77 Bay Window WRX/subarugears conversion

[Mason]

Hello, Long time lurker here and I figured its about time I put what ive been up on thesamba. I've had this bus for about 9 years and have been working on it off and on. I'll upload what I have picture wise and would like to hear your questions of concerns of how I'm going. Plan is to get it running then tear it all apart and finish body work and paint. Shooting for around 300hp with a TD05, STI injectors, IGV deletes, tune and intake/exhaust.

2002 WRX donor 140k something miles
subarugears box is built and installed along with their mount kit using stock suby crossmember
running a aluminum belly rad with dual spal fans
hydro clutch
still need to do wiring
finish cooling sys (shroud/fan mount). all cooling pipes are done along with the modified crossover manifold.
need to build intake plumbing for turbo/intercooler
and build exhaust, i'm not happy with the one I previously did because of turbo location.

[fokker100]

Hi Mason,

I just want to say that it is so much fun to drive. Right now I have about 175hp with the modified cams.
I would probably be scary at 300hp, unless dismantling a 911 for suspension and brakes wise.
I am not the builder, as it is Skills that built it, and I wouldn’t be surprised if he jumps in this thread.
But you seem to know what to do, and I can’t wait to see the finished product 😁

Welcome in the Busaru club!

[Mason]

Thanks man I can’t wait to drive let alone start it. Here she is all nestled in
[img]

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[airschooled]

Damn, ow THAT is how you do a hydraulic clutch!
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[Mason]

haha yeah I had some steel lying around and I like mechanical things. I won't have to worry about it thats for sure.

[Mason]

Been working on the radiator/fan shroud but of course I ran out of argon tonight. Also got my short oil filler that won’t interfere with the turbo mount location.

[Mason]

Finished up the radiator shroud and got the fans mounted. Finally installed all the coolant lines a radiator. Onto the fuel sys

[ImAddicted]

There’s something about seeing people with fabrication skills (that I do not possess), doing quality work - especially in places no one will typically see - that gives me the same sense of awe and appreciation for beauty I get when I see a hawk or wolf in the wild. It’s why I love reading Skill’s threads (among others), and now this one.
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1979 Transporter (sold)
KC1MUR

[skills@eurocarsplus]

interesting clutch master setup. i do mine a bit differently but that is so much better than many i have seen. mine is basically tucked up under the pedal pan, next to the booster.

i never posted because out of respect for those who paid me to do it i didn't feel it was right to show all the work it took to get the stock pedal to work.

good luck with it. i'm assuming you're going with a AWIC setup? seeing a NA 2.5 built for torque is a hoot to drive this should be pretty scary. i like scary
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[Mason]

I’ve thought about a AWIC but I keep hear people talking about heat soak in the sys. Currently trying to figure out a practical place to put the stock top mount. The ones I’ve seen just throw it on top of the motor but it’s performance can only be marginal Without good airflow. I’ve tossed around the idea of putting it in the battery tray somehow with ducting to the side vent.

[skills@eurocarsplus]

AWIC is the way to go if you size it right. or run the a/c compressor to a killer chiller

https://killerchiller.com/

ideally you want IAT's at about 10*-15* above ambient and obviously the lower the better
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[panel]

Mason.......good work! My turbo header is very similar. I'm running an AWIC.
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My '65-Subaru EJ20 Turbo conversion

[Mason]

More reading on awics is needed I guess. Dude your bus is legit I’ve been following it for awhile. What air to water are you running? Also are you still running the purge valve and how did you integrate it into the stock bus fuel vent if you kept it?

[panel]

I'm running the http://www.frozenboost.com/air_water-ic/compact-liquid_air-intercooler-p-209.html one. And their water pump. I initially bought that small rad from eBay in the build link but have now purchased their heat exchanger-> http://www.frozenboost.com/water-to-air-heat-exchanger/air-to-water-radiator-p-1063.html. I did add a reservoir this summer for added capacity. Actually it's a fuel tank I grabbed from Amazon and relocated the holes etc to meet my plumbing. I took out the foam and the level sensor also.

I did have to modify the intercooler also to fit my tight engine bay constraints.

https://shoptalkforums.com/viewtopic.php?f=19&t=141357&start=120

As for the purge valve I'm not running one cause I'm running a stand alone fuel management. I purchased the wrong year JDM MY99-00 Turbo Forester engine(EJ20) and ECU. My fault due to not enough research. Plus it seemed everything you do to the intake/exhaust etc on these turbo engines required a 'tune' which I wasn't about to take it to the tuner every mod I did.
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My '65-Subaru EJ20 Turbo conversion

[ivwshane]

[Abscate]

He’s in a competitive business and is fastidious in detail, which racks up hours of time, for which he gets paid some fraction.

Giving his designs to enable people to do this in a shoddy way and undercut him makes no sense and is a reasonable position.
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.ssS!

[ivwshane]

[Mason]

Welded in the coolant drain and got the TGVs removed and ported them.

[babysnakes]

[skills@eurocarsplus]