My '99 RS coupe swap project

[Danny Boy]

I went to the swap meet today up in Maine and met a bunch of NES guys, so I figured I'd post up some pictures of my project.

I've got a '99 RS coupe that used to be N/A with Cams. Now I'm putting an EJ205 into the RS.

Anyway, on to the pictures.

1999 STM Subaru Impreza 2.5RS

http://i247.photobucket.com/albums/gg137/dannyboy7777/DSC_0732.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/DSC_0729.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/DSC_0258.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/CIMG0400-1.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_0308.jpg

How the engine looks now:
http://i247.photobucket.com/albums/gg137/dannyboy7777/Picture005-4.jpg


I still need to wire it all up and reinstall the interior. Hopefully starting it up before December.


>>List of Modifications<<
Engine
EJ205 motor
Helix Up pipe
BPM GT series turbo back exhaust
Cobb Tuning battery tie down
Cusco motor mounts
Cusco tranny mount
Exedy LW flywheel
ACT HD pressure plate and street clutch disc

Suspension & Brakes
Megan Racing Coilovers
20mm FHI Rear sway bar
Kartboy solid rear sway bar end links
Kartboy Exhaust hangers
’06 WRX 4-pot/2-pot brakes with ’06 rear hubs
Agency Power SS brake lines
Motul RBF600 Factory line DOT 4 racing brake fluid
Hawk HP+ brake pads
RacingBrake rotors
Paranoid Fabrications Front Fender Braces
Rear Camber bolts
Corner weighted

Drivetrain
Kartboy Short Shifter
Cobb Tuning hardened shifter bushings
JDM V2 or V3 WRX Mechanical Rear LSD (Installed at 76,xxx miles. LSD had 36,482 miles.)
JDM mLSD rear axle shafts
Kartboy Rear Diff / Cross-Member Bushings

Interior
JDM V6 STi front seats
Scroth Rallye-4 harness (black)
Kartboy Shift Knob (black with custom red under shift pattern)
Rubber accordion shift boot
Alpine CDA-9856 head unit
Pioneer TS-D161R 6.5” rear deck speakers
Infinity Reference 6012si 6.5” front door speakers
Trunk light kit
Prodrive Floor Mats
Painted roof liner and other roof pieces and controls black
Trunk Lift springs from a wingless Impreza L

Body/Lighting/Electronics
Removed OEM navigation pack (replaced with center pop-up compartment)
Removed OEM remote entry and alarm system
Hella Supertones painted flat black mounted in the grill
Amber corners
JDM Taillights
Version 5/6 JDM replica front lip
Painted side skirts
JDM rear spats
Debadged SUBARU on trunk
35% Tint all around
Rolled front and rear fenders
Pounded out inner rear fender dimples
Wingless
Impreza L 3rd brake light
Removed stock fog lights
Replica JDM V5/6 Fog light covers
Painted hood vents completely STM
Bumper vents painted STM


Wheels & Tires
Winter: 205/55/R16 Dunlop Winter Sport M3’s on OEM 16”x7” 5-spoke’s
Summer: 225/45/17 Dunlop Direzza Sport Z1 Star Specs on 17”x8” +45mm Black Enkei RPF1’s

[bratman18]

Looks great!! I bet the swap was a lot of work. Can't wait to see it up and running!!

[jmb1983]

:munch:

[Danny Boy]

Looks great!! I bet the swap was a lot of work. Can't wait to see it up and running!!

It's not done yet, but it's been about 2 months so far of working on it all the time. It'll be worth it tho. :)

[bratman18]

Yes it will!! I always wanted to do this to mine, but never had the place, time, or money. I love turbo swapped GC's!!

[Danny Boy]

Yes it will!! I always wanted to do this to mine, but never had the place, time, or money. I love turbo swapped GC's!!

It's something I've wanted to do pretty much since I bought the car 4 years ago. And then blowing the headgaskets in the old motor seemed like a good excuse to go turbo. :devil:

I'm just thankful my parents let me leave my projects on jackstands in their garage for months on end.

[jessickascarling]

wow your car is going to look great when it's completed!

[RCKSTR]

:welcome: to the forum man, great looking swap!!

[Danny Boy]

wow your car is going to look great when it's completed!
That's the plan!

:welcome: to the forum man, great looking swap!!
Thanks, I'm actually surprised I never really heard about this forum before. I come from the RS25 and nasioc forums.


Speaking of which, if you want to check out my build thread over on rs25.com, here's the link:
http://www.rs25.com/forums/f145/t68813-danny-boys-silver-rs-coupe-beginning-til-now.html

[SF5boost]

car looks amazing. cant wait to put my motor back in.

[apkarian100]

Welcome to NES! I've followed your build on RS25. Really nice! Hope to see you at some meets.

[Seraphinwolf]

Oh! I knew I'd seen those first two pics before! Tim's "Never Back Down, Never Give In" thread on RS25.com
Look'n good dude!

[Danny Boy]

Oh! I knew I'd seen those first two pics before! Tim's "Never Back Down, Never Give In" thread on RS25.com
Look'n good dude!

Yeah, that's an epic thread. Those pics have been floating around for a while. There's nothing like borrowing a DSLR put on auto settings and having it take better pictures that you'd imagine possible. :lol:

[Seraphinwolf]

Yeah, that's an epic thread. Those pics have been floating around for a while. There's nothing like borrowing a DSLR put on auto settings and having it take better pictures that you'd imagine possible. :lol:
Yeah they deff look good. I need to clean up the car and get the paint situated to even think of pictures of the wagon... the SVX... needs paint redone and acorn dents removed. :unamused:

[mdungelman]

Great car man. When do you hope to have it on the road?

[squeethebee]

Car looks great man! Love swapped GC's, oh wait, that's why I am building one too!! I think yours looks hot on those wheels though man, my favorite ever!!

ed

[Oscar_Meyer]

these threads are neato.... I wish I had the patience to do this to my RS...

[Subygirl8330]

great project!

[Danny Boy]

Great car man. When do you hope to have it on the road?
Thanksgiving time hopefully.

these threads are neato.... I wish I had the patience to do this to my RS...
I'm actually surprised that I do have the patience. :lol:

[Danny Boy]

I finally got the swap running!

It idles now but dies/stumbles with throttle input. Also has some CELs. It's almost there now. :)


http://i247.photobucket.com/albums/gg137/dannyboy7777/th_MVI_0839.jpg (http://s247.photobucket.com/albums/gg137/dannyboy7777/?action=view&current=MVI_0839.flv)

[Oscar_Meyer]

I have discovered UR secret amongst the rubble of parts, tools and garage storage... NOT the big blue cooler probably pre-loaded with his favorite meds..

http://i247.photobucket.com/albums/gg137/dannyboy7777/CIMG0400-1.jpg

Again with the great job on the RS....

[squeethebee]

Dude, that is SICK. I can't wait to start mine up and start working out the bugs too!

ed

[Danny Boy]

I have discovered UR secret amongst the rubble of parts, tools and garage storage... NOT the big blue cooler probably pre-loaded with his favorite meds..

Again with the great job on the RS....
Thanks! The cooler is my go to stool when working in the garage. Makes getting that next beer a lot easier. :)

Dude, that is SICK. I can't wait to start mine up and start working out the bugs too!

ed

Good luck!

I've got Matt Miner from Wicked Inovations (So. RI) coming by today to help me debug the car. He's also tuning the car but I doubt we'll get that far today.

[squeethebee]

Thanks a lot, Good luck with getting everything figured out, hopefully its something simple!

ed

[bratman18]

Awesome, congrats!!

[Danny Boy]

Turns out the ECU was tuned for 20 lbs of boost and 650cc injectors. With a stock map flashed on it, the car runs a lot better. The MAF is confirmed to be wired correctly. It still hunts at idle and there are issues with the TPS, IACV, and TGVs.

CELs:
1086
1088
1089
1491
0122
0508

I'm going to attempt to figure out what's actually wront going pin by pin for these components. All indications seem to be that the wiring is screwy though.

[RCKSTR]

sounds like progress to me :up: not too much longer and you'll finally be able to enjoy all the hard work :devil:

[Danny Boy]

A little update for you guys.

I had the RS towed to ECS because I couldn't figure out the electrical issues.

ECS found a pin on one of the main engine connectors wasn't making proper contact. That solved all the CELs. However, they also discovered that the block was trashed.

They're taking care of me though and are rebuilding a different shortblock for me. Hopefully it'll be back and better than ever in a few weeks. :)

[bratman18]

Well that's good and bad!! Good to hear everything is getting worked out!! Pics when it's done!!

[squeethebee]

What do you mean by trashed? You staying 2.0, or building a 2.5??

ed

[Danny Boy]

staying 2.0

It was not salvageable because of deep scratches in the cylinder walls.

[Bu11dogg2]

I love your car :)

You should def enter it into the "ride of the month" once it's done :)

[Danny Boy]

Thanks!

There's still a few more things it needs before I'd consider it worthy for ride of the month though.

I'm trying to source a JDM rear seat and will reupholster the doors to match the seats.

I also want a bigger rear sway bar and a new front lip.


I picked up a Bosal/SPT twin tip axle back exhaust yesterday also that I need to install later on.

[Berge56]

Looks great dude! Can't wait to see some finished pics!

[Danny Boy]

She's all back together and running well. Just need to get tuned now. :)


http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_0854.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_0856.jpg

[RCKSTR]

look'n good :up:

[SubyFr3ak]

We'll have to do a swapped suby meet :lol: seems to be a lot of them on here now :p

[Danny Boy]

look'n good :up:
Thanks!

We'll have to do a swapped suby meet :lol: seems to be a lot of them on here now :p
That would be awesome. I don't see hardly any GC's let alone swapped ones in my area.

[SubyFr3ak]

That would be awesome. I don't see hardly any GC's let alone swapped ones in my area.

Well, I think there are 4 between me and Burlington up my way :p

[Bu11dogg2]

Who's doing the final tune?

[02bugeyeoutback]

Looks great:D

[Danny Boy]

Matt Miner of Wicked Innovations (Rhode Island) is doing an open source road tune for me.

[snownick]

Looks great man! Luving the GC's!

[Danny Boy]

So there has been another setback.

The motor spun bearing(s) around 2000 miles after the SB got rebuilt. I'm in the process of figuring out what happens next.


bad noises:
http://i247.photobucket.com/albums/gg137/dannyboy7777/th_MVI_0879.jpg (http://s247.photobucket.com/albums/gg137/dannyboy7777/?action=view&current=MVI_0879.flv)

glittery oil:
http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_0887.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_0890.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_0891.jpg

[squeethebee]

It took me until that last pic to figure out your problem, needs more FMIC!

In all seriousness, I believe tacoornot on here posted a good condition 2.0 short block, that would get you back running real quick if you didn't want to rebuild your current block.

ed

[Danny Boy]

It took me until that last pic to figure out your problem, needs more FMIC!

In all seriousness, I believe tacoornot on here posted a good condition 2.0 short block, that would get you back running real quick if you didn't want to rebuild your current block.

ed

:lol: My car looks really out of place without a FMIC parked there.


I may be interested in that SB, but first I'm waiting on ECS. I towed the car back down to them to tear down the motor. I'll find out soon enough what they are willing/not willing to cover.

[Danny Boy]

I haven't been on here in a while and the RS still doesn't run, but should very soon. I'll have to make it to a NES meet once she runs again. Can't wait to not have to drive my Taurus everyday


EJ257 / EJ205 Hybrid here I come!

[Berge56]

hybrid FTW! Are you having your 2.0 heads machined to fit the 2.5 block?

[Danny Boy]

I was going to but machine shops were giving me a large headache and were taking waay to long, so I had the heads pulled from there. Decided to just use a thicker EJ25D headgasket. Should be fine with the levels of boost I plan on running.

[Berge56]

I was going to but machine shops were giving me a large headache and were taking waay to long, so I had the heads pulled from there. Decided to just use a thicker EJ25D headgasket. Should be fine with the levels of boost I plan on running.

What head shop were you using? Honestly the larger head gasker is only going to cause you big issues down the road. First your car will be more likely to detonate, headgasket will be more likely to fail and the heads will not flow correctly since the combustion chamber is not matched.

Any good tuner/engine builder will tell you to not use thicker head gaskets. I just don't want you to have more down time and another motor build a few months down the road. :up:

[Danny Boy]

I've done my fair share of research and gathered opinions from some knowledgeable people. Seems like the consensus is that machining the heads is the "right" way to go about a hybrid build, but that a thicker head gasket works in most applications. Since I'm not planning on running meth, crazy boost, race gas, etc, I don't think there is a huge risk in going this route. The EJ25D headgasket was recommended to me over a cometic thicker gasket because of the fewer layers it has and the less likely the gasket itself is to fail. I've decided to roll the dice on this one and see how it pans out.

[Subyspeed]

Good luck and nice build

[Berge56]

Sounds good mang! Just wanted to make sure you were aware. :)

[yaya]

Good luck with the build.

(Though, I can't believe you want to take a shortcut now after all you've been through. If you need a shop in New England that can do the CNC work let me know... my heads are there now getting this treatment)

[Seraphinwolf]

Good luck.

I'm with Yaya on this one. It's worth the lower risk to just do it "right" and have the heads machined. :( I wanna see this thing running damn it!

[Danny Boy]

Good luck.

I'm with Yaya on this one. It's worth the lower risk to just do it "right" and have the heads machined. :( I wanna see this thing running damn it!
That's what I went into the hybrid build thinking as well. I just wanted it done "right". Then I ran into machine shop issues. I thought about sending the heads out to CA for EQ Tuning to do their CNC work, but thought that sending the heads across the country and having the car/motor in pieces in yet another state was a recipe for disaster. I've made the decision to just do the thicker headgasket and I'll have to just keep my fingers crossed and hope for the best. From all my research and from Paul's (owner of ECS) personal opinion, this should be a relatively safe bet to make.

I can't wait to row through some gears whenever she finally gets done. :devil:

[Berge56]

(Though, I can't believe you want to take a shortcut now after all you've been through. If you need a shop in New England that can do the CNC work let me know... my heads are there now getting this treatment)

I believe this head shop is local and one of the best in the country.

[Danny Boy]

Well, it's too late now to change it but thanks for the advice. :)

[Berge56]

anytime. Just looking out for a fellow subie owner. :up:

[Bu11dogg2]

GL man!

Not to beat a dead horse.... But it's never too late to have your heads machined.

On top of what was mentioned above.... You'll get bad gas mileage too

[Danny Boy]

I picked up the RS on Tuesday and had all day today off for Veterans Day to work on the car. I installed my 22b hood vents, put on the summer wheels/tires just for kicks and washed/waxed/cleaned everything. I found and fixed the source to a large leak I had in the car too.

http://i247.photobucket.com/albums/gg137/dannyboy7777/ECSTune.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/afrpsiECS.jpg



The puddle in the back seat:
http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_0964.jpg

Since I just had to take the RS to work yesterday I put a seat in after pulling the carpet out to dry.
http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_0970.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_0991.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_0985.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_0987.jpg

And my goofy ass with the RS
http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_0992.jpg

I found the leak and think I may have fixed. Hopefully its a permanent fix but we'll see. Had to get the fender off to really see the problem. Water was draining from the windshield gutter right onto the grommet for all the wiring passing thru the fender (which subsequently had a hole in it from when I ran the WRX wiring harness).

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_0993.jpg

I also rearranged the garage and talked my mom into letting me park the RS on the previously cluttered side. So this winter the RS will be living indoors for the first time since I've owned her. :)

[Berge56]

Awesome! Glad you found and fixed the leak. How does she drive?

[yaya]

Is it all broken in then? How is she running?

[Seraphinwolf]

Issolate the leak yet Dan?

[Bu11dogg2]

Looks clean!

Nice work!

[Danny Boy]

Awesome! Glad you found and fixed the leak. How does she drive?
Drives very good but I can tell I'll be wanting a bigger turbo pretty soon....maybe a project for next winter. :D
Is it all broken in then? How is she running?
Runs great but still only about 200ish miles on the setup. ECU still isn't ready for inspection either. I gotta get one soon since the last time it passed was in January 2009.

Issolate the leak yet Dan?
Yup, all fixed (hopefully). Seemed to hold up to my garden hose test.

Looks clean!

Nice work!
Thanks! I need to get out to another NES meet now.

[Berge56]

Since it has been 2 weeks how many miles do you have on the new setup? Did you get a final tune?

[Danny Boy]

700ish miles so far and running great! Final tune is the one shown above (221 whp, 280 wtq).


Just went into winter mode over the Thanksgiving weekend too:

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_1037.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_1036.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_1033.jpg

[hiprsha666]

So did you end up going with the thicker head gasket or machining the heads? I didnt see how that all turned out.

[Danny Boy]

I ended up just going with the EJ25D thicker headgasket. So far it's working out great for me. The next time the motor comes out (hopefully not for a long time :lol:) for a bigger build I'll definitely get the heads machined.

[squeethebee]

What are you running for a clutch? I can't believe how stock your engine bay looks:lol: car is SCREAMING for more power mods!

ed

[Danny Boy]

Yes it definitely needs more power. I think I'd be happy with 300-330 hp and ft-lbs at the wheels. The next upgrade (unless I decide to sell the car in a year or so) will be turbo, injectors, fuel pump, TGV delete, head machining, turbo inlet, intercooler, etc. For now, I'm just going to have fun with what I've got though. :)

[hiprsha666]

I ended up just going with the EJ25D thicker headgasket. So far it's working out great for me. The next time the motor comes out (hopefully not for a long time :lol:) for a bigger build I'll definitely get the heads machined.

Cool! Glad it is working out. The car looks good.

[Berge56]

Yes it definitely needs more power. I think I'd be happy with 300-330 hp and ft-lbs at the wheels. The next upgrade (unless I decide to sell the car in a year or so) will be turbo, injectors, fuel pump, TGV delete, head machining, turbo inlet, intercooler, etc. For now, I'm just going to have fun with what I've got though. :)

Nice! I like the future upgrades. :devil:

[Danny Boy]

Nice! I like the future upgrades. :devil:
I've discovered that boost is highly addictive. :lol:

[Berge56]

it's a hell of a drug! - Rick James

[Danny Boy]

Well, the RS survived the trial-by-fire road trip this past weekend. Didn't have to bust out any tools or spare parts the whole way. Now I've got ~1400 uneventful miles on the new setup. :)

Boston --> Albany --> Sunday River --> Boston
~650 miles in 35 hours

And I averaged ~30 mpg highway with the roof rack on!


http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_1039.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_1040.jpg

[Seraphinwolf]

And what was your average total for the trip?

[Danny Boy]

I didn't calculate for the whole trip but I'd say high 20's for the overall average.

[Bu11dogg2]

Not bad!

[Seraphinwolf]

Very nice!

[Berge56]

How's this beast running?

[Danny Boy]

Better than ever. Just got her into summer mode too with some updates.

I finally replaced my old lip which I broke 3 years ago too. :lol:

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMAG0050-1.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMAG0048.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMAG0052-1.jpg

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMAG0055.jpg

reupholstered the door cards to match the JDM grey on the seats....now I just need to source a rear seat to match.
http://i247.photobucket.com/albums/gg137/dannyboy7777/IMAG0040.jpg

[25rSTI]

Good job, she's looking great.

[Seraphinwolf]

Oh did my posting on your RS25 thread remind you you had an account here too? :lol:

[Danny Boy]

:lol: Guilty!

[Berge56]

Interior looks great.

[[JT]]

nice car, where did you find your seats at?

[Danny Boy]

Classifieds on rs25.com

[Danny Boy]

Matty took a cool photo of my car at SM5:
http://i247.photobucket.com/albums/gg137/dannyboy7777/DSC_00419.jpg

[DHGurs]

Your car is awesome!

[arcadia25]

Hey i think i saw that sexy car the other day.....

Sent from my SPH-M920 using Tapatalk

[Seraphinwolf]

We shoulda traded wheels before I went on the dyno then trade back.

[Danny Boy]

Your car is awesome!
Thanks!

Hey i think i saw that sexy car the other day.....

Sent from my SPH-M920 using Tapatalk
It was parked next to this green unicorn thing I think....

We shoulda traded wheels before I went on the dyno then trade back.
Shoulda. You put down 129whp right?


I just got home from my graduation!
It's official now....got my B.S. in Mechanical Engineering!! :) Time to start the real world now.

[Danny Boy]

http://i247.photobucket.com/albums/gg137/dannyboy7777/IMG_1794_AC.jpg

[boxer3maine]

nice shot...
I am constantly looking the left sides of subes.

door line is right away for me.

[DHGurs]

Your car is so damn clean, love it!

[Berge56]

Nice snail.

[Danny Boy]

Your car is so damn clean, love it!
It's clean now but the Hawk HP+ pads leave so much break dust.....wheels need to be cleaned constantly. :unamused:

Nice snail.
:lol: Thanks....it was an impulse buy off ebay.