Out with the old...in with the new...Britain's Racecar Development, Subaru Engine, Lotus Suspension! Time to go racing! Options

[Britain Smith]

For those who don't know me or the car, I have a '74 914 that is a dedicated AX car. It previously had a high compression 2.7 6-cylinder motor and made 205hp/205ft-lbs at the wheels. This set-up wasn't all that bad considering that it won the 2008 and 2009 914 Shootout events, however the quest for more speed continues.

Here is the car in the 2010 season trim.

(IMG:http://www.914world.com/bbs2/uploads_offsite/dragracevws.com-364-1291656786.1.jpg)

I have recently sold the 2.7L 6-cylinder engine and all the remaining 914/6 conversion parts. I have used the proceeds to fund the conversion to Subaru power. Now most would say that a Subaru conversion can be done on a budget, however I have found that the money goes flying out the window when doing something like this.

Regarding the engine...logical choice would be to go for a EJ257 2.5L USDM STi engine. However, all the SCCA rules for AX are built around displacement which in turn dictates the minimum weight. Therefore, I have gone with a JDM STi version8 Spec-C engine which is a 2.0L, twin-scroll, hand ported/polished, 8500rpm animal. I will get slightly less hp and torque numbers than the 2.5L, but save 150lbs of weight.

[Britain Smith]

So, I have been working on the conversion for about a month now and have made significant progress. My goal is to have it running on the dyno by end of Jan. That will give me time to clean it up and complete some of the cosmetic items before the season starts.

Here is the engine as it arrived:

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656788.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656788.3.jpg)

First thing I did was strip it down to the longblock and start cleaning things up.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656789.4.jpg)

It is mated to the original Porsche 914 transmission with an adapter plate from Outfront Motorsports. Because I now have the Porsche bolt pattern, I could use my Porsche engine stand yoke...Bonus!

(IMG:http://www.914world.com/bbs2/uploads_offsite/l25.sphotos.l3.fbcdn.net-364-1291656789.5.jpg)

Here is a nice view...factory ported heads.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656809.1.jpg)

Ok, back to work...

I mounted a Outfront Motorsports alternator relocation kit to flip the alternator to the side. I also flipped the intake manifold as this is how it will fit into the car.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656809.2.jpg)

Now for the moment of truth...will it fit...more specifically, will it fit like I want it to. Here is the first stab into the chassis.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656810.3.jpg)

[Britain Smith]

First thing I did was cut out the 914/6 bulkhead engine mount in front of the engine...you will see why I did this in just a bit. You can also see the nice stainless steel fuel lines that I installed here.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656827.1.jpg)

Back to the engine block. The JDM Spec-C came with an external oil cooler. This engine also had an additional sandwich plate for oil temp sensor. This stack was way too long and would put the oil filter at the lowest point of the car.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656827.2.jpg)

This is how long the oil filter mount bolt was to accommodate this length. I have since ordered and fitted a oil filter mount bolt from an N/A engine and it eliminate all the extra lenght so now I just have the oil filter mounted directly to the block.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656827.3.jpg)

[Britain Smith]

I purchased the Synic Motorsports header which is equal lenght, but not exactly for a twin-scroll set-up.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656847.1.jpg)

With the header installed on the engine, you can see the engine mounts that I am utilizing for the conversion. They are actually for a Vanagon conversion, but with a little modification they fit just fine.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656847.2.jpg)

Back to the header...the first order of business was chopping off the pipes right after the merge collectors...getting closer to a twin-scroll set-up.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656848.3.jpg)

The only problem was that when I cut off the pipes, I was faced with a failed attempt at properly building a header. The merge collectors were not the highest quality that I have seen.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656849.4.jpg)

Little bit of time with the die grinder and they look much more acceptable now...and I bet the flow better.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656849.5.jpg)

Ok, now with the header mounted you can see my thinking on the positioning of the turbo.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656850.6.jpg)

With the engine back in the car and everyone suspended with straps, you can see how the turbo will fit just perfectly in the factory recessed firewall location.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656851.7.jpg)

To get the turbo in the correct orientation, I had to re-clock the compressor side. To do this, I took off the small retaining bolts/clips, applied a little heat and some motivation from a mallet and it popped right off.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656851.8.jpg)

[Britain Smith]

Now that I have an idea where the turbo will fit and how the headers route around the engine, I could fab up the engine mount bar. The bar attaches to the Vanagon mount that I showed earlier and extends to the frame rails. At the frame rails, there are rubber bushings. Here is the engine suspended in the car for the first time.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656988.1.jpg)

Now I just have to connect the dots between the exhaust ports and the turbo...

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656988.2.jpg)

Here is the turbo hard mounted to the engine mount bar. I had two threaded bungs machined that the turbos mounts to.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656989.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656989.4.jpg)

I found it difficult to source JDM uppipe and downpipe flanges for my use, therefore I just had them waterjet at a place down the street. I am running external wastegates so the internal wastegate port was blocked off. They turned out fantastic and if anyone needs a pair, just let me know and I can get them cut for you.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656989.5.jpg)

Using left over piping that I had cut off the header, I fab'ed up the connecting pieces for the header to the turbo.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656990.6.jpg)

Here it is mounted in the car...everything fits like a glove.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656990.7.jpg)

With the turbo mounted in this location, the gravity drain has no where to go to get back to the oil pan. I was very restricted on space, so I had to fab up a custom drain pipe using the oil coolant hard lines off the engine.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656990.8.jpg)

It is all downhill back to the oil pan...just barely.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291656990.9.jpg)

[Britain Smith]

With the engine mounted, it was time to address some necessary items on the chassis. First off was the radiator. Here is my first mock-up of the radiator location. This one is 16x22, however I went with a 14x22 to add some additional clearance. It will mounted it at about a 30deg angle in the front trunk and vent it out the hood. It will also have a Spal fan mounted to help with cooling while sitting in the pits between runs.

My tiny 5 gallon fuel tank is just not going to fit properly and I will probably have to make a new one that is narrower and wider.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657017.1.jpg)

The radiator lines are Gates Yellow-Strip hose snaked throughout the body. In the front, I opened up some of the body panels and run the lines thru.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657017.2.jpg)

In the cabin, the lines jog over to the frame rails and down what used to be the heater ducting tubes.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657017.3.jpg)

In the engine bay, they come out of the heater duct tubes and will connect to the engine.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657017.4.jpg)

One issue with the engine mount bar that I fabricated was the clearance for the thermostat housing cover.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657018.5.jpg)

After a little sleuthing around ebay, I decided to take a chance on a Subaru 3.0L engine thermostat housing which was for sale for pretty cheap. Here you can see the differences.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657018.6.jpg)

Low and behold, it fits and gives me just enough clearance...

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657018.7.jpg)

[Britain Smith]

While waiting on more parts, I decided to start tackling the wiring nightmare. Unlike a lot of swaps on here, I have no WRX to compare to. Nor was I able to initially locate the proper wiring diagrams. Therefore, I started by mapping out the entire engine harness. This should be all the wires that I need to make it run.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657038.1.jpg)

Here is my daughter lending me a hand.

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Here is the harness about 90% done. I have a few more issues to work out in regards to main power and ignition power, but it is basically ready. I will clean all of this up and make it look nice and pretty after the engine is running.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657038.3.jpg)

Here is the engine with the harness back installed and just about completed.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657038.4.jpg)

[Britain Smith]

The beautiful pair of Turbosmart wastegates, Turbosmart Blow-off Valve, and Turbosmart Fuel Pressure Regulator...pure works of art.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657087.1.jpg)

[Britain Smith]

From this weekend.

First order of business was rerouting the water coolant lines coming off the waterpump housing. The Outfront Motorsports bracket interferes with the stock routing of the heater hardline and the line that goes to the coolant reservoir tank was pointing in the wrong direction after it was relocated. Therefore I got some extra hardlines and starting cutting and welding away.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657137.1.jpg)

Here is the pipe off the back of the water cross-over pipe. I am obviously bypassing the heater core but that line was interfering with the bulkhead.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657137.2.jpg)

Fab'ed up a small bracket to secure the Turbosmart FPR to the intake manifold. Had to order some additional AN fittings for the fuel line routing $$

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657138.3.jpg)

Finally got started on the exhaust downpipe routing. Here is the front section, however I still have to stuff two wastegates in here.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657138.4.jpg)

Here is the routing down the length of the car. You can also see the bracket I made to secure the Coast Fabrication Muffler.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657138.5.jpg)

This muffler weighs less than 5lbs. This one was scuffed a bit so I got it less than half off...gotta love the scratch and dent sales. I sure hope it is quiet enough to pass sound regulations...if not, I might be adding another.

(IMG:http://www.914world.com/bbs2/uploads_offsite/sphotos.ak.fbcdn.net-364-1291657138.6.jpg)

Got to get some additional flanges cut at the waterjet place today and then I can finish up the wastegate routing.

-Britain

[Britain Smith]

Well, that is about a month worth of effort...time goes by quick when you are doing this sort of stuff.

-Britain

[JmuRiz]

Looks like a lot of work, I'm sure it'll be a rocket seeing the motor you got rid of to upgrade to this!

[Britain Smith]

Looks like a lot of work, I'm sure it'll be a rocket seeing the motor you got rid of to upgrade to this!

Yea, I hope I choose the right path. The car might actually end up slightly lighter with this set-up.

-Britain

[McMark]

So awesome! Everything looks really great!

[Cupomeat]

VERY nice, Installs like this make me want to consider a Porscharu conversion.

Can't wait to see more! (IMG:style_emoticons/default/popcorn[1].gif)

[URY914]

Nice work. Go to see someone doing something different.

[McMark]

however I still have to stuff two wastegates in here

Why two wastegates? Staged?

[Britain Smith]

Because it is a twin-scroll turbo. If you merge the two headers for a single wastegate then the benefits of twin-scroll in terms of exhaust pulses is lost.

-Britain

[Rand]

Nice work Brit! Can't wait to hear your impressions after racing it.

[McMark]

Because it is a twin-scroll turbo.

Apparently I have some Googling to do tonight.... (IMG:style_emoticons/default/idea.gif)

[0396]

Very very nice! I can only wish I had the skills to do what you've just accomplished!

Once done..your going to kick some A with that set up:)
Congrats and good luck!