ok so I'm currently rebuilding my 1999 wrx classic , I've lapped all valves etc, done the shims , std crank shells and rod shells etc, forged con rods and std pistons and rings , don't want forged as it's a daily and forged dailey is a bad idea, generally they cause more ware on the bores and a good tune and healthy maintenance will be key to what i want , i want around 300/ 330hp , so my question is what injector size do i need and turbo , I have a 255 walbro pump already , decatted, streight through 3 inch exhaust and standard ecu, I use as a daily so what would be best for injectors and turbo , currently have a td04 , I'm a mechanic and I'll do all the work myself so not looking for lengthy how too and not too stuff but s guide to what I need , I know td05 is laggy as I've driven them but can a td04 cope with 18psi say and still give me 300 320 bhp or do i need a td05 and if so which size 16g 20g etc , I know vf22 is a good turbo but my god are the expensive unless someone on here has one for sale ? any help will be appreciated, ive already converted to coil on plug and im running top mount but lookong for a bigger one as i dont want front mount as its too laggy and blocks the rad, the top mount should provide enougb cool air witj the giant scoop on the bonnet lol thanks guys

 

Injector size 550 cc Pinks Sti or 565 cc WRX>06 Dark Blue will be fine and will be at 80-85% Duty cycle for 330 bhp

Mine are the WRX 06 and I run a SC36 turbo at 330 at around 1.4-1.5 bar for a daily you would only need 1.2 bar to get you 300 and a strong torque curve.
this has a 33% lighter wheel for faster spool , I used to run a TD0516G and swapped for that reason.

You might consider a TD04 hybrid build which boosts and creates torque fast at much lower revs but will leave you out of puff at 320 or so .
On a true daily in town probably makes the most enjoyable experience to drive.

You might also take the SC38 for more potential top end and a slightly lower pressure.

A WRX Intercooler will do , but a Sti TMIC V8 ( I swapped to this ) will give you a bit more latitude for 330-350 , but they all suffer from heat soak at the lights
a water mist spray from the Sti would be useful but not essential , use your standard air intake and a Subaru or Cosworth air filter at this power level.
I didn't bother to use the Sti scoop , but I use the WRX MY 05 sized one and width opened the blanking under the hood to feed the Sti TMIC.

To help the torque at lover revs , raise the CR to somewhere around 8.5 - 8.7:1 that will still give you plenty of Mapping headroom for boost development
but will help you a great deal in the sub 2500 rpm range. So if you do that on a Std WRX head ( Vol 49cc from memory )
To achieve this consider a single drop down from a 1.6mm to 1.2mm gasket or from a 1.2mm to a 0.8/0.7mm or of course skim the head and measure cc of head first.

Your mapper will thank you for adding a 3 port boost controller as this makes the control of boost easier to achieve.

Edit a Harvey up pipe (mid size) will help spool rate a bit too,

Enjoy

 

thanks for the info that's perfect , I will do just that , I'll look in to the hybrid and I'll get the injectors you mentioned , I'll invest in a bigger intercooler , and I can ditch the headlight output for water spray and use it for the intercooler, I appreciate the reply thanks pal

 

Don't you have some logs showing how this turbo behaves on ej205 (preferably 3rd gear pull from 2000RPM ahowing RPM, MAF, Load, Boost, etc)?

 

Hello Uxon , I only bothered to ask for the power run. So here that is.

I had Martyn give me a switch in the center consul next to the handbrake.
I normally run on the low boost position and this shows 1.2 on my gauge , there is very little difference in performance in the range to 5000rpm
( which you would need for a daily driver ) the higher boost is switched and reaches max 1.5 but is deliberately tailed off at 5600 rpm

I would note that , there is probably a bit more max power to be had after 5800 rpm , but I specifically asked Martyn not to push the top end for a headline number.
It is a EJ207 engine is using Mahle pistons and Manley rods on race ACL bearings ARP bolts can take it for sure with 11mm oil pump , the clearances are bigger
and they mostly don't make the mileages that a tight clearance Sti Hypereutectic piston should, so I'm giving this forged build a longer life by keeping the revs down
if I change my mind and track again , then I can still change this and not have to worry about it.

For @sheldrake001 The missing items which this build regrettably does not have , is a higher CR ratio , mine is currently around 8.1 :1 on a 1.2mm Gasket , and 93mm (1mm overbore pistons)
I had also done some minor cleaning up of the head chamber to remove hotspots and indexed the spark plugs 3mm deeper into the chamber. These are not essential tweaks but give me
more peace of mind. but they did also increase my chamber volume slightly by a couple of cc. If you go higher on the CR you can expect to gain more throttle response / torque in the sub 2500 range,
but I would note that although you will make it a more tractable day driver , you will drop the maximum boost level that the mapper can give you before hear hears detonation, and then needs to pull timing.
So you will sacrifice some max torque / top end power as more heat is generated by the higher compression. In my case it would not have mattered much as I don't care about the headline numbers
and so I should have put a 0.8mm gasket in place for a >8.5 CR though personally I would not want to push it more than 8.75 :1 I would expect to see perhaps10lbft more torque at 2500rpm by doing that.
A small number yes but you need all you can get when rolling around in town traffic. It also only helps you until boost starts to be developed. The other item missing is a good exhaust manifold. ( Mine is the Std WRX but I use a Harvey Uppipe )
I'm also using a single 3inch Sports Cat down pipe funnel into a 2,5 inch pipe and Prodrive back box. The 2.5 system is fine for the SC36 turbo but the Sports cat will cost some response and of course eventually cap your max power.
But I stay legal this way.

 

I have 97 car with hybrid TD04
Fuel pump like yours and also an SX fuel pressure regulator set to 3 bar (standard), The standard one can be slightly variable was what I was told
I run 1.35bar and haven't needed to change the injectors so original 380s
If you're in there, its worth putting a lightened flywheel in too. Had mine skimmed I think from ~ 16Kg to 9Kg, there is NO issue at that weight with stalling
The turbo does run out of puff just below 6000rpm but I see that as a bonus as my first engine did 215,000 miles
Good luck

 

OP What route did you decide on ?

I added the latest curve, I was unable to improve on the sub 3000rpm.

To do so you are left with choices. Raise compression ratio, add variable valve timing from the Sti + wiring loom spur or of course add cubic capacity ( normal choices 2.1 / 2.35 / 2.5 ).
the top end power might have be marginally improved with a full 3 inch , ( I still run a 2.5 Prodrive back box ) .