555tom

iTrader: (2)

Hi, heres a little info to why this project came about. Got the chance to buy a 555 V2 sti wagon, at a very good price, BUT had hit a wall.

Car was immaculate inside and out, minus the crashed bit!
Was completely standard other than the speedline wheels, tein suspension, and the front splitter.

After doing various insurance quotes i found a company that would insure me on a subaru sport with unlimited mods! Either way this thread is about the build so i do not want comments such as would have been easier to buy a wrx/sti/uk turbo! Wheres the fun in that? and i also enjoy a project, and done lots of re-shells in the past.

Doner wagon.



A trip to wales and back i picked this up. Subaru sport, body work was good, standard again not that this mattered alot, due to it would get stripped back to bare shell!

Crap pics sorry!



Next step was to completely strip the sport back to its bare shell, i didnt really want to splice wires together and generally just bodge an sti engine into a sport. Wanted litterally every part, every wire EVERYTHING swapped over, even the door looms, and brake pipes.

Havnt got loads of pics of the conversion as i was always to busy and forgot to take the pics, heres a quick selection!





Added a V5 spoiler. Not genuine, plan to source a genuine one soon!

555tom

iTrader: (2)

Next was a open mouth 3inch down pipe, fully wrapped in dei heatwrap. Connets to a full jasma system which i love as its very quiet!



Engine finally in, after full dash and loom swap. Bumper placed on hence the gap!

All fluids and a service was carried out before i started.



Also from the crashed sti the lower arm had bent, and was a steel item, so took this oppourtunity to upgrade to the alloy lower arms!



After everything was checked over and to be running fine, was sent off for its mot which is passed.

Couple of pics when it was first on the road.



Friends evo 7 at around 340bhp

555tom

iTrader: (2)

Not my plate but wanted to see what it looked like!



Clear front indicators, also have side repeaters but not fitted in pics.
Painted e/c folding mirrors
Painted skirts, rear spats not done yet
STI rear lights

555tom

iTrader: (2)

After a few weeks of driving, i did notice the car wasnt pulling as hard at the top of the revs as it was lower down. I was confident this was down to the slanty V2 intercoolers and my v4 bonnet and undertray.

Rather than modify my zerosports V2 undertray to fit the facelift bonnet, i bought a V3 alloy sti intercooler, which would benifit the engine aswell, and also require no modification to the undertray.

Abit of hacking and alloying welding the old DV take off, modding a V2 samco the intercooler was on!

Also couldnt resist putting a filter on for abit more noise (sorry!) Now has a resonator delete aswell.



WOW!!!!! What a difference, was really pleased with the results, car pulled better throughout the whole rev range! After a few search's on here saying it was to much hassle, i completely dissagree!

Another few weeks passed, and i was running the wagon V2 ecu which should be around 260BHP, i also had a decat on so wanted to uprate the ecu as many say running a decat on the standard map can cause issues.

Bought a ecu off a member off here sells alot of the chips carnt remember his name off the top of my head but well recommended!

The chip was already in the ecu so was plug and play. Mapped for UK fuel, and should boost 1.1 bar safely.

The results were great, made a huge difference, and along with the new intercooler felt very quick, has proven itself against the evo 7 and a fq 360!

555tom

iTrader: (2)

Unfortunately the fun had to end somewere, and i knew it would happen at some point, It did give me a good 6 months of fun, a piston ring had gone, compressing the bottom end and popping my dip stick out and the contents of the sump over my bay!

Currently the engine is out on a stand waiting to be stripped down.

These are the plans:

-Build my old engine up around the new v3 bottom end (already got)

-550cc injectors with carl davery fitting kit

-Reverse inlet (hassle i know but i want to do it, i hate lag)

-gt2 spec intercooler flipped upside down to shorten pipes to the inlet.

-20mm alloy spacers to lift the inlet up to allow for front entry turbo

-Front entry td05 16g

-Simtek ecu

- Ported up pipe and manifolds from harvey full wrapped.

- API clutch

Im sure there will be other bits along the way. The reverse inlet, i want to do it because i think it looks alot neater, reduces lag (even if its minimal), and i dont use the aircon.

Aiming for 340bhp, once the engine has been mapped and running, i will have my old block to forge in the future, which SHOULD be a closed deck engine.

hhh1234

iTrader: (17)

good to c ur going to be using a proper ecu now rather than those chips, i wouldnt have one anywere near my car

555tom

iTrader: (2)

Stripped down the engine tonight, did a compression test on all the cylinders, 3 were good, but the 4th was not!

Few pictures.





No damaged to the heads, so going to order all the gaskets tonight so i can start the rebuild.

dazdavies

iTrader: (22)

You'll need a block, that one's goosed!

555tom

iTrader: (2)

Daz if you read a few posts above all will become clear...

"-Build my old engine up around the new v3 bottom end (already got)"

Would never try and rebore the old bottom end! as you say its well past it.

f4la k

iTrader: (1)

The block with the fcuked piston is not a closed deck, And i think thats what daz is sayin, the block with the fcuked piston is not goin to be any good for a rebuild in the future as its shagged.. Maybe make a coffee table.

DJ_Jon

iTrader: (7)

Good project. Does your insurance company know that its got a turbo lump?

555tom

iTrader: (2)

Yep i know its not closed deck! From what ive read i thought the 555 v2s came with closed deck! never mind!

Also the new V3 bottom end already has pistons, crank, rods, so when i meant build it up i meant with heads, inlet.. nothing from the old bottom end will be used...

And jon read the first paragraph!

DJ_Jon

iTrader: (7)

I did read the first paragraph, i just asked if they knew it had a turbo fitted.

555tom

iTrader: (2)

un-limited mods, includes any engine from the impeza range...so yes

scoobyd00999

iTrader: (1)

Name of your insurer would be good ,mine goes mental at the slightest change

DJ_Jon

iTrader: (7)

Are you a trader? That's a great policy if its at a reasonable price, please share the info as I'm considering a gas turbine conversion on mine & would like to know where to insure it.

much love...

555tom

iTrader: (2)

Trader and ive been with them 5 years! Classed as private use aswell...

scooby-sti-dave

Small update. Alternator is flipped over on the standard bracket but modified to suit. Quickly mocked up a tensioner that im happy with.


First picture shows the tensioner fully up.



All the way down....



Quick pic with the inlet manfold turned round for picture purposes and to check clearance.



Genuine subaru headgaskets have arrived, along with new head bolts, rocker gaskets, and cambelt.

Will crack on tomorrow and get the heads on, and timed up.

P1Drifter

iTrader: (7)

is that a phase 1 manifold (hard to tell from your pics) if it is the bonnet wont shut due to the idle valve. You need to modify it so the throttle body will fit to the front instead of turning it around

scooby-sti-dave

Hi yes its phase 1 manifold, and i know it wont fit, just turned it round as i wanted to see what it looked like...if only it was that easy...