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Old 11-08-2023, 12:41 PM   #1
SpdDmn
Scooby Newbie
 
Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default SpdDmn's 2008 WRB FXT Sports Limited (Canada)

*** Posting for posterity, in case my home forums disappear***

After my first 2007 Forester XT was written off in May 2015, I started searching extensively for the perfect Forester to build. I went through a progression of 2006 FXT in Regal Blue Pearl, then a 2007 Sports FXT in black, before finally finding the unicorn... May Long Weekend 2016, exactly a year later, this car was listed in Kamloops - only a short (6 hr) detour on the way home from Kelowna! Being a holiday Monday, we had to stay over to Tuesday, only to find out the dealer already had a deposit on it and she was coming to get it the next day. Heartbreak. We asked him to call us STAT if anything changed, and dinner time Wednesday, we actually got a call - she didn't end up taking it! Pushed through the paperwork, had it trailered back to Calgary, and waited for my funds to recover...

2008 WRB Forester XT Sports Limited

Stock form:



- 5MT turbo
- leather, HID headlights, heated seats & mirrors
- only 143,000 km on the clock

This trim combo is practically unheard of in Canada!


I purchased a 2004 STI donor car and have gradually been accumulating parts for the build. It also needs a full paint job to fix up the sad, sad orange peel from the dealer's quick & dirty Maaco job. WHY? It hasn't been in an accident, zero rust, very minor dents & scuffs.... Another several thousand to spend...

Performance
- Borg Warner EFR 6758
- Turbosmart IWG 75 dual port wastegate actuator
- Custom -4AN Teflon/SS braided oil feed, water cooling lines, -10AN oil drain
- VEX Performance custom-built EFR stock location kit - 3" S304 piping fully back-purged and TIG welded in-house
- Apex'i Universal WS2 muffler - S304 stainless
- Injector Dynamics ID1000 injectors
- Walbro 450 (model #F90000274) fuel pump (465 lph @ 40 psi and 13.5V (14.1 amps) in gasoline)
- Radium fuel rails and custom -6AN Teflon/SS braided lines
- Radium fuel pressure regulator (adjustable)
- IAG Billet TGV Deletes with 3mm phenolic spacers
- Aquamist HFS-3 water-methanol system
- Vex Performance Crystal Methanol 51:49 Water Methanol
- Perrin Equal Length Headers, DEI heat wrapped
- AMR aluminum turbo inlet pipe - custom welded blockoffs/bungs, powdercoated wrinkle black
- 3-port Boost Control Solenoid
- GR STI top mount intercooler
- Process West hood scoop splitter
- Tial blow off valve (blue)
- IAG Performance Street Series AOS
- Killer B oil pickup
- Killer B oil pan with baffle
- Cobb SF airbox
- Apex'i power intake
- Samco hoses (various)
- Cobb Accessport v3 fully tuned by Airboy Tuning - RESULTS
- Cobb E85 Flex Fuel support - Never :'(

Drivetrain
- Full 6MT swap - R180 rear, STI drive shaft, lateral links, axles, crossmembers, steering rack, 5x100 knuckles
- ACT SB10-HDSS Heavy duty street clutch ACT T1S-S07 Mod-Twin 225 HD Rigid Street up to 700 tq
- Exedy lightweight flywheel for 2004 STI
- Whiteline rear subframe locking bolts
- Whiteline steering rack bushings (came with '04 STI!)
- Kartboy "comfort" rear diff crossmember outrigger bushings
- Kartboy front and rear shifter bushings
- TiC shift linkage bushings
- Kartboy XL exhaust hangers
- Kartboy 6MT short shifter + bushings

Suspension
- KW variant 3 coilovers - factory rebuilt
- VEX Performance custom 1.25" billet aluminum saggy butt spacers
- 24mm SuperPro rear swaybar
- Whiteline swaybar stout mounts
- STi endlinks
- Whiteline adjustable lateral links

Brakes
- Front and rear 2004 STI Brembos
- Front and rear DBA 4000 slotted rotors
- Front and rear Endless MX-72 brake pads
- Endless S-four Brake fluid
- Front and rear Goodridge SS brake lines
- Grimmspeed master cylinder brace

Wheels & Tires
- Volk ZE40s - 18x9.5 ET+43, bronze, 5x100 (summer), 65-56 hubcentric rings
- 245/40R18 Nitto NT05s
- 8mm wheel spacers (rear)
- ARP extended wheel studs (front & rear)
- OZ Ultraleggeras - 17x7.5 ET+48, custom orange powdercoated, 5x100 (winter)
- Hakkapelitta 8s studded winter tires
- WedSport SA72Rs - 17x9 ET+42, silver, 5x100
- BlackLion 235/25R17 with oversize studs


Interior & Exterior
- JDM FSTI cluster
- custom Ortiz cluster surround dual gauge pod
- Innovate ECF-1 (4-in-1 for wideband O2, fuel temp/pressure, ethanol %)
- Aquamist HFS-3 red gauge
- JDM v7 hood scoop
- JDM FSTI CrossSports grille
- JDM FSTI double DIN nav pod
- JDM STI 6MT knob
- Cosworth oil cap
- Wrinkle black powdercoated intake manifold
- Custom plates "RODKNOC" (:grin
- Full paint and body restore by Prah Paint Works
- JDM Cross Sports rear bumper with optional lip
- SYMS replica SG9 hatch wing
- JDM Cross Sports Zenki side skirts
- JDM Forester STi rear waist spoiler
- JDM Cross Sports darked out headlights
- LaminX tail light overlays
- Diode Dynamics interior LEDs, HP3 license plate, HP3 parking light "eyebrow" LEDs
- Nexus7 (2013 Wifi 16gb) in-car install, clock pod location, hardwired. Timur's kernel & pem, Tasker profiles (ugh), BT OBDII for TorquePro... In Progress!


My goals are street-reliable (not necessarily daily driven) respectable power that comes on as early as possible, with lots of torque, solid handling and no mushy braking. This car may or may not see winter. We have no local track (yet) but this should cover light track and autocross.
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Old 11-08-2023, 12:42 PM   #2
SpdDmn
Scooby Newbie
 
Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

**Reserved for professional photos**

Knockin on Rod's Door by Wong0ne, on Flickr

Knockin on Rod's Door by Wong0ne, on Flickr

Knockin on Rod's Door by Wong0ne, on Flickr


Local meets:

DSC06344 by Rachel McLean, on Flickr

DSC03405 by Rachel McLean, on Flickr

DSC06695 by Rachel McLean, on Flickr

DSC06345 by Rachel McLean, on Flickr

DSC02711 by Rachel McLean, on Flickr


Last edited by SpdDmn; 11-08-2023 at 06:35 PM.
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Old 11-08-2023, 12:44 PM   #3
SpdDmn
Scooby Newbie
 
Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

September 19, 2016
Spent the weekend doing the first big chunk of work! So much more to go, but I'm super pumped to get something started!

Starting with my donor 04 STi, we pulled the rear cross member out:


I picked up a set of KWs used, and Ryan had them sent out for a rebuild and new spring perches, bump stops, etc. Got them all re-assembled and initially adjusted height, rebound and compression (Note to self: bump is bottom).


Initial Height (A) = 85 mm
Initial Rebound (small top) =
Initial Compression (lg bottom) =

Re-installed (should've sprung for new springs!):


Installing the rear crossmember from the STi into the FXT - Ryan recommended Kartboy "comfort" outrigger bushings, because he's old and doesn't like a bumpy ride :P

Last edited by SpdDmn; 11-09-2023 at 10:46 AM.
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Old 11-08-2023, 12:46 PM   #4
SpdDmn
Scooby Newbie
 
Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

September 19, 2016 cont'd
Meanwhile, this was my job - sandblast the rear DBA 4000s from the STi to reuse. I already had a set of BNIB 4000s to go on the front. Also cleaned up the swaybar bushing brackets, and attempted to blast the RSB itself, but I'd have been there all day.


I got a choice of Endless MX-72 and SSM for brake pads. The big advantage to SSM in reviews is how little they dust (like, rated at zero dust), but the MX-72s weren't far behind (8/10 rating) AND they had better ratings for initial bite and pedal feel - two of THE MOST important things to me, after living with my bugeye's and OEM Foresters' squishy brakes. I might hate squishy brakes even more than a limp clutch feel!


Encountered a couple differences between the FXT and STi: the ebrake adjustment cable is shorter on the STi, and the ABS sensor is female coming from the outside of the car (as opposed to male on the FXT). The STi's ebrake handle and bracket are flipped compared to the FXT's, too - the ebrake handle on the FXT is nearer the driver's seat. That meant swapping the little adjustment cable out of the ebrake assembly, rather than tossing in the whole assembly.


All put back together!




Probably can't really tell from that photo ^^^ but the rear wheels have a serious positive camber going on... Adjustable Whiteline lateral links?!
I think I still need/want saggy butt spacers. Looks better just slightly higher in the rear, rather than dead even (imo).
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Old 11-08-2023, 12:52 PM   #5
SpdDmn
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Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

October 2, 2016
In lieu of actually working on the Foz this weekend, I got to unbox some of my new goodies! It was like Christmas!

The catback I went with - Apex'i WS2 universal 80mm (3"). I wanted a sizeable rolled tip. I hope it's loud enough!



Instead of cutting and welding TGV deletes, Ryan ended up convincing me to buy a set, plus phenolic spacers. Which I'm sure do something, and I'll learn what at some point. These sure are shiny, anyways!



Grimspeed master cylinder brace. The Perrin one I had in the bugeye was a good improvement, so I'm excited for this!



I bought this Killer B oil pan, baffle, and pickup tube used for a great deal. No sloshing oil for all those aggressive turns I'll make... Cleaned up the silicon sealant today, ready for install.





And a little eye candy for the engine bay! It's almost WRB, pretty much made for it!

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Old 11-08-2023, 12:54 PM   #6
SpdDmn
Scooby Newbie
 
Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

How bad is the orange peel?

Grabbed a couple pics yesterday, finally. I had my old Toyota Paseo wetsanded and polished back in the day, starting from similar conditions... lots of work but it turned out not bad.
What concerns me too on the FXT are a couple areas that are worn down or not hit with paint (ie they sanded and primed and didn't reach the edge of the hatch with paint??). It's an open invitation for rust!

Plus bird poo!


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Old 11-08-2023, 12:57 PM   #7
SpdDmn
Scooby Newbie
 
Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

Another awesome busy weekend! We managed to pull 2 engines and 2 trannies in one day!

On Sunday, I helped re-install the front crossmember and '04 STI steering rack, control arms, tie rods, etc. We also replaced the FXT's hubs in the front, because the donor STI had some sweet ARP extended wheel studs, which my wheels aren't wide enough for NOW, but down the road may be... And at $50 a corner, who's going to scrap those?!

'04 cross member and steering rack, fresh out of the donor:



My contribution, cleaning up the LCAs a bit:
Aluminum STI control arms were always unobtainium awesomeness when I owned my bugeye (which was subject to the LCA recall notice but never rusted enough to justify STI LCAs!)



Here's the donor 6MT (note to self: tranny code TY856WH3MA)
Quote:
[table]
[tr]
[td]MODEL RANGE[/td]
[td]TRANS. CODE[/td]
[td]1ST[/td]
[td]2ND[/td]
[td]3RD[/td]
[td]4TH[/td]
[td]5TH[/td]
[td]6TH[/td]
[td]REV[/td]
[td]T.R.[/td]
[td]F.D.[/td]
[td]CENTER DIFF. TYPE[/td]
[td]FRONT DIFF. TYPE[/td]
[td]NOTES[/td]
[/tr]
[tr]
[td]US Impreza WRX STi MY04[/td]
[td]TY856WH3MA[/td]
[td]3.636[/td]
[td]2.375[/td]
[td]1.761[/td]
[td]1.346[/td]
[td]0.971[/td]
[td]0.756[/td]
[td]3.545[/td]
[td]1.000[/td]
[td]3.900[/td]
[td]DCCD (35:65)[/td]
[td]A.P. Suretrac[/td]
[td]automatic DCCD system[/td]
[/tr]
[/table]


Apparently with the tranny already out, for another hour's worth of work, it was easiest to fully pull my FXT engine. We'll be doing injectors, TGVs, spark plugs, timing belt... And neither of us have Subaru Tech hands!






Since the intake manifold is coming off, I've got the opportunity to clean it up. My dilemma is HOW I want to - just sandblast it? Sandblast and paint it (and what colour, and how do I avoid flaking)? Get it powdercoated (we don't have a good source)? Grind and polish it to chrome shine?
And now I've been searching up engine bay porn (yeah, not using those keywords exactly) and trying to decide on my colour scheme. Ridiculous? mebbe...
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Old 11-08-2023, 12:59 PM   #8
SpdDmn
Scooby Newbie
 
Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

22-23 October 2016

Just a few things before heading to SEMA the week of October 29 to Nov 5. Pulled off the intake manifold to sandblast before powdercoating, cleaned up a few bits, installed the Killer B oil pan, baffle and pickup tube.

Also did a leakdown test (too bad we didn't remember to do a compression test before the turbo was out!). Excellent numbers across the board (2% leak on all cylinders), so we'll wait until this engine pops to tear down and fully build it!

Before & after sandblasting the intake manifold:


Killer B internals:
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Old 11-08-2023, 12:59 PM   #9
SpdDmn
Scooby Newbie
 
Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

20 Nov 2016

Finally got a few more little things accomplished, after a hiatus for SEMA!
Sunday, we did the timing belt service while we're waiting for my intake manifold to come back from powdercoating sometime this week. I was playing with my DSLR, so only a few pics.

Timing covers, tensioner, idler, pulleys, & oil pump removed:


Upgraded to an 11mm GR oil pump. The extra depth will move a small percent more oil.


Behind the timing covers and upper cam, there's a second oil feed banjo bolt. We removed the screen inside it, to help prevent oil starvation.


All back together with new tensioner, idler, pulleys, and of course belt!


And a little useful bling! Tomei timing belt guide:
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Old 11-08-2023, 04:10 PM   #10
SpdDmn
Scooby Newbie
 
Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

3-4 December 2016

My intake manifold and turbo inlet came back from powdercoating! Turned out exactly how I was envisioning:





Throttlebody and three bar MAP sensor installed on the intake manifold:


Then back to the engine; IAG TGV deletes installed.


Early Christmas present came in! Super ballin' Radium fuel rails, which I wasn't budgeting for myself (yet), but will complete the setup to run ethanol! Installed with ID1000s:


Intake manifold installed. We did the secondary air pump delete, with custom VEX block off plates (little red and black billet pieces on the back of the engine):


Test fitting the turbo inlet pipe... Should be able to make it fit, with a little wiggling.. It's 3" diameter, whereas the silicone ones are typically 2 3/4", besides being flexible to squish in!
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Old 11-08-2023, 04:12 PM   #11
SpdDmn
Scooby Newbie
 
Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

10 December 2016

Another weekend working away on the Foz

Installed my Perrin EL headers (which I wrapped back in the summer). Plus a block heater, because #dailydriven



So I did not realize that you have to clock (rotate and adjust) your turbo hot and cold sides, so that the wastegate actuator arm, the up pipe, and inlet hose, are all correctly positioned. You can see the Turbosmart wastegate actuator so we can run higher boost pressure. We didn't end up keeping the FullRace BOV block off plate (which means I get to run a Tial BOV! waappssshhhh)



We started fabricating the custom lines for the turbo; oil feed and drain lines, and coolant. Which I apparently neglected to take any installed photos of!
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Old 11-08-2023, 04:14 PM   #12
SpdDmn
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Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

26 December 2016 - 2 January 2017

Lots of post-Christmas work on the Foz commenced. We literally worked every day this past week, so much work and soooo close to being complete! There is amazing work on every custom bit on here, and I learned a TON. I'm also an expert at running electrical wire anywhere it needs to go. Seriously, no plastic panel can defeat me :P

It was decided that I should run a Walbro 450 fuel pump so that I can run ethanol in the future without issues. We can also upgrade the injectors without increasing the pump capacity.
*Note to self* There are two 450 LPH models; this is the F90000274, not the F90000267. The 274 has higher internal pressure valving for higher fuel pressure. It also needs higher current for max fuel flow.
SPECIFICATIONS 465 lph @ 40 psi and 13.5V (14.1 amps) in gasoline



Accessing the fuel tank in the back of the Foz was pretty fun... But I did manage not to wreck any trunk foam, or seat carpet! The OEM setup with sock, pump, filter; filter internals. Everything is in line inside the tank, which I guess is easy for installation of the new pump.



The new setup. The install kit includes Teflon tubing for E85 compatibility.



A little out of chronological order, I got the upgraded wiring run for the fuel pump a couple days later. It goes from the battery in the engine bay, down along the driver's side kick panel, across the rear seat area (following the gas door release cable). You can see the relay added in the left side of the photo, which triggers power to the pump. Ground is just in the foreground. Sorry, my electrical knowledge is subpar... I knew I wasn't going to remember this properly!

The second photo shows the red power wire to the fuel pump, alongside the release cable. The white clip with twisted black and white wires is the wheel speed sensor for ABS. The FXT has a male to female connection, and the STI had female to male connector ends... so we ended up with male to male, which doesn't work very well. Spliced in the FXT's female connector.

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Old 11-08-2023, 04:16 PM   #13
SpdDmn
Scooby Newbie
 
Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

Back to the engine, almost ready to go in!

We put in Denso Iridium spark plugs, then tested for air leaks. A few tiny soap bubbles showed at the throttlebody and TGVs, under 20 psi air pressure.



Lastly, we installed my ACT clutch and lightweight STi flywheel. The ACT is SB10-HD-SS which according to ACT's site, means Heavy Duty pressure plate and a Performance Street disc.



And then, the big moment! Engine going back in!




Stay tuned!
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Old 11-08-2023, 04:18 PM   #14
SpdDmn
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Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

With the engine back in place, we could get the shifter and tranny back in, as well as hang the downpipe. I got Kartboy front and rear shifter bushings, and TiC shift linkage bushings. I think everyone ever hates installing that rear bushing, but it's so worth it with improved feel/response!



Setting the tranny in place, and installed with the FXT tranny crossmember. I just came across this thread from and am now worried that's not right, although we put the driveshaft in. I'm going to follow up about this..



Top view with OEM (FXT?) pitch stop mount. I wasn't around for this custom harness fabrication (better ask what this is too!)


Here's the custom downpipe I wrapped:
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Old 11-08-2023, 04:19 PM   #15
SpdDmn
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Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

We got back to suspension - pulled the coilovers again to install 1" custom billet spacers, then added the Whiteline adjustable lateral links.



Here's a (poor) photo comparison of a brand new OE lateral link (black), the Whiteline adjustable one, and my 2004 STI (rusty) one. It's supposed to show that the new OE and rusty STI ones are the same length, while the Whiteline is longer. It seems to have fixed up the positive camber I had going on on the rear wheels, at least!


Lateral links installed! We moly-coated EVERYTHING, because Whiteline is so prone to rust



We also upgraded the rear subframe lockout bolts:
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Old 11-08-2023, 04:23 PM   #16
SpdDmn
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Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

Christmas break 2016 progress - cont'd!

So engine's in, tranny's in, turbo and exhaust are fitted... Now the finer details! We fabricated custom Teflon/SS braided lines for all fuel lines, and ran the electrical wiring for the Innovate 4-way gauge (ethanol content, fuel pressure and temperature, and air-fuel/boost), and the Aquamist water-methanol setup. I was in charge of all running of lines under the dash, since I'm 5'5 and WAY more flexible! :P

First off, the Aquamist HSF-3!
Thanks to Canonshooter's pics on NASIOC, we decided to re-purpose my washer fluid reservoir for water meth. It worked out pretty well, with only a couple extra "speed holes" to mount the pump. There's lots of room in that area, and the tank holds 1.75 4-gal bottles of methanol. We might have overfilled it, since it started leaking out of the reservoir's seam near the top... not sure if that's a plastic failure, or a design feature.. Once it drained off some, it's been dry and solid!


Cleaned up the tank (er, after this pic), and drilled the hole for tank level sensor (failsafe switch if the flow pressure becomes too low):


And the outlet from reservoir to pump:


The pump came with a rubber mounted bracket to minimize vibration (and to cover those couple extra speed holes!). You can see the line from the reservoir to the tank here. The outlet line from the pump was run from the fitting (center of the pic) up behind the tank alongside the filler neck:


And then the line goes through the flow sensor and high speed valve, which are after that 90-degree fitting.
Aquamist's system (the PWM, "precise water metering") measures exactly how much flow is entering, and how much is required based on fuel flow signal from the ECU. The "fast acting valve" FAV (little black box angled in the pic) gets constant pressure from the pump, which it jets in a quick pulse spray as needed so it can inject the right amount for the fuel flow (more methanol if you're givin' er, or less when you let off the gas).

Kinda hard to see, but we also have an Aquamist high pressure inline filter just before the 90* fitting. We're experimenting with pre-turbo meth injection, so the filter will remove any particulates from the washer tank, before they can clog up the jets.


To the the fuel flow signal, you tap into the factory ECU, going to the Aquamist HFS3 controller box. It's so factory, you can't even see the Aquamist wiring! :P (It's behind the big factory wire bundle)


The Aquamist gets power from a good fused ignition 12v source (again, electrical voodoo....). This is the only pic I really grabbed:


Here's how I ran the Innovate and Aquamist wiring, up under the fender liner. It comes out below the dash near the fuse box in the pic above, and from there I ran them to the center console below the double DIN compartment where the HFS3 controller box is.
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Old 11-08-2023, 04:24 PM   #17
SpdDmn
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Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

More install, plus Subaru goodies!

The gauge output wires for Aquamist and 4-way Innovate come from the center console to my gauge cluster, which I WAS going to run an SMY cluster surround...... But after finding the right one used for a great deal, it turns out the FXT gauge cluster is NOT the same as a GD Instead, we're ordering this Ortiz cluster surround.

I've got a sweet JDM FSTi cluster I bought used a while back, going in while everything is pulled apart. Still need to get it odometer-matched to mine.
Although I was a little worried about bright spots in my gauges, I went to put in the 74 SMD1 mini wedge LEDs from Diode Dynamics. BUT, they're *just* too big to fit through the holes. Stock cluster bulbs for now!

Stock vs JDM (STI tach to 9000rpm... km's to 180 :P )





My Christmas order of Subaru parts came in too! I got (or had stashed for this occasion):
- Double DIN navigation unit surround for the upper dash, complete with mounting brackets
- genuine Sports STI lip (with hardware)...... good god this was $moneyyyy$
- JDM FSTi "cross sports" grille with the STi badge (birthday present last year ;D )








I'm going to join the Nexus7 headunit install crew, using the double DIN surround. I've got AutoMate and Android Auto APK's kicking around and am pretty familiar with rooting and flashing ROMs (but not ****ing with kernels), but I need to read up some more on what wiring & adapters will give me the cleanest install.
I'm crossing my fingers that EcuTek gets around to porting their ECUConnect app to Android, so I can datalog and watch parameters in real time through the Nexus7! Y'know, Android makes up more sales than iPhones these days.... jus' sayin : For now, I can always mount my Cobb AP, especially while my setup is new and we're modifying things on the fly.
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Old 11-08-2023, 04:25 PM   #18
SpdDmn
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Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

Annnd a few pics, how she sits at the moment!



Wire up boost control solenoid






dat booty! :biggrin:
#rodknoc



Things to do this weekend:

- get midpipe - axleback welded up and installed
- wire boost control solenoid
- fabricate / put together intake (Cobb SF box + Apex'i filter?)
- install intercooler
- flash basemap from Airboy Tuning (thanks Sunny!)
- alignment? probly overrated..
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Old 11-08-2023, 04:28 PM   #19
SpdDmn
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2002 WRX
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14-15 January 2017

First start up this weekend!!! ;D ;D

Final things were installing the IAG air-oil separator:


Topping up with all new fluids (Motul Gear Competition 75W140 in rear diff and transmission, Motul Sport Ester 5W50 engine oil, and Motul Inugel Optimal Ultra coolant):


That Mac tool on the coolant overflow is a neat tool - it creates a vortex of air passing from the shop air hose to an outlet tube. That causes a vacuum from the car's cooling system lines out through another tube, which is measured by the pressure valve on the overflow tank. If pressure starts to increase while the vacuum is applied, you know you have a leak in the cooling system, before you fill up with coolant!
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Old 11-08-2023, 04:29 PM   #20
SpdDmn
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14-15 January 2017 cont'd

We messed around getting the GR STI intercooler installed for WAY too long. Gonna be a PITA to remove it for any future work...
The stock splitter *just* fits, but I might modify my v7 JDM STI splitter to seal around it (it's the same dimensions as the stock FXT, but not as deep/tall), or spend the big $$$ on a Subtle Solutions splitter, which has the same dimensions as well - nothing to fit the longer and wider GR intercooler. Maybe something custom-fab...
You can also see my temporary Tial BOV installed. Mine will be Tial's blue colour, to match the other accessories :P


The air intake and box setup turned out mint! The shop had Cobb's SF intake box for GD on hand, and this Apex'i intake cone filter.. which turned out to fit perfectly in the Forester!



READYYYYY......


GO!!


Gauges and Accessport are showing things!



VIDEOS
--> start up, and the exhaust from the underside.
It fires up quicker than any Subaru I've owned, no crank-crank-crank-fire, just FIRE :P Maybe due to the larger ground we added.
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Old 11-08-2023, 04:32 PM   #21
SpdDmn
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17 January 2017

Exhaust welding started Sunday - my downpipe was done in the summer, but the midpipe to Apex'i WS2 muffler needed to be fabricated.
I've never had equal length headers before, and it does sound different. And with the 3" all the way back, virtually straight the whole way... it's pretty damn loud!!

When the downpipe was fitted up in August: (it still mates up to a stock catback, kinda handy)


Tacking the 90 degree bends, and tacking the muffler in place.
Meticulously positioned just past the bumper, so it (hopefully) doesn't melt, and angled pretty straight coming out:


Pretty welds!


Plus in-house custom fabrication badges!




On start up, we had CELs from two different oxygen sensors we tried were toast. Today, my new replacement front O2 sensor came in, so we can install that right away. The exhaust hangers were welded on as well. We need an alignment, but that should be it... Possible first test drive tonight!! ;D
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Old 11-08-2023, 04:34 PM   #22
SpdDmn
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Just a quick update (and a lack of photos)...

We drove the car a little on a basemap, not yet tuned, to see if anything came up before it gets fully tuned. It was making some ugly noises starting off in first gear, coming from the driveshaft. We had installed the FXT crossmember, which you can see some excellent pics here, showing how it's quite a bit different than the STI one, causing the driveshaft to be mis-aligned and making the horrific hammering when starting off in mine.

You can sort of see here, where the driveshaft would come in contact with the FXT crossmember:


So switching to the STI crossmember solved that, BUT now the downpipe which was custom-fit for the stock FXT crossmember was hitting the STI one.. It was also super close against the firewall, causing the v-band clamp at the turbo to leak significantly. This past weekend, we got the lower section of the downpipe re-fitted so it wouldn't hit the STI crossmember, which also shifted it so it's further from the firewall. AND, I didn't have to re-wrap all that pretty DEI wrap! :P The axleback also sits a little closer to the bumper, as tucked up as possible without melting stuff, heh.

The good news is, it's sorted out enough it could be tuned this week, if timings and weather work out.
The sucky news is, I have a transmission issue. I know, 6MTs never fail.... except this one It's making some harsh vibrations in 5th and 6th gears, which were even worse when I ran through the gears on the hoist (not masked by soft winter tires or the noise of the downpipe like our roadtesting. We think it might be coming from the center bearing, NOT synchros or gears themselves, so there's that at least!
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Old 11-08-2023, 04:35 PM   #23
SpdDmn
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4-5 February 2017

My tranny was making some awful noises on the shakedown drives, so we had to sort that out before the tune. We first thought was due to the driveshaft hitting the crossmember, since we didn't swap out to the STI one originally. Did that and then found the downpipe hitting the STI crossmember, so our welder had to re-fit the lower portion. Still no luck.... So a couple weekends ago, Ryan pulled the center differential out of my 6 speed to replace all the bearings. We've come across the center diff howl in one of my other FXTs but never with a 6MT.. Guess they're not 100% bulletproof :P

Crossmember, downpipe and driveshaft out, shifter and reverse lockout cable disassembled (for the second time in <2 months!):


Something you don't see every day (hopefully). Look at that expensive blue lifeblood...
Center differential gears and bearing(s), with the DCCD in the background. Disassembled and removed the journal bearing that was likely causing the noise. I think the yellow plastic thing in the housing is a sensor for reverse gear (which wasn't reliably turning on the reverse lights):


See the pitting around the races inside? Click to zoom in, pretty crazy!


Cleaned up the rest; there was some scoring on that bearing in the foreground. Press-fit the two new bearings on that other gear thing.


This is everything re-assembled into the transmission, before replacing the housing. Which caused a lot of cursing to get each gear/bearing to line up properly...



Seems successful now! We drove it and didn't get the bad vibrations in 5th and 6th gears; in fact I couldn't hear anything over the exhaust... as you'd hope for a transmission, right!


Next day I installed my custom Ortiz cluster surround for the Innovate ECB-1 4-way and Aquamist HFS-3 gauges!
Innovate seriously needs to consider a quick disconnect at the gauge itself, because I spent ages pulling all my neatly tucked wires back from the center console, through the pod, and tucking again. Argh! Aquamist was a single ethernet-looking cable that plugged into the back of the gauge.

Overall, I like it. The finish is matte painted which could get damaged easily, and should NOT have yellow microfiber towels (or paper towels) used on it... Heh. The Innovate doesn't push-fit very well; I need to add some tape to get it pushed in fully, once all the tuning is done. Also have a silver bezel for it, so both gauges will match!


(haven't got the JDM cluster odometer-matched yet)

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Old 11-08-2023, 04:36 PM   #24
SpdDmn
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Join Date: May 2007
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Vehicle:
2002 WRX
Aspen White

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Not too much going on this weekend on the Foz, but I did get this sweet Process West TMIC splitter! Fits like a glove to the GR TMIC and my scoop.





Peaking inside the (super JDM scoop, you can sorta see the fins directing air onto the TMIC:


Can't wait to see what it does on the dyno after tuning!
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Old 11-08-2023, 04:37 PM   #25
SpdDmn
Scooby Newbie
 
Member#: 150058
Join Date: May 2007
Chapter/Region: W. Canada
Location: Calgary, AB
Vehicle:
2002 WRX
Aspen White

Default

Not too much going on this weekend on the Foz, but I did get this sweet Process West TMIC splitter! Fits like a glove to the GR TMIC and my scoop.





Peaking inside the (super JDM scoop, you can sorta see the fins directing air onto the TMIC:


Can't wait to see what it does on the dyno after tuning!
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