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Old 08-19-2007, 12:00 AM   #1
PhilSine
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98 OBS-T, 91 Legacy SS

Default 98 OBS-T build

Well...its time for my story and build results.

Shortly after I bought my car, a friend of mine informed me that he had a 3" turbo-back exhaust from an 02 WRX and that it would bolt right up to my 98 OBS in terms of mounting locations. It wasn't just any turbo-back, it was a cat'd stainless steel Borla turbo-back. So, I had my local exhaust shop fab up a race pipe complete with O2 sensor bungs and proceeded to install the pipe. Prior to the install, I bought a Borla header for the EJ22 single port from a fellow board member for $175 shipped. After bolting on the header-back exhaust, I realized how loud it was. The exhaust shop owner and son agreed that it was the loudest, meanest sounding sport-compact exhaust they had ever seen (it was Harley Davidson loud). They loved the boxer rumble as did I but the noise wasn't too enjoyable and I felt it would only be a matter of time before I got a ticket for my exhaust. I drove for just over 4 months with that exhaust as loud as it was and managed to not get any tickets. Shortly after bolting it on, I started exploring options to quiet it down. I knew I always wanted a rally car and knew that I'd need more hp in order for the car to compete even in an amateur class so, I started researching what it would take to turbo my car; after all, I already had a cat'd down-pipe.

Step one was to do research and see how much boost I could run and have the car be reliable. I read several posts where some ran 11 psi reliably and other posts that had engines blowing at anything above 11 psi. With that info, I settled on around 8 psi as not to get too close to the limit. I started researching and ordering stuff and the more I researched, the closer I came to my decision. For about $1200-$1500, I could have a high compression turbo'd Subaru. As the project went along, the final bill ended up around $2k but that was because I had to buy a second used turbo for $200 due to the first turbo having a cracked housing in the center part. So, $1800 was my final tally with respect to the original build had that turbo not been bad. It could have been cheaper but I opted for a safer, more reliable, and consequently more expensive engine management system (Greddy E-Manage Ultimate) and underestimated the prices on a few things like a wideband O2 sensor and controller cable. The Ultimate was worth it. Prior to this project, I had no experience at all with turbo's, wideband O2's, or engine managemet. Here I am, 6 months after the research began and 4 months after the initial build and the car runs great. One thing that I did that I felt was key to the project was a compression test before I loosened one bolt for the turbo install. I'm still tweaking it a little and my clutch has worn as a result of the extra power and will be getting it replaced (already bought a 9.5 lb flywheel and will buy an ACT clutch) in the next two months but its been worth it. If my reliability maintains, in two years or so I'll add a Tein suspension, weld in a roll cage, racing seats, etc. and hit a few rally events in my area. Nothing serious, just some good fun in a controlled environment.

Parts list...
3" cat'd stainless steel Borla turbo-back
Borla NA header
Custom up-pipe
'05 STi yellow 550cc injectors
'04 WRX fuel pump
'04 WRX TMIC
'04 WRX TD04 OE turbo
Cooler plugs (NGK BKR7E-11)
New Borg Warner premium Super-mag core spark plug wires (PN: CH74166)
Greddy E-Manage Ultimate engine management system w/ultimate cable (bought seperatly) and O2 sensor option harness (bought seperatly).
Innovate Motorsports LC-1 wideband O2 sensor and controller cable.
Several brass tee's and fitting for oil feed/pressure sending unit tree.
3/16" brake line for turbo oil feed from tree.
Rubber brake hose from steel line to turbo from some unknown automotive brake caliper application. I used it because it meets the pressure and heat standards necessary and it has a banjo fitting.
A bunch of NPT elbows and fittings to make oil drain connect from turbo to valve cover fitting.
Oil drain fitting bought on eBay to bolt and RTV to valve cover. I had to remove the passenger side cover and use flat headed lag-style bolts with the heads on the inside as not to interfere with the valve train.
Turbo exhaust gaskets from Subaru (they're the cheaper and better from Subaru than the eBay ones).
Several other exhaust gaskets for the header and cat-back sections.
Several hundred feet of wire feed because I'm such an awesome welder and I like welding the same header over and over again.
A whole bunch of hose clamps for every hose I added or spliced into.
Hoses of varying sizes for vacuum, PCV, coolant, intake junctions, etc.

I think that's about all of it.

Pic 0...CAI

This is what my engine looked like pre-turbo

Pics 1-4...home-made up-pipe








I had fun trying to snake the up-pipe up and around teh CV shaft.

Last edited by PhilSine; 08-19-2007 at 10:12 PM.
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Old 08-19-2007, 12:05 AM   #2
PhilSine
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02 WRX Wagon (WRB)
98 OBS-T, 91 Legacy SS

Default

Pic 5...Heat Shield


Luckily I had some scrap aluminum around that serves well to protect the essential wiring in that area.

Pic 6...Oil Drain

This has since changed a little to eliminate where it was pinching and restricting flow but the concept stayed the same.

Pics 7 and 8...Oil sender/feed tree




I emptied a few auto parts stores Dorman cabinets out trying to put this together. I tried to do it with the alternator intact but ended up having to remove the alt to get things in and tight.
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Old 08-19-2007, 12:12 AM   #3
PhilSine
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98 OBS-T, 91 Legacy SS

Default

Pic 9...Side view with turbo



Tight fit, but its in there

Pic 10...TMIC W/O turbo on


Painted flat black to hide better under the hood scoop

Pic 11 and 12...Flipped TB




Since I can't change the laws of physics, and the accelerator cable and BPV can't occupy the same space, I had to move one or the other. I chose to flip the TB in order to be able to leave the BPV in its OE location.

Last edited by PhilSine; 08-19-2007 at 11:08 AM.
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Old 08-19-2007, 12:17 AM   #4
PhilSine
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98 OBS-T, 91 Legacy SS

Default

Pic 13...Overview of near finished product


All that's left to do is to route the outlet of the BPV to the intake to quiet it down.

Pic 14...Close-up of final product

Notice the pipe that connects the output of the BPV to the intake? In my case, this helped responsiveness a bit and stopped my fuel map from getting way too rich at partial throttle.

Pic 15...Guages


Finally, my information center. From left to right...Oil pressure (Autometer Cobalt), AFR (digital) (V-Guages...very nice), Vacuum/boost (30 in/hg-20psi (Autometer Cobalt)).

I opted for vacuum/boost because I like to know what my intake is doing at all times so I can spot evidence of vacuum leaks.

Last edited by PhilSine; 08-27-2007 at 09:42 PM.
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Old 08-19-2007, 12:21 AM   #5
PhilSine
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02 WRX Wagon (WRB)
98 OBS-T, 91 Legacy SS

Default

So...that's it for now. Have a few pin-hole header leaks (paper thin Borla headers) and the BPV to intake tube which I have all the stuff for I just need to finish re-connecting the power cable to my garage so I can use my welder and I'll be done short of getting a MBC because my turbo only puts out 7 psi and I'm aiming for 8 as stated above. The OBX MBC's seem nice as they're the only ones on eBay that advertise failure protection. I might build a new header from scratch that's not as thin.
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Old 08-19-2007, 12:36 AM   #6
PhilSine
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98 OBS-T, 91 Legacy SS

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Start to finish side-by-sides

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Old 08-19-2007, 01:17 AM   #7
EPskate
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nice, how's the car feel?
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Old 08-19-2007, 11:01 AM   #8
PhilSine
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98 OBS-T, 91 Legacy SS

Default

At this point I'm not really sure how the car feels to its full potential because just as I got it close to dialed in with tuning the clutch went south very fast and I haven't had a chance to drive it hard through all the gears.

Prior to the clutches current condition, and without a really good tune, it definately feels fast. The speed is really deceiving. Off the line, its a bit doggy because after all; it's still a NA EJ22. Once the turbo kicks in full and I hit the meat of the power band, it really takes off. At no point does it really pin you to your seat like a muscle car might but when you look down and realize that you're giong 90 mph and you barely just took off, you understand that it is a decently fast car.

It's certainly not a drag racer but that's not what I'm building it for anyways. That 4k rpms plus power band is right where I need it to be for hard 3rd and 4th gear driving. On the dirt, it breaks the tires loose when up-shifting in 1st through 4th so I'd say the power is there.
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Old 08-19-2007, 11:08 AM   #9
mxpunk
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Nice! Been waiting to see these pics for awhile.

If you put some t-leg pistons in there and crakn up the boost I think you'll be making enough power to break the tires on dry pavement.

A boosted NA 2.2 motor looks like fun as a stock 2.2, IMO has a nice torque curve in NA form.

So let me get this straight..you made an up pipe that puts the turbo in the stock location of a stock subaru turbo motor? Sweeet
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Old 08-19-2007, 11:13 AM   #10
PhilSine
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98 OBS-T, 91 Legacy SS

Default

It will break the tires loose on dry pavement but not for very long because of the AWD and all. Best rubber I've laid is about 3 feet long from all four wheels. It was kinda cool to see the pavement after because the ass-end kicked out just a tad and you can distinctively see all four tire marks. It won't break em loose in anything but 1st. Does anybody's AWD break em loose in 2nd or 3rd on dry pavement?
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Old 08-19-2007, 12:41 PM   #11
Handsdown
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no, not unless they have far north of 500 hp.


this is a great build! that e-manage ultimate must really be doing its job well. good work!
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Old 08-19-2007, 02:33 PM   #12
silentt
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I loved your writeup to go along with these pictures. There are a few more here than what you e-mailed me and things really make sense now.
Thanks a ton for your help with my endeavours and I'm glad to see that your project worked out. I can't wait to see what it'll be like once you get the new clutch, MBC and tune it up.
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Old 08-19-2007, 06:03 PM   #13
midnight2.5rs-t
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had my friends wrx with 405 at the wheels break loose in third, but i was driving it kinda hard.
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Old 09-07-2007, 07:40 PM   #14
SubaruImpreza_power
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Is that a Wrx intercooler? How did you get it to fit?
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Old 09-08-2007, 12:36 AM   #15
PhilSine
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98 OBS-T, 91 Legacy SS

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Quote:
Originally Posted by SubaruImpreza_power View Post
Is that a Wrx intercooler? How did you get it to fit?
Yes, that is a WRX intercooler (see parts list at top of thread for all parts used and from what vehicles). <---Not trying to be a smart-ass but rather noting that I listed parts as best as possible so anybody desiring to duplicate my efforts has some sort of a shopping list.

I got it to fit by trimming the output of the TMIC, trimming the input of the TB, and beating the crap out of the firewall with a big hammer while avoiding the vacuum (or maybe brake) lines that run along the firewall in that area.

I'm not sure if you're a fan of convincing things to fit in that manner but its my outlook that if you're modding the car like this, you're probably not too concerned with resale. I know I'm not.

Feel free to toss as many questions my way as you want and I'll do my best to help you out.
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Old 09-08-2007, 01:05 AM   #16
SubaruImpreza_power
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Quote:
Originally Posted by PhilSine View Post
Yes, that is a WRX intercooler (see parts list at top of thread for all parts used and from what vehicles). <---Not trying to be a smart-ass but rather noting that I listed parts as best as possible so anybody desiring to duplicate my efforts has some sort of a shopping list.

I got it to fit by trimming the output of the TMIC, trimming the input of the TB, and beating the crap out of the firewall with a big hammer while avoiding the vacuum (or maybe brake) lines that run along the firewall in that area.

I'm not sure if you're a fan of convincing things to fit in that manner but its my outlook that if you're modding the car like this, you're probably not too concerned with resale. I know I'm not.

Feel free to toss as many questions my way as you want and I'll do my best to help you out.

dang I just saw the parts list dunno how I missed that.. but anyways the fitting of the IC can you just pound on the firewall and not have to trim the TB or is the unavoidable?
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Old 09-08-2007, 09:57 AM   #17
PhilSine
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Quote:
Originally Posted by SubaruImpreza_power View Post
dang I just saw the parts list dunno how I missed that.. but anyways the fitting of the IC can you just pound on the firewall and not have to trim the TB or is the unavoidable?
To do it all again I would simply have gotten a slightly smaller intercooler. Bout 1.5" less of width (front-to-back) would have done just fine and an inch thinner than that would be sweet.

Doing what I did is unavoidable if an OE TMIC is your only option.
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Old 09-08-2007, 10:56 AM   #18
SubaruImpreza_power
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Quote:
Originally Posted by PhilSine View Post
To do it all again I would simply have gotten a slightly smaller intercooler. Bout 1.5" less of width (front-to-back) would have done just fine and an inch thinner than that would be sweet.

Doing what I did is unavoidable if an OE TMIC is your only option.
yeah I guess a FXT IC would be a good fit but I'm stuck thinking now go with the EJ18 or stick with trying to get the EJ22 N/A
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Old 09-08-2007, 01:43 AM   #19
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FXT intercoolers > wrx intercoolers for NA-T projects on gc body cars!!!
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Old 09-08-2007, 01:45 AM   #20
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Quote:
Originally Posted by mxpunk View Post
FXT intercoolers > wrx intercoolers for NA-T projects on gc body cars!!!
Hmm forgot all about that
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Old 09-08-2007, 03:26 AM   #21
i2onin
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nice build.
any chance of you making another uppipe, or posting dimensions of your custom uppipe?
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Old 09-08-2007, 10:00 AM   #22
PhilSine
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Quote:
Originally Posted by i2onin View Post
nice build.
any chance of you making another uppipe, or posting dimensions of your custom uppipe?
That's a tough one. It was an all eyeballed fabrication with no real set dimensions and in order to duplicate it I'd have to remove it and all that stuff. It'd need to be made worth my while before I'd consider doing that.

So...make it worth my while and I'll do it.

I'm not trying to come off as a greedy jerk but with this car being my daily driver and it being a pain-in-the-ass to drop the up-pipe I'm reluctant to do it.

If I can figure out how to do it without dropping the up-pipe I will. Also, if there is enough of a need to, I can look into having several made by my local shop just as I will be looking into having replica single port Borla headers made.
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Old 09-10-2007, 02:28 AM   #23
i2onin
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Quote:
Originally Posted by PhilSine View Post
That's a tough one. It was an all eyeballed fabrication with no real set dimensions and in order to duplicate it I'd have to remove it and all that stuff. It'd need to be made worth my while before I'd consider doing that.

So...make it worth my while and I'll do it.

I'm not trying to come off as a greedy jerk but with this car being my daily driver and it being a pain-in-the-ass to drop the up-pipe I'm reluctant to do it.

If I can figure out how to do it without dropping the up-pipe I will. Also, if there is enough of a need to, I can look into having several made by my local shop just as I will be looking into having replica single port Borla headers made.
how about if i send you a hyper rev impreza owners bible?
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Old 10-17-2007, 11:13 PM   #24
dome24
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any word of having some up/down pipes made?
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Old 05-21-2020, 12:21 PM   #25
Favila889
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Default Obs 98 owner too

Hi i have a obs 98 i was looking into your parts list for the borla turbo-back catd did you have to contact them directly to get it and the wrx oem parts do you know of a good market place where scooby owners sell there oem after installing aftermarket
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