-Spooky-

Got some interesting pics of the engine build going on so thought I’d start up a project thread on here…

Car started smoking one morning on cold start so it got taken to Chris Palmer Auto's in Bristol for Spencer to take a look at. They found masses of petrol in the sump. 600 hydro carbons to be precise! Told this would normally be below 100. The cause it still unknown until my engine is stripped down but look like number 4 has an issue –

Compression Test Results: Pistons 1-3 = 155-160psi, but number 4 down to 135psi.
Leak Down Test Results: 1-3 = 10-15% but number 4 = 22%.
Spark plugs: 1-3 were black where it had been running lean and number 4 had a fine glaze of oil over it.
There was a small amount of tiny swarf particles found in the sump.
Bores and top of pistons and valves etc look of with the camera (although he can’t seen them too well with the camera) but it’s feared the side of the piston might be where the issue lies, and the small bits of swarf could have blocked but the oil pump cause the loss in pressure.


So anywho I had to make a decision and after about a month of research bugging the hell out of other specialists, mappers, and Techy gurus I opted to go for a 2.1 Stroker Kit, capable of 550bhp. I only wanted to rebuild once and didn’t want to be restricted by the build spec, this is what we decided on:


Actual build outsourced to Advance Automotives, build by Nick Johnson.

Closed Deck Block with under piston oil squirters
Striped, cleaned, honed and bored
Rear thrust converted
14mm head stud converted
Machined block faces and modified oil ways
2150cc Stroker kit
New 2.5 STi nitride crank cross drilled
Manley steel H section rods and ARP2000 bolts
Mahle 2618 race material lower deck stroker pistons, rings and pins
ACL full RACE bearing set
Full gasket/seal set
0.6mm 3 layer Cometic head gaskets
ARP 14x12mm head bolt set
Skim and clean cylinder heads
12mm RCM modified high flow oil pump
New cam belt, rollers, and tensioner
New modine oil cooler
New sump pan and pick-up
New water pump
Fuel lab 3 port adjustable FPR with braided lines and pressure gauge
Reversed fuel rails
Cossie sump baffle plate
RCM light-weight pulleys nickel plated
Cool running thermostat.


Then for uber-blingness I am getting parts painted or powder coated in 74F / Red / Black and replacing bolts with shiny stainless options:

Painted block
Rocker covers
Header tank
PS pump reservoir
Timing belt cover
Pulley cover
Fan shroud
Rad brackets
Fuse box cover
Ancillary brackets holding alternator / air-con / PS pump etc



I already have:

Engine External:
HKS 3” Hi-Power Strait through Centre pipe
HKS 3” Hi-Power back box
H&S 3” Decat downpipe
GT spec Gen II Tubular unequal length headers,
Harvey Smith Custom up-pipe,
Headers DEI Titanium heat-wrapped
Up-pipe DEI Titanium heat-wrapped
Downpipe DEI Titanium heat-wrapped
RCM Hi Flow Induction,
Lateral Performance MD321T Turbo,
Power Enterprise 550cc flow matched injectors,
Bob Rawle Remap,
Walbro 255 Fuel Pump,
NGK PFR7B spark plugs gapped to 0.6,
3 port boost control solenoid,
Ported throttle body,
Insulating manifold spacers,
Header tank spacers,
GT spec Gen II FMIC,
J Performance High capacity Aluminium Radiator,
Exedy Single Plate Organic Clutch,
Fidanza 4.4kg Lightweight Flywheel,
Prodrive Slam Panel,
Full Samco setup.
Heavy Duty Battery,
Hot coolant throttle body mod.
HKS SSQV DV,
SETRAB 26 row Oil Cooler with custom made stainless braided lines
Group N Engine mounts
PowerFlex Polyurethane Exhaust Hangers

Handling:
Prodrive Alcon 330mm Brake Upgrade,
330mm Godspeed Rotors
316mm rear Brembo 2pot conversion,
Whiteline 22mm adjustable ARB,
Whiteline rear Droplinks,
Whiteline front sway bar bushes
Whiteline steering rack bushes
Whiteline front anti-lift kit,
PowerFlex Wishbone Bushes
Prodrive geometry Stage 1 fast road setup,
Anodised blue split bells,
F+R Braided Hoses,
Ferodo DS2500 Pads,
Goodyear Eagle F1 tyres

Here’s how the car looked before she went in…

















Here’s the build so far…

Sourced myself a Closed Deck Block pair with under piston oil squirters –






Worried by this at first, but once taken to 92.5mm it wouldn’t be an issue as it would machine out.




Block cases @ Advanced after inspection




UV crack testing




Pressure testing




Measuring bearing parent bores




14mm head-stud conversion




Rear thrust conversion




Bore alignment template before rebore




Bore to 92.5mm








Cleaning the cases











Crankshaft assembly
























And that’s where were at at the moment! My engine and heads are all coming out the car next week so should have some more pictures then!



Cheers!

Spooky

dazzaturbo

thats quite a car my friend. stunning.

dazzaturbo

birds fit aswell.

Fai17

iTrader: (2)

nice spec...

beef-on-the-bone

iTrader: (5)

very impressive build!! certainly know where you're headed........

SkullFudge

Nice one Spook

-Spooky-

Cheers Guys! Will be ran at just the other side of the 400bhp door untill i can afford the injectors, ECU, Box and other supporting mods to push for further!


Latest update, bottom end is now complete

Just waiting for Spencer to whip out my old engine and get the cylinder heads off and over to Nick for long build to be completed.


































Also got this pic sent to my phone late last night… Rocker covers, PS tank, Header tank, various front end bolt on block brackets all tarted up! Just need to paint my timing belt cover, and a few other things and I’m done.

brockalightus

iTrader: (2)

looking like a very well thought out project.............sweet

-Spooky-

Cheers brock! i did think about it alot, but no matter how much i thought i covered everything i just keep on adding to the list LOL

trails

iTrader: (41)

great pics, good to see how its evolving in pictorial form

-Spooky-

Cheers Trails!

Just a wee update.


Ordered an RCM billet timing belt guide
HKS LTD Edition Rad Cap (1.1)
HKS Oil Filler Cap


Tuesday night I took a road trip to pick up my powder coated bits too. Got some nice new shiny bolts for them today! Not sure how the Allen key style will go down on the rocker covers, but no biggie to change them back over.

PS Pump Reservoir and Header Tank








Rocker Covers








And just another shot of the Aircon / alternator / PS brackets / Slam panel brackets







Also got a few bits sand blasted for me to spray myself in 74F blue, will post picks when they are done.

Will be picking up the MD321T Saturday morning and most likely adding a few more things to the list while I’m at the garage.



Really really looking forward to Saturday! I get to see my car again, I haven’t seen it since 01/10/09

trails

iTrader: (41)

phaw, amateur...I've not driven mine since 28.01.09, you have a while to go to catch me

-Spooky-

Flippin ek!


you must have forgotten what it was like to drive by now?

trails

iTrader: (41)

pretty much...although I have driven a few different impreza's in the meantime, but that just makes me want mine back even more

-Spooky-

That must have been torture! Had a passenger ride in a mate's impreza at about 230bhp. It seemed like a rocket! fastest car i've been in other than that in the last 6 months in the companies 1.6 astra

god knows how quick this is going to feel

frayz

iTrader: (7)

Mere boys!

Haven't driven mine since August 2008!!

trails

iTrader: (41)

had a go in a 330S and that was quick although deceptive due to the linear delivery through the twin scroll, my hack is a mkI 2.0 focus so its fun but not quick.

one of the reasons I'm sticking my 18g back on before the GT30R...I want it to scare me not kill me

scoobyschef

iTrader: (6)

nice build mate, ive got a set of heads that nick has already preped for me, im not needing them now and there located in bradley stoke

jim

dazdavies

iTrader: (22)

Top Trump you all on this one.

I've owned this car 2 years and haven't driven it yet!!!!!

-Spooky-

Will be using my P1 heads for the time being... cheers Jimbo




LOL you crazy ****!

be awsome when you do get behind the wheel though Daz!

utaka

and looks like you never will now eh daz

trails

iTrader: (41)

lol, for once I'm happy not to be competitive with either Frayz or Daz...who's is going to be running first though?!

Tim W

iTrader: (1)

Ahem...



(Mine was off the road from May '04 to October '08, and I've not driven the other one yet despite having owned it since Dec '07)

Fai17

iTrader: (2)

hahahaha

now go and finish all the projects out there

stevebt

iTrader: (8)

I'm sure david wallis can beat everyone on this

belliott69

iTrader: (3)

great looking build there fella, good luck for the rest of it.

-Spooky-

Took an early morning road trip with my mate dan to Bristol this morning to see the crazy west country folke and drop off my blinged up goodies!

took a stop off on my way to collect my new tubby too. Wasn't a great start me on the phone to Matt both saying were in Costa coffee before realising we were at different services, but a burger king and 10 miles later i picked up this baby, Lateral MD321T










Got to CPA and after a cuppa when to have a butch at my baby, she looked so lonely tucked away in the back, cold, with the lights off






Fitted a new headunit while i was there and done some shiny nut and bolt replacements under the bonnet






Before leaving tucking her back in for the weekend...









Estimated time of completion is about 3 weeks now, so long as i don't add anything else to the list. Although i did add a few more things to the list already today, DOH!

dazdavies

iTrader: (22)

How do you work that out then?

It will be done this year, of that I'm certain. I'm only a clutch and an ECU short of finishing it

Spooky,
Atleast your cars indoors with a nice cover on it.
Mine is subject to the elements on the driveway LOL

-Spooky-

You're not wrong Daz, i was tempted to leave a little heater next to her to keep her warm too

glad its inside and dry though, especially with all that snow and rain recently!

Grant74

iTrader: (10)

You not thought about a baffled sump while the engine is out of the car? Lot better than a sump plate!

Looks like a lovely build- just got mine back after a week and thought that was long enough!