My Gen 2 wagon project.

[Al]

After I sold my Gen 1 wagon I bought this wagon locally. Looked like this when I got it.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon001.jpg

I snapped up a set of 04 titanium WRX wheels for it and lowered it with super low wrx front and low Gen 2 sedan rears. Threw on a set of 277mm brakes as well.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon002.jpg

I wanted to build something a little different so I procured a GTB engine and box. The plan is to turf the twins and run an 03 JDM STI twin scroll turbo using a modified set of tuned ebay headers.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon003.jpg
http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon005.jpg
http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon006-1.jpg
http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon004.jpg

The up pipes from the headers were chopped of and seperated and two new pipes run up into a profile cut twin scroll flange. Pics to come.

In the meantime the car was caught in a hail storm and insurance partly paid for a respray with gold pearl added to the paint. I also added a rear wing, colour coded mirrors and sidestrips, TT Bonnet and an RX front bar.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/fezzawagon007.jpg

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/fezzawagon008.jpg

I got a set of R32 GTR callipers for a reasonable price and went about adpting them to the liberty hubs. These fit with 325mm STi brembo rotors. The adaptors were milled from a chunk of mild steel.
The rears are yet to be done as I haven't decided on a rotor size yet.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/fezzawagon012.jpg

They fit under 17" WRX wheels with a 6mm spacer and the Nissan machined off the calliper.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/fezzawagon010.jpg

I picked up a power FC, Z32 meter and undisclosed injectors(believed to be ~650cc).
The plan is to run the Z32 meter on the pressure side of the turbo at the outlet of the 100mm ebay intercooler. I am making a custom harness ATM to accomodate this and the 01WRX coils with built in ignitors(orignal ignitor is deleted). I will also move the boost solenoid and map sensor to tidy up the strut tower area.

I am hoping for ~200atw with a huge midrange from the twin scroll. There will be updates as I progress.

[scooby85]

u stole my wrx rims idea on the gen2 al! :P

[hendo]

Nice project Al.
I like the brakes, but are there any legal issues involved with running 6mm spacers in QLD?

[Fergo]

ahh so this is this beast you were talking about mounting the afm on the pressure side after I had that post about it.

keep us updated with plenty of pics.

[Al]

Nice project Al.
I like the brakes, but are there any legal issues involved with running 6mm spacers in QLD?

Probably, but moreso with using custom made brake brackets. They are For Offroad Use Only at this stage.

It's just an experiment to see if they are a better option then std 4 spots or Brembos or somewhere in between.

[Cruisin92]

Looking very nice there Al.

I've gotta ask.... why the relocation of the AFM and for what benefits?

[Al]

Stops "PFC Disease". Bigger turbos with direct intakes and airflow meters cause reversion problems with the afm. If you mount it on the pressure side there is no such issue. I don't think it is commonly done here but I thought I would try it and report. I will still leave provision for mounting it in guard though(There will be parallel wiring for the afm to either side of the engine bay).
I am going to contact Westwood from rexnet(and here) to discuss tuning at some stage.

The car looks OK atm but nothing special in the engine department. I want to do a lot more engine bay and wiring detailing on this car's build to showcase what amauto can do for customers.
And all without upsetting the minister for love and finance. :D

[so00be]

hey Al it looks tops!
just wondering did u use a vf36 or vf37? im looking at running a twin schroll on my my95 wrx motor.

[naif]

nice work AL, wil be great too see when it is done :wink: you seem to really like those GTB engines :D

[Al]

It's a 37, non ball bearing.
36's are rarer than 37's.
I believe the basic difference is the same as between 30 and 34 i.e. the bearings and a little response.

The exhaust flange is huge on these which makes it a bit tricky to twist mount and support. Not really a simple up pipe change that's for sure.

[LIBRT!]

nice work look forward to the completion cheers LIBRT!

[greecegun]

u stole my wrx rims idea on the gen2 al! :P My thoughts exactly!

[Az]

gen 2 + twin scroll = teh win?

[Al]

Here's a couple of pics of the twisted twin scroll work in progress.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagonengine001.jpg

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagonengine003.jpg

Dump pipe is a mockup.

[nick e[v]ans]

Looking good Al. 200kwatw in that wagon will be a nice little sleeper.

[Al]

Dave tells me he has an STi cut lined up for you in Japan Nick.

[naif]

that looks great Al, what size pipes are those for the up pipe?

i have been thinking of doing a twisted setup in my car, and i went and talked to the engineering shop who welded my fmic piping, they charge $55/h for welding/machineing etc aluminium. twisted TD05H here we come :wink:

[rs guy]

what more can i say Al

thats amazing :tu :D

[callan_01]

Update on your car Al ?! It may convince me to give you some more business!

[gradg]

Man i had no idea that was the engine sitting there when i was up there :P

Looks tops mate.

AM Auto make the werld spin.

[Tank Subie Wagon]

Hey AL have the same setup PFC with Z32 with mounted on the pressurised side of the turbo, after the intercooler, runs perfect between gear changes dont get agitated AFM and the restrictions of intake off the front of the GT3040, can send you some photos if you like mate. although its on a nissan lol

I figure if its tuned for where its located it shouldnt be a problem. good work its looking hot, you go with the gold pearl option through the green, how does it look in the sun?

cheers
Luke

[XXXR]

nice work champ! its looking goood!!

[SHEPPO3930]

always got time for your work Al

[Al]

Update. Finally got time to finish this car off. The PFC is long gone, as is the gearbox(webby's car) and engine(on loan) so I bought a complete GTB from Japan through BMI and had it chopped. It's done 115k km and looked in reasonable condition.

The twins are being used as wheel chocks and the twin scroll setup is on. Gave the engine some quick maintenance and some parallel rails and got stuck into removing the long suffering EJ22 and auto. Got the driveline and brakes all in today and the dash and wiring out.
Tomorrow is wiring in after fitting the alarm and modifying the loom for V3 Sti ecu then I'll get onto the exhaust and fmic.

Pics. I shielded the up pipe with ACL material. Will use the same for a brake and clutch master shield.


http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon001-1.jpg

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon004-1.jpg

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon005-1.jpg

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon006.jpg

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon007-1.jpg

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon008-1.jpg

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon009.jpg

[BJM]

Can't believe I didn't see this thread before now :eek:

Nice work Al :tu

[40southern]

Very impressed Al. Did you say your business was relocating to Tassie :-)

[smoov]

I rikey a rot!

[Datman]

looks good mate, cant wait to see how it goes with the twin scroll.
Mick

[Al]

Spent the last couple of days sorting out the harness and wiring in an alarm.

Kicked it in the guts this afternoon after dodgying up the afm to connect to the iac piping only. No exhaust, no intercooler, fired up first click.

Nothing much to show until I get the exhaust and intercooler done tomorrow and the next.

Here's a couple of pics of the custom wastegate actuator I had to make because I couldn't find the right one. It's a TFO35 diaphragm with a cut and shut TT 2ndary exhaust actuator rod.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon001-2.jpg

Here's the insturment cluster, everything works, just had to rejig the door open light as the Legacy has 5 seperate circuits but Liberty's only have one shared circuit.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon003-1.jpg

[SHEPPO3930]

nice, would be interested to see how this goes with the twinscroll turbo.

also, lovin the up pipe heat shielding, probably wont rattle i reckon!!

[BenTZ]

great work there al! may i ask why you went a twin scroll turbo rather than an aftermarket item?

[Nathan|RST|]

I wish I had a STi spare parts bin to play with.

[Al]

I'm covered in cut-off wheel smutz and burns, here's the exhaust.

Dump. Decided to go bellmouth on this one.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon001-3.jpg

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon002-1.jpg

Yes, I am going to shield everything around the turbo.

Rest of the exhaust.
Cat is 06 STi.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon003-2.jpg

They don't call them Super Drager's for nothing.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon004-2.jpg

Intercooler this arv.

[B-rad]

looking farking sweet AL by the way, i forgot to update you, coilpacks with joined ignitor outputs, no sweat!

[d_generate]

If you are using the stock V3 computer it will be interesting to see how it goes with this set up.

[Al]

Finished off the intercooler piping and a lot of fiddly stuff today and got it running and through it's first heat cycle at 4.30. It runs nicely and is very throttle responsive(RA ecu's usually are anyway). As expected, it doesn't have much boxer note, instead it has cackling extractor noises and a flatter tailpipe note. It still sounds good though, not like an SR or anything.

Front shot. Now has projectors and fogs all courtesy of the GTB donor car.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon001-4.jpg


Engine bay with pipes.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon002-2.jpg

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon003-3.jpg

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon004-3.jpg

I hid the pressure exchange and map sensor in the inner guard.

Rear shot, sans flash as my battery was low.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon006-2.jpg

Will dig out a shot of the GTB while still in Japan and post it later.

[SHEPPO3930]

probably sounds alot like the ol' nissan FJ20 turbo :D

looks really good Al, and i must say, it's nice to see you spending time on your own projects.

[Soop]

Al, your an artist.

[kunifa]

that is amazing al.
nice sticker on the back.
roughly what would it cost for you to do that to my car?

[Al]

Here's the GTB waiting for the knife in Yapan.

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/GTB.jpg

Kunifa - It'd prolly cost about $12k to do it with a twisted single scroll. More if you used a V3 STi cut as they are more expensive than the GTB. I have my hand up for more GTB's if they can get them.

[cruisEH]

Hey Al, looks awesome. that should be agorgeous car to drive.. you just got to get handy with a toothbrush and paintbrush and bucket of soapy water and give that bay a good tubs.. Will look as nice as the rest of the car then.. LOL Doesnt TOMO do detailing???

Fantastic work.. as always..

PS spoke to Matt, he will be in touch re freighting the dash..

[rs guy]

thats awesome work Al:tu

so thats what you do on your days off :)

[gradg]

Wikkid wikkid.... Jungle is massiv.

Looks beut Al, almost everything you post up makes me want to go FMIC....

[bosc0]

how rockin is that sticker!!! :)

[Al]

Very rockin Boscologist. :)

She's all done. Got a new radiator and a pair of hoses for it this morning and banged them in. Also got some 98 while I was out to dilute the pov fuel.

How's it go you say? Good, it is very torquey down low, pulls out of corners in the wrong gear really well. It comes on song at around 4K and goes like it should. It's running about 17 psi which drops off to about 15 in the high revs. I have read that this is common on twinscrolls, likely due to the twin gates in the exhaust housing being more efficient.
It's quite different to the power delivery of most other EJ20 turbos in that it doesn't hit like a ton of bricks at a certain rpm. I'm finding it hard to describe, much like most rexnet guys that have gone twinscroll.

The rest of the car is great, handles good with the Bilsteins, low springs and GTB bars and steers nice without the stupid variable rack(has a V2 STi rack).
The GTB seats are 1000 times better than the GX seats too.

Here's a couple of finished engine shots after I cleaned the bay for Paul. :D

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon001-5.jpg

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon002-3.jpg

http://i65.photobucket.com/albums/h219/AL_RS/Fezzawagon/Fezzawagon004-4.jpg

Success, now who wants to buy it so I can finish that 2J VK before fossil fuels no longer exist.

[SubbyRS]

']Success, now who wants to buy it so I can finish that 2J VK before fossil fuels no longer exist.
I would love to buy it Al, seriously.....PM me the $$$ if you don't want to post.

[Al]

$17k. Based on the vehicles unmodified value and how much it would cost for us to do the work. We are building an RX sedan with all the same gear bar the twin scroll shortly as well.

[cruisEH]

Al thats a lovely looking machine.. Someones going to be very happy with it..:D

whats the stuff you are using as heat shielding, and where did you source it?? I could use some of that :D

time for a well earned coldie :P

[Al]

It's ACL heat shield material. You can get it from any parts shop. Comes in a 300x600 sheet for about $70. It can be moulded into any shape you want if you have the patience.

[nick e[v]ans]

Sexytime Al. $17k for the wagon yeh?? That's pretty damn good value.

Is the power delivery similar to an 05 GT lib? Is there an easy way to get the turbo to hold boost to redline without replacing it? EBC?

You reckon it makes the 200kw you were estimating?

[Al]

Getting it to hold boost would be no probs with an ebc. The ecu controlled solenoid is tuned for a completely different turbo and intake/exhaust system so it is not surprising that it isn't quite right.

It's not making 200atw atm, needs a lot more boost for that. 180 would be fine for a nice fast streeter, it should do that with 18psi.

[so00be]

looks good Al!!! good to see it finished. so the vf37 is the bushed twin schroll hey? is the vf36 the same but ball bearing?

[Al]

Yep, VF37 = twin scroll 30/35. VF36 = twin scroll 34.

[bosc0]

']It's ACL heat shield material. You can get it from any parts shop. Comes in a 300x600 sheet for about $70. It can be moulded into any shape you want if you have the patience.

I was going to resort to stealing some off the VE Ute out the back until i real the above... i haven't been able to find it anywhere.
Bursons?

[Al]

We get it from coventry which is like Bursons. Google is your friend. http://www.aclperformance.com.au/prod_heatshield.htm

[bosc0]

i love goog's....

[4ce_full]

the ACL heatshield stuff should be available at your local supercheap store, located in the gaskets/brakes aisle, thats providing the store layouts are the same (they should be), like al said about $60 for a pack i think.

[so00be]

any sound clips to post up?? im sure lots of us would like to see how it sounds. or an in car vid lol...

[nick e[v]ans]

+1

Don't think i've heard a decent EJ20 twin scroll with an exhaust before.

[Al]

The wagon has a new owner as of tonight. A mate of GradG's, Adam, took delivery of it this afternoon. Hope he enjoys driving/owning it. I was happy with how it turned out but it's time to move on so I have bought an identical 97 green GX wagon auto, only this one is std. I like variety.

Have fun Adam.

[Mouse]

do you plan on modifying this one?

[rs guy]

i think he will

cant help himself :tu

good work Al

[Al]

do you plan on modifying this one?

No, but I probably will anyway.

[el capitan]

Hi all what is that bov you are using it looks like a mitsubishi item?

[Al]

It's a 97/8 WRX Bov. They work really well. Absolutely zero compressor noise(flutter). I think it is a mitsubishi design. When I first got the engine running I was checking turbo oil supply because of the lack of noise from the turbo when free revving it. Every other setup we had done with no or aftermarket bov resulted in loads of compressor noise so I had to make sure the turbo was still spinning. :)

I'm having stupid thoughts about H6 NA's in the new wagon.

[gradg]

The car made it home safe Al :) Adam is more than pleased, he's a forum member but has only been reading. So i dare say a few of the QLD members will see it out and about.

Had to stop by the servo and plug in the LHS headlight in mine tho :P haha which i noticed after the sun had well and truely gone down :P