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 Post subject: CRAZY CUSTOM EJ207 V6 99' FOZ BUILD!
PostPosted: Fri Jul 04, 2014 9:58 pm 
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I Say: Big power doesn't always break traction...
Vehicle: 99' EJ207 STi FORESTER

Posts: 92
Location: SYDNEY
Hey guys,

Some of you have probably seen this car on here before (MOD17)

I have bought this car and am finishing the project and getting it engineered and registered in NSW (like I have already done with my fully custom turbo commodore ute ;)

All work is done by me :) And as I am a builder who works during the week and most weekends this is being done each arvo/night after work (so unfortunately things will be a bit slow)

Ok so this car came to me with a fair chunk of work done, things already done:

-JDM EJ207 v6 STi motor swap
-07 WRX 5 speed box
-Apexi Power FC ecu
-HDi FMIC Kit
-BC BR Coilovers
-BBS copy 18x10.5" wheels with 225 stretched rubber
-3" exhaust with 3.5" axle back
-STi interior and dash
-Rear whiteline sway bar, HD links and lateral links

Lots more, but I cant think of now. Will add as I remember

Ok so here are some pics when I got it.
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So first on the agenda was getting rid of that battery taking up so much valuable room (also where my charge piping, catch cans and battery distro box will be.

So i decided to do a very clean, concealed and unique boot mount. I took the spare tire out, cut the mounting hub out, flattened out the bottom of the spare wheel well and mounted the battery down with the hooks from the OEM battery tray. The spare wheel then when flipped the opposite way fits over the top perfectly!
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The setup I ran is 0ga double insulated welding cable from battery, through a grommet in the wheel well, down under the car above the tail shaft then up thru to the cabin behind the shifter to a battery isolation switch mounted in the centre console. Then from there in goes thru the firewall, to the starter motor, then from the starter I ran a 4ga cable to the distro box mounted on the inner fender where the battery was (which the fuse box connects to)
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The next thing to tackle was the exhaust. The existing exhaust was, well it could of been a lot better. It needed to be raised and also configured differently (also will be putting a varex to pass noise test later on) I also got rid of those crap 2 bolt flanges and did v-bands. Anyways its mounted probably the best ive seen on any subie and it wasn't quick ;) think the hours i spent on this would be in the 20's.

V-BAND DOWN PIPE
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DOWN PIPE TO MID PIPE
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MID PIPE
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AXLE BACK
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With that now done, my next move was to the intake manifold and intercooler piping. While the usual bolt on piping kits etc are ok for just bolt on, I am not a fan of long unnecessary piping and mediocre aesthetics ;)

I also sprayed the turbo comp housing while I had that off to clock it :)

SO; my plan is to reverse the inlet manifold, clock the turbo so the outlet is facing the other side, run cold side piping up through bottom of battery tray (instead of through narrow gap between radiator and motor)

First stop was the manifold. So off it came, stripped down, cut up and custom tig welded with an enlarged plenum, custom throttle cable and coil pack mount. I also incorporated a vacuum manifold/tree for easy access for vacuum/boost sources. Then just feathered existing paint back, etch primed then resprayed. PLEASE NOTE; This wasn't as quick an easy as it seems ;) about 15 hours went into this manifold haha
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That's as far as i've got so far, I will be updating this as I go and when i get time to sit down on the computer :)

[UPDATE 14/7/14]
Ok so i've got most of the intercooler piping fabbed and painted. Only one little bit to go from under batt tray to FMIC. I have cut out very close to a whopping 1500mm of piping in my custom setup, which is quit a lot 8-)

So i have gone 2" from turbo then up to 2.5" under overflow tank, 2.5" thru FMIC up till the underside of battery tray, then the pipe thru the tray increases to 3", then 3" all the way into the throttle. I also welded a 3" pipe onto the throttle to angle it downward a bit to clear hood and so i could have a straight coupler on the throttle. I tig welded on the inside then smoothed it out with some JB weld, so the flow is pretty clean.

I still have to fab up a custom airbox on the intake pipe which will fill the hood scoop area.

Here's some pics so far:
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Ive also got my gauge pod and gauges in, took a quick pic for you also.
From left to right: Fuel pressure, AEM Wideband, Boost
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I also have my GFB Gforce II half done too :thumbs:

[UPDATE 20/9/2014]

Ok so since last time I have got a fair chunk done. I will try remember everything.

So I ended up plasti-dipping the wheels with matte black (they match the car a lot better and look phatter IMO)
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After speaking with my engineer I had decided to change the airbox setup and utilise the factory airbox (as testing for a custom airbox would be upwards of $1000 all up) I managed to JUST fit it in the guard infront of the drivers wheel. I also had to get a front reo bar (for obvious reasons) so I had to go down to a 600x200x80 FMIC and have mounted it on a mad slant to have less protrusion out the front for those low driveways ;)
You can also see from the pics I made a custom mesh grille too.

AIRBOX/FMIC PIPING
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UPDATED INTERIOR
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I have also designed and fabbed my own custom baffled catch cans with AN fittings which can be fully disassembled and cleaned etc. Also a custom mounting bracket utilising T-Bolt clamps for quick removal of cans.

CUSTOM CATCH CANS & INTAKE PIPING
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The 2 weapons side by side
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I have also:
-Replaced both rear axles and axle seals (inner and outer)
-New diff oil
-Replaced leaking front transmission seal
-New transmission oil
-New engine oil/filter

I also have to replace the current stretched 225/40r18 tyres with 255's for the engineer.
I will be selling these tyres when they are swapped so if anyone wants them, let me know. They are pretty much brand new lexani tyres with easy 95% tread

I also have the 600x300x75mm HDi FMIC that I removed, I will sell that if anyone wants it.

I have got the car running nicely, no leaks, and am in the process of tuning off boost for emissions test.


THINGS TO COME:

-INTERCOOLER PIPING
-INTAKE PIPING/AIRBOX SETUP
-GAUGES AND EBC
-REAR DRIVE SHAFTS
-FRONT SHAFT/GEARBOX OIL SEAL
-TUNE
-EMISSIONS TEST
-ENGINEER
-REGO

DOWN THE TRACK:

-CUSTOM T04E TURBO SETUP
-EXTERNAL WASTE GATE SETUP
-POSSIBLY A BEE*R REV LIMITER
-MAFLESS
-4 POT REXY BRAKES

STAY TUNED!


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CHECK OUT MY FULL CUSTOM JDM EJ207 FOZ BUILD!
http://ozfoz.com/forum/viewtopic.php?f=5&t=46362&st=0&sk=t&sd=a&start=0

MY YOUTUBE VIDEOS
http://www.youtube.com/user/V6boosted
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Last edited by boosted_v6 on Sat Sep 20, 2014 6:02 pm, edited 3 times in total.
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 Post subject: Re: CRAZY CUSTOM EJ207 V6 99' FOZ BUILD!
PostPosted: Fri Jul 04, 2014 10:08 pm 
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Posts: 7525
Location: ....
I didn't even know he sold this!
Awesome work man!

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 Post subject: Re: CRAZY CUSTOM EJ207 V6 99' FOZ BUILD!
PostPosted: Fri Jul 04, 2014 10:11 pm 
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I Say: RUM - more than a breakfast food.
Vehicle: MY17 Hyundai Elantra

Posts: 979
Location: Tamworth
Good stuff. Great to see it still part of the OzFoz community!

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 Post subject: Re: CRAZY CUSTOM EJ207 V6 99' FOZ BUILD!
PostPosted: Fri Jul 04, 2014 10:24 pm 
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Vehicle: V4 STI SF5, RWD, Caged :-)

Posts: 1607
Location: Gold Coast, QLD!!
Looking good mate. i like the direction this is heading!!

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SF5 Forester.. SH9 Forester.. 89 Brumby (Brat).. 92 SVX.. Tuned by STI Legacy.. Happy Family
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Tony rocks up to track days with a jack, bucket of shafts and rattle gun haha


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 Post subject: Re: CRAZY CUSTOM EJ207 V6 99' FOZ BUILD!
PostPosted: Fri Jul 04, 2014 10:31 pm 
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I Say: Big power doesn't always break traction...
Vehicle: 99' EJ207 STi FORESTER

Posts: 92
Location: SYDNEY
Thanks guys. Yes, definitely stay tuned there's gonna be plenty more cool stuff coming :)

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CHECK OUT MY FULL CUSTOM JDM EJ207 FOZ BUILD!
http://ozfoz.com/forum/viewtopic.php?f=5&t=46362&st=0&sk=t&sd=a&start=0

MY YOUTUBE VIDEOS
http://www.youtube.com/user/V6boosted
LIKE AND FOLLOW ON FACEBOOK
http://www.facebook.com/boostedbuiltgarage


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 Post subject: Re: CRAZY CUSTOM EJ207 V6 99' FOZ BUILD!
PostPosted: Fri Jul 04, 2014 10:43 pm 
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Vehicle: My01 GT Lux

Posts: 312
Location: Sydney
Finally got a thread going ;) it's gonna be a killer foz when its done! You need a pic of the new bonnet haha

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 Post subject: Re: CRAZY CUSTOM EJ207 V6 99' FOZ BUILD!
PostPosted: Fri Jul 04, 2014 10:45 pm 
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Vehicle: V4 STI SF5, RWD, Caged :-)

Posts: 1607
Location: Gold Coast, QLD!!
your IC route sounds similar to mine. (and your exhaust looks similar too :thumbs:) are you going to try flip the core?

i like the fact you relocated the throttle intake. (i tried rotating the manifold whist keeping the stock turbo position, clearances sucked)

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SF5 Forester.. SH9 Forester.. 89 Brumby (Brat).. 92 SVX.. Tuned by STI Legacy.. Happy Family
jiggabite wrote:
Tony rocks up to track days with a jack, bucket of shafts and rattle gun haha


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 Post subject: Re: CRAZY CUSTOM EJ207 V6 99' FOZ BUILD!
PostPosted: Fri Jul 04, 2014 10:56 pm 
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I Say: SQUIRREL!!!
Vehicle: MY99GT, MY04XT, MY14XVS650A

Posts: 9208
Location: Narre Warren, Mexico, AU
This was a unique Foz already, now you're taking it to the next level!! :thumbs:

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 Post subject: Re: CRAZY CUSTOM EJ207 V6 99' FOZ BUILD!
PostPosted: Sat Jul 05, 2014 7:12 am 
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I Say: Big power doesn't always break traction...
Vehicle: 99' EJ207 STi FORESTER

Posts: 92
Location: SYDNEY
GT_Tony wrote:
your IC route sounds similar to mine. (and your exhaust looks similar too :thumbs:) are you going to try flip the core?

i like the fact you relocated the throttle intake. (i tried rotating the manifold whist keeping the stock turbo position, clearances sucked)


I'd been wondering if anyone had a similar IC route ;) Rotating the Mani was my initial plan, but soon realized that even with my 10mm phenolic spacers it was not gonna work and then there was the fact that the turbo inlet wouldn't fit, coilpacks and all the mounts would need to be changed, so hey, just cut it up and made it fit properly Haha Lotta time thinking this one through and getting it to work.

Good question about the fmic core, I'm not sure yet, even leaving it with pipes on the bottom gives crazy short piping regardless. I estimate that in what I've done I've probably lost close to 1m in piping haha

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CHECK OUT MY FULL CUSTOM JDM EJ207 FOZ BUILD!
http://ozfoz.com/forum/viewtopic.php?f=5&t=46362&st=0&sk=t&sd=a&start=0

MY YOUTUBE VIDEOS
http://www.youtube.com/user/V6boosted
LIKE AND FOLLOW ON FACEBOOK
http://www.facebook.com/boostedbuiltgarage


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 Post subject: Re: CRAZY CUSTOM EJ207 V6 99' FOZ BUILD!
PostPosted: Sat Jul 05, 2014 7:53 am 
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I Say: Nowhere near as much as I used to!
Vehicle: Gone but not forgotten-MY08 XT

Posts: 16235
Location: Sydney, AUS
Nice work!

Re: the varex, has your engineer said he'd approve it? They are specifically prohibited by the relevant legislation so I didn't think an engineer would touch them.


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