2004 STi engine build

...:UPDATE:....
So it's almost been two years so it's time to follow up and edit this thread...
I ended up getting the short block built by True Street Industries in El Paso and they brought it down to Phoenix once done. The heads were machined and assembled by Car Parts Machine Shop in El Paso so all I had to do was throw the heads on and drop in the engine.

Starting with the mod list:

Manley 100mm pistons
Manley I-Beam rods
ACL main and rod bearings
Killer B oil pickup
11mm oil pump
GReddy oil catch can
GSC 272 camshafts
GSC +1mm valves
GSC Beehive valve springs
Cometic head gaskets
ARP head studs
TGV deletes KSTech block off plates
Gates timing belt and kit
Gates a/c and alternator belt
Cobb crankshaft pulley
Fujita intake
Agency Power Turbo inlet
Forced Performance td06 20g
Walbro 255lph fuel pump
Modded side feed 900cc injectors

As of two weeks ago, the whole car was completely done and tuned through IA Performance. Unfortunately after 120 miles, I started hearing some internal noise so I took it to RA Worx/Snail Performance out here in Phoenix to get checked out. Turns out there was too much RTV used while assembling the case halves so it got into the oil galleries...long story short I need a new crankshaft, bearings obviously, and a new block (or sleeves )

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Also here is a clip of the car when I first fired it up
http://instagram.com/p/tGNG5zkE6Q/

Why not just delete the TGV yourself and just spend $60 on the Cosworth Delete Plates? That's what I did. Same thing….

Also, why are you using GSC? You could go with BC cams stage 2 or 3 (272 or 280) for much cheaper than the GSC price you listed. Also Tomei makes a set that's about $50 cheaper. Go with a Deatchwerks 300+ pump, it actually pumps out approx. 380 lph at cheaper than the 340. I've been running it and I love it, drops right in too.

Ok so as far as the TGV deletes im gonna need a little bit more info from you because $60 sounds way better than $750 lol
As far as the cams I might just go with the BC stage 2 along with some BC valves! But im now stuck with the valve sizing
Whats up with the short valves/long valves and should i look into the +1mm?
I think im just gonna run stock turbo, injectors, and fuel pump after the build just until i save up some more.

I don't really know about sti but BC for evos are a waste of money, I have gsc s2 on my car and F*** love them. 1000cc are very big for stock turbo well if it was on an evo lol im very ignorant when it comes to sti's

ER04STi wrote:Ok so as far as the TGV deletes im gonna need a little bit more info from you because $60 sounds way better than $750 lol
As far as the cams I might just go with the BC stage 2 along with some BC valves! But im now stuck with the valve sizing
Whats up with the short valves/long valves and should i look into the +1mm?
I think im just gonna run stock turbo, injectors, and fuel pump after the build just until i save up some more.

Pretty simple to do. You actually don't "HAVE TO" really even spend $60 if you want to do it the cheap and simple way.
Method 1: When deleting the tgvs, for maximum airflow you remove the plates and bar that holds the plates, dremel out the extra metal "stopper" flap, and install the plates where the tgv motors used to go. Will need to have the holes for the bar filled with solder or other fill of choice (something that will not come loose and get sucked into the valvetrain and cylinders). To do it this way, you will get a check engine light for a TGV error until you tune the ecu to stop looking for it.

Method 2: Simply remove the plates and dremel out the extra metal "stopper" flap. Re-install the bar and tgv motors/sensors. No plates necessary. No check engine light

Both methods will remove airflow. Method 2 is acceptable for most unless you''re trying to chase big numbers and push limits, as it only get's a little less airflow than method 1. The only reason you would want the APS is because you're chasing absurd HP numbers.


A question for you as you seem to be somewhat on the fence now with what you think you want. What is your ultimate goal for the car? Are you chasing numbers, making a dedicated drag car, autocross car, etc...? Is there a specific hp goal in mind? How do you want the car to behave?

I ask this as that when you start going with oversize valves, larger cams and adjusting CR, you're going to drastically change the way your car behaves.

evo my evo wrote:I don't really know about sti but BC for evos are a waste of money, I have gsc s2 on my car and F*** love them. 1000cc are very big for stock turbo well if it was on an evo lol im very ignorant when it comes to sti's

Yea plus the GSCs are just a few bucks more but im still looking around. as far as the injectors they are staying stock until i upgrade my turbo lol

WANTED wrote:

ER04STi wrote:Ok so as far as the TGV deletes im gonna need a little bit more info from you because $60 sounds way better than $750 lol
As far as the cams I might just go with the BC stage 2 along with some BC valves! But im now stuck with the valve sizing
Whats up with the short valves/long valves and should i look into the +1mm?
I think im just gonna run stock turbo, injectors, and fuel pump after the build just until i save up some more.

A question for you as you seem to be somewhat on the fence now with what you think you want. What is your ultimate goal for the car? Are you chasing numbers, making a dedicated drag car, autocross car, etc...? Is there a specific hp goal in mind? How do you want the car to behave?

I ask this as that when you start going with oversize valves, larger cams and adjusting CR, you're going to drastically change the way your car behaves.

Thanks! Overall im looking to go for 450-500whp range. Its still going to be my daily till i get another car (big mistake i know) but will be taking it out to the drags, maybe a few autocross events. Not wanting to go to big on this thats why im going with stage 2 cams nothing higher.

I did find some GSC +1mm valves so ill probably go with those. Quick question though, for a 500+ whp application, do you think the oem gasket set will hold or should i upgrade to some cometic gaskets?

If you do +1 mm valves you're going to need more machining and stuff done. I run bc cams and bc oversized valves and I have no problem with them. S*** even the cylinder that melted, the valves are still perfectly fine. Bc makes good stuff. Honestly, I never even heard about gsc until recently. Brian crower himself is very nice as well and has helped me in past situations where I messed up a cam after my motor spun a bearing and he hooked me up with a new one for $50.

I absolutely HATE cometic gaskets in every application I have ever used them in. They always fail prematurely be it in a built or stock car.

While they may cost more, there are better aftermarket options for HGs out there. You'll probably be okay with the stock HG with the headstuds, but if you're going to put all that time and money into the motor how much more is the cost of a good quality HG.

STi2eNvy wrote: Honestly, I never even heard about gsc until recently.

Great googely moogely!!!!!! Where in the heck have you been that you haven't heard of them? GSC makes some good parts.

I'll have to do some research lol. Edwin cosmetics do suck, spend a little more for cosworth

Forgot to mention, on those TGV's you could also have them ported by a machine shop for a little more air flow for still significantly less than those APS ones.

Ok so I can forget the TGV deletes & cometic head gaskets lol. What do you mean more machining? I was jst planning on getting valves, springs, retainers, cams, and porting out the heads

You can port your tgv's like you can port your head to a limited extent if you so choose.

Here's the grimmspeed service

I was going to port everything myself at school but we don't have the machinery to do it I would do it by hand but I don't trust myself enough for all the ports to come out the same lol so decided to take everything to a machine shop. Anyone know a good one where I can take the heads/tgv's? I don't wanna pay $500 per head either lol

Car Parts & Machine shop on texas ave

Same place Lisa told me about but never gave me an estimate lol I guess ill call them tomorrow or maybe even stop by if I get the heads out

No offense, but you definitely get what you pay for when it comes to precision work like that.

Yea I understand & might as well if I'm going that deep into the build for a few hundred more. It'll take me more time to save but it'll have to wait.

Here's some pics of Mondays progress, continuing on it today.

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Just hurry up and yank that mess already. Worst case scenario, all you need is a chop saw, a scissor jack, and a case of beer to get that crap out of your engine bay.

Lol I got it all out yesterday! The thing is I only got 4 hours a day to do it at school so that means rushing all the time & no beer

I'm gonna take some beer in a McDonalds cup
Anyway here are the only pics i took yesterday

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So I finally ripped apart the block & found out everything was actually in pretty good condition. Still rebuilding it regardless And probably will be selling so one of the WRX guys can rebuild

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woah woah woah. You may be selling the STi shortblock? hmmm

I think he probably meant the internals. However, a WRX guy can't use those internals lol