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A few people have mentioned posting a tread on my build over the next few weeks to share my learning (including mistakes, I’m sure there will be many) and get other peoples advise (who’ve already done similar work). Here we go!
Car is a 05 sti type uk, running on standard internals at the moment, made 410/340 when mapped a couple of months ago with the following mods:
I thought this was enough (for a couple of weeks at least )
The 321t and 650’s were put on with the intension of bumping power to the 450/450 mark with a new short block when I’d saved enough (original budget was £5k). A lot of emails, a few visits and a couple of months later (and the budget out the window ) she’s now booked in at Pennine for a lined 2.5 cdb.
A summary of the spec is listed below, items shown in red are still to fit (will update progress as I go). Most parts have been supplied by Mark at Lateral (think I've paid for your next 3 years holidays over the last 6 months Mark). Pat fitted and mapped the Solaris and will be doing the final map hopefully by the end of July (as long as I get the engine run-in in time and he can fit me in).
Over the next few weeks I’m going to asking a lot of daft questions so bare with me. I’m no expert and am learning as I go (part of the fun/torment of messing around with cars , lol). If I start talking rubbish correct me I don't mind as I've probably picked the rubish up from someone else.
Engine Details:
2.5 Short Block (based on EJ2.0 closed deck block machines and fitted with Pennine custom liners, with rear thrust converson and oil squiters...)
14mm Stud Conversion
14mm Studs (Pennine)
Standard EJ 257 Crank
ACL Race Bearings
Lateral/Crower Rods
Lateral/Wiseco Stroker Pistons and rings
14mm Dowels (Pennine)
Standard oil Pump
CDF Lightened Aux Pulley Wheels
Air Con Stripped Out
Reworked Standard Sti 2.0l VVTType Uk Heads (Small Port)
Heads modified for 14mm Studs and dowels
Cleaned ports, remove casting marks etc.
Fit new 1 piece Inlet Valves
Fit new 1 piece Inconel Exhaust valves
NGK 8’s (Plugs)
Standard Cams
Oil Cooler with -10 Earls Lines and Fittings (mounted behind front grill, remote filter)
Lateral Baffled Sump
Fuel System/Cooling
Spec C inlet Manifold (main reason is to give a little extra room for the 76mm intake pipe)
Carl Davey Billet Parallel Fuel Rails (with Earls -6 hose and fittings)
Custom rail adaptors
Carl Davey Tufnol Inlet Manifold Spacers/Insulators
PE 800cc Injectors (Flow matched by Lateral)
Fuellab Fuel Pressure Reg (Mini)
Bosch 044 Pump (Mounted in-tank)
‘Big’ K&N Filter in the wing (Hyperflow Cold air feed piped to inner wing)
Hyperflow Monster Front Mount Intercooler[/i]
Hyperflow Oil Catch Can (Now relocated to back right of engine bay)
ECU:
Solaris (Syvecs) S6GP Generic ECU (with Cal switch)
Inovate Wideband and Controller
3 Port Boost Solenoid
Lateral 3 Bar Map Sensor
Odessey 680 Battery
Turbo/Exhaust/Induction:
MD321V turbo with ceramic coated exhaust housing
RCM 76mm intake pipe
Lateral GT Spec Headers (heat Wrapped)
Miltek Decat downpipe (3")
Miltek centre section (3")
Blitz Backbox (modified to give 3” right through)
Suspension:
AST Sport-Line Suspension Kit
Whiteline Anti Roll Bars (front and rear
Whiteline Anti-Lift Kit
CDF Solid Alu drop links
4-Wheel Alignment etc by Power Station
Interior:
Defi BF Gauges (Oil Temp, Oil Pressure, Boost, Exhaust Gas Temp, Fuel Pressure)
Innovate Air Fuel Ratio Gauge (on A pillar)
S204 Dask Kit (Red Hazard Button)
Also arrived some very sexy Carl Davey Fuel rails, cheers Carl, look fantastic. Was orginally going to fit Perrins until I saw the pics Duncan posted of these.
Rails are meant for standard sti intake manifold with tumbler 'deletes' so I need to machine some billet adapters for the fit (waiting for injectors from Mark so that I can take some measurements .
Location: Pennine Subaru 01422845007, Lateral Performance 01923 238477, Jolly Green Monster and Syvecs :-)
Posts: 7,738
Definitely not, you could run two intank walbro for that power but a single will let you down. If you you want to stay single pump how about a Bosch 044?
Not expectimg 550, lol, just read my post and it sounds like that, sorry. Picked the 550 up from Andy Forest's site. Expecting upper 400's so will look into this .
While I'm on with this here's my first question (you'll wish you hadn't posted after this). I have three fuel lines under the bonnet:
One to the filter (then onto the injectors)
A return line from the regulator
A thrid line
Whats the third line?
Can you help, just currious? And whats the small plastc in-line fitting
Right, managed to get a couple of hours work in on the car today, stuck for bits at moment, injectors should land tomorrow, will be able to make a start on the adapters for the rails.
Spent today making up the lines, took me about 2 hours to do the first one then 10min for each fitting after that . Carl sent me a Earls guide on how to assemble the fittings which helped but what ever you do don't use a hacksaw to cut the braided hose (it just makes a mess of the braid then you can't get the braid through the fittings) this took me two hours to figure out . I eventually used a drimel with a small cutting disk which cut through the braiding like butter and didn't upset the braid at all (super neat). The fittings are still quite fiddly tho (cursed Carl a few times, sorry Carl if you felt your ears burning a bit today), but end result is fantastic, lets hope the rest of the bits arrive from Mark tomorrow so that I can finish off the mainfold.
Pillar pod also arrived today for new innovate Air/Fuel ratio gauge (runs from wideband which is already in, plugs into a serial out on the controller so no soldering etc) and red hazard light button should arrive tomorrow as well. Part fittied pod and removed swicth in preparation.
Location: Unleash the beast Mr Zen Performance....477.8 bhp @ 1.3 bar on V-Powaa only....with more to come....
Posts: 3,229
Dave - welcome to the Chy/Pennine Subaru world!! Nice list of parts and pics too.
The wr1 in the right side of Chy's workshop is mine! Like you I've used Mark @ Lateral for most of my parts and Pat had already installed my Solaris last year in Aug - yep the full works of calibration switch with als and launch control. Like you I was running 422/400 but decided that was not enough! Ask Chy about his special "rings" set up for the future.
You may want to consider getting your down pipe and headers coated by Zircotec, speak to Chy about it - see below link to my post:
Cheers JP4, saw this link when you first put it up, they look fantastic , do you know it they can coat 'used headers'. I assume they must media blast the headers before they coat them?
Cheers Dunx, I did wrap the braid in PVC but was still a nightmare, as soon as you take the tape off to fit the 'fitting' the bloody braid starts to expand (as if its spring loaded). Got the knack of it by the end tho and there isn't a braid out of place or scatch on any of the fittings at the moment (famous last words as I still have one more to do ).
I need to get pics up of the bits I've made and more detail up rather than just pics of new bits.
I'm back on the 26th Dave, so you'll have around a week to do a 1000 odd miles and get a full on remap ready for my return Think you should aim to max out the turbo with how ever much boost is needed! lol.
We Could go to TRL for a RR day with Murf, Mark etc maybe......although I'll have the weakest powered car there.......so maybe not!!
Made a little more progress over the past few days on the adaptors for the spec c manifold.
For those that haven't seen yet I'm going to fit a spec c inlet manifold which is a 1 piece item without the 'tumbler deletes'.
- The benefit of this is the extra room it provides where the intake pipe fits onto the turbo (the standard type uk manifold can 'nip' a 76mm pipe, caused by the bolts whcih hold the intake to the tumbler deletes, this can reduce flow). This isn't a problem if you go rotated but my budget wouldn't stretch to this .
- The drawback of the spec c inlet is that the rail fixing points on the spec c manfold sit lower down and I couldnt find and any aftermarket spec c rails.
Injectors landed on Saturday so was able to offer them up and measure what I need for the adapters. See pics of rails and injectors fitted:
See copy of sketch for adaptors:
Adaptors were started today, should get them tomorrow to test fit before we carryout the final machining. I'll put a better copy up of the drawing once I know they fit in case anyone else goes the same route .
Remaining parts also landed from Mark at Lateral on Saturday , will put some pics up later this week for those people like me that like looking at shiny new bits :
Excedy twin plate
md321V
76mm intake
Set of 8's
PE 800's
Fuel lab mini
Can you not turn the fuel rails the opposite way so the bolt holes are underneath the rail?
That way I'm sure one of the holes lines up (albeit with a spacer) and the other hole is about half hole out, which would need the lug cutting off and re-welding in the right place..?
Looking good though, and the 2.5/MD321V will make a great road car.
The injector 'ports' aren't symmetrical so you cant turn them round (is difficult to expain) have tried the rails every-which-way they will go but this will be the easiest and neatest way of doing it. I'm machining the adaptors from alu billet so they will match Carl's rails and should look neat.
The Widow Maker (Newage 2.5 cdb build)
) 
) she’s now booked in at Pennine for a lined 2.5 cdb. 
, lol). If I start talking rubbish correct me I don't mind as I've probably picked the rubish up from someone else.
.
. I eventually used a drimel with a small cutting disk which cut through the braiding like butter and didn't upset the braid at all (super neat). The fittings are still quite fiddly tho (cursed Carl a few times, sorry Carl if you felt your ears burning a bit today), but end result is fantastic, lets hope the rest of the bits arrive from Mark tomorrow so that I can finish off the mainfold.
Not really, I wouldn't have a clue.
they will go but this will be the easiest and neatest way of doing it. I'm machining the adaptors from alu billet so they will match Carl's rails and should look neat.
