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Old 12-10-2010, 10:20 PM   #1
psychorunner
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Default 2005 STI into 2002 Bugeye Swap

So I have seen very few "build" threads on swaps and about a month ago I started my own and now it is about finished so I thought I'd start this and if anyone has any questions about this specific swap or possibly others I'd be glad to help.

About two months ago I was driving my "stage 2" WRX that put out a whopping 227 whp or so and started hearing a nasty chatter in 1st gear. It kept getting increasingly worse, so I drained just a little bit of gear oil out of the tranny and out popped a gear tooth. The car still drove through 1st gear, but I knew it was a matter of time before the tranny completely took a dump. I happened upon a totalled 2005 STI that had been rolled. My thinking was I didn't want just another 2002 WRX tranny that would break again anyway, so I might as well tackle a swap sell the parts and spend about as much for the swap as I would have for a decent tranny anyway (seemed logical at the time).

Heres a few pics of how the STI looked.








Biggest issue on this was that the pass side was pretty mess up. The rear axle, strut, control arms, bearing, and kuckle were all broken or bent as you can see. But the brake caliper was fine. Just had the axle rebuilt, found a used strut, replaced the bearing and bought a new front and rear knuckle from the stealership. Also, both BBS wheels were bent up pretty bad so I scored some off ebay that had a little curbrash for cheap. In total and extra $700 or so if that. We decided to just use the WRX control arms from the front and rear and they've been working out well. The only difference is that the WRX ones are steel instead of aluminum. Engine ran fine but the intake manifold had a crack that needed welding and the intercooler did as well (both easy fixes)




And so tearing apart the STI starts...





We had a forklift handy, so instead of pulling the motor and tranny out the hard way through the engine bay, we kept everything together for the most part, unbolted the subframe and lifted the body off the subframe, got rid of the body and started pulling apart the WRX.






Forklifted the body up again, then move the STI stuff under and dropped the body of the subframe.





Bolted it all in, got the wiring in and everything hooked up and...it didn't start. It probably took us two days to figure out we had the fuel lines mixed up to the fuel rails. Then it started up just fine. But wouldn't rev past 3000 RPM. Another two days of buttoning up other stuff and troubleshooting and we found that the sensor on the DBW gas pedal sensor was broken. This also caused the DCCD to not work and a handful of other little problems. Got a new gas pedal of a legacy and we were in business! Finished up the wiring and the interior:








Finally got it on the ground and on the road. Took a while to figure out a handful of boost leaks (crappy 90 deg elbow, crack in Intercooler, forgot to put 3 bolts back into throttle body). Took it out for a drive and realized the the wipers didn't work. We had forgotten to re-pin the wipers because we used the WRX wiper motor. In turn the motor burned out so we got a new motor and long story short the wipers worked great!


Still have just a few odds and ends to fix, but the majority of it is done and I've even been able to have fun in the snow!





Here's a link to more pics if anyone's interested.

http://s999.photobucket.com/albums/af113/psychorunner/05%20STi%20into%2002%20WRX%20Swap/
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Last edited by psychorunner; 12-16-2010 at 08:42 PM.
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Old 12-10-2010, 11:48 PM   #2
psychorunner
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Old 12-11-2010, 03:06 AM   #3
02NIGHTHAWK112
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looks so clean man, I have the same plans for my bugeye
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Old 12-11-2010, 04:18 AM   #4
psychorunner
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Thanks!

Last edited by psychorunner; 12-14-2010 at 10:34 PM.
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Old 12-14-2010, 10:37 PM   #5
psychorunner
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I thought I'd throw in that this cost about $2500 in the end after I sold most of the major parts left from the WRX.
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Old 12-15-2010, 02:03 PM   #6
lesterwrx7
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Do u change the rear end to an r180 3.90 ? Can u use the wrx axels on the rear iheard u need to change huds caps too . I wannt hear front some one who done it.
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Old 12-15-2010, 09:13 PM   #7
psychorunner
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Quote:
Originally Posted by lesterwrx7 View Post
Do u change the rear end to an r180 3.90 ? Can u use the wrx axels on the rear iheard u need to change huds caps too . I wannt hear front some one who done it.

We took the R180 rear diff and used the STI rear axles. If you keep the R160 or use it at all you have to go in and change the R&P gear. If you use STI axles you have to use STI hubs unless you do a hybrid axle build. And there are plenty of threads on here about the hybrid axles from what I remember.
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Old 12-17-2010, 01:59 PM   #8
tuesdaysgone
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Does everything from the blobeye fit straight over to the bugeye?

In particular, brakes, transmission, interior?
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Old 12-21-2010, 06:52 PM   #9
psychorunner
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Quote:
Originally Posted by tuesdaysgone View Post
Does everything from the blobeye fit straight over to the bugeye?

In particular, brakes, transmission, interior?
Yes, as long as you take everything and switch it over. all subframe pieces have the same mounting points. For the interior, all seats bolt in the same spots, the dash supports switch right over and the dash boards and accessories will switch right over.
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Old 12-22-2010, 10:47 AM   #10
GrimmSpeed
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I am glad you pulled this off! Chad our engineer and I were going to buy this but decided to wait a couple days to figure out where we would tear it apart, and you snatched it up before we could get to it, but I am glad it went into good and very capable hands! Congrats!

Will
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Old 12-25-2010, 12:03 AM   #11
psychorunner
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Quote:
Originally Posted by GrimmSpeed View Post
I am glad you pulled this off! Chad our engineer and I were going to buy this but decided to wait a couple days to figure out where we would tear it apart, and you snatched it up before we could get to it, but I am glad it went into good and very capable hands! Congrats!

Will

Thanks! I'll have to swing by Grimmspeed sometime so you guys can have a look at it if you'd like! I'm glad it worked out as well as it did!
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Old 12-25-2010, 10:19 PM   #12
navydub
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Awesome! Definitely inspiration for the rest of us
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Old 12-26-2010, 12:52 AM   #13
arco
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nice to see others do this too. I have the engine from the JDM Version 8 STi (2.0L STi), matching JDM gauge cluster, 05 USDM transmission, brakes, wheels, suspension, JDM Version 7 STi front seats, USDM STi rear seats, and a bunch of sti odds and ends.
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Old 12-27-2010, 05:10 PM   #14
psychorunner
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That sounds pretty sick!!
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Old 12-27-2010, 10:46 PM   #15
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Did you swap both the front and the rear STi subframes onto your bugeye? I know the rear is needed for a full STi trans & sus swap, but will the bugeye stock front subrame work with 05 STi sus?
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Old 12-28-2010, 08:39 PM   #16
psychorunner
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Quote:
Originally Posted by BlueHeavenWRX View Post
Did you swap both the front and the rear STi subframes onto your bugeye? I know the rear is needed for a full STi trans & sus swap, but will the bugeye stock front subrame work with 05 STi sus?

I swapped the front subframe, but not the rear subframe. The rear subframe actually worked, but just had to use the WRX lateral links that are steel instead of aluminum. As far as the front subframe, the only thing that I would think that could make a difference is the steering rack. I don't know if the WRX steering rack will fit in the front STI subframe or not. Hope that helps some!
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Old 12-28-2010, 09:10 PM   #17
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Quote:
Originally Posted by psychorunner View Post
I swapped the front subframe, but not the rear subframe. The rear subframe actually worked, but just had to use the WRX lateral links that are steel instead of aluminum. As far as the front subframe, the only thing that I would think that could make a difference is the steering rack. I don't know if the WRX steering rack will fit in the front STI subframe or not. Hope that helps some!

Thanks that helped!

Ohhh and awesome idea using the forklift as a make shift lift. That made me look up used forklifts in my area, hoping to find an electric or propane one for under a grand, but they were all like $2-3K.

I can get a 10,000 lb lift and install it myself for around $1,800. I just need a garage high enough for it
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Old 12-28-2010, 09:40 PM   #18
psychorunner
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yea! it worked out pretty well, I just happened to have a good friend who had one. I would definately just go for the lift too if I was to buy one, then you can actually do work under it without feeling like the whole car is gunna fall on you! Good luck with your swap!
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Old 01-16-2011, 09:22 AM   #19
buru2
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DUDE!! im having slight problems between the Same years vehicles. i went NA with it sadly bc thats what i had laying around from a previous wreck. the wipers caught my eye. i am about to do that now.

http://oksc.org/forum/viewtopic.php?f=4&t=8239

cant rev over 3k and bogs down til it nearly dies. mix and matching 02 wrx fuel rail, stock 07 NA rail, 07 fuel pump, jdm 03 fuel pump, f.p. regulators, etc.

i need to get this done ASAP so i can drive home to colorado from Oklahoma where i and my car are curently. any input would be AMAZING. Thanks
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Old 01-16-2011, 07:10 PM   #20
psychorunner
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So you did a 2007 2.5i swap into a bugeye? So what exactly are you using for fueling? I see two different fuel rails listed and two different fuel pumps...So I'm just a little confused, but I'd be happy to try and help.
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Old 03-08-2012, 08:28 PM   #21
psychorunner
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