RexNuts Subaru Forums

Hi Rexnuts,

Well basically this started out as my car, but has now become project car for the business. Posted are results so far, but the future will be Cosworth intake manifold and tvg deletes, Hyperflow Stage 2 Sump, the new Garrett X series (GTX3582R), bigger injectors and rails and up the boost. Hopefully will see around 350 on 22psi, if this is even possible We will find out.

Currently running at 315kw at 19 psi on the first power tune. New engine has only 4000km's on the clock, so will wait until 8000km's before turning the boost up.



The Parts List
Cosworth Full Engine (Long Block)
AVO turbo back exhaust
GT Spec Headers HPC
Garrett GT3582R
Autronic SM4
Autronic Knockboard
APS DR725 Covert Front Mount Intercooler, custom piping (2.5inch)
Apexi AVCR
Cosworth Timing Belt
Walbro in tank Fuel pump (500hp)
Hi flowed STI injectors to 880cc
Process West External Surge Tank and Bosch 044 Fuel Pump
Hyperflow Front Mount Oil Cooler
Hyperflow Oil Catch Can
Exedy Twin Plate (Hyper Comp-R)

Suspension

Tein Superstreet Coilovers
Whiteline front (22mm adjustable) swaybar
Whiteline rear (24mm adjustable) sway bar
AVO front and rear end links,
Whiteline rear heavy duty mounts
Whiteline anti-lift kit.




Cosworth Engine Specs

After several years of testing and development, the Cosworth CS600 series High Performance Subaru EJ25 long block has arrived. The CS600 series is designed for extreme track day use and the demanding performance enthusiast. Each assembly is precision built by one of Cosworths skilled craftsmen using the finest components from our parts catalog to ensure maximum reliable power and performance. Starting with a new Subaru EJ257 semi closed deck block, we meticulously hone each bore to guarantee perfect piston to cylinder wall clearance. The block is then assembled with our Forged Pistons, motorsport grade Forged H Beam connecting rods along with our high performance rod and main bearings and a new STI Forged crankshaft. For maximum performance, an optional steel billet crank is available (CS600X). Once the cylinder block assembly is completed, we install a pair of our CNC machine port-bored Big Valve Cylinder heads with our proven S2 camshafts complete with valve lash set to our specifications. The cylinder heads are secured with our high performance 11mm steel studs and sealed with multi layer steel head gaskets. Finally, we install one of our blue-printed, high pressure oil pumps for maximum lubrication. This proven engine combination has been used by top teams to win events in both North America and Europe.

Specifications

New Subaru EJ25 STI Engine case
New Subaru EJ25 STI Forged Crankshaft
Cosworth Forged H-beam Connecting Rods
Cosworth Forged Pistons 99.5mm
Cosworth motorsport Tri-metal bearings
Balanced to within .5 gram
Complete blue-print assembly
Enlarged Intake and Exhaust ports
Large diameter stainless steel intake valves
Large diameter Inconel exhaust valves
Hi Rev, Dual valve springs
Titanium Retainers
Hardened Steel spring platforms
Multi angle valve job
CNC Machined port finish
Knife edge port divider
Cosworth S2 High lift camshafts - KK3920
Valve lash set
Cosworth high pressure oil pump
Cam covers
Cosworth serial number
2004-06 STI with single AVCS cable throttle -Asian/European market application

Very Nice

I arrived

Would love to hear how that cosworth engine sounds.

Here's a quick video of the cold start when i first got it back http://www.youtube.com/watch?v=j_2NzI1nhzE

We have since redone the twist mount due to oil problems.

Awesome

Video .. Best ..

I new I should have done the porting on my block and heads. fk.....

i creamed.

Faaaaaaaark that sounds beast!

Thanks for the comments everyone. I have the Autronic tuned properly now, did about 7-9 hours on the tune so the car really drives well. Almost standard besides the clutch and the the sound

We have launch control set to 5500rpm, so i was going to go to some closed roads and do a bit of 0-100 tests, took forever to get used to this twin plate clutch and the rediculously lightened flywheel.

Just out of interest from people who are using external wastegates, do you plumb them back or screamer, i have screamer at the moment and its just so so loud, thinking about getting it plumbed back in.

This might sound stupid...but why does it sound like that?

Big cams!!! The car does settle down and idle better once its warmed up a bit. My tuner has spent a couple of hours on coldstart since that video.

My 272/272 cossy cams aren't loving life at the moment due to my stock heads.

Trying to find 99/00 STI heads is a pain in the ass, though.

Almost at the point where saving for Cosworth heads and getting the motor taken out again and more stuff done to it seems like the easier (but very more expensive) options.

My built block wants some love! If only I won the Lotto ...

We can do rediculously good prices on cossie gear at the moment as we are a distributor and the exchange rate is awesome. PM me if you want a quote. The heads from cosworth are just awesome, best part of their range IMHO. It will be cheaper as you already have the cams!

The motor is already built. 272 cams, forged 100mm pistons + crank, billet rods, etc. I just didn't have much cash left over for a proper valve job + heads not that porting stock WRX heads would have been worth my while.

I need coin for a lot of things, though. Mainly:

Larger TMIC/FMIC. Undecided which way I want to go.
Cossy intake manifold if I decide to go FMIC
99/00 STI heads or Cossy heads
GT35 or equivalent
Hardened 5 speed gear set.

The problem is money. But I have got a new job recently so it should sort out a few issues.

With that engine I would only go FMIC especially with gt35 and cossie intake manifold.

Ill PM some prices for you for future reference tomorrow as I will have to look up the heads without cams. They are pretty reasonable atm though and be perfect for that set up.

Looking forward to it!

Is it just the cams or is it a combo of all the cosworth parts? Might have to start collecting some parts

I would say the whole engine goes into it, they spend a lot of time on research and development and i guess that shows when im making 315kw at 19 psi and full boost at 4000rpm. It feels better than the old sti 2.0L/vf34 combo, but with massive top end I have a Cossy manifold sitting here, so i might have to put it on and see what happens

If you need a good price on any parts just let me know

Fair enough. If only I had a spare 20k sitting around for a new engine! How does a Cosworth manifold differ from what you've got on at the moment?

Basically its a high volume inlet manifold with larger and smoother flowing runners and larger plenum. When you are chasing big power, the standard manifold starts to become a restriction. If you have a look at my dyno sheet, power starts dropping off after 6900rpm, this is due to the restrictive intake manifold according to my tuner.

Cosworth Intake manifolds through testing have proved to not lose power down low while making substantial improvements in the mid-high end.

Maybe I'll have to look at one of those too, with cams and new rods

They are all in stock We have the intake manifold's on sale at the moment for $1399 (RRP $1899), price won't be beaten

I can't wait to get one on and see the results...

Are those cams in your engine 272s?

278/274, they are the bigger cams.

Cosworth do the bigger cams in their heads as they do a major port job and oversize valves, springs etc so they can make use of the bigger cams.