Levy's 98 2.5GT boost build

[NZXTInerTia]

So every time I go to make one of these build logs I always try and put this big introduction to how I got the car, etc. so this time I'll keep it simple so I can actually keep you guys updated.

Bought the car with a blown motor, dropped my rebuilt EJ25D in it (Rebuilt 2/10/2015), and converted it to a 5MT when the 4EAT stopped shifting.

I'm building a custom up pipe for my Borla Rep UEL headers, stock WRX turbo, cheap eBay down pipe, WRX intercooler, at 5PSI. I have another EJ25D block on standby so I'm ready when this one acts up. My eventual plan is a EJ22/EJ25 hybrid motor for boost.

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[foohfooh]

Nice headlights and fog setup. What did you retrofit those headlights with if you dont mind me askin?

[NZXTInerTia]

Nice headlights and fog setup. What did you retrofit those headlights with if you dont mind me askin?

They're Morimoto MH1 Retrofits with 6000K bulbs, 35w Ballasts, and a Morimoto MotoControl to run them. I make custom headlights so it was a must.

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[M@D H@TTER]

They're Morimoto MH1 Retrofits with 6000K bulbs, 35w Ballasts, and a Morimoto MotoControl to run them. I make custom headlights so it was a must.

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What would you charge for a setup like that? I'm curious about my options for upgrading my '97 Outback's lights (aside from JDM swaps).

[NZXTInerTia]

What would you charge for a setup like that? I'm curious about my options for upgrading my '97 Outback's lights (aside from JDM swaps).

The JDM headlights in stock form are easily just as bad as the factory halogen reflector headlights. Typically a build goes like this.

Projectors ~$135
Bulbs/Ballast/Relay ~$150
Paint/Custom shrouds ~$35
Labor can be anywhere from $150-$300 depending on how much is done with the build.

Then of course I'd need your lights to work with.


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[Tylerhartman]

Them headlights are sweet, I'm so torn between Retrofits or JDM's. I love The TRS Morimoto Mini H1's, I did a Custom retrofit on my Honda Element and haven't regretted it. Great lookin' wagon, Subbed for updates ;)

[NZXTInerTia]

Them headlights are sweet, I'm so torn between Retrofits or JDM's. I love The TRS Morimoto Mini H1's, I did a Custom retrofit on my Honda Element and haven't regretted it. Great lookin' wagon, Subbed for updates ;)

The problem with the JDM headlights is they have incorrect output for US streets. A Morimoto FXR can be swapped into a set for kick ass results. These are retrofit brackets made by Custom Brackets and Designs. https://sl-i.net/FORUM/images/imported/2015/12/685c4c1cc4c0f296e4af60689abfab50-1.jpg


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[NZXTInerTia]

Got my snail today. Stock 04 WRX turbo. The rotated housing one is good, the stock one is blown. So I'll take the WG and compressor housing off the blown turbo and mate it with the good CHRA. https://sl-i.net/FORUM/images/imported/2015/12/00f86b61f2db47b2a61e06e67e52b647-1.jpg


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[NZXTInerTia]

Decided to do some work with my corner lights tonight. They didn't match my headlights very well. These will have Morimoto switchback LEDs that will eventually be in conjunction with the Halos I'll be adding when I redo my housings.

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[NZXTInerTia]

So, slowly I collect parts for my turbo setup. Stock WRX header, stock WRX up-pipe, STi downpipe, and got a Y-pipe for my TMIC. Also picked up a cheap boost gauge.

Need a water pump and a few other bits. https://sl-i.net/FORUM/images/imported/2015/12/ba45305c8b807e18ea176ca9a87a81fe-1.jpghttps://sl-i.net/FORUM/images/imported/2015/12/bbbc65bb68d3db1ee208f4458d0251e4-1.jpg


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[NZXTInerTia]

Short of finding a bolt hole I'll have to helicoil, Y-pipe is installed. And I dug up a water pump, I got it from O'Reilly from an error in their system. (I work for them for one of my jobs). Now I'm basically down to hardware, small bits like bolts and gaskets.

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[NZXTInerTia]

Made one stock turbo out of my two, shaved down my throttle body, fixed my TMIC tonight. I'll start shaving/preparing my spare phase 2 intake manifold tomorrow. I'm also probably going to completely cut out and weld the BPV flange flat to clear my throttle cable pulleys.

All and all, a productive night. Soon I'll be bolting a blown EJ25D to my stand, so I can test fit everything before tearing my car apart.

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[grayguy]

I'm glad you got the Jesus clip off lol

[NZXTInerTia]

I'm glad you got the Jesus clip off lol

I was quite proud of that little pliers I toasted up and bent to make it work lol

In other news, this upcoming Friday is surgery day, when everything gets pulled apart!

Hardware was acquired today! https://sl-i.net/FORUM/images/imported/2015/12/fbeff0434082db1c85a57d9f50670134-1.jpg


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[Shaz]

Nice one mate, look forward to seeing how it all goes!

[NZXTInerTia]

Little more hardware tonight. Picked up the 90 degree fitting for my oil return, oil return hose (yes its petroleum rated), and I shaved my throttle body down a tiny bit more. Then my oil feed line came in the mail, so that's cool.

My schedule goes as such, Tuesday I'll be driving to see a friend about 150 miles away to get my up-pipe, Wednesday I'll be visiting GrimmSpeed to get all my exhaust gaskets, cherry blossom red paint, and a few other small knick knacks along with pulling my stock airbox, and notching my pitch stop mount for my TMIC. Then comes Friday morning, surgery day. That's when I hope to have everything pulled apart and done!

My goal is one day, morning to close. My realistic goal is 2/3 days.

My intake is figured out, so that's ready to go. And I also picked up an E-clip, because I needed one.

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Oh, and we got 6" of snow this morning.

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[NZXTInerTia]

Well, in the ever extensive venture to get everything to fit as smoothly as possible, I cut off my BPV flange and will have it welded flat tomorrow. While I was at it I shaved off about 1/4 off the intercooler outlet. I also got my fitting threaded into my valve cover for the oil return hose.

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[NZXTInerTia]

TMIC is in the shop and we be welded tomorrow morning! Pictures to follow.


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[Shaz]

You going to paint the valve covers or just leave them as is?

[NZXTInerTia]

You going to paint the valve covers or just leave them as is?

As turbo yoda said in the gramps build. Aluminum is fine lol.


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[Shaz]

Haha fair enough mate. At least give them a good clean!

[NZXTInerTia]

Haha fair enough mate. At least give them a good clean!

Yes, definitely. After I installed the 90 elbow for the oil drain I scrubbed it down a good bit.


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[Strykr]

Build looks good so far! Keep up the good work!

[NZXTInerTia]

I forgot to pick up my intercooler from my welded before my six hour trip north. So, I'll pick that up tomorrow.

But, I got an up-pipe, and a thermostat housing! $20!

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[grayguy]

I like the pile of parts in the back, I didn't realize you had all of it with you haha

[NZXTInerTia]

I like the pile of parts in the back, I didn't realize you had all of it with you haha

I'm taking it to my buddy's house tonight, so the picture just felt necessary haha. I still have to cram my cherry picker, and ~10 slabs of card board in there haha.


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[NZXTInerTia]

All done! Off to GrimmSpeed for gaskets.

https://sl-i.net/FORUM/images/imported/2015/12/fe9d08556a9c7f7fd2e0b960ca15755d-1.jpg


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[NZXTInerTia]

And, GrimmSpeed gaskets. These are awesome quality, extremely thick. Definitely worth the money, my dad came with me so I got local and military discount.

https://sl-i.net/FORUM/images/imported/2015/12/52f594ad6ad665602642d420bd8f84ce-1.jpg


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[Strykr]

All these years dealing with them and I didn't know they had Mil discount.. :/ LOL

[NZXTInerTia]

All these years dealing with them and I didn't know they had Mil discount.. :/ LOL

I was pleasantly surprised.

Also, clearance pictures.

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[Strykr]

Wow that's close, you measure 20 times than cut or was that luck to be that close lol. How's it fit with the torquebox / intercooler support u-bar?

[NZXTInerTia]

Wow that's close, you measure 20 times than cut or was that luck to be that close lol. How's it fit with the torquebox / intercooler support u-bar?

That was a few measurements, and then some guessing lol. I have no idea about the u-bar, since I've removed it due to the manual trans having a different bracket.

I also did this, so that's cool.

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[NZXTInerTia]

Ignore this page

[NZXTInerTia]

Last final touches. Going to my buddy's heated garage tomorrow at ~7am.

Plugged the emissions junk ports on the TB, and I'll be deleting the EGR. Which is already removed, I just have it pulling clean air. So that should clear a good bit of space.

I also think I'll be doing the fuel injection direct feed mod or whatever. To have both rails fed fuel evenly, it will be easy to remove the intake with the engine out. So I may as well to ensure the longevity of the build.

I also talked my friend with a 2.1 Stroker WRX into "selling me" his STi Y-pipe in case my stock one doesn't fit. So that's a plus, because I can extend that one slightly.

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[NZXTInerTia]

Super, super busy three days. Here's a teaser! I'll give you guys a full rundown tomorrow.

https://sl-i.net/FORUM/images/imported/2016/01/947c6c3df81d7cebf47aefc6d4fbfe44-1.jpg


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[Strykr]

Looks like it's nearly complete from what I can see from the picture. Congrats and hope it's a blast to drive, definitely jealous I can't wait to get my build together!

[NZXTInerTia]

So here it is! My 2.5GT-T!

The build was completed in three days flat, it would have been two, but I'm a complete and utter idiot and messed some things up, and wasted a good bit of time on others.

So before I get into detail, let me tell you everything that I didn't do, that I wish I would have done.

First being the wiring harness, it needs to be moved off the passenger side of the engine, to the center of the engine, something that can't be done easily without modification. I ended up extending the oil sending unit, and temperature sensor unit wires, wrapped the whole harness in heat resistant tape "Cool Tape" was the brand name, and routed it underneath the water pipe. I still have my spare 98 Intake Manifold that will have the EGR flange cut and welded shut, along with being shaved, and painted cherry blossom red. I also have the original wiring harness from the engine that came out of the 98. This harness will be completely stripped down to wires, completely extended by about 5", and each sensor wire will be individually wrapped. I'm pretty damn anal about wiring, so the harness will be done very professional and clean looking.

Second, I wish I would have done the wiring harness, because that would have cleared the 50/50 fuel rail mod that I was going to do. Something I fiddled with for about three hours before quitting and installing the factory hardlines back in place. When my new fancy intake gets installed, this will be done, and will be thought out a lot better.

So, now that that's covered I'll go into detail.

First thing that happened was the engine got taken out. I had the engine pulled in about 40 minutes. I pulled every single piece of top hardware, went under the car, and removed every bit of bottom hardware. Doing it this way saved me all the timing of going up, down, up, down, and so on. We've been pulling Subaru engines since the 80s, so I doubt this is any news to anyone but myself, I just thought I'd share how efficient this way was.

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I then installed my turbo water pump, if you can pull an engine and turbo your car, trust me, you can pull the belts and instal a turbo water pump. OEM or NO-EM as I say, that's why I went this route instead of a header that would fit an M/A water pump.

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Belt installed. Now here's the absolute STUPID part.... :sad2:

I used the wrong timing mark on the crank. Everything was aligned perfectly, and I've done numerous Subaru timing belts both SOHC and DOHC. For some reason, in my mind, I thought the arrow on the pulley was TDC, and completely skipped past the mark on the striker plate behind it.. I cranked it a few times like this two. Then had to pull it apart a second time, fix the timing, and it ran flawlessly. Thank GOD I didn't damage anything, I would have been crushed on top of feeling stupid as is! Ha! So learn from me, and repeat after me. Keyway down, Arrow right, notch up! Yay! :hello1:

https://sl-i.net/FORUM/images/imported/2016/01/5e9450c2c871dc0d6a42a81f712bfd0c-1.jpg

A comparison of the stock throttle body to my modified one.

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Starting to take shape.

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I then drilled, and welded my 02 bung into the up-pipe, and bolted that on. I also made a support bracket, that pushed the turbo back as much as the stock flex pipe would allow before being too strenuous on the joint. You can somewhat see how I mounted the O2 sensor, it sits above the subframe, and is a good location for a sensor if you're using a T-Leg header like I am, which doesn't have the bung for the O2. The wiring for the sensor was wired up to the top of the engine with the rest of the harness. Making it all plug and play, easy peasy.

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Here's a picture of the rerouted, slightly modified, wiring harness. You can "kinda" see how its routed to clear everything. Yes the chassis side of the harness reached with no problems.

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Take note, the stock WRX Y-pipe will not work. Don't even try it. Even with a super short throttle body, it just was way too stiff and way too short. It didn't even come close. My best friend, where the build was being done, was super generous, and let me "buy" his STi Y-pipe since his car is parked for the winter. This fit with zero modification, minus the shortened throttle body. Although its a little tricky to get on, I will just have my welder weld on an extra 2" or so on the STi Y-pipe, which will make things all around easier.

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I then ran to the store and got two P-traps, they had these super tight bend angles on them, so they were perfect. Notice the hose running to the top, this is what I used for my idle valve, it is 1/2" pipe. THIS IS TOO SMALL FOR THE STOCK SETUP AND WILL RESULT IN THE ENGINE CHOKING FOR AIR!! The whole setup is being replaced tomorrow morning, with 3/4" pipe with a LOT less bends and a LOT more airflow, similar to the stock setup. The existing barb will be using for the case breather setup that I will be working on. For now the PCV system is completely plugged, and the case breathers are venting to atmosphere.

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Then my girlfriend fell asleep, I never quite figured out how, since I was making quite the racket with the grinder.

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I then notched my subframe. This is only temporary until I can find a T-Leg one, or remove, and heavily modify/reinforce my spare one on my parts car. I had to stab and pull the engine four different times because my notch measurements were not accurate to a STOCK Up-pipe. The measurements used were from a car equipped with A: An Outback with Subframe Spacers, and B: A much smaller invidia Up-pipe. Finally, the engine was dropped in. Same method of doing all the bottom parts, and then all the top parts.

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[Strykr]

Congrats!! She looks good in the bay:)

[NZXTInerTia]

So. I fixed this stupid idle/misfire issue I've been having. Apparently the stock intake manifold ground doesn't like being moved, so I put it back in the factory location and it runs flawlessly. So that's cool. I also installed some 6 heat range plugs (colder), and warrantied my spark plug wires since they've been pulled apart a few times. The idle hose setup was also changed for the better. Then for shits and giggles I stuck the fuel filter from my parts car in it, the filter only had about 200 miles on it so why not. Seemed to flow a bit better.

Next thing to conquer is going to be a catch can setup.

https://sl-i.net/FORUM/images/imported/2016/01/f0356e86d82c96a969a97de19d73e247-1.jpg

BKR5EIX-11 that was in the car.

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[NZXTInerTia]

So it's snowed about six inches here and it's about -7f here. Block heater is plugged in, and I'm driving four hours tomorrow. So it will be a nice test of the reliability of this build.

I also replaced my PCV with a vacuum barb, and I removed the plug above the stock vacuum port, and added another barb. My MAP sensor, boost gauge, and FPR are now all on their own vacuum sources. Sadly when I was doing this, and realized my boost gauge nylon hose had come loose from the T, and was leaking. So I've been pushing 7-8psi the last four days or so, so that was a little upsetting. Everything is now hooked up solid, and I have a check valve in my MAP sensor line to bleed off some boost.

I'll be picking up a wideband gauge, and a 2.5" stainless cat-axle exhaust pipe that I'll make my own axle-back for. So that will bring this build farther towards completion, for now.

https://sl-i.net/FORUM/images/imported/2016/01/a6f0df4ac83a05c4364692aa3b5eae70-1.jpg


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[BDAlex95]

Coming along very nicely, is there anything done to the motor? Aside from a rebuild.

[NZXTInerTia]

Coming along very nicely, is there anything done to the motor? Aside from a rebuild.

Nope, it is a bone stock, 130k, new head gasket engine.


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[NZXTInerTia]

I got some professional pictures taken by a close friend of mine that drove up from Indiana (to Minnesota). Enjoy!

https://sl-i.net/FORUM/images/imported/2016/01/d5f2e57ccfe3d134230ed50308b134ea-1.jpg
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So, it's cold here. -12f and -25f after wind chill. I have my car plugged in, lol.

Things have been slow since its been cold so things haven't really been progressing much. I took out my plugs and gapped them to the WRX range .026, and I removed my roof rack. I've decided to cut my pre-cat in lieu of my AEM UEGO that will be installed in the up-pipe more than likely. I also need to rethink my oil drain, and seal up a leak in the fitting itself.

I acquired an STi mid pipe, and will be making a custom axle back for it soon. I also got a WRX breather pipe for free, so I can finally setup my case breathers.

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As a nice little side bordem project, I disassembled my damaged heads V2 EJ25D that came in the GT, this will eventually be paired with the V1 heads for an 8.8:1 compression, for a good daily driven 7psi car. You can see the seized cogged idler pulley that caused the timing failure.

https://sl-i.net/FORUM/images/imported/2016/01/04de8372ca0c7952df4eeae975980bad-1.jpg
https://sl-i.net/FORUM/images/imported/2016/01/8ae219c902108faae55ecb0d27eff701-1.jpg
https://sl-i.net/FORUM/images/imported/2016/01/b75cce8ad0a385f843690e3b5538f5de-1.jpg

Both sides of the engine soaked in gear lube for a day to prevent rust before wrapping and storing.

https://sl-i.net/FORUM/images/imported/2016/01/3a663522ddf599c3e2ea5a6f217cf14e-1.jpg


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[NZXTInerTia]

Little update. Got creative and mounted my new gauges down below the radio bezel. I'm pretty content with this placement, it helps with the stealthiness. The vent mounted gauge will be returned (since it's cheap junk), and I'll be replacing my stock vent.

Otherwise, I gutted my pre-cat in preparation of my wideband, and fixed a small oil leak I had out of my oil drain fitting. I also picked up a 2"-2.5" 90 degree coupler that will replace the temporary PVC setup.

https://sl-i.net/FORUM/images/imported/2016/01/2b59a8b3fc5da94293e12b6728dcd718-1.jpghttps://sl-i.net/FORUM/images/imported/2016/01/712809ea7447791bcecaab57b3e2ecd5-1.jpg


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[NZXTInerTia]

Finally, my coupler came and I got the enthusiasm to get creative. I finally have a proper intake, and tell yah what, if this didn't increase the performance tenfold. That PVC must have been so restrictive, I can't even comprehend the difference. So, if you're doing an N/A-T. Prioritize a proper intake!

https://sl-i.net/FORUM/images/imported/2016/01/c874c93ef31c6249171797e3638daf12-1.jpg

I also started to get the case breathers organized. These will be running to a catch can as mentioned earlier.



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[redboat]

car looks really good

[NZXTInerTia]

car looks really good

Thank you!

Sorry I haven't been more active guys, I broke my iPhone 5S, which I have Tapatalk installed on. That's normally how I update this, upload pictures, etc. I also am moving, and got a new job making a ton more money!

So for a quickie update.
Catch can has been installed
Downpipe has been shortened
Wideband has been installed
AEM Tru-Boost has been installed
BC coils have been purchased
And I have a wicked set of headlights to show you guys.

Carry on.