other side.

ticky

I guess your going to connect dv to the other side of the tmic. Why not use the standard dv. Some good pictures in the link below.

http://bbs.scoobynet.co.uk/showpost....19&postcount=3


Btw whats the yellow cylinder thing by the powersteering pump?

Ken Ross

Oil pressure sender, on an "Extension" pipe, as there's no room under the alternator

Ken Ross

I want to place the dump valve as close to the throttle body as possible. As this seems to be the "better" place for it.

Ken Ross

Got the guys at work to weld on a DV pipe. Seems there is 4 types of filler rod for aluminium, was on the 4th before it works, I'm told.

Also didn't have any pipe the right size, because the tube I took was steel and you can't weld steel to aluminium, so got a pipe turned out of aluminium bar.

The joys of having access to a teaching fabrication workshop.

Picture quality is poor as taken with phone.