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Old 04-06-2010, 01:06 PM   #1
JRach
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Join Date: Dec 2004
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Location: North Seattle, WA
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98' SF5 STI
93' GF8 (rally)

Default 3rd swap in progress, 04' STI -> 98' Forester

I picked up this Forester back in August, and immediately started thinking how I wish I had started with a Forester as the recipient of my first swap (03' wrx -> 96' GF8).
So I sold the swapped wagon almost immediately to pay for a donor car for the forester.
After not too long, I picked up a damaged 02' WRX, but it didn't need much work to get back on the road, and I didn't want another 2.0 liter swap.
So after waiting for the right deal to come along... 8 months have passed and I finally found a donor 04' STI with only 61k miles!

I initially started a thread in the NWIC section 8 months ago... here's that post...

2 winters ago I did a full 03' wrx conversion in my 96' impreza wagon.

http://forums.nasioc.com/forums/show....php?t=1434059

Last winter I swapped a 06' wrx into a 02' TS wagon. (284whp/325 lbs. tq. on kito's dyno)

http://forums.nasioc.com/forums/show....php?t=1745176

So Friday (last August) I picked up this...




So I got it back to the shop on Saturday, and went and started working on it for the first time yesterday.

In about 5 hours I got this much done...

Got some work done today.

I pulled the exhaust, axles, hubs/knuckles, control arms, drained all fluids, pulled the tranny and motor!

Fluids draining


Tranny out


Engine out


As for plans for the car, I want to make a "fast" daily driver, but keep it pretty subtle.

Here's what I have in mind, so I can use it for reference later... i'm sure i'll change my mind a few dozen times before it's done.

Shooting for 400hp/400tq at the wheels on pump gas, still undecided on the turbo choice. Also, brakes... haven't decided if i'm going to go with the brembo's, or swap on some 4/2pots from a 06'/07', to keep my wheel choices open, and allow the use of 16" wheels (or my 15" rally wheels).

I was hoping to find an 05' so I wouldn't have to swap over to the 5x114.3 bearing/hubs/knuckles, but that will get done as well. (thank goodness for dual drilled wheels)

Seeing how the only rotors I could find that fit over the 290mm parking brake but work with the wrx 06' rear brakes are much more expensive than I anticipated, i'm pretty sure i'll just source some 04 brembo's, and switch the rotors once I find some 5x114.3 knuckles.

The car is getting a full swap, so Dash, Center console, auto HVAC controlls etc will all be swapped over. Not a huge fan of the usdm sti seats (and they didn't come with the car), so i'm still not sure what front seat's i'll go with (evoIX recaros if I can find some).

Wheels/tires. Already have some 17x8 wheels w/ 245/45-17 WS60 winter tires mounted up for next winter, and most likely some 17x9/9.5 Rota Grids with some 255/40-17's for summer.

As I mentioned this car will be a daily driver, so suspension isn't going to be too crazy. I'll do an occasional auto-x, maybe even a lapping day for fun, but again, comfort/function comes first, so it's not getting dropped very aggressively. I already have some cut 06' wrx sedan strut housings for some koni inserts and looking at either going with the jdm pink wagon spring I already have or the Epic engineering springs (leaning towards the epic springs, as i've been driving around with the pinks for the last 6 months and they're a little harsh for me). Only think that makes me want to steer away from the koni inserts, is when i switch to the 5x114 knuckles. Other things related as the swap progresses, groupN tophats, engine/tranny mounts, along with replaceing the following bushings... steering rack, rear diff, rear outrigger, front/rear shifter, trailing arms and either new bushing in the lateral links or i'll spring for some adjustable links.

The motor/turbo set up will remain stock until I build the motor and shoot for the hp goal I mentioned earlier (minus the FMIC which will happen right away, as I don't want to go with a hood w/ a scoop).

Speaking of, anyone know if they ever made a forester scoopless aluminium hood?

Alright, I think i've covered everything for now. I'm off to go get a few more hours in on the car. Today i'm hoping to have the gas tank/rear subframe/diff, and front crossmember out, along with the interior stripped
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Last edited by JRach; 11-25-2011 at 03:45 PM.
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Old 04-06-2010, 07:45 PM   #2
JRach
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98' SF5 STI
93' GF8 (rally)

Default

Went in today and spent a good 3 or 4 hours on it.

I was going to focus on pulling the subframe/diff, and front crossmember, but decided to strip the interior first

First I pulled the carpet. Then the dash and dash beam...


Then got cracking on the wiring harness from headlight to taillight along with the heater core/blower, pedal assembly and everything else inside the car.


EMPTY! (before i pulled the pedals )


Hopefully tonight/tomorrow the fun part begins!
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Old 04-07-2010, 09:51 AM   #3
kheff46
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silver

Default

looks wicked! im tempted to do my forester now the engine is torn down. keep this updated please?

--keith
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Old 04-07-2010, 11:08 AM   #4
morrocco88
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Rotated BW S256 6speed

Default

Very Nice, a sleeper forester!

Dude, I almost had a buyer for that swapped wagon you were selling. What shop are you working at? When my Legacy is done, I will come over there and take you for that ride you wanted.
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Old 04-07-2010, 02:11 PM   #5
Duderotomy
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2007 Forester XT Sports

Default

Keep up the good work, I've got a similar project sitting in the driveway waiting for the shop construction to be finished.
For the record though, no there isn't a scoopless aluminum hood for the 98-00 SF Forester. There is a scooped carbon fibre version available from Liberal, but it's like 1200 bucks before shipping through JapanParts.
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Old 04-07-2010, 02:44 PM   #6
JRach
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93' GF8 (rally)

Default

Quote:
Originally Posted by morrocco88 View Post
Very Nice, a sleeper forester!

Dude, I almost had a buyer for that swapped wagon you were selling. What shop are you working at? When my Legacy is done, I will come over there and take you for that ride you wanted.
I'm working over at EAT in kirkland. Unfortunately they're closing their doors here shortly, so I need to hustle and get this thing finished.
But i'm definitely still up for that ride! Can't wait to see how the powerband on that 2.1 motor feels!

Quote:
Originally Posted by Duderotomy View Post
Keep up the good work, I've got a similar project sitting in the driveway waiting for the shop construction to be finished.
For the record though, no there isn't a scoopless aluminum hood for the 98-00 SF Forester. There is a scooped carbon fibre version available from Liberal, but it's like 1200 bucks before shipping through JapanParts.
Thanks for the info... I think there's a few Aluminium SF hoods out there with a scoop... maybe i'll just have to hunt one down and do some bodywork to delete it
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Old 04-08-2010, 03:06 AM   #7
JRach
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Join Date: Dec 2004
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Location: North Seattle, WA
Vehicle:
98' SF5 STI
93' GF8 (rally)

Default

More progress today! Got there at about noon, and worked until about 8pm... with an hour break for lunch

First I pulled the crossmember out of the STI, along with the brake master cylinder/booster and clutch master/slave cylinder. Then dropped the Rear subframe/diff/hubs/lateral links out of the STI



Once that was out the STI was pretty much totally bare!
So I pulled the forester in, and threw it up on the lift to start draining the fluids.



Pulled the front drive axles, exhaust, driveshaft, heat shields, stipped out the interior, pulled the seats and carpet, then dropped the rear subframe/diff/axles/lateral links/swaybars and hubs



Then dropped the gastank and emissions crap



And finally got the R180 diff, sti subframe, lateral links, axles, trailing arms, hubs and gas tank into it's home (in the forester!)



Shot of the hubs... proof it made it's way home Just need brembos now!



Dont worry, the stock suspension is going away for some KYB AGX's w/ jdm pink wagon springs tomorrow... until I decide which route to go
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Old 04-09-2010, 07:33 PM   #8
JRach
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93' GF8 (rally)

Default

Didn't get much done yesterday... had to work last night (and again tonight), and had to work on a customers car yesterday and today.

Got the tranny out of the forester today, along with prepping the engine in the forester for removal. Gonna go back tonight after work to pull the motor and with any luck put the 6 speed in its new home!
For sale
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Old 04-11-2010, 01:47 PM   #9
Cabron13
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Very nice .......... wish I had the space to do something that wild!!
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Old 04-13-2010, 07:39 PM   #10
JRach
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98' SF5 STI
93' GF8 (rally)

Default

Got about 3 hours of work in on it today.

First I pulled the motor out of the forester...


Then started pulling a few random things from the engine bay. I picked up some WRX 4/2pot front and rear brakes to keep my wheel options open, so i threw the fronts on. (still have to put the KYB struts/jdm pink wagon springs on)


Then I got the 6speed tranny and driveshaft put into place.


Now I just need to clean the engine bay up a bit, finish stripping out the dash on the forester, and then do all the wiring and drop the motor in
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Old 04-14-2010, 09:44 PM   #11
Maverick7531
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2002 WRX - '04 EJ257
w/ ECU & Fuel -'04 5MT

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Hey... Im in the middle of an 04 STI swap as well... its going into an 02 WRX though. I'm really whinging it... I mean I'm a very capable mechanic.. and my Pap is a MASTER... but he's a Chrysler guy, and I've never done this type of swap.

I'm at the Wiring step as of tomarrow. Just ripped the dash off tonight, and the wires are all loose, but still in place.

I don't have a doner car... as far as wiring goes i just have: Pedals, Steering column, Fuel pump(both drop ins) and emmisions crap, Engine, Body/dash and engine harness, and the ECU.

My goal is to use as much of the 04 harnesses as possible, but as little as possible if that makes sense to you(I have to make everything connect to my connections like PW and Door locks, etc...)

This is my biggest concern as of right now!:
I am trying to analyze if it is possible to splice wires and keep my stock manual A/C system intact.. but just run power to the nessecery units. ...I'm trying-I don't feel like springing for that system... Plus I HATE AUTO CC!

U got some advice at all?
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Old 04-15-2010, 02:00 AM   #12
JRach
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93' GF8 (rally)

Default

Got a couple hours in today. Doesn't seem like much happened (worked on a customers car for 4 hours), but i pulled the fenders, got all the wiring out of the forester engine bay, and got the dash out of the forester. Tomorrow i'll finish pulling the remaining wiring harness back to the taillights out of the forester, and pull the heater core/dash bar and start puting the STI stuff in.


Maverick- sending you a PM now
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Old 04-15-2010, 10:49 AM   #13
Duderotomy
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2007 Forester XT Sports

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great progress man... <subscribed>
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Old 04-15-2010, 11:10 AM   #14
haunt
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bought some pugs off your pops the other day, told me a bit about the progress. super jealous man! keep up the amazing work.
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Old 04-16-2010, 04:03 AM   #15
ALTRDTA
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Black on Black

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Should be a fun build and very sleeper-ish
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Old 04-17-2010, 02:26 AM   #16
JRach
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98' SF5 STI
93' GF8 (rally)

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Got a bunch done today.

First I pulled the heater core and blower motor out, along with the dash bar. Tomorrow or Sunday i'll get the rest of the wiring out of the car and start splicing


Then I put in the Kartboy front and rear shifter mount bushings, installed the driveshaft, front drive axles, steering rack castle nuts and exhaust heat shields along with the kartboy exhaust hangers
(can kinda see the shifter bushing up there)

Next I threw together the stock tophats with the jdm pink wagon springs and the kyb AGX's...

Then I got bored and wanted to see what my REALLY inexpensive winter wheels would look like on the car... hard to get a feel for it with it off the ground and with the fenders off.
ALT 17x8 wheels with Blizzak LM25 tires in 245/40-17. Should make for a somewhat grippy winter tire when I'm not heading to the mountains to ski


Can't wait to see what this thing will look like once it's on the ground and all together!
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Old 04-20-2010, 06:07 PM   #17
98foreza
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document the wiring for us please!! take lots of pics of the
harness merging
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Old 04-24-2010, 05:47 PM   #18
sr20dehauler
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A true sleeper!
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Old 04-25-2010, 08:18 PM   #19
JRach
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93' GF8 (rally)

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After a couple rough days filled with pre/post friends wedding shennanighans, I got some work done today.

Mostly took the time to modify the pedal assembly so the STI pedals would bolt into the forester, I also modded the dash bar and mounts so the Dash would fit properly.

Now that the hard part is over (and my ecu arrived in the mail!) I can start splicing the wiring and get serioius about finishing everything up. Also need a gauge cluster and cheap FMIC as well, but need to sell a few more parts first to afford it.

STI dash in a forester w/ STI pedals!
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Old 04-26-2010, 12:45 AM   #20
eurospek
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Subscribed.
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Old 04-26-2010, 08:20 AM   #21
25rsti
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sick, i love foresters with swaps and nasty wheels....yum. awesome work
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Old 04-26-2010, 04:25 PM   #22
kheff46
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im finding my forester more and more sexy, since it's identical to your donor chassis!

im digging it! did you figure out your seat situation yet?

--keith
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Old 04-27-2010, 12:21 PM   #23
JRach
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93' GF8 (rally)

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Quote:
Originally Posted by kheff46 View Post
im finding my forester more and more sexy, since it's identical to your donor chassis!

im digging it! did you figure out your seat situation yet?

--keith

Havn't totally decided. Ideally, i'd go with some black JDM STI spec C RA seats... but havn't seen them go for any less than $950. For that price I prefer the suede recaros out of the EVO IX. For the time being i'll just throw in a spair set of wrx seats I have until I figure it out.
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Old 05-10-2010, 01:42 AM   #24
howfast?
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so how is the project today?
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Old 05-10-2010, 05:09 PM   #25
NFJ79
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I demand updates!!!
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