Trix's 05 LGT Build Thread

[VrpDCNzZfIOS]

2005 Subaru Legacy GT 5MT Limited

 

Power Mods

EJ25 decked: 0.020 - Heads surfaced: 0.010

Wiseco Pistons (Part-Number: 6598M100)

Manley Turbo-Tuff Rods (Part-Number: 14416-4)

Nitrited-crank (P-N: ???)

Brian Crower Stage-2 Cams (P-N: BC0621)

Spark plugs NGK PN:SILFR6A

Borg Warner EFR turbo (specs, reveled later, 450+whp)

1/4" turbo oil like, no restrictor (Internal in BW EFR)

3" QTP electric exhaust cutout

Stock in-tank with Walbro 378 external boost fuel pump.

STi Fuel Pressure Regulator

APS Fuel distribution re-circulation block.

APS Fuel Pressure Regulator distribution block.

APS Fuel Rails, custom modified for NPT to hard-line flare fittings.

Home built carbon-fiber turbo inlet and charge pipe.

Home built stainless-steel 3" down pipe with 3" electric exhaust by-pass.

Home built 2.5" cat-less up pipe, and 3/8" steel turbo flanges.

Home built cold-air intake and air filter box, polished. (WIP)

Home built Water-to-air intercooler kit using Frozen-boost aftercooler, polished.

Self Pro-tune with ECUFlash, Romraider, Speed Density, blow-through MAF, LC, FFS.

Home built engine wiring harness. (WIP)

Intake Manifold from a 2.5i NA early 2000s (gen 4 legacy era). Custom ported, polished, clearanced, and EGR blocked.

TVG / Injector housings from 2005 WRX. Custom ported, polished, tvg weld, and tvg castings milled off for polishing.

Phenolic Thermal manifold spacer 8mm

Home Modified stock top-feed injectors (~770cc/min based on current tuning).

Fuel pressure (Unknown, hoping 43 psi base).

 

Future

Shifter bushings for the OEM short throw (TBD)

Tein coilovers with Pro EDFC (TBD)

Whiteline Sway bar Link (TBD)

Whiteline RC correction (TBD)

Whiteline bushing kits (misc) (TBD)

Whiteline F/R 22/25mm bars (TBD)

Whileline Sway bar bushings/mounts (TBD)

Whiteline Rear Sway bar link (TBD)

Whiteline Rear Control arms (WIP)

Home built strut-tower braces. (Done)

Home built front-clip reinforcement bracing. (Done)

Home built Brake-booster reinforcement bracket. (WIP)

Home built firewall-to-strut-tower reinforcements. (WIP)

 

Audio & Gauges

All extra gauges integrated into Kenwood Double Din (see below) (Done)

Kenwood DNX962 Navigation HD at trip computer location. (Done)

JL Audio C5L 6.5" Coaxial front stage. (Done)

Sundown SA-12 in 34hz tune-ported box. (Rework In-progress)

JL Audio 400/4 front-stage. (Done)

JL Audio 1000/1 feeds SA-12. (Done)

CT-Sounds 75.4 Class A/B 4 channel (420w rms rear-stage). (Canceled)

CT-Sounds 6.5" Coaxial rear-stage. (Done)

CT-Sounds 1" Silk Dome enhanced-location-staging (second pair). (Done)

CT-Sounds 8" Sub custom molded ported tuned to 54 hz. (Canceled)

Relocated trip computer to ash tray area with custom made panel. (Done)

Premium Subaru Sub removed and replaced by Carputer laptop. (Done)

Tactrix logging with modified OBDII switched power. (Done)

LC-1 AFR gauge to RomRaider logging and dashboard. (Done)

VGA to HDMI conversion, laptop to Kenwood's video input to display romraider dashboard for all extra gauges (eg. wideband AFR, EGT, etc). (Done)

 

Brakes

Custom Master reinforcement bracket (WIP)

SS lines (On order)

DBA T3 5000 Front Rotors 2 Piece (Delayed)

DBA T3 4000 Rear Rotors 1 Piece w/handbrake surfaces. (Delayed)

Hawk Brake Pads (Done)

Dot-4 Brake Fluid Flush (In Progress)

 

Maintainance

Banjo Filter Removed (Done)

Timing Belt (Done)

Water Pump (Done)

Cam Seals (Done)

AVCS filter removal (Done)

Valve Cover Gaskets (Done)

Front Main Seal (Done)

Lower Coolant hose (Done)

Turbo Oil Return hose (Done)

MAF Cleaning (Done)

PCV Valve (Done)

Killer B oil pickup + pan (Done)

STi engine mounts (Done)

 

Tuning

Safety tune:

Zeroed CL/OL delays (Done)

Re-curved requested torque values below 25% throttle (much easier on the gas) (Done)

A little more AVCS timing in some cruise sections (Done)

Speed limiter set higher (Done)

8000 rpm rev limit with soft rev limiter and raised fuel cut. (Done)

Removed extra timing from odd cylinders "Per-Cyl comps" (Done)

Stage 3 tune with exhaust cutout open (28-32 psi max) (Done)

 

Costmetic

In the works:

18-19" wheels (TBD)

Interior trim repainting (Summer 2017)

Leather seat repair (one rip in drivers side) (TBD "seat customizations")

 

Some to-be-announced trim detailing:

Ding removal and scratch repair (In Progress)

DRL Disable (Done)

 

 

More build thread stuff for additional info coming for some of the stuff already done.

Will post some pictures here for now.

 

 

Parts not used:

Invidia Up-pipe w/Heatshield Products PN:321050

[VrpDCNzZfIOS]

Double din Install:

 

 

 

 

Speakers install

And other images:

https://photos.google.com/share/AF1QipM9bGhkmOS8hoI8sEiseuK_pwNNhLFrr-69YM7btTf2jU8JKJQcMsjlYw3Gi46r2w?key=aWxJVzdfT3lPQUM2SFZuYURvcU5ZSTVZWkN2eThR

[Max Capacity]

If you really want a CAI check out the new Grimmspeed one being built.

 

They also make nice tmic.

[VrpDCNzZfIOS]

If you really want a CAI check out the new Grimmspeed one being built.

 

They also make nice tmic.

 

+1

I just saw the group buy thread a couple of days ago and that is where I got the idea for wanting the CAI from Grimmspeed.

[Max Capacity]

I see you have a fuel pump on your list.

 

Make sure you have enough fuel supply for the increased air flow.

 

I'm about maxed out on my stock fueling, so my Tuner didn't think this intake would be good for me.

 

I'll be putting my second GS tmic on tonight, my Spec B already has one. My wagon gets it tonight. My Tuner will street tune the car on Sunday.

 

You'll want to find a Great Tuner and work with him, its very important with these cars.

 

There is a saying, "it's all in the tune" That is very true.

[VrpDCNzZfIOS]

I was surprised to see the stock tune after zeroing the OL/CL was in the mid 11 AFRs 11.2-11.8. It's probably perfect for a very well dialed car. Just surprising to see that stock. I also have a pocket street tuner doing all the tuning, does great work.

 

I have had a 2009 WRX Hatch, and a 2011 STi Sedan before swapping back to this older (lighter) body style.

[covertrussian]

I was surprised to see the stock tune after zeroing the OL/CL was in the mid 11 AFRs 11.2-11.8. It's probably perfect for a very well dialed car. Just surprising to see that stock. I also have a pocket street tuner doing all the tuning, does great work.

 

That's very lean for a TMIC application! My car, with just Invidia Uppipe, was in low 10's. With TMIC's you want to keep your AFR's below 11.2, since they are less efficient at heat removal then FMIC's.

 

Also check and post up your learning view. I bet your K&N filter is what's causing it to lean out (these cars are that picky). If your D learning (40+ g/s) is negative, then that's whats causing you to lean out, if it's positive and your that lean, you will be even leaner after ECU is reset.

[VrpDCNzZfIOS]

Learning view:

 

But it's too late anyway. Driving down the freeway today I dropped down a gear and passed a semi. About, 7 seconds later I saw some blue smoke (after I had left off throttle). Drove it nice for another 11 minutes but as I was stopping at a light after exiting the freeway, we heard rod knock. Pulled into a gas station, about half a quart low. Yesterday it was full. I think that 4th gear pass was enough to starve it of oil and torch a rod bearing.

 

Engine is getting pulled in the morning for a rebuild.

 

A note on the AFRs, the wideband gauge was re-calibrated and actual AFRs were between 10.7 and 11.3

[covertrussian]

Holy Knock Batman! Sounds like the car has more then just air filter, it could be your exhaust cut out. Sorry to hear about your block, definitely get her pro tuned when you rebuilt.

 

Detonation is what probably killed your motor, 4th gear is very long, which means you stay in detonation prone zones longer.

[VrpDCNzZfIOS]

Funny thing is, I haven't even used the cutout. More than just idling and a few quick burps on the throttle, I have been treating the engine great, staying out of boost, and waiting to get all the maintenance stuff done before leaning into the engine. Guess I should have continued that mantra until I was finished.

 

This learning view was right before the tuner richened up the AFRs. I will have him over tomorrow to pull the learning view from when the engine popped.

[Mike07LGT]

That's very lean for a TMIC application! My car, with just Invidia Uppipe, was in low 10's. With TMIC's you want to keep your AFR's below 11.2, since they are less efficient at heat removal then FMIC's.

 

Also check and post up your learning view. I bet your K&N filter is what's causing it to lean out (these cars are that picky). If your D learning (40+ g/s) is negative, then that's whats causing you to lean out, if it's positive and your that lean, you will be even leaner after ECU is reset.

 

My car leaned out right after I installed a k&n drop in filter and threw a cel. I quickly removed it and replaced it with a normal paper filter and have had no issues since

[VrpDCNzZfIOS]

Took a while, but the engine is finally out. I had to re-roof my house so I was only taking like 2-6 bolts out of the car per day and today was the day I finally got it out.

 

Tear-down time shall commence. Then I will start cleaning things up, measuring, machine work, ordering parts, etc.

 

I see what appears to be a weird crack in my turbo compressor housing. It looks like it was minor enough to not have caused any problems but it does make me curious for more information if anyone has any to describe what I am seeing?

 

 

 

 

 

 

 

 

[Max Capacity]

Stick a small mirror down the turbo and get a better look.

 

You should contact JmP6889928 and see about having that rebuilt if you plan to keep it.

[magnusonsubie]

Definitely contact JMP. He will be my go to when I decide its time for a new turbo. Was going to do it this fall but priorities changed for me with school.

[rebourne]

Sub'd... and I might have question about the cutout later...

[VrpDCNzZfIOS]

The cam pulley bolts, OMG... After applying nearly 400 ft/lbs of force I got each one free without damaging or breaking anything.

 

Got the passenger side head off and did a quick measurement of the bore. Things are looking very promising.

 

 

 

[VrpDCNzZfIOS]

So a new motor was built, but it got a little bit carried away with the simple forged pistons rebuild. Ended up with everything. Forged pistons, rods, crank. Valves, BC stage 2 cams, high rev springs. 11mm oil pump, heads and block surfaced and bored out.

 

Because of all that I decided to go with a slightly bigger turbo. Then I thought about spool, lag, power, so I decided on a slightly bigger turbo again. Then right before I ordered I went with a slightly bigger turbo again. So ended up with a lot of slightly biggers.

 

The motor is in. TVGs removed, ported, and polished. intercooler polished, manifold cut, grinded, polished. Misc bits cleaned up, sanded, polished. I probably have 100 hours of work into just trying to make things look nicer or function better.

 

Starting on the plumbing work this week. charge piping, turbo up pipe, inline-booster-fuel-pump, water pump, tubing etc. Still have to mount the pumps before I can plumb them. The wiring harness is mostly torn apart. Going to remove tvg wires, replace some wires, and change a few pigtails (switched to top-feed from side-feed) injectors and they have a slightly different pigtail clip.

 

The wiring harness is being tucked so probably a lot of additional work to be done. The goal is to try to get the engine/cam break-in procedure done by this weekend. Then start finalizing location of all the wires/plumbing, etc.

 

More info coming soon. The build should start going much faster now.

 

 

 

 

 

 

 

 

 

 

 

 

 

[WRX USA]

Pics aren't working.

[VrpDCNzZfIOS]

Are they fixed now?

[Merc6]

Are they fixed now?

 

For me they are. Makes me want to add more stuff to my build list when I shouldn't. My cams are questionable and I need new ones so it's very tempting.

[STIGIT]

interesting project. keep up the good work.

[subi_life]

Holy shit what size turbo is that?

[dieselsquid]

Air/water intercooler looks like it's from a mr2

 

-Squid

[oODanKNesSOo]

Subd. Saweeeeet build man... can't wait for the unveiling of everything from power to audio and beyond. Sickness!

[VrpDCNzZfIOS]

Thanks everyone for the nice comments

 

Hard-line fuel system is pretty much complete finishing up the return line once I get one more fitting. Then I just have to make a few wires for the alternator and starter, connect battery, install radiator, and add fluids. Then see if she will start and break-in some cams.