andythejock01wrx

Keep us updated - this is interesting !

What are you doing about brakes ?

andythejock01wrx

PS - remind me not to accept a lift off you until the brakes and suspension are sorted.

carbon

just got some sti brembo's and sti prodrive shocks and springs collecting tomorrow.

Picking up the clutch and bits from subaru this morning.

FMIC is in, will post some pics very soon.

dash is coming out today hopefully. collect the new subframe on monday 8am, ready for a good day.

saxx

iTrader: (5)

errrr... id definately listen to scoobyclinic about the gearbox..

good luck...

carbon

why? Dont come out with a comment like that and have no explanation!!!! I thought we were all here to help each other.

Scooby clinic recon 6 days to change the car wiring loom?

Will have to see, using GX gearbox, GX flywheel and a modified Sti clutch, clutch plate and bearing. its all coming together a bit more now.

Pics are on my phone....

Tonight i promise.

Krinara

Wow, what an interesting project. Can't wait to hear and see the final result!
It's interesting to read that the GX and WRX have the same gearbox. Why are the WRX's more expensive then?
Anyhow, good luck with your monster GX!

TonyBurns

iTrader: (3)

Your going to need to do some serious thinking about that gearbox/rear diff (2k ish) and brakes (500+) so add that to your figures... the standard gearbox will fall apart, its not designed to take that sort of power, even a wrx gearbox wont hold up too long with the torque these engines can pump out, your 12k would have been better spent on an STi with all the bits on to start with, your figure is rapidly approaching the 8k mark if its not already passed it, nice to see you going for this but tbh, your fighting a losing battle when you could have the real thing for less cash

Tony

TonyBurns

iTrader: (3)

Same gearbox but not the same gear set?

Tony

ScoobyDoo69

iTrader: (17)

As Tony said, same box, different gear box and ratios. He will eat the GX gearbox! Having owned a sport before my WRX I can tell you they are different before anyone contests.

carbon

is anyone speaking from experience saying that the gearbox will smash??? or just saying what they presume will happen because of a huge increase in power. What exactly will smash that cant be replaced or made stronger?

TEG motorsport recon different, and im confident of putting it in with the GX box.

If not I can get a box and rear diff for £450 so it isnt a great deal of extra cash. Im hoping that with the lighter GX flywheel and 5 speed box its going to be a bit quicker acceleration wise.

Brakes are sorted, Sti brembo's will be on tomorrow night.

Its worrying that people give in so easily these days. When i spoke to scoobyclinic about the box they said exactly the same, that it would smash.... i asked what the alternative was, they said buy a sti.. They cant supply me with a stronger gear box or suggest alternatives so the project stop's. If that was the case countrywide the country would be in more of a shambles than it all ready is!

I own my own fabrication company, and if i took the same attitude as other companies have taken I would have given up ages ago.

The engine will be fitted, and i will be proud of it when its done. Its a very exciting project and not an easy one. I like a challenge

ScoobyDoo69

iTrader: (17)

You can buy a WRX gearbox and it will be fine.. for a bit. I know of people who have broken sport gearboxes in the sport, let alone with the WRX engine. It is not made the same. 1 hard launch and it's dead, or you'll boot it on the motorway and strip a cog !

carbon

A sport is a compleatly different car to the GX. There older classic shape car's, are they even 4wd?

Why would it strip a cog, surely the clutch would fail first?

I would expect the clutch to be the failing part, but not to strip a cog.

carbon

couple of pic's

Intercooler


carbon bonnet



pre-strip and conversion



ecu



more to follow, shortly

carbon

new tyres



new block waiting to go in!



old block out and flywheel striped, along with the gearbox housing ready to make the clutch fit.



gearbox striped, ready to be lowered and clutch / flywheel / engine joined together, then lifted into car, new subframe then to be bolted up underneath it.



the old subframe, sits too high, sti one must be smaller in some way will find out monday!



the daily driver and general run about. V8 power!



done for today now. Up early in the morning to collect brakes and suspension and some other bit's!

Its all good.

ScoobyDoo69

iTrader: (17)

They have the same engine, gearbox ,etc. Just a different body, hence heavier and slower!
how would the clutch give way if the clutch is designed for the power and the box isn't? You're putting an Sti clutch on right? That won't slip, instead it will take the pressure out on the gears. Good luck to you, but seriously, just go and buy a wrx gearbox and rear diff and you won't have to worry as much as the gx box! Even with the WRX box I'd worry, let alone a GX box :|

carbon

was going to put a hybrid of a sti and a gx clutch, but it wont fit. so im going to have to fit my flywheel off the gx, the gx clutch and gx clutchplate to the new engine.

I personally cant see why the gx gearbox wont take the power. why isnt it as strong? can someone tell me a reason why, perhaps the metal used in machining the cogs is different? we shall see!

ScoobyDoo69

iTrader: (17)

It's just not made the same, it's made using cheaper materials for a cheaper car. So it's not as strong. If you're using a gx clutch.. then that will probably slip almost straight away after a few miles. Or your clutch will just constantly stink. If it could handle the power, do you not think Subaru would have fit them to the more powerful models also to save money ? ?

carbon

no I think they would fill a booklet up about DCCD etc and how its 6 speed and try to justify the 20k price tag. Or try and develop something that is as technological as its well known rival.

A 6 year old 5 speed box isnt up there with the techno giant's. But it may be capable.

and seriously how much do you think subaru pay to manufacture a gearbox? i bet the difference in GX and STi cost wise is very very little. So there is no benafit to them other than Public relations wise.

Like I keep saying we will see. Engine and loom will be fitted by tuesday night / wednesday so it shall be tested then. I have another gearbox available so im not at a total loss.

I have nothing to loose by trying it.

Spyder550

Does your GX box have a cable operated clutch or Hydraulic. As the cable operated clutches are conventional push clutches where as the clutches generally fitted to Turbo's are pull clutches. The gearboxes/bellhousing are different because of it too. You can use a non-turbo 2.5 push clutch which are available in an uprated format from Exedy. In the project I am building I did look at using a 2wd non-turbo box mated to a turbo motor but the cost of the uprated 2.5 clutch meant. It was easier to use a turbo box and convert it to 2wd

carbon

thats where the problems came fitting the sti clutch. Mine is a pull clutch and because of this is sits a lot flatter in the bell housing and the clutch casing. THe sti is a push clutch and about 8/9mm bigger radius of it so meant it didnt fit at all.

I dont mind replacing the clutch more often as its not a big job. Im trying to stay within buget and a new box would mean that im not far off failing.

What size is the 2.5 clutch? will it fit in place of my GX item?

Thanks for the comments I appreciate your help.

Spyder550

Sure you haven't got push and pull the wrong way around? Push or pull refers to the clutch cover plate
Is your existing set up a cable operated jobby if so the clutch is push. If you have a pull clutch you will have a hydraulic cylinder and when you seperate the pull clutch gearbox from the engine you have to remove the clutch arm yoke from the bearing by removing the pivot

Spyder550

Oh you can get the 2.5 non turbo push clutch in 225-230 diameter

Explaination about the clutches here

Clutch

The Exedy USA website lists the clutches you can get
EXEDY Globalparts Corporation

carbon

yeah there the right way round, i have a yoke that is too small to fit the Sti bearing, it goes around either side of the GX bearing and slots into two holes.

It also has a hydraulic cylinder on the pedal too...i think.

The clutch arm yoke has been removed, thats when i noticed the difference. with the differences in size on the clutchs i cant even take them apart and make a hybrid, siza is the issue.

carbon

looking at the exedy website there may be some hope of getting a 2006 wrx in the same format, they seem to have changed to pull clutch for some reason? and also the 2004 us ones are pull type.

mmm, maybe there is some hope for a stronger clutch!

whats your verdict on the actual gearbox spyder550?

Spyder550

Personally I would say use a turbo box, as you can use OE clutches and parts then. Exedy UK don't stock the uprated non-turbo stuff for 2.5's (I rang them). The uprated clutches in the US aren't cheap either, even before you import one.
Best bet would be to get a turbo box, I paid £300 for an 05 5speed one via ebay, and sell your existing one.

As regards your subframe, the turbos have sunken area to the outside of the engine mounts, this is to clear the up-pipe. The non-turbo's don't have this, well at least in classic shape. I would guess from your comments your GX doesn't have the sunken area either. I have a unused turbo one you could have for nowt but I am at the wrong end of the country

Gear Head

iTrader: (2)

I just don't see the point of throwing all that cash at a gx.
Does the car have any sentimental value?
And don't have a pop at other people just because they don't agree with you.
They did say in the beginnng that you'd need a different box.......and look at what you may now have to buy.

carbon

yeah thats right it has a sunken bit where the exhaust goes. but my GX sits higher. Thank you very much for the offer mate, hopefully one day i can be as generous to you, but i think your a little too far away. Im picking one up in the morning from Grade A subaru. £75 plus VAT!!! Robbers!

I have been offered a p1 box or a wk300 for not a bad price, I dont have to giv an answer till next weekend either, so im hopeful at trying my old box first. Fingers crossed it will take the power until im ready for stage two (bigger turbo, injectors,fuel pump, fuel rail and some headers). which will be mid september.

carbon

i didnt think i had a pop at anyone. I havnt had to buy anything yet.

A lot of people just reply with, yeah your box will smash, who have no justification to this. Just going on what they assume will happen.

like iv said before, the difference between the GX and a cheap Sti is £8k, If i spend that on the GX, im looking at 350-400bhp and a green one! I dont want blue, black, silver or white! I want a green Sti.

TonyBurns

iTrader: (3)

Carbon, on the gearbox front you seem to be missing the point a little....
The difference between a clutch and a gearbox is that a clutch is designed to have some slip in it, the gearbox is designed to take "torque", a lesser gearbox wont take said torque as its all weight on one single point of metal in most cases, you put 300lbs of torque on a single 1 inch piece of metal for instance (thats the weight of 2 grown men btw 1 foot from said piece of metal) and expect it to hold when its designed to maybe take 200lbs max?
Also cost of making a 6 speed box over a 5 speed box, is there much in it? well probably more expensive for the 6 speed box, better materials and a thicker/stronger/less flexing casing so material cost is probably the greatest cost outside of the developement that is
The 5 speed box has been around for 20+ years, they just keep adding bits to it, strenghtening parts and hoping for the best, the 6 speed box is (back iin 2000) a brand new developed box, its been designed to take 450+lbs of torque, the 5 speed normally struggles over 300lbs (strips cogs etc, even standard 215lbs of torque cars can strip these ) but see the price of designing a brand new gearbox, your talking hundreds of millions of pounds, its not cheap, its not a 1 million quid design and chuck it in.
Your project will actually end up more expensive than buying a car, and the down side is that (if they still made them) an STi wagon would still be the better of the 2 but give it a go, use the GX gearbox, then replace it after a week with a wrx one, then after a month replace it with the STi one that has been recommended from the start
Keep putting the prices of the parts up and good luck with the rest of the bits oh and with the STI rear diff for the gearbox, you get the rear 2 pots that can be added

Tony

Gear Head

iTrader: (2)

A white range rover and a green sti. What class.