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Old 08-17-2019, 06:20 PM   #1
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default I am back! 2005 STi rebuild project

Well, after close to ten years, I have come back. Which is funny because now approaching my mid-thirties, I am not longer a "stikid," but I will keep the name for nostalgic reasons....

Brief history:
I have been here for a while. My Join date is December 2004, but before that, I had another name (I think wingswestwrx), and that was in early 2002. My first Subaru was a 2003 PSM WRX which I bought new in 2002. I then purchased one of my favorite cars of all time, a 2005 OBP STi in 2004. I had that car till 2010 when I sold it. I have had some other fun and fast cars since then. Including a couple of SS Camaros and a ZL1 project. But I always missed my 05 STi. After my wife and I had my daughter, I did what a lot of new fathers do and sold my fast car (2013 VR ZL1) for a truck. Well, my daughter is now three, and the truck is being paid off. It was time for me to get back into a project.

The STi:
Since I sold my 05 STi in 2010, I have been looking at the market. I have watched 2005 STi's go for next to nothing then shoot way up and fluctuate in price. I set a budget of $12,500 tax and reg included. I didn't care about mileage because I want a restoration project. I am keeping this car forever, so I have time to do whatever is needed to make the car what I want it to be.

I found a car listed on Craigslist for $11,500 with 159,000 miles with a rebuilt motor occurring 108,000 miles. The body looked good, no major rust, but showed its age. The car had also sat for three years, abandoned by the second owner. The car was local, and after speaking with the person selling the car, I began to negotiate with the seller. I told him my plans and that I don't expect a car that sat for three years to be a daily driver. With that being said, I will take it as is for $10,000. After a compression test was done, a deal was struck, and I loaded up my trailer and went to pick up the car.


at the end of the day, I had a 2005 STi on the trailer with a Yukon full of parts (not my truck) and a big smile.



Once I got home, the car was limped off the trailer, and first set of the problem became apparent. The seller told me that the power steering had a leak, and it needed to be fixed before driving. Well, it did leak, but it wasn't small... The first thing I had to do to get this car on the road was to address the rack. I ended up rebuilding the rack with all new hard lines. I also replaced seals and some of the soft line that had dry cracked. I then frond that the oil cooler hard line had rusted out and snapped, causing a cooling leak. All that was fixed using OEM Subaru parts (Ramsey Subaru Parts Dept is great).





Next project was the brakes. I replaced the old collapsing, worn, eroded DBA rotors with some new OEM rotors. I decided to go with OEM rotors for the time being to shake the car down. The car had a fresh set of brand new Hawk brake pad still in the box in the trunk, so I used those. While refreshing the brakes, I added some braided lines to wrap everything up. Well, as many of you know trying to remove Brembos usually end up in stripped calipers and snapped bolts. Well, each caliper suffered from this. All the calipers were helicoid, and the hardware was replaced using OEM bolts. The left rear caliper was in pretty bad shape. The Helicoil did not take and pulled back out, and the bleeders on both sides were stripped. I purchased another brand new caliper, again thank you Ramsey Subaru, for a heart-stopping price.





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Last edited by stikid2005; 08-28-2019 at 07:23 PM.
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Old 08-17-2019, 06:21 PM   #2
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

Getting ready for the road, I looked over everything in the engine bay. I found that the car had provided a winter refuge for a squirrel. There was at least 35lbs of chewed acorns everywhere. That was fun.... Fearing my electrical was compromised I checked every connection, ground, anything worth gnawing on. I found no nibbling. What I did find was lose grounds, broken clips, unplugged vacuum lines, and a hole in the turbo inlet the size of an avocado. All that was fixed including sourcing a Perrin turbo inlet which replaced the stock unit. The car came with the V1 Turboxs turbo-back which was bent as a result of the second owner backing into a wall causing the muffler to cave in. So I ripped that out retaining the shorty downpipe. I added an o2 sensor bung to the top of the DP and had buddy weld that up for me. I ordered a straight pipe from P&L Performance because I am ignorant, fabbed up a test pipe to replace where the catted Turboxs mid-pipe use to be. To save some time and money, I used the scrap exhaust for my material with new Vibrant flanges and a flex pipe. I plan on doing a custom rotated setup in the future. I didn't want to buy another stock location DP just to replace it down the road. It sounds great. I am pleased for now. (headers next)












Last edited by stikid2005; 08-19-2019 at 10:05 PM.
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Old 08-17-2019, 06:21 PM   #3
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

The last thing I needed to purchase was a set of tires. The tires on the car were so dry rotted I was nervous using them as rollers. I picked up a set of 245/40/17 Toyo R888r's.



After draining out the three-year-old gas and filling her up with some fresh 93, she was ready for her first drive. It was good, very good. She was a little rough at first, but now she feels great! Still, a ton to do... Like Allot. But I can't explain how happy I am to be back!








Last edited by stikid2005; 08-19-2019 at 10:08 PM.
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Old 08-17-2019, 06:26 PM   #4
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

Last night I wrapped up some work to make the old girl look as she should. The grill was in bad shape. The painted had faded and felt rough. I sanded everything down, fixed some broken tabs, and began the process of filling and painting. After I was done, I added my original JDM badge from my first STi that I have saved all these years, and also reused the grill mesh and STi badge from my old STi. Came out great! Sorry for the poor pictures. Images will get better I am just grabbing quick shots with my phone.






Last edited by stikid2005; 08-19-2019 at 10:09 PM.
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Old 08-17-2019, 06:34 PM   #5
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

Next weekends project is to make a list and order all the OEM stuff for the body. This includes the front bumper which I will be doing some cool stuff to. I also have to install some stuff that I have already and finishing the push-lock hood pins. I also Have put the second motor on an engine stand and start tearing it down. More on that later.


Last edited by stikid2005; 08-19-2019 at 10:10 PM.
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Old 08-19-2019, 09:58 AM   #6
horsePOOGAS
Scooby Newbie
 
Member#: 450712
Join Date: Jul 2016
Location: Indiana
Vehicle:
04 STi
WRB

Default

I wish the pictures worked... Would like to see this thing come back to life.
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Old 08-19-2019, 10:15 AM   #7
1VIPWRX
Scooby Specialist
 
Member#: 107554
Join Date: Feb 2006
Chapter/Region: Tri-State
Location: some where in NY
Vehicle:
03 03/07
yellow

Default

need pics..glad your back.
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Old 08-19-2019, 04:09 PM   #8
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

ohh man for real??? I can see them on different computers and networks???

edit: figured it out... had the synced to my Google account.
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Old 08-19-2019, 05:21 PM   #9
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

Ok, so the pictures should work now. If you still don't see pictures let me know.

I also just order this.



As it is impossible to find a Cusco lip anymore. This one is from S2 Auto Designs. It aπparently has a longer lip section.

I will also be picking up my brand new OEM bumper soon. I have some other modfication ideas planned for the front bumper but this is a good start.

Last edited by stikid2005; 08-20-2019 at 09:15 AM.
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Old 08-19-2019, 07:51 PM   #10
horsePOOGAS
Scooby Newbie
 
Member#: 450712
Join Date: Jul 2016
Location: Indiana
Vehicle:
04 STi
WRB

Default

Still not seeing any of the original pictures. But I am seeing the new ones you posted.
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Old 08-19-2019, 09:23 PM   #11
08redWRX
Scooby Newbie
 
Member#: 186068
Join Date: Aug 2008
Chapter/Region: South East
Location: NC
Vehicle:
2019 STi
DGM

Default

^^^Same

Would love to see the originals! Glad you found the car and welcome back! I've been missing since 08 but just recently joined the subaru crew again, also in my mid-30's.
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Old 08-19-2019, 09:44 PM   #12
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

Quote:
Originally Posted by 08redWRX View Post
^^^Same

Would love to see the originals! Glad you found the car and welcome back! I've been missing since 08 but just recently joined the subaru crew again, also in my mid-30's.
These are the before pictures haha. as long as you can see the car parked outside of the garage then all of them have been posted. every post should have a set of pictures.

Last edited by stikid2005; 08-19-2019 at 10:11 PM.
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Old 08-20-2019, 07:44 AM   #13
horsePOOGAS
Scooby Newbie
 
Member#: 450712
Join Date: Jul 2016
Location: Indiana
Vehicle:
04 STi
WRB

Default

Now they all show up
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Old 08-26-2019, 09:33 PM   #14
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

The new Cusco style lip came in from S2 Auto Design. I could not find an OE one and even if I could I am not sure I would want to ruin one of the few remaining by cutting it up. The lip looks very good and seems very well made but I still have to see about the fitment. The packaging was ok, made me a little nervous but the lip seems to have made it all the way from California unscathed



(don't mind the haze on the headlight. I am still wet sending that one before I wrap them)



I am waiting on the new OEM bumper and driver side wheel well cover to come in so I can pick that up. This week I will be finishing the push pins on the hood before I cut it up, dropping the oil pan and adding the Killer B baffle and pickup, and addressing alignment and centering the steering.
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Old 08-28-2019, 07:03 PM   #15
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

I picked up the new oem front bumper and just loosely fit the lip. If I can get out to the shop later tonight I am going to try and mock it up on the car.



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Old 08-30-2019, 12:26 AM   #16
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

I had a packed couple of days off. I could not make it to the shop allot. I did get a few parts in so Hopefully after this weekend (I am working) I can throw a few hours at the car on Monday and Tuesday. Tonight I started a quick project.

I really don't like the grey look of the SPT intake. I am not staying stock location so buying another intake is just a waste of money. So I decided to re-coat it with some VHT wrinkle red. The filter was also replaced with a K&N and a cleaned up the hardware.



Oven baked



Came out great. Cure further overnight. Even after an hour in a 200-degree oven it is still just a bit soft, Handelable, but I don't want to risk it.

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Old 08-30-2019, 05:09 PM   #17
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

Installed the intake today.





I also got the new lip and bumper tested fitted. Very pleased with the fitment of the lip!







Sorry about the bad pictures was fighting the sun and didn't have enough time.
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Old 08-30-2019, 06:52 PM   #18
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

Part of the plans for Monday



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Old 08-30-2019, 09:03 PM   #19
1VIPWRX
Scooby Specialist
 
Member#: 107554
Join Date: Feb 2006
Chapter/Region: Tri-State
Location: some where in NY
Vehicle:
03 03/07
yellow

Default

i like where this is going
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Old 08-31-2019, 06:00 PM   #20
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

well, today progress. I am very happy. time to build an air box that will act as a place holder for the new setup in the future.









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Old 08-31-2019, 06:01 PM   #21
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default






Last edited by stikid2005; 08-31-2019 at 06:07 PM.
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Old 08-31-2019, 06:06 PM   #22
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

I do not plan on driving this car in bad weather like rain or snow but. If there is an event or something and I can't help it then my plan is to make a block off plate. that will go over the duct with a seal. I will use a few of the bolts to secure it stopping water from getting in there.

this is just for a reference. I used the piece I cut out of the hood to give you an idea.

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Old 09-06-2019, 03:26 PM   #23
stikid2005
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Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

Well over a week later I got the duct installed completely...about 4 days ago I had to check myself into the hospital. Turns out I had a bad infection in my lower GI. Luckily nothing was damaged and antibiotics should clear me right up. Because of that, I missed work and some overtime so my plans of ordering some new parts have been slightly delayed. Today I felt good enough to walk around the shop and I got a little antsy so here you go.

all bolted down and sealed up to the hood.











Also, a new workbench and racks are being built in the back. Thanks Dad! haha.
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Old 09-07-2019, 06:51 PM   #24
stikid2005
Scooby Specialist
 
Member#: 76228
Join Date: Dec 2004
Chapter/Region: Tri-State
Location: Tri-State NJ
Vehicle:
2005 STI
Aspen White/Seibon carbon

Default

I felt much better today. I was able to fix my steering issue (steering wheel had to be straightened after the rack was reinstalled). I also mounted the front bumper with the proper hardware and clips. Lip need a little more adjustment and the bumper is being pushed out just a tad by a damage bumper support beam that I will be replacing.

Anyway, I went out for a drive and the car feels lightyears better than the first test drive. A quick picture from the drive. Enjoy the weekend!

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Old 09-08-2019, 12:22 AM   #25
1VIPWRX
Scooby Specialist
 
Member#: 107554
Join Date: Feb 2006
Chapter/Region: Tri-State
Location: some where in NY
Vehicle:
03 03/07
yellow

Default

any power goals?
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