nelsmar's rebuild thread.
 

https://dl.dropboxusercontent.com/u/...d/_B9A1401.jpg

I figured it was about time I started a build thread (rebuild thread?) as I am constantly text, pm’s, and emails asking what’s new with my build! So I figured I would finally jump on it and get one going!

As many of you know I had an engine failure a while back. There are a numberer of threads on it including a tear down thread. My previous build was a vortech supercharged stock motor pushing out 360WHP on E85. However due to tuning issues I ended up with engine failure throwing a rod out of the block.

Waiting for a tow truck...
https://dl.dropboxusercontent.com/u/...20DSCF0784.jpg

Oddly I have an amazingly low number of photos of my car. Considering I shoot professionally I am not quite sure how that happened. Oddly enough the majority of the photos of my car are of it sitting on a flat bed. HAH! Once it runs I’ll hopefully jump in and actually take photos of the car moving forward. :)

I decided to overbuild my engine for my own power goals. I honestly just wanted a 300-350WHP daily driven small RWD sports car. With my previous setup I was quite pleased and felt the power was more than needed. This car won’t be a drag queen. I enjoy canyon carving and spirited drives and fully plan on doing light track days once the car is running again. During my build I tried to pick a turbine that would fall in the efficiency range of the high 300’s WHP keeping well in the efficiency range to keep my charge temps low for track days. I also wanted to make sure I had something that could handle 400-500+HP on E85 for occasional joy. If I ever get bored I tried to make sure I had enough room to bump the power up without having to do a full tear down. At one point I was going to sleeve and do a full valve setup and port job but then I realized I would be dropping out of the efficiency range for my power desires as I would like to enjoy the car at the track and a 300WHP FRS is well beyond my driving skill.

Ideally I want to rebuild the car and keep it looking & sounding as near stock as possible. I want to have a little bit of an exhaust tone, but very minimal. More so just a slight bit of sound at idle. I quite enjoyed my last setup with a stock exhaust as the car sounded and looked completely stock from the outside but gave quit a kick once you throttled in.

https://dl.dropboxusercontent.com/u/...d/DSCF0684.jpg

Here is my current part list:

Current Power Parts
New shortblock from Subaru
OEM Valves & Retainers
Custom CP 11:1 Pistons with crown coating & upgraded wrist pins
Custom Carillo H Rods
ACL rod bearings
ARP2000 Head studs
Modified oil pump
Kelford Valve Springs
ACT 6 puck sprung street clutch
DSS Axles

Other MISC Parts
KSport Coilovers
Zeitronix ECA-1
Innovate LC-2
P3 Gauge (likely to be replaced with home-made setup)
Enkei RPF01 18x9.5 +38
Retrofit Source HID retrofit
KOYO Radiator

Pending Parts on Order
JDL EL Turbo Kit
GTX3071 .63 AR
JDL 3” Overpipe
JDL 3” catless Front Pipe
JDL 3" single exit exhaust
Greddy SP Elite Muffler - Temporary
Spal fans (one thick one thin)
Custom fan shroud

Planned Parts List
Full blown fuel pump canister + Walbro 485
ID 1000cc injectors
OIL Cooler
Voodoo13 LCA
Frodo Pads
DBA Rotors
Undecided catch can

Long Term Parts List
Work CR Ultimate in WMB (unless I change my mind)
Front Splitter
“Mellow” rear diffuser
Vertex Skirts

Undecided Parts
Trunk Lip
??? Front Lip
Vented Catch Can Setup (I need to decide this asap)

I will be tuning the car my self. And already booked 20hrs of dyno time to dedicate to the car to make sure the tune is extremely well rounded in every scenario on every fuel mix.

Misc Pictures:

https://dl.dropboxusercontent.com/u/...d/IMG_0893.jpg
https://dl.dropboxusercontent.com/u/...d/DSCF1040.jpg
https://dl.dropboxusercontent.com/u/...9390397%29.png
https://dl.dropboxusercontent.com/u/...d/IMG_4458.JPG

Old vs New axles:
https://dl.dropboxusercontent.com/u/...31453.1024.jpg

https://dl.dropboxusercontent.com/u/...d/DSCF0021.jpg
https://dl.dropboxusercontent.com/u/...d/DSCF0803.jpg
Old Dyno:
https://dl.dropboxusercontent.com/u/...20wAFR%202.jpg

I'll post up more pictures of the build once I catch up on some work. I have a bunch from the tear down & assembly of the new block.

Reserved

And as an update about my current build status... The engine is assembled and ready for install. However somehow I did not notice that my #2 exhaust cam was damaged. I am currently searching for a new one... Looks like I might just have to bite the bullet and over night one tomorrow. :(

From Jaaaaaaaaapan?

lol luckily they had one in the US. I just overnighted it, it will be here tomorrow at noon. =x

Stupid Cam...
https://dl.dropboxusercontent.com/u/...d/IMG_4163.jpg

And some more pic's of assembly.
https://dl.dropboxusercontent.com/u/...d/IMG_4608.jpg
https://dl.dropboxusercontent.com/u/...d/IMG_7163.jpg
https://dl.dropboxusercontent.com/u/...d/IMG_3095.jpg

Stock rods that came in the short block. I am not quite sure what to do with these... It was cheaper for me to buy a shortblock than just the crank & block halves.
https://dl.dropboxusercontent.com/u/...d/IMG_2507.jpg

My new itty bitty turbo.
https://dl.dropboxusercontent.com/u/...d/IMG_8463.jpg

I may have missed it, but whos doing the motor build? Good luck man! Will be following along.

Originally I was going to be doing the entire assembly. However due to me being INSANELY busy at work the last few weeks (I tapped 120+HRS in the last 7 days iirc) I haven't had time to assemble the block so I had my friend over at Goodspeed Peformance assemble the block for me.

Now that's a sweet pic! :cheers:


...

Call Harry if you need to overnight parts from JAPAN.


Congrats on your birthday!!

I keep seeing your desperate sounding posts for help on Facebook. I already offered my help if you decide you don't need someone local, haha.

You take awesome pictures.

In for awesome pictures.

:cheers:

Just for future reference you could have PMed me to build it ;)

We haven't even met! lol. Well other than a hello while I was drunk one afternoon. I wanted to do it 100% my self but life is just too damn busy -.-. At my current rate if I didn't have my friend assemble I wouldn't be installing until mid summer.

Meh apparently subaru had a problem with the shipment of my cam... What a waste in $$ to overnight it... -.-

Damn i need to catch up...who wants to assemble my motor?!? lol :P

Can't wait to see this together...there should be some nice setups done soon!

Yes we need yours running!! I've told ya before I'll gladly help you wrench in any way I can to get you rolling! I told Ronnie to tell ya my friend ordered a few extra sets of head studs and is selling them for a fair price! Once mine is setup I'm gonna have to start stopping by daily pestering you to start tearing your shit down :) let's just boost the stock block you have in the shop! I'll even help ya tune it or sit down with tony @ ums and help him out :P

oh my godness dude!

You could not pay me to sink all that time and money on that pile. However, when you are done I am opening a shop called @FA20Club2 . I can do your tuning for you or my new associate I just hired, @Vishconti

Holy hell its been a busy 2 weeks... Finally got a new cam in & a few other misc valvetrain replacements. Hoping to finish assembly this week and install this weekend but may have to go out of town and push it off to mid next week. Looks like my turbo kit is pretty much finished and ready to go on next week. Lots of pics to come ;)

That's awesome news bro!!!! :cheers:

As per usual I had more delays... Work has been hell. The driver side head should be assembled tomorrow. I stopped by JDL today to talk about random bits, looks like my kit is all done. (and has been for a bit now). I need to sell off my current fuel system and buy a new set of injectors & fullblown walbro kit.

The rough part is I have started to lose any desire to work on the car. The Arizona heat is starting to come in and the minor memory of the joy the car once brought me (before it was supercharged and plagued with issues due to tuning issues) is slowly fading. :(

Today is day 146 of my car being on jack stands. *sigh*.

Trust me I know how you feel. I had several projects in the past and dealt with the lame long waiting game. Hang in there Nelsmar! You're almost there!

Stick with it man. When you are about to quit just think about @Frs300 and how long he waited and you will feel better about your situation, haha.

That damaged cam picture looks like it may have had a lack of lubrication? Looks like it had some bluish marks on it?

I am doing a small write up about some of your feelings today, about my weekend in the garage. Shit gets old, and the returns aint worth it sometimes namely when you have a career etc.

If you don't enjoy the weekend working in the garage, then I agree that the returns might not be worth it. I generally get more enjoyment from the process than the returns.

More like... When all you do is wait for parts in the mail the project isn't fun. When it comes to actually working on the car? Thats fun. :) That is why i have been losing the desire. Because its just been endless waiting!

@nelsmar, I've got the cash. I'll take that 65c & injectors off your hands today for the price we discussed a while ago, today if you'd like :-)

On phone I am. Therefore, if mistakes I make, Frank Oz blame you should.

Well shit I might have to do that... hit me up later this evening. lol I can pull the pump out tomorrow or Sunday.

This. And yesterday it was 100F out. So the realization that im going to be sweating my ass off instead of enjoying a winter build hit me. lol! I hate wrenching in the heat!! I was really hoping to enjoy working on the car in a sweater in the cold!

I am the opposite haha. I HATE wrenching in the cold and the rain. I only have a one car garage despite owning 4 vehicles, so I do my wrenching in the elements in my drive way generally, and I will take a 100 degree 100% humidity Florida summer day over a 35 degree wind chill Florida winter day.

Gotta love pay checks :-)

On phone I am. Therefore, if mistakes I make, Frank Oz blame you should.

What is rain, precious? What is it, eh?

On phone I am. Therefore, if mistakes I make, Frank Oz blame you should.

Rain is what happens when the damn Florida air just can't hold any more moisture on a hot ass summer afternoon.

Moistures? What is moistures, precious? (check my location) :D :bonk:

On phone I am. Therefore, if mistakes I make, Frank Oz blame you should.

Damn it seems like its one thing after another... But it looks like its time to make some major progress this week! I just rush ordered a new DI (ends up one may have broke during the engine failure) and the engine is 98% complete. Front cover goes on today and i'll be picking up tues/wed and taking the day off work to complete accessories install & flushing out my fuel system. I still have some 6 month old e85 in the tank I need to dispose of before firing it up. Lots of pictures to come this week!

F5 F5 F5 F5 F5 F5

Damn it, still no pics. :lol:

oooo

https://dl.dropboxusercontent.com/u/...d/IMG_5838.jpg

Time to pickup the block and re-attach everything. :)

fill with oil before starting :bellyroll: