Thanks to Everyone for the comments and the positivity, i really appreciate it 
Well it's been a while since my last update, as you all know i've been threatening to scrap the project, well i'm not going to lie i nearly bid on a TT with a knackered engine a few weeks ago.
Most of this feeling about scrapping it came from the thought of IVA'ing the car and i kept looking at the shear amount of work i had left to do.
So i put the project on hold for a while.
Anyhow a few weeks ago i started working on it again and love is back
Unfortunately money is tight at the moment so i've been trying to progress the build without spending to much just before my holiday.
My friend who put a EZ30 6 cylinder in his impreza had loads of 3" pipe and bends left over from making his exhaust so i got all his left overs for nothing..... i did think about making a large 4" section directly after the turbo then reducing it down to 3.5" but as money is tight 3" will do for now and be ok for good hp.
Once i've got it on the road and fully tuned i can then try swapping parts out and seeing what can be improved on.
I've also been trying to work out coolant runs / wiring looms so after looking into detail about the coolant i found the connections for the heater matrix were going to be in the way of the down pipe.
After some research I've found some 90 degree OEM plastic connectors from various different models over the years so i've ordered some of them.... in the mean time i decided to try and give as much clearance to the Heater connections so angle the down pipe towards the engine.
Cut some pipes up to get it angled away from the matrix connections and used a normal 1.5R 3" bend for the main bend down, there is a section of mirror polished pipe in there that i'll rough up to match the rest once it's all welded up -
Even with the downpipe angled away from the connections the space is still too tight to use the standard 45 degree connections.
Once i get the 90 tight connections it should be better but will still need a nice heat shield making up.
Next pipe (a 30 degree bend with one of the tails cut off) tacked into place to get the pipe somewhere near area where it gets complicated
And to think i was going to try and squeeze a 3.5" pipe through there
Once i had the second bent pipe into the general area i could then work out the next couple of bends, had to cut and move the bend a few times to get it looking right... then i cut a tight radius bend in two right up the middle so i could bring the pipe though giving the most clearance to each side.
Bendy
Fitted -
Annnnndddd the welding gas then ran out so had to give up on the exhaust for a while.
Next i need to order a good quality stainless flexi and some 3" v-band sets.
I have a few silencers from my mates spare impreza systems but i think i'm gonna order some Magnaflow boxes offof good old Ebay as they look good quality.
Trying to keep the project moving forward a few weeks ago i ordered a load of silicon pipes / bends etc to work out the coolant paths. I already have a Forge coolant pipe set but it doesn't include all the pipes required so i've been looking at whats required, what i've got missing etc and how i'm going to work out the coolant paths with that big silly turbo in my engine bay.
Anyways i've managed to work out how i'm going to do it - by making stainless "hard pipes" to pass under the turbo / Manifold then up to the matrix connections.
I'm well aware of the need for adequate heat protection for the turbo and manifold so i'm going to order some heat wrap / heat sleeves and some aluminium sheeting up to make heat shields. I'll probably order some reflective adhesive tape stuff also.
Next job i decided to put the front cross member back onto the car to help with wiring / coolant paths etc.
I then started making a list of all the changes i need to make to the wiring loom.... this is due to the BT conversion, SEM inlet manifold so throttle is on the other side as will be the boost pipes, N75 boost valve position, MAP sensor etc etc.
I also removed some of the EVAC / SAI wiring.
I replaced all the flexible conduit on the sensors that needed lengthening / adjusting position.
Also due to the turbo placement i needed to adjust the loom so the coil pack wiring so the wires were away from the turbo.
There is also a relay box mounted where my turbo is so i stripped it all down and removed what i could (SAI Power cables) and re-wrapped the loom / rerouted the relays into the plastic trunking to keep it all looking tidy -
Relay box -
Relays mounted into trunking and loom re-wrapped in fabric tape -
Trunking cover cleaned up and installed -
Part way through moving the loom for the coil packs and various other sensor movements -
Still got to work out the G266 Oil Temperature / Level sensor wiring, as my INA shallow / baffled sump doesn't have place for one.....
That's it for now, thanks again for the continued support and i'll update again when i have something worth writing about.
Cheers,
Graham.
Well it's been a while since my last update, as you all know i've been threatening to scrap the project, well i'm not going to lie i nearly bid on a TT with a knackered engine a few weeks ago.
Most of this feeling about scrapping it came from the thought of IVA'ing the car and i kept looking at the shear amount of work i had left to do.
So i put the project on hold for a while.
Anyhow a few weeks ago i started working on it again and love is back
Unfortunately money is tight at the moment so i've been trying to progress the build without spending to much just before my holiday.
My friend who put a EZ30 6 cylinder in his impreza had loads of 3" pipe and bends left over from making his exhaust so i got all his left overs for nothing..... i did think about making a large 4" section directly after the turbo then reducing it down to 3.5" but as money is tight 3" will do for now and be ok for good hp.
Once i've got it on the road and fully tuned i can then try swapping parts out and seeing what can be improved on.
I've also been trying to work out coolant runs / wiring looms so after looking into detail about the coolant i found the connections for the heater matrix were going to be in the way of the down pipe.
After some research I've found some 90 degree OEM plastic connectors from various different models over the years so i've ordered some of them.... in the mean time i decided to try and give as much clearance to the Heater connections so angle the down pipe towards the engine.
Cut some pipes up to get it angled away from the matrix connections and used a normal 1.5R 3" bend for the main bend down, there is a section of mirror polished pipe in there that i'll rough up to match the rest once it's all welded up -
Even with the downpipe angled away from the connections the space is still too tight to use the standard 45 degree connections.
Once i get the 90 tight connections it should be better but will still need a nice heat shield making up.
Next pipe (a 30 degree bend with one of the tails cut off) tacked into place to get the pipe somewhere near area where it gets complicated
And to think i was going to try and squeeze a 3.5" pipe through there
Once i had the second bent pipe into the general area i could then work out the next couple of bends, had to cut and move the bend a few times to get it looking right... then i cut a tight radius bend in two right up the middle so i could bring the pipe though giving the most clearance to each side.
Bendy
Fitted -
Annnnndddd the welding gas then ran out so had to give up on the exhaust for a while.
Next i need to order a good quality stainless flexi and some 3" v-band sets.
I have a few silencers from my mates spare impreza systems but i think i'm gonna order some Magnaflow boxes offof good old Ebay as they look good quality.
Trying to keep the project moving forward a few weeks ago i ordered a load of silicon pipes / bends etc to work out the coolant paths. I already have a Forge coolant pipe set but it doesn't include all the pipes required so i've been looking at whats required, what i've got missing etc and how i'm going to work out the coolant paths with that big silly turbo in my engine bay.
Anyways i've managed to work out how i'm going to do it - by making stainless "hard pipes" to pass under the turbo / Manifold then up to the matrix connections.
I'm well aware of the need for adequate heat protection for the turbo and manifold so i'm going to order some heat wrap / heat sleeves and some aluminium sheeting up to make heat shields. I'll probably order some reflective adhesive tape stuff also.
Next job i decided to put the front cross member back onto the car to help with wiring / coolant paths etc.
I then started making a list of all the changes i need to make to the wiring loom.... this is due to the BT conversion, SEM inlet manifold so throttle is on the other side as will be the boost pipes, N75 boost valve position, MAP sensor etc etc.
I also removed some of the EVAC / SAI wiring.
I replaced all the flexible conduit on the sensors that needed lengthening / adjusting position.
Also due to the turbo placement i needed to adjust the loom so the coil pack wiring so the wires were away from the turbo.
There is also a relay box mounted where my turbo is so i stripped it all down and removed what i could (SAI Power cables) and re-wrapped the loom / rerouted the relays into the plastic trunking to keep it all looking tidy -
Relay box -
Relays mounted into trunking and loom re-wrapped in fabric tape -
Trunking cover cleaned up and installed -
Part way through moving the loom for the coil packs and various other sensor movements -
Still got to work out the G266 Oil Temperature / Level sensor wiring, as my INA shallow / baffled sump doesn't have place for one.....
That's it for now, thanks again for the continued support and i'll update again when i have something worth writing about.
Cheers,
Graham.
