a few pics of my project so far

[Jay762]

Coming along nicely - I see you have a tube of copper slip there, after using that for years with brakes and high temps making it run everywhere and stain badly I switched to the mechanic friendly Molyslip Ferroslip product

[savage bulldogs]

Don't worry jay I have lube for every occasion 🤔😂😂

Copper slip for exhaust and general bolts .

Red grease for brakes (doesn't harm rubber seals ).

White grease (anti fling) .

And some strawberry flavoured stuff for my nuts 😉😂

[savage bulldogs]

I'm "lucky " enough to be back at work because I'm currently converting a ww2 bombing planning office into private dwellings,  which means I'm on my own and in the middle of a airfield (miles from anything or any one ) .

Unfortunately that's slowed progress on the scooby atm though 🙄  .

I got the pump back from pat Seager and the full set of hi temp exhaust headstuds turned up too , so here's a pic showing why I didn't use the "kit bolt" unfortunately first time around.

The bolt on the toothed idler has no makers /identification marks,  no shoulders (like the oe one above) and just didn't look good quality but I trust the suppliers choice and looks ain't everything lol .

So water pump ,idler pulleys, hydraulic tensioner fitted (again 🤐 ) cams dialed in and kevlar belt fitted .

Kept the tape over the inlet ports and fitted the thermal spacers (bolts would be to long otherwise) and old inlet so it was ready to lift . Timing belt covers and crank pulley torqued down, too .

 

I struggled to get the engine through the shed door on my own "built up" ,so fitted the headers, up pipe ,turbo, clutch and flywheel  (with new spigot bearing) outside. 

Engines currently just sat in the bay 😊but hey at least it's finally in it's proppa place 😉

When it comes to running in , I guess I'll have to use it to get to work 😇 and yes I've already asked the owner If i can "use" his disused runway 😊

[savage bulldogs]

So old inlet removed and head intake ports taped up , to make it eaiser to fit downpipe, starter ect at the back of the bay 

I had kept the turbo intake covered but removed it for the pics , as I've kept everything spotless during the build and don't want anything getting into the intake tract 😉

Rinsed the inlet , intake pipework, fmic pipework and core through with petrol .Then fitted complete inlet manifold with fuel rails ect still attached ,along with alternator and started to re run fmic pipework. 

P.s pump ,coolant pipework, vacuum lines, fmic and intake pipework ect fitted. Filled up the coolant and primed the oil system by turning the engine over with the starter motor and spark plugs out .

Plugs and coilpacks in coolant topped up and ready for first start up 🤔🤞

[savage bulldogs]

Turned the key to first stage a few times to prime the fuel system and check for fuel leaks .

Cranked it over and ......  

😊😊🥳

Keeping a eye on coolant levels and checking for any fluid leaks for the first 5 mins , oil pressure and temps look good .

 

I heat cycle my engines stationary for a few days and then drop the oil and refresh before driving anywhere. 

So seeing as it's only got 10 w 40 mineral oil in atm , it sounds quite quiet for a 2.1 forged bottom end on cold start 😎

Once up to temp on the first heat cycle , I noticed a slight coolant weap from near the thermostat. Tbh I forgot to buy a new thermostat 🙄 so due to lockdown postage being slower than usual I cleaned and refitted the thermostat and seal (or lack of seal lol)

 

So as a whole I'm very happy with the build so far and have a new hi flow stat and seal on it's way 😊

 

 

[savage bulldogs]

Fitted the new thermostat and swapped out a couple of those crappy coolant spring clips for proppa jubilee ones .Ran it up to temperature a few times now and the heat cycles are complete now ,without any leaks this time 🤐🙄😊.

So slapped the front end back on this morning 😊

Just gotta drop the mineral oil out ,fit a new filter and refill with some millers running in oil . Then she's ready to tax and take to Tesco on it's essential maiden voyage 🤞

[stuartie]

Looking awsome as always bud 👍, mine's is looking a bit sorry for itself just now, i've nearly got it all ready for paint just all the wee fiddly bits to rub down 

[savage bulldogs]

Cheers stu , tbh it doesn't look any different to when I removed it but it sounds a lot quieter and hopefully first drive will go ok tomorrow 🤞

 

I'm sure in a few months you'll be happy with boost n burble back in your life 😉

[savage bulldogs]

Well seeing as it's her 26th birthday this month and it's finally in one piece...

I took her for a few pints of amber nectar (vpower) to celebrate her birthday 😊

Happy to say the 20 mile essential round trip went well ,apart from gaining a screechy power steering pump and afr very slightly lean at cruise (14.9) .

Once I start to use more throttle ,later during the running in process and if it gets leaner . I'll try upping the fuel pressure very slightly to compensate for the extra cc ,as it's now a 2.13 cc instead of a 1998 cc . Obviously once run in it will be remapped ,as the little increase in capacity, cams and turbo upgrades will need to be tweeked in 😉

As for the p.s pump,  I have replaced it once before, with another 2nd hand pump but the early v1/V2 pumps are known for leaking.  So guessing I'll be looking into doing a "newage p.s pump conversion " soon 🙄

Well I need something scooby to do again now 🤔😂

[savage bulldogs]

Not much of a update but I've backed off the actuator arm pre tension and that seems to have brought the afr in closer to where I'd like it 😎

I'd also changed the angle of the turbo intake pipework but since found out the adjustment had caused the pipe to rub on the bonnet 🙄

So I had a search through the box of joiners and ally pipework I have to hand and have added a 90° silicone elbow and a slightly shorter angled piece of pipe . This has repositioned the filter in a better place to get cold air too 😎

So couple of pics of new intake pipework route .

 

And a couple of the car basking in the sun ,after a good coat of wax  .

only done 75miles so far but so far so good 🤞😊

[savage bulldogs]

Been back at work this week and the a4 daily had a flat Battery and was blocking the scooby in 🙄

 

Tbh it turns that was a good thing ,as midweek I noticed a couple of patches under the scooby 🤔  I'd bought some cheap exhaust wrap to go over the old stuff on the headers ,so got it up in the air to sort that and investigate. 

Soon spotted 2 minor coolant weaps 🙁

I had been using fuchs coolant with water and noticed everything looked a bit fury in the coolant system on teardown.  I found a nearly new core in the scooby scraps shed for a automatic , so thought I'd fit that so the coolant system was fresh . Ihaven't a clue where it cam from (never owned a auto anything) but guess I know it will be going......

 

in the bin 🙁🙄😂

Its Leaking bottom right corner between plastic end cap and core .

 

The oil cooler modine hoses and spring clips are the original 26 year old ones , so they've done well but the combination of the hoses going hard and the spring clips going weak ,have lead to it not sealing properly 🙄

So new modine hoses ,clips and crossover pipe ,along with a new (possibly ally) radiator needed .

Before run in can resume 😊

[savage bulldogs]

Decided to go with a ally rad ,rcm/samco oil modine pipe kit and a new genuine sti header tank cap .

 

So hopefully the weather's dry over the weekend I can start to run in again and use it for the commute to work next week 🤞

[savage bulldogs]

Dodging in and out of the rain showers today but I managed to fit everything eventually 😎

I drained the coolant system (again) removed the leaky rad to give me a bit more space ,to get to the oil cooler pipes at the front of the engine. 

The new samco hoses where a really tight fit onto the water pump ,new crossover pipe ,oil cooler and block take off . So that coupled with the new cheap exhaust wrap ....made this one of my least favourite scooby jobs for a long while 😏

I fitted two of the new pipes to the crossover pipe and then filled a swear jar fitting the rest but with the pipes being such a tight fit and the new spring clips being so strong .. . I'm sure it won't be leaking again anytime soon 😊

The ally rad Alyn @asperformance supplied has a slightly bigger core and 50mm thicker end caps but it fitted fine 😎

Only issue I did have was my cheapy rad cooling panel needed to have a couple of bits cut out either end , to fit round the bigger end caps . Then a few notches cut out of it for the rad shroud and expansion bottle hardlines to bolt through. 

So everything back together ,coolant refilled ,blead and run up to temp with the new sti header tank cap . Test drive went fine and "bang the leaks are gone " 😊

Looking forward to the Tuesday commute going back to work now , to start clocking up these running in miles at last 😉

[savage bulldogs]

First 250 miles done and I'm enjoying the commute to work 😎

Although it does keep distracting me whilst I'm working on the scaffolding 😊

still seem to have a coolant pressure issue though ,as its started weaping elsewhere now 🙄  . Only thing I can put it down to is the high flow stat I fitted 🤔

After looking at pictures of the "high flow stat " and comparing it to a standard stat , It actually looks like it might actually restrict flow . 

So I've bought a oe stat to replace it , hopefully that will resolve the either restriction or increase in flow 🤞

[ROSSCOSM]

You”ll need to start bringing your car cover so you can get on with your work 😂🤣😂

[savage bulldogs]

Took out the aftermarket "high flow stat " and took a couple of pics to compare it a oe stat shape and bore size .

 

Surprisingly the one on the right is supposed to increase "flow" and the one on the left is oe . The oe one has more movement on the diaphragm and a bigger bore plunger,  so to me it looks like the aftermarket one is more restrictive and would probably only increase pressure 🙄

This is to try and explain why I always use a stationary heat cycle process when running engines in , although a lot of "professional engine builders " dont .

So I always use a magnetic sump plug to catch any small metal particles floating in the oil and after a few stationary cycles with mineral oil....

You can see the sump plug has a small amount of metal attached to it , from the honing burs and bearing coatings at first start up (normal) .

This is after 250 miles at 55% and 0.6 bar max , hardly any metal particles on the plug 

So the first start metal particles are not running around the oilways during the running in period 😉

I've only done 30 miles on the new oe stat and fresh running in millers but so far ... no issues 🤞

[savage bulldogs]

480 total running in miles done and 160 miles since changing to the oe stat ....

Still no leaks or coolant loss 🥳

Started feeding the low boost target in further up the rev range but I've only kept a low 0.65 target whilst running in. 

 

So I'm now using most of the throttle and rev range ,as the engine has loosened up nicely. 

I have a afr gauge and can monitor knock but the afr is a little rich , increased displacement (now a 2.13) and more aggressive cams will mean the map definitely needs tweaking before adjusting the boost anymore. 

 

The ally rad I got from Asperformance seems to have reduced the max coolant temperature by 5°, doing the same journey in the same conditions but I still haven't been stuck stationary in traffic yet (so can't comment on all round performance yet ) 

So I'm booked in at clive attowes next friday 😊

 

 

[savage bulldogs]

Turned up at Clive Attowes in Norwich at 8 am and found I had some nice turbo retro petrol for company.

 

which was just as well as I wasn't allowed inside the workshop due to social distancing 

Can't lie it didn't start off the best as I seemed to loose some spool on the way there 
This turned out to be the wastegate not shutting properly anymore  yep after changing the spring and finding the right amount of actuator arm pretension... I'd forgot to tighten a lock nut 

Once light and part throttle fuelling was done he started to feed some boost in and it started to spin the wheels in 4th . Strapped down tighter the 565cc nismos soon made a respectable 375hp /355flbs at just under 1.4 bar .

With heat soak setting in nicely he broke for lunch to let it cool off a bit in front of his fans . The apexi does what its asked but for some reason it's always picked up false knock as the boost comes in . Here's a old pic of the oe engine ,turbo and apexi /knock sensor, showing a blip in the graph .

This particular ECU, knock sensor and car has always done it , even with oe engine ,2ltr forged and now the 2.1 . We're almost 100 % sure its background noise (something rattling against or tapping on the block or chassis)
As there's nothing in the det cans and attowe knows his stuff but to be safe he pulled a bit of timing in that area again , hence the blip in the new graphs and my long winded explanation too 

I finally ended up with 382.1hp /351flbs and 565cc injectors at 92% 

 

The turbo seems to spool fairly well for a 20g , hitting 1 bar about 3.6k on the dyno and still has a bit more to give .

I'm happy with the build and how the car drives /pulls but will probably get some 850cc and either a linkg4+ or emu black ECU in the future..... these things do tend to snowball 

[savage bulldogs]

Haven't done much to the scooby lately,  other than drive and enjoy it 😊

Did pop out on fathers day for a little b road blatt and upset a s5 v6t on a slip lane pull . My daughter took a little vid of a national speed limit pull for her "insta" 

So thought I'd chuck it on the build  thread ,excuse the defi alarm going off .

it's set at 1.5 bar and the car currently makes 1.55 bar but i suppose it does show how quickly it hits peak boost after a gear change  😊

[savage bulldogs]

I've just been enjoying it still ,so decided to actually do some boring stuff and bit of "simple maintenance" . While fitting the engine I'd noticed the steering rack gators were looking worse for wear and front brakes needed a clean (squealing at low speed) .

Well it should've been a 2hr job but that soon escalated into 4 hrs ,once I realized both tie rod to track rod lock nuts were well and truly seized 🙄😡

Little bit of heat .

 

 some tool improvisation for leverage and they finally came off .

New gators fitted ,Threads cleaned and regreased. .Brakes were proppa filthy,  no wonder the pads weren't returning properly and starting to squeal a bit 🤐

Cleaned and regreased. 

guessing I'd better make the most of the day off and give em a testing now then 😊

 

 

 

 

[Jay762]

Time well spent - and of course a test post fitting is definitely appropriate 👍😁

[savage bulldogs]

Good news is the brakes ain't squealing anymore 😎

But having to used heat ,anti seize and wire brushing ment I'd lost the locknut position mark on the drivers side 😏

Seeing as I'm gonna have to get it re aligned I dug out a few bits that I've been waiting to fit for about 2yrs....

 

Whiteline anti lift kit, super pro front wishbone bushes and a cusco H brace 😊

As most things on the car were removed and greased when I first got the 94 sti , it came apart fairly quickly,  with only one balljoint being a bit stubborn. 

I'd bought some billet hamber detox c rust remover to clean up the nuts and bolts I removed 

You mix it with water and leave the parts to soak , occasionally agitating it with a brush .

Seems to do what it says on the tin , and I'm pleased with the results 😎

I also found some spare rear trailing arms and lateral links and have dropped those and the ally wishbones off at a mates garage to get the old bushes pressed out .

I'll get the links and arms powdercoated and fit new bushes at some point but for now I'm going to clean and polish the wishbones once they're back 😉

The front arches are still in good order and only have surface rust on the brake pipe bracket,  so I'll nip that in the bud and de rust and treat those while I'm there ,too .

[David Wilkinson]

Great work, especially seeing the difference of cleaning up the rusty bolts.

Some good suspension goodies

[savage bulldogs]

Cheers @David Wilkinson it's fairly clean underneath and I like to try and keep it that way but she's no trailer queen and it does get used n abused 😊

Ive had those suspension bits for a few years , as I tend to buy things if they come up cheap and hoard them in boxes in the scooby scraps shed 😊

It's just as well that I tend to keep a few spares "kicking about" as whilst under the car I noticed my grouppe headers have a crack near the collector flange 😥

They were 2nd hand when my brother fitted them to the v1sti before I owned it.

So,They've done well but after a decade ... they were well done and beyond repair 😏

Now a new set of rcm/gt headers are around £800 which would mean that a new linkg4 ECU would be put on hold for quite a while 😥 but I remembered that I still have my old oe ported headers 🤔

I hadn't gone crazy with the porting and had only "gasket matched " the flanges but the stock headers don't really restrict till 450hp and the porting should help flow a bit 😉 they've been in the shed since I put the v1sti on the road,  so they will need a clean and half the stock heat shields are missing. 

A quick call to Alyn at Asperformance with the sizes of the ports ,turbo hotside info and target hp .....

Early next day there was a parcel delivered with some dei heat wrap (for the headers) and a new matched sized "Harvey trick up pipe " (rip buddy) , to suit my set up 😎

Although I'll probably (eventually) go for a set of aftermarket 3 bolt headers with a twisted up /downpipe,  to open up turbo options and fit a 3" front entry turbo . The self ported headers and trick up pipe, shouldn't restrict the arashi tdo5 20g billet from breaking the 400hp Barrier and keep the link ECU dream alive 🤞😊 

[David Wilkinson]

On 8/16/2020 at 9:46 AM, savage bulldogs said:

Cheers @David Wilkinson it's fairly clean underneath and I like to try and keep it that way but she's no trailer queen and it does get used n abused 😊

Ive had those suspension bits for a few years , as I tend to buy things if they come up cheap and hoard them in boxes in the scooby scraps shed 😊

It's just as well that I tend to keep a few spares "kicking about" as whilst under the car I noticed my grouppe headers have a crack near the collector flange 😥

They were 2nd hand when my brother fitted them to the v1sti before I owned it.

So,They've done well but after a decade ... they were well done and beyond repair 😏

Now a new set of rcm/gt headers are around £800 which would mean that a new linkg4 ECU would be put on hold for quite a while 😥 but I remembered that I still have my old oe ported headers 🤔

I hadn't gone crazy with the porting and had only "gasket matched " the flanges but the stock headers don't really restrict till 450hp and the porting should help flow a bit 😉 they've been in the shed since I put the v1sti on the road,  so they will need a clean and half the stock heat shields are missing. 

A quick call to Alyn at Asperformance with the sizes of the ports ,turbo hotside info and target hp .....

Early next day there was a parcel delivered with some dei heat wrap (for the headers) and a new matched sized "Harvey trick up pipe " (rip buddy) , to suit my set up 😎

Although I'll probably (eventually) go for a set of aftermarket 3 bolt headers with a twisted up /downpipe,  to open up turbo options and fit a 3" front entry turbo . The self ported headers and trick up pipe, shouldn't restrict the arashi tdo5 20g billet from breaking the 400hp Barrier and keep the link ECU dream alive 🤞😊 

Nice work mate. I’m currently servicing my 96 WRX and found out that the pcv valve and breather pipes are a little knackered so I’ll be kept busy, at least I have a catch can to fit