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Old 05-29-2013, 01:49 AM   #1
RavensFan7
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2001 Ej205 Impreza L
SRP

Default 2001 Impreza L | WRX swapped daily | Damage repairs and weight reduction!

This is the progress of my 2001 Impreza L coupe. It wasn't bought to be a project like it is, but I guess it ended up that way. It's been a daily since I got it, and stayed that way after the WRX swap. It's been awesome driving it swapped the past year or so, but recently it was totaled out in an accident (not my fault). I will be slowly repairing it....it'll need the core support fixed, and some other new parts. I'll take this time to do lots of other weight reduction, fix rust, and install some other goodies as well.



Backstory:



I got the car in August 2011 with 100,500 miles. It's my first car, and it had lots of problems at the start...mostly the dealers fault and neglect from previous owners...but I started fixing things on my own. Once I read about all the swap stuff, I decided I had to keep the car. After all it does awesome in the snow, and its a blast on all the gravel roads where I live....I even drove it on the driving beach in Corolla, North Carolina once.

I messed with weight reduction, and fixing/upgrading the suspension while I gathered funds for the swap...lots of maintenance too...although the ej22 ran strong the whole time. It really was bulletproof. I had to have the transmission rebuilt last year....stupid used dealership's fault.....but was finally was able to start the swap summer 2014 and got an ej205 in and running.





Here are some up to date pictures, regardless of the different seasons:






















The goods:


ENGINE:


-USDM 02/03 ej205 (6/28/14)

-Protune by Jermaine @TurboXS

-v3 accessport

-iWire merged harness

-TGV deletes

-Grimmspeed catless uppipe, ceramic coated

-Cobb catted downpipe, ceramic coated

-02-05 wrx, Invidia q300 catback

-avo turbo inlet

-lighter crank pulley, and no p/s or a/c pulleys

-STi oil pan

-KillerB oil pick-up tube

-Rotella T6 5w40 oil



TRANSMISSION:


-'01 5mt (3.9) and cable clutch;
AndrewTech rebuild

-custom reinforced clutch fork

-'01 (oem) TOB, and pivot ball

-'06+ wrx clutch

-'06+ wrx pressure plate

-'06+ wrx flywheel

-TiC shifter linkage update and pivot bushings

-redline shockproof and motul 300 mix



SUSPENSION / HANDLING


-KYB excel-g struts (2/2/14)

-Eibach pro-kit springs 2/2/14)

-Group N front top hats (2/2/14)

-3/8 saggy butt spacers (2/2/14)

-new ball joints and outer tie rods

-18mm Outback rear sway bar

-20mm WRX wagon front sway bar (6/28/14)

-JDM GC8 crossmember (6/28/14)

-Whiteline steering rack bushings (6/28/14)

-Whiteline rear endlink bushings

-group N front-of-trailing arm bushings

-power steering delete



WEIGHT REDUCTION&DISTRIBUTION:


-Currently about 2600~ lbs.
-***Was at 2590, but the turbo engine swap and a full-size spare added well over 100 lbs back.

-Aluminum jdm gc8 hood

-USDM front bumper beam cut in half

-deleted a/c

-deleted power steering

-washer fluid tank relocated to trunk

-battery relocated to back seat

-removed hunk of metal from glovebox and under dash

-removed most sound deadening

-stripped trunk besides spare

-lighter wheels

-removed keyless entry system

-random little things. More soon.


-----------------




Here's the progress from the beginning mostly in order. I'm going to add in some dates/mileage later on. Bear with the potato pictures for the first few pages...I eventually had digital cameras and now a DSLR, so the pictures get progressively better quality.



Warning, picture heavy:





-Bought late August of 2011, bone stock L model 2.2L....Finally got some actual wheels to replace the steelies after high school and decent tires...compared to steelies and no-season.



16x7 with 205/50-16 Conti DW, the stockers were 195/60-15.







This is the oldest picture I have of my car, and the only pic from the beach driving I have left.















--Rally armors, which get used on a daily basis on PA's crazy roads











--Homemade light bar that mounts 2 hella 500's















How it looked the first winter:















--Polyurethane rear end link bushings



This is when I learned how hard pressing bushings is.....







--New outer tie rods, ball joints, and front wheel bearings.



This is when I learned to hate wheel bearings and ball joints......







This is a ball joint removal tool......mine were really stuck.







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Old 05-29-2013, 01:50 AM   #2
RavensFan7
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2001 Ej205 Impreza L
SRP

Default 2001 Subaru Money-pit (Impreza L coupe)

--ALL axles have been replaced at least once, some multiple times.

--New trailing arms, with group N front-of-trailing arm bushings already pressed in. Thanks to bigskywrx for the being able to purchase those.

--Valve cover gasket, tube seals + grommets replacement.


--Picked up an RS hood, scoop, vents, and all painted SRP, REALLY cheap. I was gonna get one when I do the swap anyway, so why not?



--A deer ran into the drivers side of my car....right into the side....literally head butted the fender....dents from the front fender to the rear 1/4 panel.

Here it is all fixed up...new door, and half the car repainted.





--Ended up painting the machined lip on the wheels to match the spokes. Don't like the machined lip, dark spoke, style.....






Meh, better than how I bought them....and somehow, the spray paint is holding up to the gravel roads.


--Dealer I got it from put some water-thin oil in the gearbox that left me with all gears grinding for over a year.
So about 2-3 months ago, the transmission was rebuilt and new clutch installed by Andrewtech. They did an awesome job. Got the TIC shifter linkage update, and 5mt pivot bushings installed at the same time.

No more shifter slop or grinding gears!




--New "taco link" front lateral links with new bushings, new rear wheel bearings, about 2 weeks ago.

--Here's how it currently sits at 134,xxx miles


To-do:
--Getting my a/c drained here soon so I can rip out the a/c system.

--Also currently looking for a 17mm rear sway bar. I already have the bar-to-frame 17mm poly bushings to match the endlinks....just need the bar. Hoping to find one/order one buy the end of the week.

--Next big thing is struts at all 4 corners.

Last edited by RavensFan7; 12-27-2014 at 02:30 AM.
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Old 05-29-2013, 02:05 AM   #3
|Rev|
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I was going to say nice car, but then I realized you are a Ravens fan

I'm anxiously waiting the first game of the season.

ANYWAYS... Nice car, I'm with you on the machined lips, I never have liked them.
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Old 05-29-2013, 02:13 AM   #4
RavensFan7
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Haha thanks.

....unless you're a Steelers fan
Edit: lol nevermind, just noticed you're from Colorado

Quote:
Originally Posted by |Rev| View Post
Im with you on the machined lips, I never have liked them.
Yea...I actually need to re-spray the wheels again soon. The spray paint held up well on gravel/dirt roads, but not to a tire mounting machine. -_-

Last edited by RavensFan7; 05-29-2013 at 02:24 AM.
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Old 06-03-2013, 08:39 PM   #5
RavensFan7
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2001 Ej205 Impreza L
SRP

Default 2001 Subaru Money-pit (Impreza L coupe)

Got my rear sway bar.



Picked up an 18mm from a '98 Outback for $25. Direct bolt-up and easier to find than one from a WRX.



Went to a u-pull-it and found an Outback with what I needed pretty quick. I didn't have any wrenches or sockets with me, only electrical tools.....the bolts were all rusty anyway so I grabbed a hacksaw from my trunk, and cut the endlinks and brackets to free the bar.





The Outback was sitting on its brakes, so I couldn't get underneath to pull the bar out the normal way....instead I had to pull/wiggle/wrestle it out from the drivers side. Took like an hour of turning/pulling/yelling/more pulling to free it completely.





Huge improvement over the tiny 13mm oem bar. The rear of the car feel SOOO much more planted in turns now...definitely the best mod so far. /albums/r557/Steelersarebeat7/1370294108_zps80b5940b.jpg[/IMG]





Also, I'm currently troubleshooting a fuel guage issue. Back seats are out and I just need resistance values for the fuel meter(s).



Tempting to keep the seats out and start stripping everything I can for weight savings.....but it's still a daily so I can't do that just yet.


Last edited by RavensFan7; 12-27-2014 at 02:33 AM.
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Old 06-03-2013, 10:58 PM   #6
tja1618
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Nice car you got there, I'd love to drop my old EJ205 in there. Let me know if you ever want to sell it, or buy the 205
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Old 06-04-2013, 09:24 AM   #7
RavensFan7
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SRP

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Well...I'll need an ej205 for what I want to do, but that'll be a little later on.
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Old 06-23-2013, 12:09 AM   #8
RavensFan7
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Last week I got new summer tires mounted. I went a little wider with 215's instead of the 205's I had. Next set of tires will be 215/55's because now I know they will fit easily.

-The tire mounting machine took off even more paint from my wheels, so I re-sprayed them again. This time I painted the whole wheels, not just the lips.
-quick sanding
-3 or 4 coats of primer
-3 or 4 coats of "gunmetal" color
-3 coats of clear
(all spray paint)

Turned out pretty good considering I did the last few coats after it got dark out.

-Washed it for the first time in a while.


-Got my a/c discharged yesterday, and finished pulling out the a/c today.
Getting to this bolt on the compressor was the most difficult part.


-Compressor out:


-Pulling the condenser:


-After looking at all the bent fins on the condenser I concluded the radiator needed some protection from bugs and stuff:


-I cut a rectangular piece of mesh/screen to go in front of the radiator where the bumper and grill opens up, secured by cheap Velcro and hot glue. Cant even tell any of it is there. It's not much, but better than nothing:



-Here's all my weight savings:


Total weight dropped: ~31 lbs

I'd like to get the car 100 lbs lighter by the time I do the swap, so this is a good start.

Hoping to finally get new struts and springs soon.

Last edited by RavensFan7; 06-25-2013 at 06:31 PM.
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Old 06-23-2013, 02:52 PM   #9
Longinus
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Great job on everything! I love GC's being saved and improved. Good move on your part for painting the chrome lip on the wheels. Nice lightbar.
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Old 06-23-2013, 06:07 PM   #10
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^ agreed
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Old 06-24-2013, 12:07 AM   #11
RavensFan7
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Default 2001 Subaru Money-pit (Impreza L coupe)

Quote:
Originally Posted by Longinus View Post
Great job on everything! I love GC's being saved and improved. Good move on your part for painting the chrome lip on the wheels. Nice lightbar.
thanks!
Quote:
Originally Posted by Tillis View Post
^ agreed
...and thanks!

Last edited by RavensFan7; 12-27-2014 at 02:34 AM.
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Old 01-23-2014, 01:27 PM   #12
RavensFan7
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Long time no update....been doing a lot, but never felt like updating....but now I got this thread and one over at rs25, so I can keep track of all my stuff....well atleast try to.

--Since the last update, I've done lots of weight reduction. The a/c was the start of my weight savings. Next was the trunk:
-no donut
-no tire well cover thing
-no carpet
-some paneling removed
-some metal removed
-sound deadening removed


--Changed up my aux. lighting set-up. Moved the hella 500's to the bumper and bought some rigid industries LED's...and they are bright!
Stock headlights:


Headlights + LED floods:


On two SPST switches:



--picked up an RS wing


--More sound deadening removal. I used dry ice:
~under rear seat
~passenger side floor
-drivers side floor



The only stuff left is on the firewall and trans tunnel.


*more weight savings
--deleted washer fluid tank
--removed hunk of metal from glovebox
--lightweight crank pulley
--power steering delete
--lighter intake

Last time I got it weighed it was 2590....but since then I've added the full size spare which is around 35 lbs. Once I get a lighter battery and remove some more stuff I hope for mid 2500's with the full size spare.

Stuffing the rack with wheel bearing grease for the power steering delete:


Empty engine bay:

Last edited by RavensFan7; 01-23-2014 at 04:11 PM.
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Old 01-23-2014, 01:27 PM   #13
RavensFan7
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--rattle-canned the wheels a darkish gold for winter.

--Michelin x-ice xi3's on right now. Been getting use out them this winter:

I have new struts, springs, group N front top hats, and all the other stuff waiting to go on in the next few weeks...just waiting on a few more parts.

...and since I decided on a swap a LONG time ago, I finally got started on that. Blown up ej205:

Bought that 2 weeks ago, and I've been tearing it apart in my house with hand tools. Got the heads off last weekend, and finally got the damn pistons out tonight. Gotta go get a 12 point socket to finish removing the case bolts and I can split the block.


Had to get creative for the c-clip things:

Looks/feels like it was rod bearing from #4 that died. This is my first Subaru engine teardown, but everything else looks pretty clean to me. Cross hatching is good right? Hoping to have it all ready to drop in, harness and all, by spring.
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Old 01-23-2014, 01:30 PM   #14
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Got the block apart: #4

Everything else looks pretty good. Just gotta get it all to a machine shop next, to see how it looks in the nitty gritty and see what needs to be replaced.

Now here's a problem I ran into while splitting the block. I broke this:

Also broke this little bracket off whatever this piece is: Atleast that is replaceable and I can just bolt another one on....the oil cooler bolt issue may be a real problem....
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Old 01-23-2014, 01:39 PM   #15
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Good stuff man. Keep plugging away. I really cracked up seeing this photo because I've totally been there... haha
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Old 01-23-2014, 02:28 PM   #16
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Strong work!
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Old 02-02-2014, 08:10 PM   #17
RavensFan7
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Sorry, this update is mostly iPhone pics.

--Last week there was single digits everyday, and a fuel leak developed. I smelled gas occasionally, but the super cold days allowed me to see exactly which hose was leaking....so I replaced this little guy:

--Since the ej205 is completely torn down I've been cleaning up the parts to get it ready for the machine shop.
Squeaky clean valve cover:

--FINALLY got rid of the stupid accordion shifter boot. Also cut the shifter down and re-threaded it back to 12x1.25 so I can use my stock knob. Got bored and made a few "knobs" out of random stuff....but this is the only one that turned out OK:
It's from that ej205. Not permanent.

--This weekend my impatience got the best of me and I decided to do my struts and springs myself. I rented some spring compressors and used all hand tools....wasn't too bad! Had to get some special sockets and wrenches but me and another friend got it done.

My car had the original L model struts/springs which were basically all blown. Since mine is about 200 lbs lighter than an RS, I think the RS stuff would lift me. I also didn't want to go too stiff because I really like the gravel roads around here. So I went with:
-KYB excel-g struts
-Eibach pro-kit
-Group N front top hats
-standard rear top hats
-cut bump stops
-3/8 saggy butt spacers
Broke all these:

Really evened out the ride height....not too low, and not too stiff. Maybe an inch drop. Maybe. Before, I could EASILY fit a full fist up front and the back sagged a lot...Took out some body roll, less squat/dive on accel/braking. Pretty happy so far, just gotta drive it on gravel/snow....also make sure everything seated properly.

Finished up at like 2:00 pm today, and just barely made it to my 3:00 pm alignment:

Last edited by RavensFan7; 02-02-2014 at 09:05 PM.
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Old 03-04-2014, 10:11 AM   #18
RavensFan7
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2001 Ej205 Impreza L
SRP

Default 2001 Subaru Money-pit (Impreza L coupe)

Im always doing something with the car, but I don't wanna make a bunch of small updates, so here's the past few weeks since the last update:

Had some fun before the big snow came through the other week:


--The snow stopped for a little and I ran out to get some all weather floor mats. The nicer ones seriously weighed like 30 lbs. so I got the cheapest, thinnest ones I could find. These will definitely get the job done, and weigh next to nothing.


--Almost forgot about weight reduction....although I'm kinda running out of stuff to remove. A lighter battery is in the plans but I'm working on little stuff. Hope to be back in the 2500's soon, since the full-size spare bumped me back up a little.

Got started on removing some metal from the trunk. I already kinda started this before but I got more of it out. There's some rust on the right corner so even more will probably come out later....not sure if that was any type of "bracing" but if so I could easily add some vertical structure back (3rd picture, lol).
After that I want to remove the jack bracket/mount, and the two tabs that held the spare tire cover. There's also some wires + their connectors I can trace, pull back, and cut.



Also removed both the broken cup holders. Kept the front part for the one on the dash so it looks nice and neat like one is still there....the one in the center console was all messed up and always fell off the little track. Probably going to remove the entire center console and get the rest of the sound deadening soon.

Last edited by RavensFan7; 12-27-2014 at 02:38 AM.
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Old 03-04-2014, 10:14 AM   #19
RavensFan7
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--Finally got that evaporator out last week. Combined weight with leaves and stink bugs was around 3 lbs.



--Cleaned up the block halves and valve covers. Used chlorinated brake cleaner and probably turned my driveway into an EPA disaster. Missed some spots and ran out of brake cleaner but most of the gunk is off.
The heads are supposed to be good, but I think I want to check them out and maybe refresh them too.

--Sunday night I disassembled the ej20 heads. Other tools didn't work, so I used the c-clamp idea I read about, and it worked awesome. Then yesterday I cleaned the heads and valves/springs/retainers....everything looks pretty good...but I think I want new valves at least:




Last edited by RavensFan7; 03-04-2014 at 10:24 AM.
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Old 03-04-2014, 10:18 AM   #20
RavensFan7
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Also last week I broke my fog lights...stupid ice...the LED's are fine though. I filled the old holes and crack from where the lights broke from their mounts, and sanded it all down. I was about to finish re-spraying that spot but I got snowed out...2nd picture is how it will basically look like for a while:
I don't really like it...might get some circle lights again...or maybe I'll try to get a new/different bumper paint matched this spring...I've always liked the v3-v4 (I think) bumper.

On the bright side, since the engine is all the way disassembled and some-what clean, it's ready for the machine shop! Gonna drop it off in the next few weeks...it'll probably be there for a month or so...which means I can start gathering parts.
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Old 03-04-2014, 02:23 PM   #21
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i like where this is going. good luck on your engine build/swap. this makes me miss my old rs coupe...
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Old 03-04-2014, 07:51 PM   #22
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Quote:
Originally Posted by subyrally View Post
i like where this is going. good luck on your engine build/swap. this makes me miss my old rs coupe...
I always see people saying they miss their first gen Impreza's...that's why I couldn't bring myself to get rid of this car, even when it had tons of issues. I really like the older Impreza's and I plan on getting another L or RS as a spare soon.

...that way I will be able to drive a "GC" impreza no matter what.
I'm just hyped to get this first one swapped.
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Old 03-04-2014, 08:00 PM   #23
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I'm anxiously waiting the first game of the season.
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Old 03-27-2014, 06:56 AM   #24
RavensFan7
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...and so it begins:


The massive gathering of parts that is. Still needs ecu, but that should be the WRX harness I need.

Yesterday I dropped off the ej205 block and heads to the machine shop. Roads are rough around here


...and as of lately, I rolled over 150,000, put the washer fluid tank in the trunk, and some more weight reduction.


Removed more sound deadening on trans tunnel. Also removed other weight but don't feel like listing it all:


Wires and hose for washer fluid, and trunk set-up:



Last edited by RavensFan7; 03-27-2014 at 06:46 PM.
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Old 03-27-2014, 07:21 AM   #25
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I thoroughly enjoyed reading through your thread. I love the older imprezas, I wish I had one as a project car. Good luck with your build, love what you've done so far.
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