2004 STI--slow and steady rally build

[DonkeyyKongg]

I decided to start this so I can log everything I have done to this car and get some feedback.

I bought my money pit of a car at the end of 2019 and it has been in and out of the shop getting a built motor with some bolt-on goodies, transmission rebuilt, and dyno tuned.

When I bought the car it didnt sound right, the transmission was grinding on 4th and 5th had a bigger turbo with no tune. The monkey I bought it from put a new oem short block in himself....he didnt pull the pin from the bell housing and cracked the transmission so the car ended up being more of a money pit than I initially thought... but I couldnt help my self with the 04 WRB STI.

the day I brought it home...
https://imgur.com/dMBZdRN

I had every intention of turning this car into a stage rally capable car, so I wasnt too worried with what it looked like on the inside/outside.

This build will be slow going, doing what I can to it when funds/time allows it.
I have been doing rallyx in my old car 2011 wrx hatch for the past 3 years (2017-2019). the 2011 wrx was hit while parked outside my house in 2019 but now I have my 04 STI because of it

I took the car to a local shop that specializes in Subaru repair/upgrades called m45. While there they did a full inspection on it and pretty much told me my car needed a new engine/radiator and calipers/rebuilt transmission. I gave them the green light to proceed with the repairs. knowing the engine was crap I decided to go with a built motor, built by m45. After the build/break-in was done with it was tuned in house by Snail Performance.

after the being in and out of the shop so much, the wife and I took it on a cruise to the mountains.
https://imgur.com/MWoZEfT

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[DonkeyyKongg]

I will update this section as build goes on...

Engine:
Wiseco pistons
Manley Rods
ARP custom age 625+ head studs
STI crank

COBB EBCS
Turbo Smart BOV
COBB fuel rail
ID 1300 injectors
AEM 340 fuel pump
TGV delete
Flex fuel kit
Perrin(?) intake
Grimm Speed catted down pipe
20g turbo (no name on it)
MELE light weight battery mount
Odyssey PC680


Suspension:
is currently Tein, I am planning on changing them to Flatout Suspension gravel coil overs in the future


in the process of 4/2 pot conversion. Will be selling my 04 Brembos/rotors in the near future..

Dyno Sheet:
https://imgur.com/Sl1NGtf
STI TMIC is holding me back from more power, but I like where its at currently but do plan on Upgrading my TMIC and proceeding with flex fuel for my next visit to M45/Snail Performance in the late future

[DonkeyyKongg]

The car had a starting issue every now and then, I would just get a click of the starter and nothing else. My wife would have to push start me when it would happen.
I changed the battery first, thinking it was the culprit. I went with a MELE mount and light weight battery.
https://imgur.com/jPi9X2M

Soooo the battery wasnt the issue...I changed my starter. It wasnt the starter either....I cleaned my engine bay grounding.. still nothing. I remembered seeing a viper alarm paper in the initial paper work I got with the car. I didnt have the viper alarm key fob...I pulled down the dash plastic dash panel under the steering wheel. found some jankey wiring from the pervious owner. hes a monkey...
https://imgur.com/ADwPMt3

I removed all of it and wired my ignition harness back to normal. I havent had and Issue with starting it since.

[DonkeyyKongg]

The cars speakers were butt cheeks but I didnt want to lose my music while still drive the car daily. I bought some motorcycle speakers from amazon and went ahead and made a relay panel behind where the radio used to be.
https://imgur.com/zbdmZju

https://imgur.com/OTCeTo8


Made my switch panel out of some aluminum I acquired from work.
https://imgur.com/uy9jLzs
https://imgur.com/GmojZ9m

Everything all wired in to the switch panel
https://imgur.com/9Maxe7B

dash put back together. the blue lights are extremely bright at night.. will black them out soon.. left to right >> 1) nothing 2) music 3) nothing 4) usb with built in volt meter. the blank/music ones will eventually be abs delete and pod lights etc...
https://imgur.com/AwkZnlU

speakers/amp----
speakers are under both seats and in the trunk, amp is mounted in the glove box. volume adjustment is the knob infront of my shifter next to the 12v outlet. works pretty well imo. I can hear the music clearly when im on the highway. my brother said it sounds like phone speakers, but hes boujee so
https://imgur.com/hljB4XW
https://imgur.com/mW1KpIX

[DonkeyyKongg]

My wife bought me a Chase bays intercooler sprayer tank to replace the big bulky OEM one. I need to extend the water hose, and I would like to relocate it to the side of the trunk.. another day..
https://imgur.com/bzcuY1w

she bought me a new shifter and boot too
https://imgur.com/n98t7t6

[DonkeyyKongg]

I lost one of my front fog light covers and decided to do some brake cooling instead of just replacing them. I found a diy thread here and went for it. I bought some fog light covers that where meant for fog lights, I cut 4"-3" PVC reducer to fit the holes in the covers.

https://imgur.com/oKz9Ct2

I made the cuts with a sander wheel on a dremel. slowly until I was happy with the fitment.
https://imgur.com/vg7g2LB
https://imgur.com/VvrRfvO

clamped down and ready for some jb weld.
https://imgur.com/N9iYJYb


for the second fog light cover, I put some blue tape on the cut pvc coupler and cut out my cut marks. then transferred the blue tape the full pvc coupler and marked where to cut. saved me a bit of time for the second one.
https://imgur.com/AkGD2jD

I wasnt happy with the way the front looked. you can see the size different in the front, I wanted it to be a smooth tunnel. idk if it would help in the cooling aspect at all. I bought some bondo, never used it before D: but figured it couldnt be tooooo hard to do.
these are both of the one side...the other side turned out chunky... I was too slow on the smoothing process. sand off and re apply soon.
https://imgur.com/H9vsG9U
https://imgur.com/qoWas12