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Rosssub's Single Turbo Conversion.


Rosssub

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Almost over it now. :) I forgot to mention that they also removed the steering column universal for some reason with out marking the shaft, I drove home with the steering wheel now at 2o'clock. Muppets...

 

Turbo removed showing snapped lower DP bolt:

DP_fix_001.jpg

 

Broken bolt drilled out, thread tapped and new bolt installed:

DP_fix_012.jpg

 

Turbo back in and all back together:

DP_pre_service_002.jpg

 

The new twin scroll dipstick arrived today, got it right this time unfortunately $72.45 delivered.

OEM twin scroll EJ20 dipstick, p/n 11140AA120

 

Here is the OEM EJ20 twin scroll dipstick above the standard single scroll EJ20 dipstick:

Dipstick_001.jpg

 

Twinscroll:............Single scroll:

Hot full-428.0mm-------455.0mm

Full-----433.5mm-------465.0mm

Low------464.0mm-------486.5mm

Tip------484.0mm-------503.0mm

Dipstick_002.jpg

 

The car's going back at 1pm tomorrow to get another downpipe made, fingers crossed this time it's ok and nothing else is broken. :) Still waiting on the turbo blanket...

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Got a couple of questions for you ross as I have a feeling my bottom end is creeping up on me.

With my be5 ver 5/6 sti ecu is going to be the easiest in terms of wiring. There was a ver 7 ecu local but I would need to wire in AVSC, correct?

What kind of running gear have you got atm?

also; I read somewhere that the gearbox crossmember will get in the way of the downpipe is that true?

Edited by iphillipnz
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What rev is your BE? BE/BH5A-B-C match the version 5-6 WRX/STI ECU plugs. Then the BE/BH5D-E match the version 7 ECU plugs.

The only other thing to worry about is the compression ratio match, engine-ECU.

BE/BH a/b/c 8.5:1 - Version 5/6 WRX 8.5:1

BE/BH d/e 9.0:1 - V7 Forester ECU?

Version 5/6 STI is 8.0:1 so will need the matching engine (or thicker HG), so if your in for a new block shortly that's the one to go for.

Edit: I've got all stock BH5B running gear, 5spd. For now... :) Yes I think any single turbo OEM DP will hit the TT gearbox cross member, just enough that you cant do it up.

Edited by Rosssub
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All set up again for downpipe surgery:

Downpipe_installed_001.jpg

 

Freshly made 2.5inch downpipe removed ready to wrap. Turbo end sleeved over the Spec C bellmouth:

Downpipe_installed_002.jpg

 

Straighter pipe with tidier bends, the bottom end nicely done with no inner restrictions:

Downpipe_installed_006.jpg

 

Heat wrapped and ready to reinstall:

Downpipe_installed_007.jpg

 

New downpipe in:

Downpipe_installed_008.jpg

 

All back together again awaiting a PTP turbo blanket and some boost. :)

Downpipe_installed_009.jpg

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 Rosssub said:
All set up again for downpipe surgery:

Freshly made 2.5inch downpipe removed ready to wrap. Turbo end sleeved over the Spec C bellmouth:

Downpipe_installed_002.jpg

Every time I see grind marks on a simple weld like that reminds me of this;

rottenecard_7639217_bn29gdkwxv.png

Looks much better than their first attempt though!

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I didn't want to, very limited options over here. They definitely wont see it again though...

 
On ‎12‎/‎07‎/‎2014 at 11:38 AM, tydon said:

god sh*t rosssub looking good!

Thanks Tydon, I'm stoked with the way it's come up. :)

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still think you should have specified mandrel bends, that crush bend restricts you to about a 2 inch diameter in that section. still, a lot better than the first attempt!!

Yeah the fact that they didn't have a mandrel bender and would have to order bends in, should have been enough of a sign for me to take it to Christchurch.

It wont be on there forever though, I wouldn't mind trying something like the Grimmspeed divorced DP out one day.

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 Rosssub said:
Yeah the fact that they didn't have a mandrel bender and would have to order bends in, should have been enough of a sign for me to take it to Christchurch.

Well you'll have to pop up here anyway to one of the meets to show off your new setup :)

I'm sure I'm not the only one who's keen to see it running.

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Well you'll have to pop up here anyway to one of the meets to show off your new setup :)

I'm sure I'm not the only one who's keen to see it running.

Definitely will, asap. :)

 

I sorted my fuel pump wiring yesterday, the same as in Gazzy2000's conversion/wiring thread. Having the pump wired to come on with the ignition was annoying me, though it was cool hearing the fuel flow through the fuel lines with the engine shut off.

 

The BE/BH ECU gives power to the fuel pump relay to switch it on, but the V5/6 WRX/STI ECU earths the fuel pump relay to switch it on.

 

The fuel pump relay is the lowest round relay, beside the cabin fuse box. This is the fuel pump relay loom plug pulled out, then the black earth wire cut ready for soldering:

Fuel_pump_ECU_fix_001.jpg

 

A length of wire soldered on, then run to the STI ECU and connected to pin 21/plug 134. Then the loom re-taped and plugged back in:

Fuel_pump_ECU_fix_002.jpg

 

Then I jumped in the boot to bypass the BH fuel pump relay controller, left of the jack is the BH muffler flap control motor:

Fuel_pump_ECU_fix_005.jpg

 

I then pulled out the rear left interior panel to get to the BH fuel pump relay controller:

Fuel_pump_ECU_fix_008.jpg

 

Then removed the black plastic jack box:

Fuel_pump_ECU_fix_009.jpg

 

BH FPRC unbolted:

Fuel_pump_ECU_fix_010.jpg

 

Then I pushed the FPRC loom out above the wheel well and cut the loom plug off completely:

Fuel_pump_ECU_fix_011.jpg

 

A bit of soldering and the BH FPRC is bypassed, now my fuel pump works as it normally would. Loom re-taped and pushed back in:

Fuel_pump_ECU_fix_013.jpg

 

While in there I've removed the BH muffler control motor and thrown it in the spare parts bin, (0.3kg of weight reduction):

Fuel_pump_ECU_fix_012.jpg

 

The car has developed a very light surge when cruising, more noticeable when cold. Also a slightly hunting idle, worse when cold.

 

I'm pretty sure I've cooked the BE/BH O2 sensor having it post turbo. Before ordering a new V5/6 STI O2 I've done a quick boost/vac leak test.

 

Air box lid/MAF housing removed and the intake blocked off, then clamped:

Fuel_pump_ECU_fix_014.jpg

 

Then 15psi with an air compressor into the BOV hose, throttle held open:

Fuel_pump_ECU_fix_015.jpg

 

No leaks at all, it holds pressure perfectly. Until 25psi, then a tiny pin hole leak through the passenger side Y-pipe gasket. Not enough to cause an issue but I'll order a pair of new Y-pipe gaskets this week, p/n 21896AA010.

 

Also soon a genuine version 5/6 WRX/STI O2 sensor from partsouq, $145 delivered:

https://partsouq.com/en/search/search?q=22690AA321

 

At 2003kms now on the new engine, I hadn't changed the sump plug washer on the last few oil changes so it was very slowly seeping. Also I didn't really like the way the valve train sounded hot with the Fuchs 5w30. I don't think it holds it's consistency as well as the Castrol edge 5w30, but they are both pretty dang thin when draining hot.

 

Today I've changed to Penrite Racing 10 fully synthetic 10w40 for the next 5000km, with a new sump plug squash washer. No more leak and a quiet, happy valve train hot and cold:

2000km_service_001.jpg

 

Including filling the new oil filter completely before fitting, the twin scroll sump took 4.6L total. Perfectly on the full mark.

 

Still cruising round on WGSP with more balls than it's ever had. Still patiently waiting for the turbo blanket... :)

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 Rosssub said:
What rev is your BE? BE/BH5A-B-C match the version 5-6 WRX/STI ECU plugs. Then the BE/BH5D-E match the version 7 ECU plugs.

The only other thing to worry about is the compression ratio match, engine-ECU.

BE/BH a/b/c 8.5:1 - Version 5/6 WRX 8.5:1

BE/BH d/e 9.0:1 - V7 Forester ECU?

Version 5/6 STI is 8.0:1 so will need the matching engine (or thicker HG), so if your in for a new block shortly that's the one to go for.

Edit: I've got all stock BH5B running gear, 5spd. For now... :) Yes I think any single turbo OEM DP will hit the TT gearbox cross member, just enough that you cant do it up.

Thanks for the info mate. Mine is a BE5C.

What type of AFM is needed for V5/6 STI ECU?

Have a couple more questions that i cant remember right this minute lol!

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I just brought a 3inch downpipe second hand :P (Still showing the chrome) for $100... I'll keep an eye out for you (I'm in chch) if I see something I'll PM you)

Car is looking mint btw! Stoked to see you progressing so quickly! Makes me want to twin scroll mine now haha

Edited by slystiguy
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I could smell oil after coming home today, luckily it was only the turbo oil feed starting to leak. When getting new copper washers I was given a pair of fibre banjo washers to try, but I haven't fitted them:

Boost_contrtoller_install_001.jpg

 

I got sick of waiting for the turbo blanket to arrive and connected the OEM boost solenoid today.

 

Before fitting hoses I removed the OEM 0.8mm VF36 restrictor pill and went straight up to a 1.0mm pill. Guessing the 0.8mm would boost spike majorly, (V6 STI/VF36 twin scroll).

 

With the 1.0mm pill fitted it still spikes to over 20psi. So this afternoon I've fitted a cheap HDI EBCr that was brought over a year ago and never used.

 

I figured the controller may as well go where the Zerosports sequential controller used to live:

Boost_contrtoller_install_004.jpg

 

HDI EBRC Controller installed, no gain adjustment at all:

Boost_contrtoller_install_005.jpg

 

EBC boost solenoid installed into the solenoid control box and boost hoses connected up. Still running AFM/MAF I've bleed the 3-port EBC solenoid back to intake, rather than VTA:

Boost_contrtoller_install_006.jpg

 

Now I'm waiting for the battery to charge up after messing round for a while. Hopefully the el'cheapo HDI EBC works as it should. :)

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First trial drive with the new EBC, turned up full it would only just get to 10psi. So I came back home a fitted a 0.8mm restrictor pill in, between the turbo and boost solenoid.

A lot better, completely stable, finely adjustable boost. Currently running 1.1bar/16psi, with the HDI dial set just over half way.

I think the HDI controller has a pre-set gain level, or I need to try some different pill/hose arrangements out. Initial spool seems slower now, when I was expecting the opposite.

But either way, I'm grinning from ear to ear. :)

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