Merc6 Build Thread

[Merc6]

I have been off and on a few years with my build and figure it would be a good idea to make a thread here. Original thread modified a bit to simplify 8 pages(I remember when it barely broke 3 pages). I'm also gonna delete pics and shrink some pics to make it load better. Home computer loads it just fine but the comp I'm on now is kinda etch-a-sketch

 

When I 1st got here from another LGT member. Already Stage 2 just about.

 

http://i90.photobucket.com/albums/k280/merc6/LGT/DSCI4186.jpg~original

 

http://i90.photobucket.com/albums/k280/merc6/LGT/DSCI4189.jpg~original

 

http://i90.photobucket.com/albums/k280/merc6/LGT/DSCI4195.jpg~original

 

 

Eventually it looked this this with minimal things here and there and a better tune than what came with the car and APV1

 

http://i90.photobucket.com/albums/k280/merc6/LGT/IMG_0647-1.jpg~original

 

http://i90.photobucket.com/albums/k280/merc6/LGT/IMG_0632_1.jpg~original

 

http://i90.photobucket.com/albums/k280/merc6/LGT/IMG_0644.jpg~original

 

Later on I swapped from 07 Shrek B to 06 Limited Interior. Went through some unemployment issues so the swap was worthwhile for me since it wasn't a 'Huge Downgrade"besides non folding seats. 06 seats aren't 05 friendly so I ended up later swapping out the 06 passenger seat with another 05 limited passenger seat. *Some pics borrowed from original owner for sale ad.*

 

http://i90.photobucket.com/albums/k280/merc6/LGT/1444636158_f112fbba76_b.jpg~original

 

http://i90.photobucket.com/albums/k280/merc6/LGT/1443757875_a2341dd93d_b_1.jpg~original

 

http://i90.photobucket.com/albums/k280/merc6/LGT/9D39D885-7676-4878-A191-06761DD02411_zpszbteov6q.jpg~original

 

http://i90.photobucket.com/albums/k280/merc6/LGT/04.24.2013%20981_zpsr2gbdn8h.jpg~original

 

Fast Forward to Today's view

 

http://i90.photobucket.com/albums/k280/merc6/LGT/942759C5-933D-421F-992A-6155F595A88C_zpsbfrqzjz9.jpg~original

 

I finally ate the original VF 40 near Halloween time of 2010. It was swapped out to a low miles VF 46 with another oem radiator and everything was cleaned (as pictured below). I didn't replace the oil cooler or turbo oil lines.

 

http://i90.photobucket.com/albums/k280/merc6/LGT/2CF41F3B-C377-4307-B927-819466766AFB_zpsvxsrkzdf.jpg~original

 

2 and a half months and about 5000 later I got multiple knocks going on and a very glittery dip stick.

 

 

Engine was pulled while I was away on a deployment *Down range*. After searching for "drop in engines" and only finding $6000 200K mile engines or "not tested if ran before pulled" listings we decided to just start over with a new engine. Financial issues (to keep it short) came up in between the multiple attempts to buy parts for the build and builder going AWOL with the original motor after it was pulled. Now that it's finally paid off, some of the money that was tied up is free to proceed again.

 

Here it patiently sits miles wise.

 

http://i90.photobucket.com/albums/k280/merc6/LGT/2E0E27FE-012A-48B5-8CA2-5A139D507603_zpsi6fskbtw.jpg~original

 

My current HP/TQ goals are 300 to 350 wheels or just shy of it.

 

My last drag strip passes were 13.35 @ 96 MPH with H rated tires on Capital Raceway In Crofton, Maryland.

 

My mod list when it last ran before "parked -n- pulled"

 

*OEM VF46 Turbo

*OEM STi UP

*Stromung Divorced Waste gate shorty front DP + PERIN catted rear DP

*PERRIN TMIC

*GFB GT BOV 50/50

*Cobb Front Sway

*Blitz Air box Grille replacing front half of OEM Air Box

*Mid Pipe Resonator Deleted for 2 bullet style resonators

*2 Aero Turbines used as rear cans

*Custom Angle Cut Pypes Quad Tips

*Kumho Ecsta AST

*Hawk Pads

*Hayden Tranny Cooler

*2005 Legacy GT Wheels Painted Gloss Black

*2006 Legacy GT Limited Tan Interior Swap

*35% Tint

*Prosport Boost gauge in a CasopoliS Cubby pod

*Jazzy Aux

*TheGrilleGuy Stiletto Black insert

*Black Rally Armor UR flaps W/ white lettering

*YourLEDshop White Puddle, Trunk, License Plate, and Map LEDs and Red Dome LED

*No Name generic 15 Inch Sub in generic build a box and unknown amp(will look and see)

*Shaved trunk badges

*Tune was opensourced by Dynamic Power Solutions in Gaithersburg, Maryland

 

What I have currently acquired since then for the rebuild is

 

*OEM 2008 EJ257 Short Block B25C 704 with BBBB pistons 10103AC040

*OEM VF 52 now JmP rebuild with 11 Blade Billet wheel 14411AA800

*OEM Engine Gasket Set (2005) 10105AA720

*OEM 05 LL Bean Wood MOMO Wheel 34311AG18AJC

*OEM Timing Belt 13028AA240

*OEM Head Bolts 11095AA042

*OEM 10MM Oil Pump 15010AA300

*OEM Closed Impeller Water Pump 21111AA026

*OEM Oil Cooler 21311AA151

*OEM Oil Control Valves X's 2 10921AA020

*OEM STi I/C sprayer tank

*TIC FU Cam Bolts

*LIC Aluminum Half Moons

*GrimmSpeed 3" Down pipe to Factory Cat-Back Exhaust Adapter

*GrimmSpeed ECBS

*GrimmSpeed Cold Air Intake w/ Shield

*Infamous Performance & Tuning Filtered Turbo Oil Supply Line Kit V2

*AVO Induction Silicone Turbo Inlet

*Mishimoto Radiator Hoses

*Venair 5 Piece Ancillary Silicone Hose Set - Vacuum

*Venair 6 Piece Ancillary Silicone Hose Set - Cooling

*Venair BPV Return Silicone Hose

*Tein Springs

*Mevotech LCA

*Turkeylord Blue Tee replacement

*Lamin-X tinted Tail Light Overlays

 

[Max Capacity]

You buy the gasket set for your year car. See my click here link.

[MrTris]

And also throw out that Mobil1 unless you want to replace a turbo again, too.

 

You'll get "just shy" of 300, (dyno depending) on that 46, but, really no more unless you upgrade your fuel system.

 

You should really consider replacing the oil cooler. It's another $200 --

[Merc6]

I got the oil cooler, but at almost $300 Running Amsoil in the Cruze and will be running it in the legacy after break in. One of my fellow mods on that forum is a vendor and can hook me up with a preferred account once I start buying engine and trans oil for this car. I'm also going to need rotors all around as well as pads. I also need the drivers seat belt clicker to kill the seat belt light. The drivers seat belt clicker is mechanically safe but the cord to the part that detects the seat belt is on is busted. This is the interior of an 06 and this is the 3rd car it's been in the 3rd interior trim update that this car had to the best of my knowledge. Another item I need is the passenger seat belt bolt as 05 they bolted the seat belt to the seat and 06 they just bolted it to the B pillar. Already found out the 06 passenger seat bottom is not gonna work and had an 05 seat shipped and waiting to go in as well. last think I can think of is the drivers side door seal by the back door is torn. It's still functional but an eyesore to piss me off every time I approach the drivers side of the car to get in. I also got the body PDF file for that when that day comes. Last I checked that was like $150-$200 for it.

[Merc6]

I also have the handbrake boot to replace that one but the plastic black frame is broke. How easy is it to swap and glue those from the original donor? Steering wheel is starting to show age and the leather seems like it's peeling and fading from it. I've taken the wheel apart for my Cruze a few times to dip it but haven't touched the legacy one, how hard is it? I also saw a few 05 STI wheels and airbags, would the air bags be a direct swap or would I just need the swap the air bag covers out?

 

I meant to post pics of all I have and need to do but I been all over the place.

 

What I currently have is

 

2008 257 block E25C 704 with BBBB pistons

Timing belt

Oil cooler

STI I/C sprayer container and line

2005 Passenger seat

Hand Brake boot w/ broken black frame

 

What I Need is

 

*05 Gasket kit (Got)

*Rebuild kit for the VF46 since it's contaminated? (Upgraded to VF52 11 blade)

*Water pump and other pulleys (Got new pump, pulleys still playing by ear)

*New oil pump, did it matter if it was 10mm 11mm 12mm (Got new 10mm)

*Oil lines and banjo bolts (IP&T filtered line)

*Torx Bolt to secure passenger seat belt to seat (Got from part out)

*Drivers seat Clicker to kill the seatbelt light(already removed speaker from ecu) (Still Need)

*Send the heads off, will I need anything that doesn't come i that master engine rebuild gasket kit? (Still need)

*Will the cams need anything done to them? (Got a better set)

*Might as well take the TGV delete plunge, do i go composite or send my stockers off? (Gonna do locally)

*For fuel system upgrade, is that pump, injectors and regulator? No E85 for me, it's too far a drive to get and my Ohio to NJ commutes I only found 1 station with it just past Breezewood DMV exit. (VF 52 upgrade with 11 blade Billet compressor, gonna do pump and injectors to take full use of it)

[Merc6]

Here was the video before cuz pulled the motor.

 

[MrTris]

I also have the handbrake boot to replace that one but the plastic black frame is broke. How easy is it to swap and glue those from the original donor? Steering wheel is starting to show age and the leather seems like it's peeling and fading from it. I've taken the wheel apart for my Cruze a few times to dip it but haven't touched the legacy one, how hard is it? I also saw a few 05 STI wheels and airbags, would the air bags be a direct swap or would I just need the swap the air bag covers out?

 

I meant to post pics of all I have and need to do but I been all over the place.

 

What I currently have is

 

2008 257 block E25C 704 with BBBB pistons

Timing belt

Oil cooler

STI I/C sprayer container and line

2005 Passenger seat

Hand Brake boot w/ broken black frame

 

What I Need is

 

*05 Gasket kit

*Rebuild kit for the VF46 since it's contaminated?

*Water pump and other pulleys

*New oil pump, did it matter if it was 10mm 11mm 12mm

*Oil lines and banjo bolts

*Torx Bolt to secure passenger seat belt to seat

*Drivers seat Clicker to kill the seatbelt light(already removed speaker from ecu)

*Send the heads off, will I need anything that doesn't come i that master engine rebuild gasket kit?

*Will the cams need anything done to them?

*Might as well take the TGV delete plunge, do i go composite or send my stockers off?

*For fuel system upgrade, is that pump, injectors and regulator? No E85 for me, it's too far a drive to get and my Ohio to NJ commutes I only found 1 station with it just past Breezewood DMV exit.

 

See my engine rebuild shopping list -

 

Oil pump can be rebuilt with a seal kit, if you're up to the task. Stick with the 10mm, though, you can jump up to the 11 with no super ill-effects, it's just not recommended.

 

You shouldn't need new oil lines and banjos unless they're damaged/broken; Brakleen should do the trick.

 

Heads will be about $400. Send off heads, cam caps/towers and cams so that they can set the lash; grab the grey/green valve guides from the gasket kit -- you need 16 of 'em. (Also possibly valve stem seals?)

 

Unless you have damaged your heads, the cams should only need to be inspected. Look for excessive wear (marring/scratches/scrapes) on the cams and in the journals. If you have too much wear, you'll need to replace them. (05 STI/any single AVCS cams should be sufficient)

 

If you have access to a die grinder, or know someone who does and you've got 20mins and a few beers, you can grind the TGVs down yourself. Honestly, for how simple it is, it's not worth the money spent to send 'em off to get redone. Busted Finger Motorsports makes some nice TGV deletes, though, and the price is good, too. YMMV.

 

Fuel upgrades typically consist of new pump and injectors. Since you have an 05, you may want to consider going to top-feed injectors before you do any upgrades.

[Merc6]

I'll most likely look around and see how much "Fun" it is to convert to top feed.

 

Another question for parts is OCV's I take it since I had lots of "Glitter in the oil" I should replace them again? They were replaced just before the turbo went. I got a CEL for them and ordered them. I don't remeber the CEL exactly, when I googled it back the Nasioc thread said it was a change OCV or rebuild engine CEL. Couldn't have been more spot on.

(2 OCV's added to inventory)

 

As promised, Pics of what I have. Click for larger view.

 

http://i90.photobucket.com/albums/k280/merc6/LGT/th_0ef6c535.jpg

 

http://i90.photobucket.com/albums/k280/merc6/LGT/th_0ce7e9ec.jpg

 

http://i90.photobucket.com/albums/k280/merc6/LGT/th_02051931.jpg

 

 

http://i90.photobucket.com/albums/k280/merc6/LGT/th_55B179CC-5667-49B0-BEE0-D7033F49C9EE_zpsisrtgy96.jpg

 

http://i90.photobucket.com/albums/k280/merc6/LGT/th_54418079-E8A5-4D55-A121-11876D6FB756_zpsst6cwm5e.jpg

 

http://i90.photobucket.com/albums/k280/merc6/LGT/th_981706A0-E78C-4D42-96C4-6FC142663255_zpsitelutag.jpg

 

http://i90.photobucket.com/albums/k280/merc6/LGT/th_BFE2C367-6410-4A98-A7C6-8EA52700BC14_zpspsod2h9j.jpg

 

here is the passenger 05 seat I need to swap in for the airbag and seat belt light. I need the torx bolt that goes in where the blue line is

 

http://i90.photobucket.com/albums/k280/merc6/LGT/th_B604015F-28C1-433E-8970-F694CBC8FB77_zpsb56ojarp.jpg

http://i90.photobucket.com/albums/k280/merc6/LGT/th_F17285B3-F68D-4277-8570-0BD00A91759E_zpsvljirlv5.jpg

 

Also how hard is it to swap the seat controls knobs from seat to seat?

 

05 seat showed up looking like this

http://i90.photobucket.com/albums/k280/merc6/LGT/th_D485A845-07AE-42BB-A067-B4CD1F17027A_zps61lbmjpi.jpg

 

Current 06 seat in the car looks like this with working motors, knobs and no seat belt attachments.

http://i90.photobucket.com/albums/k280/merc6/LGT/th_E5DEDF32-EAF9-4F0A-AD16-487CBE41833D_zpsm4jclnli.jpg

 

For the handle, does this black leather piece just glue back on?

 

http://i90.photobucket.com/albums/k280/merc6/LGT/th_E2AE3B50-3A4C-4D59-A64F-3F84E4E4BDD5_zps0uf6tn6r.jpg

 

The shift boot looks like it is glued to the black frame, but it is already broken so it will have to take it from the old boot.

 

http://i90.photobucket.com/albums/k280/merc6/LGT/th_85E9A918-C593-4922-8811-C1468525CCB4_zpsbyp4huxd.jpg

 

Eventually I also need to do something with this. Not high on the list but I would like to swap it out. I like the shift buttons and don't want to delete them with the full on STI wheel.

 

http://i90.photobucket.com/albums/k280/merc6/LGT/th_813D7F53-EAD3-4EDC-96A4-A367656F0F61_zpssiybbwhq.jpg

 

I also managed to score this and will figure out how to set it up later on down the line.

 

http://i90.photobucket.com/albums/k280/merc6/LGT/th_B846F2CD-EE62-4CCE-946D-F288AC3BF7F8_zpsw2dhziub.jpg

 

Also need to do something about this as well.

 

http://i90.photobucket.com/albums/k280/merc6/LGT/th_5B6F8880-AE8D-42E7-8696-916E1A0CD9DD_zpskno8quj8.jpg

[Merc6]

I was on Harbor Freight and saw multiple engine stands.

 

http://www.harborfreight.com/automotive-motorcycle/lifts-stands.html?p=1

 

Was there a difference between the (2) 1000 lb engine stands and is that overkill over the 750 lb one which really isn't much cheaper?

 

I'm going to try and track down my cousin and the rest of the dead engine so I can fully see what all needs to be done.

 

Also got letters for both cars...

 

http://i90.photobucket.com/albums/k280/merc6/th_9F3FDCD9-7C3F-4002-A80B-93E684671F96_zpsbuam4r73.jpg

[Max Capacity]

Trying to open the link...still buffering...

 

I have the engine stand of four wheels, seems more stable to me.

 

The engine balancer is a nice helpful piece and a swivel hook is nice too.

 

What are your HP goals, IMO don't waste time and $$ going to top feed or TGV deletes.

 

Finally, the 1000lb is plunty. That's what I have. You'll never need the 2000lb one.

[SBT]

I bought one that allowed the legs to fold-up so it takes up less room and fits nicely into a corner when I'm not using it. Believe it's a 1K LB capacity. Six sets of casters and works great. Bought both the stand and and my shop hoist with fold-up legs for this reason. If you've got the room, then just go with a 750-1000 LB stand.

[Max Capacity]

Yes the engine hoist will have folding legs. Mine was $199 ten years ago. It fit's nicely in the 8x10 shed.

[Merc6]

Let me try this again.

 

These are the 2 it's down to then. Are they the same but different part #s? I will most likely try and go to one locally and see what they have.

 

http://m.harborfreight.com/automotive-motorcycle/lifts-stands/1000-lb-engine-stand-69886.html

 

http://m.harborfreight.com/automotive-motorcycle/lifts-stands/1000-lb-engine-stand-69520.html

 

My goals were like 300 crank but I'll settle for the 13.35 1/4 car that runs and drives like it did before it became a lawn gnome. Space is 2 car garage with no cars in it so far.

[Max Capacity]

Get the $59.00 one

[Merc6]

Add some more parts to the list. Build look like it should happen this year and I actually believe it will this time.

 

http://i90.photobucket.com/albums/k280/merc6/th_704DAB7D-EA20-4B63-BEC1-4DBBC464377E_zps551nblla.jpg

 

http://i90.photobucket.com/albums/k280/merc6/th_20BC92F3-D720-4B55-9C4E-2F2660C70A30_zpsv5lqnsqe.jpg

 

http://i90.photobucket.com/albums/k280/merc6/th_896589AF-6BE2-48FA-B490-4905A27B3359_zpsbwk09rsb.jpg

 

http://i90.photobucket.com/albums/k280/merc6/th_E29FC450-A3C3-4938-BAD7-181D6821E584_zpso1as3mot.jpg

[Mike07LGT]

What does the blitz air box grill look like?

[Merc6]

What does the blitz air box grill look like?

 

This, ended up having to mount it with a hinge as that's all I had at the time. I'll probably address that as well.

 

http://i90.photobucket.com/albums/k280/merc6/LGT/001DD45B-89A8-4312-A5E6-4087FFDC6754_zpshmxbwcar.jpg~original

 

[Merc6]

Anyone running these?

 

http://www.rallysportdirect.com/LIC-Motorsports-121811-Aluminum-Cylinder-Head-Plugs&source=GoogleBase&vid=1995-Subaru-Legacy-Brighton?gclid=CISZj5iMk8MCFfLm7Aod1XgAcg

[SBT]

Wonder what they use as the sealing surface. Surely not just metal on metal.

[MrTris]

Anyone running these?

 

http://www.rallysportdirect.com/LIC-Motorsports-121811-Aluminum-Cylinder-Head-Plugs&source=GoogleBase&vid=1995-Subaru-Legacy-Brighton?gclid=CISZj5iMk8MCFfLm7Aod1XgAcg

 

Was going to on my build, really wanted 'em. Didn't end up buying them in time.

 

Wonder what they use as the sealing surface. Surely not just metal on metal.

 

Still requires RTV, like Ultra Black. They go in just like the stock half-moons.

[CloudSeed777]

Let me try this again.

 

These are the 2 it's down to then. Are they the same but different part #s? I will most likely try and go to one locally and see what they have.

 

http://m.harborfreight.com/automotive-motorcycle/lifts-stands/1000-lb-engine-stand-69886.html

 

http://m.harborfreight.com/automotive-motorcycle/lifts-stands/1000-lb-engine-stand-69520.html

 

My goals were like 300 crank but I'll settle for the 13.35 1/4 car that runs and drives like it did before it became a lawn gnome. Space is 2 car garage with no cars in it so far.

 

I bought the (61238) 750lb stand at HF for $45.99, and the (69512) 1 Ton Foldable Shop Crane at HF for $159.99 (they were both on sale).

 

You may also check Craigslist in your area. A lot of people buy these, use them, then sell them when they are done with the work. I looked after i bought mine and there were several cranes on CL just like the one I bought, one for $100 used once.

 

I've done two pulls so far and both have worked as advertized.

[Merc6]

Going to order the half plugs once I get another coil pack for the DD.

 

Forgot to even look on craigslist, I'm always on there and it never came to mind.

[Merc6]

Ordered these

 

http://www.rallysportdirect.com/LIC-Motorsports-121811-Aluminum-Cylinder-Head-Plugs&source=GoogleBase&vid=1995-Subaru-Legacy-Brighton?gclid=CISZj5iMk8MCFfLm7Aod1XgAcg

 

and these

 

http://turninconcepts.com/tic-fu-cam-bolt-kit-single-avcs.html

[MrTris]

Oooh, you bout to have some FUN!

[Merc6]

Yep found a few options on heads and TGVs locally done. Just gotta purchase the rest of the hoses and turbo inlet.

 

Turbo is still up in the air, there was glitter in the oil so rebuild with billet wheel is serious inquiry.

 

Debating if I want something done to the valve covers or not on "just because".

 

Misc items here and there need to happen like rotors and pads but running is the goal for now.