ChicagoSam

@DoctorDaveLGT thanks for pointing out the fan blade difference between the s402 vs USDM models. The s402 nose in the garage sits over in a corner and I haven't looked in the back for sometime...thanks man!

I wonder if the radiator has any tweaks or lives in all JDM Legacy models. 

@Georgeikm thanks very much. ( I fiddle around but I don't build engines-credit goes to 'theSUBARUshop' in Tiverton RI. One stop shop for a build and  tune. )

So since the original alternator in the car has over 165k miles on it, I'll use the s402's-it  has far less miles on it but still has a lot of corrosion. I wanted to remove the front and had to drill out the 4 screws. One didn't come very easily but it's off for powder coating.

Fuel rails are on as well.

Cool! Never knew the s402 had smaller tweaks to components like the fan blades(thought the engine cover/ecu/some badging/strut bar and turbo were the only under the hood upgrades)- great grab. Thanks much for the Stateside part numbers.

Was tempted to get the washer tanks and hosing for the jam headlights. There was also a VF-58 on the Japan Yahoo auction that was of course very pricey. I have too much hay already in the car to get a loan for the vf58. One day..

Today I drilled out the 4 screws out of the alternator cover to remove the face for power coating. (Harder and harder to find oem alternators these days). One screw really didn't want to come out. 

4 hours ago, Fenrir1 said:

think ur buddies can make another one and sell/ship it to me? 

I’ll ask them- send you a PM when I get any info.

thanks

 All votes are in..landslide victory.

 I asked if anyone on FB's ,'Modified Legacys' had any opinion/experience with the Fluidampr pulley on their EJs. Sounds like the pulley is coming aboard.

( again- thanks for chiming in above )

I took off my lightweight Perrin pulley years ago-but this is different.

thanks for the eyes on- really appreciate it. ( most first impression reviews say the idle is a lot smoother after install-sounds good to me)

Coming together with OEM: Water pump/thermostat/Oil cooler lines/clamps/AVCS oil pipe/water pump lines, hoses,clamps/Cam gears(exhaust)/Center timing cover/timing tensioner bracket/Billet TGV's/ gaskets for coolant cross pipe, tensioner bracket, AVCS Can gear O-rings, Exhaust manifold, Uppipe, TGV upper and lower, and timing cover/ STI intake manifold.

Fuel: ID1050 Injectors/Injector plug and play harness adapters, Billet fuel rails/Aeromotive fuel pressure regulator/new fuel pressure sensor and harness and a braided fuel line kit( they look very tidy).

Ceramic Coating (CERAKOTE) drying on the oem headers( Subaru describes the s402 unique headers as: "Equal length/burst exhaust system" .

 (Found a gasket as well for the up-pipe. part# 44011AG020 ) I Should be all set with the manifolds for now. ( most of the engine bay is black, so I went with little color. It'll darken some after a season or two)

Some of the original pieces with corrosion will be cleaned up/coated to look in line with the new block, but some parts, like the timing belt tensioner, are pretty cheap new( $40).

New water lines ands most importantly, new clamps. 

@s402legacy gorgeous car.

As you said (FB) the factory headers are part of the s402's unique character. I  had the Tomei manifold before the vf51 turbo and discovered the up-pipe doesn't match the turbo's flange.( Tomei part # TOMTB6010-SB01A  item description says "For Twin-Scroll JDM vehicles only. Not sure why it doesn't fit the s402?)

As free flowing as the Tomei's are I'm not liking the larger Tomei header downsizing into the stock up-pipe. (If only it was the other way around.. and the turbo sits much higher with the Tomei/OEM mismatched combo). I'll stay the course and run the factory given manifold-but may add some welds to the back of the oem pipe's flange like the Tomei has.

It's a big help to have an S402 owner join in- appreciate it!

So not all twin scroll up pipe to turbo flanges are created equal. Tomei's Expreme up pipe flange is little off. AVO has an up pipe that looks like it would match the turbo, but for headers ,Tomei has a better track record. Stock up-pipe will have todo for now until I find a second hand AVO one. 

( saw too many dyno numbers to stay stock for manifolds. I'm trying to be as kind as possible for the vf51's potential)

I'd love to keep the chrome shine, but ceramic will be the way. 

@dscoobydoo thanks for the info. I read that retaining the OEM twin scroll header/uppipe doesn't completely transform the exhaust tone to a smoother pitch (keeps some rumble). 

Dropping off the headers for ceramic coating. The engine builder doesn't wrap headers anymore. His reasoning is a small spot of oil can( and has) leak onto the hot header wrap  and ignite causing a fire.

May as well powder coat some other engine bits that will be visible in front around the alternator. I'll go with an aluminum finish to try and match the block( ordered a new OEM  alternator as well-)

@dscoobydooi do like that intercooler-proper oem.

what kind of headers are your running?

thanks in advance 

The pics do make the header look tight against the pan. There's a 'decent' space-but as suggested they'll get ceramic  coated next week.  Anyone have a source for a twin scroll up-pipe gasket? 

Engine is assembled. The officially tally at this stage is:

-Built STI Ra Manley piston/Pro-H rod short block

-New OEM Subaru 11mm oil pump

-OEM Subaru full gaskets/seals

-ARP headstuds

-NGK 1 step colder sparkplugs

-OEM Subaru oil cooler

-New OEM exhaust valves

-Machine deck/heads (S402)

Always nice to see the ebb and flow of cars in the shop. I thought the two white GTs were nice then the red one showed up. Someones having some fun this weekend after a good tune.

Heat shields are off.  Glad it worked out.

I have a stock twinscroll intake manifold that doesn’t clear the IAG pan. Any thoughts for a good replacement? ( lll try taking the heat shield off meantime)

The power curve you describe is what we’re after. Are you top or FMIC? ( I’d like to keep it top mount, but it’s not getting any colder in my area so a front mount may be they way.)

I have two Vf51s. One came off an s402 engine( that’s why you buy it right?-for the turbo) too much was spent for a 255 but..

the other turbo was at auction(Buyee) and had a friend ship it to the US. Without shipping it was about $500. After importing/buying dinners for the friend it was about $750. ( the second turbo was in much better condition than the first. I’ll probably send the first turbo off the engine to Pavel racing for a rebuild)

@dscoobydoo that's nice gain in power you have there with a quick response. Sweet.

I'm sure this chart  has been seen before(it's probably on a thread here )I came across it on STINick19 S208 twin scroll VF58 conversion. ( prob a misprint? says the s402 has the ej257/actually a 255-but the comparison of the curves are great)

Thanks for chiming in- makes the adventure sound like there's a decent chance it'll be good. I'll ask the tuner( who is also the engine builder) to give all the tech details for me to share here.

 iAG oil pickup fits perfectly with a great seal. The pan’s heat dissipation  groves along the bottom are a nice touch. 

@TomahawkLabs both VF51’s were bought used. 99% sure your correct that Subaru won’t sell the S goods without some proof of ownership. 
( the turbo pictured above was in great condition and looks almost new-so I have two now. The first vf51 I bought 5 years ago came off an engine that had a lot of rain/rust in its short life)

@TomahawkLabs the turbo will  have a Cobb flexfuel in the background, so we’ll get a sampling of fuels/ 93/e85. It won’t be a huge power gain but dependability and immediate power delivery are the goals.

I’ve been searching for years for a good used HKS downpipe to pair with the twin scroll turbo. There are domestic options but I really wanted to go JDM.( fabrication was an option but almost as much work as a new one would cost) I finally bent the knee and couldn’t resist this particular pipe which is made specifically for the S402. 
fits as advertised-never had an actual “new” HKS product. It’s craftsmanship-no letdown.

Interesting color band in the exhaust valves from the S402’s engine. It’s the graphing point for  two different metals that make the valve(top is magnetic metal-but the bottom part that goes in the cylinder is not). The only concern was that orange’ish dare I say ‘rust’ color.
The machine shop/tuner said they had never seen a Subaru valve with that color. Engine had low miles, but rather be safe than sorry, we ordered 8 new OEM valves.

@DoctorDaveLGT my my- you certainly make a good case. Your car is the type of thing that made me start this journey in the first place. 

I like your badge philosophy. On the fence for taking off the SpecB badge on the back and going with the S402/STI. Best 'problem' yet with the car..