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Old 03-04-2014, 02:14 PM   #1
uglybetty
Scooby Newbie
 
Member#: 381907
Join Date: Feb 2014
Chapter/Region: South East
Location: Nashville
Vehicle:
2005 forester STI

Default the Ugly Betty 2005 FSTI build

I'm not normally one to make a build thread but this time I couldn't help myself. my name is Steven and I've lurked here on nasioc for the past few years. my last build was a 2011 STi that I ended up selling because someone offered me cash for it.

Ive been without a subaru for 9 months, and decided that I wanted to build another STi. the Ms. said No.....her reason was because she hated looking at the car itself, as it made her think of me as some mindless meathead, fratboy trying to be cool. I asked if I could build a station wagon instead.....I got an uneasy yes......but that was all I needed.

I went about looking for a very used SG FXT 5 speed that I could get for cheap and immediately tear into. found the car 3 weeks ago and only 2 hours away. 2005 FXT in Black. On the drive home, the clutch died....towed it to my garage and began disassembly. my plans are to pretty much replace almost everything except the windshield.

the list of items needing addressed before mods: she has 150k on her. she has appropriately been named Ugly Betty.

- hail damaged hood
- hail damaged roof
- front bumper scraped up
- rear bumper has a tear in it
- damage on all 4 doors, and need to replace at least 2 of the 4
- bent roof rack crossbars
- mismatched tires
- clutch died
- drivers side front axle literally fell in half upon removal of the spindle leaving the male end in the 5 speed
- never has had a timing belt service
- never has had the clutch replaced
- never has had the spark plugs replaced
- interior was smoked in
- steering rack leaks
- driver's door power lock motor is dead
- turbo has lots of shaft play
- intercooler had a little oil....not a ton.....but some
- suspension has never been touched aside from an alignment

rather than deal with each little thing bit by bit, I decided (well before I bought it) that I'd rather just go nuts as soon as she got here - which is what any self respecting car geek would do! my full plans are to do a complete STI swap including the Jdm forester SG STi pieces on the exterior, along with a closed deck built block and a rotated HTA86 turbo.

I figured I'd do it in phases......1) driveline and engine refresh to get me to.... 2) built block and rotated turbo, 3) exterior and interior. I already ordered most of the parts for the first phase. Pics to come as I get them off my camera. Hooray for DIY....which wouldn't be possible without the loads of awesome threads and helpful people that have posted things on this site.

Parts to be installed in the next 3 weeks

- JDM version 9 STi 6 speed, shifter linkage and starter
- 2005 STI engine crossmember
- 2005 STI Tranny Crossmember
- 2005 STI rear subframe, inclding lateral links and trailing arms
- STI R180 Rear diff
- STI drive Shaft
- 2005 STI 5x114 spindles and axles
- 2005 STi Brembos
- 2005 STi aluminum front control arms
- 2005 STI steering rack and u joint
- gates racing timing belt and all new pulleys and OEM h20 pump
- tomei timing belt cover
- all new rear engine seals
- STI 11mm oil pump
- killer B oil pan, pickup, and windage tray
- NGK plugs
- grimmspeed AOS
- feal 441 coilovers
- whiteline sways 27mm front/24mm rear
- kartboy endlinks
- whiteline RCA
- STI group N motor and tranny mounts
- STI OEM clutch and Flywheel (new)
- stoptech slotted rotors and sport pads, with SS lines
- whiteline and kartboy bushings
- rebuilt TD04 from BNR
- Rota 18x9.5 on michelin pilot super sports at 265/35/18
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Last edited by uglybetty; 03-05-2014 at 10:50 AM.
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Old 03-04-2014, 02:20 PM   #2
uglybetty
Scooby Newbie
 
Member#: 381907
Join Date: Feb 2014
Chapter/Region: South East
Location: Nashville
Vehicle:
2005 forester STI

Default

garage was a bit messy and has since been cleaned up and properly organized for a smooth installation and efficient workspace


off the tow truck



one of my helpers


dead drivers axle


progress


old parts


progress


rear end


engine and tranny out


on the engine stand

Last edited by uglybetty; 03-04-2014 at 03:03 PM.
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Old 03-04-2014, 03:04 PM   #3
uglybetty
Scooby Newbie
 
Member#: 381907
Join Date: Feb 2014
Chapter/Region: South East
Location: Nashville
Vehicle:
2005 forester STI

Default

JDM STI driveline


brembo


new rear subframe and lateral arms


JDm version 9 STI 6 speed and r180 rear diff


old 5 speed


new STI engine crossmember, axles, and driveshaft


on the stands


big ding


hail damaged hood
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Old 03-04-2014, 03:04 PM   #4
uglybetty
Scooby Newbie
 
Member#: 381907
Join Date: Feb 2014
Chapter/Region: South East
Location: Nashville
Vehicle:
2005 forester STI

Default

new goodies


mounts and tools


oiling system stuff


timing belt and AOS


to the scrap recyclers


bits and pieces.....pre cleaning and reorganzing!!!!
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Old 03-04-2014, 03:28 PM   #5
thetastelingers
Scooby Newbie
 
Member#: 96778
Join Date: Sep 2005
Chapter/Region: South East
Location: Soddy Daisy
Vehicle:
2008 BMWE92M3
Jerez Blk

Default

Looks like fun!
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Old 03-04-2014, 03:33 PM   #6
uglybetty
Scooby Newbie
 
Member#: 381907
Join Date: Feb 2014
Chapter/Region: South East
Location: Nashville
Vehicle:
2005 forester STI

Default

it is. the ms. got mad because I've been ignoring her for about two weeks. says I have to pay her proper attention first and then I'm allowed to play in the garage. I also love that I get to tear everything apart and get a better idea of how everything works the way it does first hand.

only two questions that I have thus far that I will investigate shortly is wiring differences between the 5 speed and 6 speed and what I need to transfer. I know I need the neutral safety switch....just not sure which plug that is just yet.

Last edited by uglybetty; 03-04-2014 at 05:18 PM.
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Old 03-04-2014, 04:54 PM   #7
krs062
Scooby Newbie
 
Member#: 98830
Join Date: Oct 2005
Chapter/Region: MAIC
Location: NOVA
Vehicle:
2004 FXT
Silver

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Old 03-04-2014, 06:59 PM   #8
silverfox45
Scooby Newbie
 
Member#: 308088
Join Date: Jan 2012
Chapter/Region: Tri-State
Location: Central PA
Vehicle:
2005 WRX
OBP

Default

subscribed! I'll eventually have to go down this route when kids start popping out. But not for a longggg time haha. Can't wait to see more!
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Old 03-04-2014, 07:11 PM   #9
uglybetty
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Member#: 381907
Join Date: Feb 2014
Chapter/Region: South East
Location: Nashville
Vehicle:
2005 forester STI

Default

I have 5 kids. Tahoe is for that. More pics tonight or in the morning. I Plan on starting the timing belt job tonight and switching out the engine crossmember and control arms and hanging the rear subframe.
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Old 03-05-2014, 02:23 PM   #10
uglybetty
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Member#: 381907
Join Date: Feb 2014
Chapter/Region: South East
Location: Nashville
Vehicle:
2005 forester STI

Default

the underside of an sti


easiest way to break loose a crank pulley...Company 23 crank tool, chain and breaker bar. no sweat


sooo dirty


yeah.....may want to look into a new oil cooler...yuck!
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Old 03-05-2014, 05:08 PM   #11
sc00ter
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Member#: 117767
Join Date: Jun 2006
Chapter/Region: RMIC
Location: Denver, CO
Vehicle:
2011 STI Sedan
DGM

Default

Looks like a fun project. i hope I get time/effort to do something like this one day.
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Old 03-07-2014, 01:29 PM   #12
uglybetty
Scooby Newbie
 
Member#: 381907
Join Date: Feb 2014
Chapter/Region: South East
Location: Nashville
Vehicle:
2005 forester STI

Default

small snag today......found out that I'm pretty sure the 11mm sti oil pump doenst fit for some reason. doesn't have the same crank keys to turn the oil pump gear. searching for a definitive answer right now on the issue. not sure if it will still be ok......last thing I want is an oil pump that doesn't fit properly to the crank keys.

crank



old oil pump


new oil pump
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Old 03-07-2014, 02:09 PM   #13
uglybetty
Scooby Newbie
 
Member#: 381907
Join Date: Feb 2014
Chapter/Region: South East
Location: Nashville
Vehicle:
2005 forester STI

Default

got it sorted.....crank still fits snug and will work without issue. just a weird observation I guess. I'd still like to know what those machined out grooves are for though. I thought all of the ej25 crank profiles were the same as far as the notching? my first time getting this in depth though. chalk it up to the learning experience I guess.
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Old 03-11-2014, 12:53 AM   #14
uglybetty
Scooby Newbie
 
Member#: 381907
Join Date: Feb 2014
Chapter/Region: South East
Location: Nashville
Vehicle:
2005 forester STI

Default

oil pan removal


old oil pickup and baffle and cleaned oil cooler....the gunk on that thing was unreal


crankcase - while I had it open I took a flashlight and inspected what I could see of the cylinders for scoring marks of any variety. all looked extremely clean and in good shape


killer B Baffle and pickup. he wasn't kidding when he says that these pieces are serious. very much works of art and engineering


new oil pan


I plan on putting in the new rear subframe tonight and will also begine working on swapping the front control arms and get the old engine crossmember out as well as the old steering rack. I will also be swapping the wiring over from the 5mt to the 6mt and taking pics for clarification on what needs to be done so that I can post them for the swap thread over on sf.org

I also talked to rick at IAG performance today for a bit. they are awesome and we talked about my build and what I plan on doing. (evil grin) great guy to talk to.
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Old 03-11-2014, 04:04 PM   #15
uglybetty
Scooby Newbie
 
Member#: 381907
Join Date: Feb 2014
Chapter/Region: South East
Location: Nashville
Vehicle:
2005 forester STI

Default

New sti subframe and lateral links in the rear are in place

Old engine crossmember, steering rack and control arms out

Td04 turbo out and ready to be rebuilt
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