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Old 05-28-2021, 12:11 PM   #1
08redWRX
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Member#: 186068
Join Date: Aug 2008
Chapter/Region: South East
Location: NC
Vehicle:
2005 Hybrid WRX
Prev: 19 STi/08 WRX

Default 05 WRX Hybrid Build/Restoration

Put my intro (3rd subie) in the General Forums, so if you want to read the back story on her check this thread out - https://forums.nasioc.com/forums/sho....php?t=2936910

Thought I start a page on the refreshing of the car. Doesn't need to be rebuilt but could use some TLC on her.

Mods list that I know of so far;

IAG Stage II block
EJ20 Heads with GSC valve train/S1 205 cams (IAG did the headwork, also chambered to match 2.5 block)
Blouch 18g 8cm
CNT header/uppipe (will be replacing that eventually)
Invidia DP
Greddy Exhaust
IAG Competition AOS
ID 1050s
TGV Delete
Walbro fuel pump (don't know which one have to drain the gas and check)
KillerB baffle/pick up (have to drop the pan to confirm)
Competition clutch stage 2
Mishimoto Radiator
Stock TMIC with grimmspeed Y pipe kit
03 WRX ECU (not sure if i'm going to keep it or go back to an 05 and get an AP)

And here are some pics of the car and what the previous owner paid for the motor work prior to parking it for 2 years with 125 miles on the new build;







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Last edited by 08redWRX; 06-02-2021 at 09:19 PM.
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Old 05-28-2021, 12:12 PM   #2
08redWRX
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Join Date: Aug 2008
Chapter/Region: South East
Location: NC
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2005 Hybrid WRX
Prev: 19 STi/08 WRX

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Started by parking the car in the garage where it will probably sit for the next couple of months while I order parts for her.



Got the car running but due to the old gas sitting in her it ran but not the greatest. What I do know is even though it ran I was still worried about the compression so wanted to check and verify that was good, which, thankfully it is.



But upon taking out the sparks plugs I knew those needed to be replaced, so ordered a new set of NGK BKR7EIX.



Will also be ordering new coil packs, ones in the car look like they're from the original engine, probably fine but for piece of mind will be ordering them.
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Old 05-28-2021, 12:12 PM   #3
08redWRX
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Join Date: Aug 2008
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2005 Hybrid WRX
Prev: 19 STi/08 WRX

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Car came with spline lugs on an older set of Subaru wheels but no key so smashed a 16mm socket on each one in order to get them off. Once all of them were off I put the car on jack stands where she will sit.

Took off the front bumper, headlamps, side skirts and front splash shields. Will most likely be replacing all of these items as at one point you can tell the car was slammed on the floor and destroyed the lower bumper.



I could tell already the pinch welds were destroyed as my pinch weld jack wouldn't even go over them they were so badly bent. Will have to straighten them out and fix them up in order to get new side skirts on them. Was a PITA to just get the push pins out due to them being smashed sideways from the pinch weld being bent over.




Took the shifter out as whoever did the transmission work decided it would be good to file part of the rod and the thing when shifting felt like a wet noodle as the front linkage was obviously never changed. Wife is ordering me the STi 5mt shift assembly for fathers day to replace it. Then I have to order the TiC linkage to add to it.





Have a lot more work to do and will be documenting as I go. Will be a slow process but I have all the time in the world to do it.

Last edited by 08redWRX; 05-28-2021 at 12:25 PM.
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Old 06-01-2021, 05:41 PM   #4
08redWRX
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Prev: 19 STi/08 WRX

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Today took off the intake manifold, TGVs, and fuel rails. Want to send the manifold and upper coolant (Mishimoto) res off to powder to get coated wrinkle black.

ID1050s I'm going to send off the ID to be cleaned and flow tested since it has had gas sit in them for 2 years now.






Also took off the turbo inlet and thankfully did because it was torn at the turbo side. Will order a new 2.5" to replace it.



Car had stock TGVs with delete kit so want to order IAG TGVs, fuel rails and lines and redo the fuel system. Will have to pick up the kit and also a new FPR.

Got a little drunk on Friday night and swam in coolant while I drained the radiator so that was fun. Need to order all new hoses as I hate the blue Mishimoto smaller ones for the upper coolant and just to have a fresh set of hoses for the radiator.
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Old 06-01-2021, 05:54 PM   #5
08redWRX
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2005 Hybrid WRX
Prev: 19 STi/08 WRX

Default

So car currently has an 03 ECU and opensource tuned by the shop that did the build for the break in tune. Not sure if I want to keep the opensource tune or buy a AP and get a etune for break in and than set up a dyno tune for when the car is in running condition. I'm very familiar with the AP and who will tune them, opensource not so much. Don't have a tactrix cable or laptop capable of loading the tunes. Unless they can be loaded from a chromebook these days I'm not sure.

What do you guys suggest?
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Old 06-02-2021, 08:39 PM   #6
08redWRX
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2005 Hybrid WRX
Prev: 19 STi/08 WRX

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Worked on the car some tonight. Took out the Mishimoto Radiator and will be replacing it with a Koyo in due time but wanted to get it out of the way.




Also took off the CNT header, later I will be removing the CNT up pipe.



While under the car I seen a broken wire hanging from the top of the firewall, also noticed the transmission had a ground wire just hanging down. Once I got in the engine bay I noticed the old ground wire for the transmission was the broken wire. Previous owner stated he had an issue with the transmission shop and that is why the car has been parked for 2 years. Took the broken ground wire out and connected the good one to the correct grounding point.



Right now I've just been taking parts off and making a list of everything I need to order, all in due time. This project was meant to be relaxing and take a while so I'm in no rush to get her running.
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Old 06-03-2021, 11:59 AM   #7
Bugeye115
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2000 Audi S4 B5

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Very nice! I'm doing a very similar build at the moment. It's turned into more of a restoration than anything. Good luck with the build!
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Old 06-03-2021, 04:29 PM   #8
Vices
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2002 WRX EJ257
WRB

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Looks great. I'm personally a fan of opensource stuff and have my car tuned via Tactrix/RomRaider. I'm in Boston so I can't recommend someone local but my guy does great work and can do remote. Feel free to message me if you want his info.
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Old 06-04-2021, 11:14 AM   #9
08redWRX
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2005 Hybrid WRX
Prev: 19 STi/08 WRX

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Quote:
Originally Posted by Vices View Post
Looks great. I'm personally a fan of opensource stuff and have my car tuned via Tactrix/RomRaider. I'm in Boston so I can't recommend someone local but my guy does great work and can do remote. Feel free to message me if you want his info.
Appreciate it but I think I'm going to go with the AP. Don't have a windows based laptop and prefer the AP as I'm more familiar with it from having it on my past 2 Subies.
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Old 06-04-2021, 01:02 PM   #10
08redWRX
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Prev: 19 STi/08 WRX

Default

Took the intake manifold wiring harness out as a lot of the tabs are broken and #3 coil pack wiring is repaired with crimps. Will be ordering the iWire harness to replace it.



Went to take off the timing covers just to verify timing when I learned that most of the bolts are all over torqued and now spinning in place. Was able to get the ride side head cover but 3 out of the 4 left side are all over torqued. Now I have to decide if I want to rip the covers out and take off all the cam gears to replace them or just say screw it and leave it alone.

One thing pushing me to take it all apart is that the car was built with an ACL oil pump and not a 11mm OEM pump. Have read horror stories on the ACL (everything has bad reports) but was thinking of taking it off and replacing it with the 11mm.
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Old 06-05-2021, 08:42 PM   #11
08redWRX
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Took off the full exhaust. Greddy looked like the flange that attaches to the downpipe was cut and rewelded because it is terrible welds. That thing will be going directly in the trash.




Took off the catless Invidia DP to get the turbo and CNT up pipe out. DP will be for sale as I want to get a catted DP. CNT up pipe went straight in the trash.



Turbo i'll be sending to Blouch to look over and rebuild if neccesary but at least look over and coat the hotside. I know its the 18g 8cm but not sure if its the XT or XT-R wheel.



Took off the PS and alt brackets as they will be powder coated. Engine bay is done besides now cleaning it up. Tomorrow will probably be dropping the fuel tank to clean it out and see what fuel pump is in it.

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Old 06-08-2021, 03:12 PM   #12
wazz_up
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The welder who made such a seam would have his hands torn off...
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Old 06-16-2021, 11:22 AM   #13
08redWRX
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Prev: 19 STi/08 WRX

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Quote:
Originally Posted by wazz_up View Post
The welder who made such a seam would have his hands torn off...
haha yea they had to be a backyard job cause if that is a true welder they have real issues.

Today installed the STi 5MT short throw with TiC shifter linkage and COBB bushings. Shifter is 100x better than what it was. That original shifter linkage was garbage.

Took out the fuel pump and it is a AEM 255 universal pump. Will probably order an AEM 340 to replace it with and keep the stock hanger for now. Will eventually upgrade or will just do a new Radium hanger. IDK time will tell. Want to build a system for future power as this car is not going anywhere. So i'd rather buy once and not regret it later.

I try and buy as much COBB stuff as I can as they give a 15% military discount so saves a lot of money and would rather spend money at a company that supports the military like that.
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Old 06-17-2021, 12:52 PM   #14
08redWRX
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Prev: 19 STi/08 WRX

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Just placed an order for IAG TGV deletes, 3mm phenolic spacers, fuel rails, braided fuel line and fitting kit, Aeromotive FPR, AEM 320 pump and install kit.

HKS EL headers should be here today, still have the intake mani that I have to take the the powdercoater to get wrinkle black plus a ton of other brackets. Still have to send the 1050s to ID to get cleaned and flow tested. Need to get that done.
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Old 06-17-2021, 01:43 PM   #15
WallopingTuba
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Red

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Great thread. Almost makes me want an older STi to play with. No room though
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Old 06-17-2021, 03:20 PM   #16
08redWRX
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Prev: 19 STi/08 WRX

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Always loved the older body styles and been looking for a while. Really wanted an STi but couldn't find one that was either 15k or complete garbage. So found this one after looking at it for a few days on FB Market. I'll turn it into a STi eventually, as this one is staying for the long haul (or at least thats what i told my wife).

HKS EL came in, did a test fit and fit right up with no issues. Purchased from a member on here and it was never even opened. Now deciding if I want to get it ceramic coated (shop about 30 mins from me does it) or just wrap the header.




Last edited by 08redWRX; 06-17-2021 at 03:59 PM.
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Old 06-18-2021, 06:05 PM   #17
08redWRX
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Prev: 19 STi/08 WRX

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Got a nice surprise package from IAG today. Highly impressed with how fast IAG shipped it and how fast UPS delivered it considering it was ordered, shipped and delivered in less then 24 hours.



Sent my ID injectors off today so hopefully should get them back in 2 weeks or so. Still have to drop off the intake manifold to powder.
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Old 06-18-2021, 09:09 PM   #18
KeithS05RS2.5
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Dark Blue

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Good stuff !!
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Old 06-19-2021, 05:08 PM   #19
08redWRX
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Spent some time in the garage today. Siphoned out most of the gas out of the tank, the rest i'll pull the fuel line and drain whats in the lines. Also replaced the Walbro 255 with the new AEM 320. So if anybody needs or wants a walbro GSS341 255LPH let me know just pay for shipping and i'll send it to you with a install kit, only thing youd need is the pre-filter.




Also started to remove the power steering lines. Wife is buying me the Chase Bays power steering kit for my birthday, well I haven't told her yet but that is what she'll be buying bahah...

The lines that attach to the rack will stay in place until I get the actual kit.



I still can't get over how clean the interior of this car is. For it being a 05 and owned for 4 years by an 18 year old i'd expect the inside to be needing a lot of work. Only needs new sun visors as they are a little wrinkled and it annoys me.

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Old 06-19-2021, 05:26 PM   #20
KeithS05RS2.5
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How much power are you planning that you upgraded from the 255 to the 320?
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Old 06-19-2021, 05:53 PM   #21
08redWRX
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Quote:
Originally Posted by KeithS05RS2.5 View Post
How much power are you planning that you upgraded from the 255 to the 320?
Right now maxing out the 18g, but buying for future proofing. Want to go rotated and closed deck in the future. So while its all down right now just upgrade what I can for the future.
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Old 06-19-2021, 06:12 PM   #22
KeithS05RS2.5
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Quote:
Originally Posted by 08redWRX View Post
Right now maxing out the 18g, but buying for future proofing. Want to go rotated and closed deck in the future. So while its all down right now just upgrade what I can for the future.

Gotcha.
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Old 06-21-2021, 03:53 PM   #23
08redWRX
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Spent a little time and just torqued the TGV and phenolic spacers down. Wanted to put SOMETHING on instead of always taking stuff off. Taped up the top and will sit this way for quite some time.





Plan on replacing as many bolts as I can with new ones. Already bought new M6x25mm Intake Manifold to TGV bolts. Need to look up the size of the rest of the rusted old bolts.
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Old 06-21-2021, 09:06 PM   #24
KeithS05RS2.5
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If you are looking for OEM bolts + part numbers this site is invaluable:

http://opposedforces.com/parts/

Usually if the prices are ok I go OEM, if not I usually go with stainless steel and cut to length. Most common bolts are m8x1.25 and m10x1.25
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Old 06-21-2021, 10:02 PM   #25
Scooby South
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51E

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Coool build.. will be interesting to see the final product. hope it comes together for you as you envisioned

Following

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