Hybrid Ej251/ej22e in the making

[dna]

I'll check around and see, if it fits I'll probably get it from you.


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[dna]

Hit the jackpot today! My neighbor who bought my old car was taking it to scrap, so I asked if I could get some things from it, ended up walking away with the Prosport boost and egt gauges, walbro 255lph fuel pump and the hood scoop all for nothing!

No progress right now though I've was out of town working last week but soon to come.


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[dna]

Update- been off of here for a few days but a lot has been going on behind the scenes!

Got just about every part I need ordered

-3" exhaust/ wrx aftermarket headers
-wideband
-greddy emanage blue with ignition and timing harness
Stage 2 clutch with new throwout bearing.

So right now I am patiently waiting for the parts to get here and get this thing running! I hauled the car up to the garage I work out to finish the final details.


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[dna]

Small update before the work begins, mocked up my gauge cluster today. I have to say it looks great,



I wanted an area where I didn't have to look to far to see the gauges, that way when I'm driving I'm not to distracted by them. I had to do a little custom fabrication to make it all work but I am very happy with how it turned out.



Now the fun begins, after work tomorrow I'm going to start piecing everything together. Wish me luck!


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[nepbug]

Ooh, somewhere I saw a really good write up on grafting in a hood scoop that wasn't a hack job. Let me see if I can find that link. He had even put in the proper supports on the backside.

[dna]

Sweet man that would be great


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[nepbug]

Here's one, it's not the one I was thinking of, but he did a good job.

http://www.rs25.com/forums/f105/t862...ck-l-hood.html

The other one I saw welded it in, this is rivets, but he did a good job hiding it.

[dna]

Here's one, it's not the one I was thinking of, but he did a good job.

http://www.rs25.com/forums/f105/t862...ck-l-hood.html

The other one I saw welded it in, this is rivets, but he did a good job hiding it.

Wow this guy wasn't playing around haha, i don't think i will go that far in-depth, but my hats off to him.

[dna]

Alright where to begin, i believe the easiest way to do this is to just post up a list of what all i got accomplished this weekend followed by pictures and foot notes haha I had to break out the computer for this post so you know its getting serious

• Installed headers/uppipe and turbo
• Drilled and tapped valve cover for oil return
• Installed walbro (fuel pump)
• Notched crossmember/ test fit engine
• re-routed fuel pressure regulator
• re-routed intake manifold wiring
• installed plug wires
• installed valve cover breathers and pcv system.
• Mocked up exhaust system (still need about a 12" piece of 3" exhaust to complete
• installed flywheel
• installed EGT probe

All that i am waiting for now is the coupler for the intercooler, my forester xt BOV (came in the mail today) and friday night i will make the oil return and feed lines. for the oil return since it will be so close to the exhaust I am going to make a 1/2 Steel tubing line with -8 (1/2') fittings on each end. i think it will look great and serve its purpose as well. So friday night hopefully, fingers crossed the engine will be going in. Then i can move on to the little details like getting the e manage wired in and my gauges wired up.



In this picture you can see how i had to bend the fuel rail basically straight in order for it to fit, to do this i just removed the fuel rail and used a brake line bender to get it straightened. Once that was done I installed a new piece of fuel hose and vacuum tube to the intake manifold, lets hope this works out.



Oil return, also wanted to show just how close the up-pipe is to the head, there is an ear on the corner of the EJ251 head that has to be removed in order to fit. Once you have done this there is maybe enough room to fit a credit card between the pipe and the head. Tight fit, worries me about the rubber cam cap on the back of the head.




You can see the cam cap here i was mentioning before, I chose this spot to install the EGT probe because there was no way and oxygen sensor would fit here on the 251 Heads, there was maybe 1 1/2" of clearance between the header and the head.



Notched crossmember, nothing special here just a hole haha i measured with the engine sitting in the bay so that i didn't have to cut anymore then necessary. If anyone needs the specs of where i cut let me know before i put the engine back in haha.



Dropping it in!



Here is the ear on the 251 heads that i mentioned before, grinding wheel and a little faith helps the heads fit much better. I'll get some better pictures soon, I am using the factory location of the TD04 which does not particularly work very well with the 251 manifold, i had to get a 90 off of the turbo and move a few things, but after that it's not to bad, time will tell I suppose.

[dna]

Quick update before I post pictures and hopefully a video, car has been fired up and seems to be running great. unfortunatley I cracked the oil return on my valve cove when I was installing the engine. So I have to see if maybe I can weld it. Until then I have it parked because once the car heats up some the leak gets pretty bad. Still have to install the rest of my exhaust.

[dna]

Been a little slow on updating my thread here lately but ill try to get some pictures and a video uploaded here soon, here's what has been going on behind the scenes.

-Finished the valve cover, welded on a 1/2" threaded fitting (so far no leaks)
-Completed the oil return line
-Hooked up cooling system and powersteering
-Test drove :smt035

Car seems to be running amazing I tried to stay out of the boost but I had to just once haha and it responded very well. Way more torque than my old ej22e. I still need to install the wideband and the rest of my gauges to see where everything stands. I replaced the PCV valve and so far the check engine light has stayed off (except when I got into boost, the ecm did not like that at all) I have a small vacuum leak somewhere because between shifts it is revving up some so I have to take another look at my breather setup. As far as idle and off boost though it is doing great, idles at 1500 cold once it warms up drops between 1000-800 like it should and purrs like a kitten on steroids haha.

[dna]

First startup

[dna]

Gauges wired in, welded in another 02 bung into my downpipe so I can run the factory 02 sensors. Started it up yesterday and so far no CEL's. Planning on finishing the exhaust soon.

[dna]

Couple month update, haven't been posting much due to lack of responses on here. Not sure if anyone even actually looks at this thread or i am talking to myself haha anyway, its now July 11th and I have been daily driving the car since early April around 40 miles a day. Car is running great, no CEL's so far, AFR's are looking pretty decent (still a little rich under boost) still running wastegate boost of 8psi. Car seems to respond really well to 8psi, although i am planning on buying a manual boost controller here soon and tuning it to 12psi. Not alot has changed since my last post, I finished my exhaust, ran coolant lines to the turbo and had to fix my intercooler piping due to it poping off all the time. Car still isn't perfect right now my exhaust hangs low because the stock wrx downpipe is a little to long for the BH, my plan is to get a ebay downpipe and shorten it about 2 1/2" that way it will go into the exhaust channel better. Also I never got around to re installing the door cards, my thought process on that is maybe if i wait long enough I i will find a nice set of outback door cards. Anyways that's about all i have for now, you guys have any questions just give me a shout.

[dna]

Ended up welding in a 1/2" bung for the oil return, i tried tapping my valve cover but after a few hundred miles it kept working itself loose and leaking.

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Few pictures of the hood scoop and with my buddies wrx.

[dna]

My Subi trio, BH leading the way!

[Go Mifune]

Oh we're reading your posts. I just don't have much to offer but appreciate all the detail and photos. Cool build and keep on posting!

[dna]

Oh we're reading your posts. I just don't have much to offer but appreciate all the detail and photos. Cool build and keep on posting!

Haha thanks man, I shall continue to post!

[dna]

So as I drive the car my desire to continue modding grows on, I'm planning on putting the car in the garage for a month or so to get a few things lined out. Here's a list...

-emanage is seeing crazy rpm input which is throwing off the tune.
-boost gauge is also highly inaccurate needs traced down.
-rear main seal is starting to leak worse which I believe lead to a clutch slip last week

Minor fixes but time consuming when you work full time and have a 1 year old daughter haha also I have been compiling a wish list of future mods on the car. Here they are...

-Lower the car on better suspension/ stiffen up the suspension over all.
-Wider wheels, better grippies, possibly fender flares? (Opinions needed)
-Some of them fancy bright headlights (my WV accent comes out)
-Standalone ecu (haltech, megasquirt or wrx ecu swap)
-Clean up my haggard exhaust

Of course there's more to come, I almost traded the car last week for a 1986 Toyota Corolla (AE86) hatchback SR20 Nissan swapped, All kinda mods done to it I could go on and on but I decided to keep the Wagon to much blood, sweat, and tears have gone into it. Although an 86 is one of my dream cars

[r3v_v3ng3]

Great job! Surpise you didn't go with parallel fuel setup to avoid bending your fuel line/regulator like that

[dna]

Great job! Surpise you didn't go with parallel fuel setup to avoid bending your fuel line/regulator like that

Thanks man! I probably would have went parallel if I wasn't so cheap haha. Also I had an extra fuel rail at the garage so I wasn't to worried about messing it up.

[dna]

So I found a 95 Impreza brighton (2-door coupe) that I should be picking up next week. Its in pretty rough shape engine wise but the body is solid. I have big plans for it (RHD, Ej20g just a teaser) so stayed tuned for updates. Also the wagon may be up for sale! Anyone interested in the BH?

[nepbug]

Man, i love this build, and I can totally relate on having a hard time doing some things with little kids at home. You don't want to miss a thing in their life so progress is slower than you'd like on projects sometimes.

Reading through what you've accomplished is getting me stoked to get back to my projects, even if I just put in 15 minutes here and there to slowly make progress.

[dna]

So I figured I should update my Legacy buddies on my new project, which I have name "Project Scrappy" So I found a 95 Impreza coupe, a body style I have wanted for a long time. Consequently the day after I picked up the Impreza, my buddy swapped out his EJ205 from his WRX so I picked it up to swap into the Impreza.


This is the day I picked up "Scrappy" (name fits it well) Pretty rough I know but the body is solid.


Here it is after the teardown began.


And here is the ej205 with 120k miles

I have a long road ahead of me with this build, so wish me luck. I've started a build thread over on RS25 simply because it is an Impreza and I feel bad to have it on here haha.
With that being said my wagon is still getting driven so I will continue to post about it. Also I have more parts then I know what to do with so if anyone needs anything just PM me and I will see if I have it. I will make a huge for sale thread soon I just have to take the time and post it up.

[dna]

Well the time has come for me to replace the brakes on the Legacy and I have a couple questions for you guys.
1. What is the best cheap factory brake upgrade, Outback, wrx, legacy GT?

2.Does the Legacy L and outrack have the same size rear brakes? I know the fronts are bigger

[Go Mifune]

I have the 2004 Legacy GT brakes which IIRC are the same as the 2004ish WRX fronts and the H6 upgrade rears. These added about 25 pounds of weight. Anyway, track tested and very happy with that combo on my '97 Legacy L. If you don't mind adding even more weight, the 2005 Legacy GT brakes are larger and add a vented rear disc. I think that the L and Outback rears are the same but best to get other opinions.

Edit- I didn't notice that your wagon is a 2003. If so then you already have my upgrade brakes and the 2005 Legacy GT brakes would be an upgrade for you.

[dna]

Awesome man thanks for the input, From looking around at different car part sites it looks like the L has a 270 mm Rotor, and 2 pot caliper. The GT or newer legacys and WRX has about a 290mm, so it should be a decent upgrade. I believe I am going to leave the rears as is for now because they are working okay, and maybe just switch to a performance pad.

[dna]

Well I ended up finding an awesome deal on some 05 legacy gt calipers. All 4 brackets, calipers and old pads for 250 with only 50k on the brakes they look basically new. Just for extra security I ordered a rebuild kit just in case and if it's not needed my old 2 pots are going on my impreza.

[dna]

Well I ended up finding an awesome deal on some 05 legacy gt calipers. All 4 brackets, calipers and old pads for 250 with only 50k on the brakes they look basically new. Just for extra security I ordered a rebuild kit just in case and if it's not needed my old 2 pots are going on my impreza.

BTW can anyone else see the pictures on this thread? They have quit working on my browser.

[Go Mifune]

First cool deal on the brakes! Second, yes your pics have disappeared.