Nice. It's a bit of work (and $$), but definitely a fun project.

This overview focuses on the EZ30R but if you haven't seen it, it's a decent place to start:

 

That looks a great starting point! Adding that to the list of bookmarked resources for this. My biggest concerns currently are the turbo inlet and plumbing the turbo

 

Apologies for this question but are the blowoff valve and waste gate vacuum controlled? I'm specifically looking towards the 04 Forester XT for parts It looks to be that way in photos and if that's the case that'll be a huge help in simplifying this project. Not a fan of hunting electrical gremlins lol

 

The wastegate is electronically controlled, but you'll have to have a piggyback or mechanical device control it in some fashion since the H6 computer is not capable of it. The bypass valve is controlled by vacuum opening when vacuum is high at closed throttle. Since this car is speed density tuned, you can just vent the bypass to atmosphere. It doesn't need to bypass back into the intake tubing.

You'll need Rom Raider and ECUFlash to change the ROM so the engine will run with boost. RR for data logging and ECUFlash for reading, editing and writing. Definitions built for my VDC may work on yours. If not, you'll need to have definitions built

You'll need larger injectors, at least 425cc, so it'll run smooth at high rpm. You'll also need a higher volume fuel pump. I use DeatschWerks and they work great. DW200 should be good, but DW300 guarantees flow.

The stock MAP sensor and ECM will see up to 5 psi. Over that you'll need a WRX MAP and will have to rescale the MAP in the ROM or run it rich enough that it won't matter over 5.

You'll need to make a spot to put the IAT - preferably after the intercooler. (On the intercooler, look at WTA Type 13. Can mount to the throttle and you can easily make the IAT fit into the joint tube or intercooler after the "radiator".)

The exhaust manifold will need to be custom fabbed with an up-pipe and downpipe for the turbo. Divorced downpipe without a cat is best. You'll then need to move the intermediate exhaust to the downpipe with minimal bends. Tight fit so the math has to be good. Otherwise, maybe a downstream turbo mounting, but then you still have fit and much more plumbing.

The auto trans doesn't like the boost. The soft shift 2-3 programmed in the TCM can't be changed and every trans I had burned 3rd. The last 2 custom built trans burned the TCC up. Again, TCM programming issues. I put in a 6 speed. Much better. (Mine is supercharged and hits up to 12 psi. Raptor)

Make sure the engine is running perfect BEFORE you put boost to it. It's high compression and any little thing will make a huge impact.

 

Thank you for the advice! Everything has been added to the shopping list including figuring out how to use an external wastegate with the td04 (probably just going to use a summit wastegate). To avoid more extensive map for now I'll limit it to around 5lbs.
Glad to see there's not too many surprises on this list. Going to salvage today to grab the foz xt intercooler and turbo. If the transmission dies after all this then so be it.

 

Went 0 for 8 on yards having any parts I needed. Boo. Guess I'm paying shipping fees.
Edit: Managed to find a foz intercooler, bpv, and coolant expansion tank for about the same as it was going to be to pull the parts 😁

 

Managed to grab a Baja Turbo hood at a salvage yard! The paint is super faded but since it was southern owned it has virtually no rust. Glad to have found one at all, especially at a yard since these hoods are never cheap.

 

I just paid $500 for a used BAJA fender and I had to do some repair on a corner. It's still Blue. Parts are hard to find.

 

This hood was only $130. That fender wouldn't happen to belong to the same baja we got the hood from in Nevada, would it? I'm still undecided if I'm going to attempt to paint the hood myself. More than likely it's getting dropped off with someone who knows what they're doing since pearl colors are hard to match from what I've heard.

 

It came out of Dallas.

Pearl is hard to match existing paint. That's why my JDM hood on the VDC is still bright white.

 

It's not perfect but it's not bad! I'm hoping since my obw is titanium I'll be able to get away with having a hood that's not perfectly matched but it'll look close enough.

 

Any recommendations how to get the vacuum for the bpv? I noticed it normally attaches to the intake manifold and I'm not sure I can replicate that in this case. I have no doubt I could find some workaround but if I don't have to drill anything that'd be nice

 

I used a plastic vacuum tee and spliced into the smaller hose at the top of the intake. You can use any vacuum hose off the intake and splice into it.

 

The initial test fit of the intercooler is rather concerning but I'm hopeful. Worse case scenario I have to switch to a front mounted intercooler

 

That's why I suggested a water to air type 13. Fit great on my H6.

Either way, if you mount it to the throttle you'll have to make the brackets to support it so it doesn't move around freely and cause a boost leak.

 

That's why I suggested a water to air type 13. Fit great on my H6.

Either way, if you mount it to the throttle you'll have to make the brackets to support it so it doesn't move around freely and cause a boost leak.

I guess you live and learn lol
The overall fit of the intercooler isn't awful, the issue arises where it meets the turbo. Not a lot of space, if any, for a down pipe due to this box of mysteries

I'm just going to do it your way since the tmic leaves no room for the IAT

 

That's the cruise control motor.

 

That could be important I might want that

 

Frozen Boost intercoolers.

Front Mount Intercooler

Add a high quality front mount intercooler for top performance!

www.siliconeintakes.com

 

Do you think the tmic could still be utilized if the turbo was relocated to where the OEM air filter is? Exhaust would still be somewhat tricky but not nearly as bad as having the turbo directly attached to the intercooler

 

That's a lot of heat to put near the ABS module. And you'd have to move the PS reservoir. I did that to make room for the supercharger. And I moved the ABS to the strut tower. But the supercharger doesn't put off heat.

 

Not quite that far forward. I'd want to squeeze the turbo between the strut tower and PS reservoir. Big ol empty space.

 

Big empty space until it's filled with turbo, up and down pipes, air intake tubing and filter. Then you're out of room.

Did you see how they made the manifold and pipes in the video. Same concept applies except the heads are single port.

 

That's the idea!

 

I don't think a turbo and pipes will fit there.

I went through all this before I boosted the VDC. Space is the enemy.

 

Just to be certain I'll grab some 2.5in pipes to get an idea of how much space I'm working with for up, down, and boost pipes.