So, it's been many many years since I've done much of anything with the evo and I want to get back into it again. The car is currently at 137k miles and I want to eventually get it solid and make 450-500whp on 93 (non-ethanol) pump gas. My question is what is better turbo to do this? I saw the zephyr and zero turbos which look like they may be up to the tasks. But besides that, I want to get suspension right, clutch, etc. Right now, the car runs fine and I'm looking to slowly start replacing stuff as I go. What would you guys start at? Suspension bushings? Turbo? Clutch?

Background of car currently.

Stock evo 9 turbo
fic 1050cc inj.
walboro 255
gsc s2 with bee hive springs.
some heavily bent ETS front mount and cheap injen intercooler piping.

Thanks for any advice! Sorry for the long read.

tl;dr
Car sat for awhile, what to do next. Suspension, Clutch, Turbo, Other? Want to make 450-500whp on 93.

 

The Zephyr and Zero are overkill for your goals but a great idea if you plan on building the engine to support higher HP of 650+. I think you could benefit from a 25G turbo upgrade,Port the OEM exhaust manifold and intake manifold if you have the funds (relatively cheap and provides great results).
You could definitely use a new intercooler if the damage is causing leakage or restricting air flow but if it isnt run it.. the injectors should get you there.
Make sure you freshen up your clutch and you should be on your way.
if the car has been sitting for a very long time for peace of mind do a timing belt job and head gasket replacement.. assuming you have stock headstuds... replace them as well.

 

Yeah, the headgasket / studs and all of that was recently replaced so i'm good there. And yeah, I was planning on going higher some day but just want something reliable and fun at the same time. Forgot to add the exhaust manifold is a buschur ported and coated unit.

What about as far as the clutch? I was reading up (again) on the exedy twin disc being meh and not lasting long at all.

 

Exedy Twin do last a pretty good time...it really depends most importantly on the tq output and the actual driver.. it's becoming more common for driver fault in the life of these twin disc clutches(premature wearing, warped etc... but besides that if you're nailing on your Evo as Im sure most people do who are making decent power the clutch wont last that long whether regular single or twin disc.
If you are on a budget I would suggest (going from most affordable to expensive): Competition Stage 3, Followed by ACT Clutch Kit, and then Twin Disc. If you use the Comp Stage 3 kit I highly recommend getting the ACT Mono loc clip... but if you have the funds I'd go straight to ACT clutch just dont get one that is overkill for your tq output esp if on stock block.. that could actually damage your trans. Once you start making over 400+ tq to the wheels and you know you're gonna be abusing your Evo then that's where the twin disc really exceeds in performance over single disc clutches. it saves the transmission.

 

That's what I got currently the ACT 6 puck it's not the best to drive either. As far as pricing I'm fine with paying the price for a good clutch that will last that i won't have to pull out after 10k~ miles to replace a disc. And if I end up trying to put down more power/tq I rather have that part covered instead of re-investing into it again.

So my short list for the build/rebuild.
zephyr
exedy twin hd
New piping/IC

entire suspension bushing replacement
coil overs of some sort
and some cusco body braces cause, why not.
then paint it and put new wheels on it

 

'd go one size higher injectors, I think I saw a string on here where everyone agreed 1200 is the ideal size for pump, also you might be running out of wally and need the next size up. I'd also look at some nice slotted discs and some whitelines,a nice exhaust manifold and Ti 3 inch turbo back if don't already have one