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Discussion Starter #1 (Edited)
I've consolidated the thread. Updated posts are 1, 2, 3 & 4.

Some of y'all know me already, I'm the guy who had the (likely first) 3rd gen with a tube bumper. It was a good learning process, but the truth remained, the 3rd gens aren't as toughly built as the GD bodies. So I traded in Roxie (WRB '11 WRX) for Bianca (OBP '06 STi). This will be my build thread for the new iteration. This was Roxie's build: 2011 WRX (Roxie) going rally style slowly

So here's Roxie before:


Built for damage:


Some desert run vids:
Desert Run 27May2012 Part 1 of 4 - YouTube
Desert Run 27May2012 Part 2 of 4 - YouTube
Desert Run 27May2012 Part 3 of 4 - YouTube
Desert Run 27May2012 Part 4 of 4 - YouTube

And as she looked at trade in:

Now say goodbye to Roxie, and hello to Bianca.

As she rolled out of the dealership:



Next to my buddies WRB '04:


And just a few mods done over the first few days (Perrin Wing Stiffies, JDM style window visors, a Killer B shift knob, some vinyl decals to represent (DirtyImpreza & MNSubaru) and a partial debadge):



And here is one of the most current pics:


And, here is a mod list of what will be going in or has gone in Installed, Not Installed & Need to Buy:

Drivetrain:
COBB OTS Stage 1 tune – 91 Octane
QwikValve Part #F105S – Short Nipple - Engine Oil Pan
QwikValve Part #F108S 16mmx1.5 w/Clip – Tranny Oil Pan
QwikValve Part #T207 26mmx1.5 w/Clip – Tranny Oil Pan
GrimmSpeed P'n'P'ed Exhaust Manifold
Killer B Oil Pan/Baffle/Pickup Tube
Killer B 1/2NPT to 1/8PT Adapter
Tigwerks Engine Mounts (and OEM Engine Mount Plates) – 60A Stiffness Bushings
Upgraded Tranny Mount
Tigwerks Power Steering Reservoir
KartBoy Pitch Stop Mount
KartBoy 6MT Short Throw Shifter & Bushings
Borla Hush CBE (will be modified for higher exit, along with rear bumper)
Tigwerks Oil Return & Power Steering Fittings
60mm Defi BF Oil Temp., EGT, Boost & Fuel Pressure Gauges
Samco Hoses and Hose Clamps
3mm Phenolic Spacers
PTP Turbo Blanket - Lava
LightSpeed Ti Turbo Heat Shield
Perrin Turbo Heat Shield GD
Universal 5 Points HKS Grounding Kit

Suspension/Braking:
Braid Winrace TA – 15x6.5+45
Yokohama Geolander A/T-S – 215/70-15
Subaru 4/2 Pot Calipers & Rebuild Kits
DBA 4/2 pot Rotors for STi
Stoptech STR660 Brake Fluid DOT 4 .5L
Goodridge 01-07 Subaru WRX/STi Phantom G-Stop Brake Lines
Porterfield R4-S Brake Pads
King Lifting Springs
Grp N Front & Rear Strut Tophat/Mounts for GDs
2006 STi OEM Struts - Front & Back – For future Feal revalve
TSS Weld-on Strut Mounts - Front/Back
TSS Trailing Arms (stock - +1") & Trailing Arm Mounts (stock - +1") - Lime Green
2x 5mm Wheel Spacers
02-07 WRX 4 POINT PINK H-BRACE
Offensive Power Fender Braces
Cusco Strut Bar & Triangle Brace
Whiteline Rear Sub-frame Lockdown Bolts

Armor/Weight Loss:
Primitive Racing 3/16” Rear Diff Plate
Primitive Racing 3/16” Aluminum Skid Plate w/ Stinger Option
Stripped Interior (carpet, insulation, some trim, rear seat belts & mounts)
Aluminum Diamond-plate Floormats
Protection Installed over Fuel/Brake lines
Rally Armor Mud Flaps (Red Logo)
Trunk Separating Nets

Miscellaneous:
Clarion CX501 In-Dash CD/MP3/VMA Receiver
ATi Dual Steering Column 60mm Gauge Pod
Sullivan Racing Aluminum Pedals - Gold Grid
Killer B Shift Knob
JDM Style Window Visors
BLOX Racing Vortex Generator
5x Perrin Stiffies (3 Installed)
04-05 WRX/STi Sedan Tail Lamp Pair
Roof Vent
Roof Scoop Fiberglass Bolt-on Rally
JDM Style Window Visors
4 Hella Supertones
Billet Aluminum Glove-box Handle
Accessory Plug 4 Way Splitter/Extension
Grimmspeed High-Lift Hood Struts
JDM Hazard Light Switch
Rigid Industries Hybrid SR-Series 10" LED
Rigid Industries Dually Hybrid 2x2 LED - 2
Impreza/WRX/STi Armrest Extension
STi Aluminum Oil Filler Cap
Subaru Keyhole Plugs GD WRX STI Impreza
Black VW OEM Sunglasses Hand Grip Holder
2004 STi Owner’s Manual Case
 

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Discussion Starter #2 (Edited)
10-13FEB2013: Installed the Cusco OS rear strut brace and triangle brace the first day. Noticeably stiffened up the rear a little bit, but required a run to the hardware stores for, you guessed it, more hardware. (My buddy Preston helped with everything this day. Thanks bro!) We also attempted to fix the leak into my power steering that was stiffening the turning a lot, and causing a horrid squeal. Replaced all the clamps with hose clamps (one day they will get replaced with something safer for hose), replaced the fluid (it was nasty and brown, probably never replaced) and replaced the O-ring that is notorious for leaking. The O-ring was super squared off, hard and warped; likely the original factory piece, like the fluid likely was. Squeal was taken care of for the moment.


That night we (Preston, 2 other Subaru buddies and myself, so 4 Subies total, 2 STi’s and 2 WRXs) went out to a local spot called “The Wall” (desert area by the Rio Grande where Jeep guys go to tear around). Threw some dust up, had a good bit of fun, did some donut-action and just generally hooned in the dirt for a bit. All fun and games until something breaks though; Preston’s STi started spewing coolant from the janky coolant reservoir he was running with his FMIC setup. Cap didn’t seal up right, but doubt that was the whole issue. All 4 of us ended up sitting around out there taking turns to refill his system with piss. (Not sure if he did a coolant flush or not before selling, if not, that’s even better.) Good times.

Next day the power steering whine was back with a vengeance. After a bunch of searching that day (the 11th) and coming up with zero (didn’t check the O-ring this time) I decided to rest that night and check it out the next day.

Checked the O-ring the following day, and sure enough, the O-ring got torn during install. Quick replacement later (including a run up to the local AutoPepNAPA-BoysZone) and the problem was finally fixed. Also increased my collection of O-rings. And since I had spare time I decided to install two (2/4 going in) of my Hella Supertones, hadn’t decided where the last two would go yet. Finished the horn install on the 19th, so I have 4 Hellas just waiting for some idiot to cut me off. Hopefully someone shits their pants and wakes up.


MAR2013: Worked on the car intermittently throughout the month. Didn’t get much done, as I was mainly just enjoying the car.
Removed my carpet and most of the relatively easily pulled foam mat, as well as the plastic venting for the rear foot-wells. Sold the carpet and the floor-mats to my buddy here who has an '04 with ugly carpet and floor-mats. Also, installed some Aluminum diamond-plate floormats (with the dead pedal also) to provide some grip, bought them off an eBay shop. They would fit better if I had the regular flooring still, but it's alright, I have them bolted in to the floors with riv nuts and small machine screws (these replaced the self-tappers that are in the pics). Last interior bits I installed were replacing the glove-box handle with a billet aluminum handle I scored off eBay and installing a cigerette lighter plug extension/splitter. Pics:




Installed some Carbon Fiber Sokie Tech hood dampers off of an eBay seller (Alvoturk9000 or something close). Great purchase, and glad I bought them. Also installed these carbon fiber goodies (grills that need some adjustment to fit correctly and a fuel door overlay that had the same issue) and some stickers (a few on the back window and some under the hood for installed parts).

[




Later in the month I started installing the 6” wide HDPE strips (6”x60” sheets in .020” and .040” thicknesses) I had purchased in the beginning of the month. These are covering the hard-lines and wiring harnesses that run along the inside face of the door sills. Started with the .020” thick strips, and later covered the front half with the .040” thick strips for added protection (no need in the rear with no back seat). They are riveted to the trim pieces on the sills and connected under the lines/wiring with more riv-nuts and machine screws, same as the floor plates/mats.


Towards the end of the month I installed a Blox Racing vortex generator, fitment wasn't the flattest, but it's not going anywhere thanks to 8-10 beefy rivets, some 3M foam tape and some E-3000 (or whatever it's called, some sort of silicone/glue, it works great). Hopefully it doesn't leak at all, but if it does, I'll fix that. Not sure how I feel about the look though. The same evening I installed a set of Whiteline rear subframe lockdown bolts. Big pain in the ass to install, but the quick spin I took afterwards left me feeling they were worth it. Then again that could be the placebo affect people get.


APR2013: Beginning of this month I received emergency deployment orders (couldn’t talk about the deployment until ~2 months after leaving when press releases were made) and left to Guam the middle of the month. I tried to get a little done on the car during this time, as well as still spending time with my beautiful wife, and spending long hours at work. Drank a lot of caffeine and didn’t sleep much during this time, and didn’t accomplish much with the car.
I removed the front seats to finish the last bits of the HDPE strip install (pieces I attached to the bottom of the B-pillar trim), and took the opportunity to get of the rattle that was coming from the underseat sub when the bass would hit. I remounted it with metal “tape” (the type sometimes used for strapping up pipes, thin metal strip with intermittent holes that comes in rolls in the plumbing aisle). Essentially did an “X” shape over the sub, and bolted the ends to the floor with machine screws and riv-nuts. Put foam tape and painters tape (holds the foam tape in place) on all the rub points and on the cross-point; increased the tightness of the mounting setup and killed any possible plastic-metal contact. I may find an alternate method of covering the strapping later on, probably just paint it black and rewrap the painters tape with electrical tape.
Second thing I accomplished was installing some of the Defi gauges (Defi-Link Meter BF gauges) I bought off a local friend I made. He had the boost, EGT and fuel pressure gauges with the control unit. I installed the boost and EGT partially, meaning I wired them in, installed the gauges and got the sensor wiring ran out, but didn’t install the sensors. Gauges are mounted in an ATI steering column cluster, the control unit got strapped down (same strapping I used on the sub) to the driver’s side of the center console, just under the dash.
Installed the new head unit I bought, since I really missed being able to use my iPod in the car, replacing the stock 6-disc with a Clarion CX501. It’s an MP3/CD player with USB and AUX connections. First radio install ever, but I accomplished it. After this got the Sullivan Racing pedals (gold grids) put in, I bled a little bit during the process, but very worth it. So pretty and grippy!!



Last thing I accomplished before I left was to get the car ready for long-term storage. Did an oil change (installed the QwikValve/Fumoto drain valve for later ease), checked the other fluids, topped off the tires and plugged up the exhaust and intake with copious amounts of foil. While I had the car on jack stands (for the oil change) I installed the skid plate. After this was all done I disconnected the battery, tossed the back seat pieces in the back (not installed, just loose), closed her up and said goodbye.

30JUN2013: Also, since this is somewhat of a journal, as well as my build thread, I'll say goodbye to my (my wife's originally) dog, Cara. She had to be put down on Saturday in VA, due to just getting really old, and having organs failing. She was an English Yellow Lab, and she would have hit 14 years old come September. I'll miss the puppy, but I know she isn't hurting anymore.
Obligatory pic of the fur-butt.
 

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Discussion Starter #3 (Edited)
AUG2013: Bought these:
One of these:


One of these:


And after I'm back home, it'll look something like this (not my car or my pic, stolen from Creel's (on DirtyImpreza) post):


Bought the brakes I've been waiting for a good deal on, '06/07 WRX 4/2 pot calipers. Also scored a few more goodies like a brand-new Killer B oil pan/baffle & pick-up combo, from a guy who wasn’t going to install it in his car, a pair of lightly used rear Grp N top-hats and bought a Contour+2 camera off Amazon.
Bought the wife a necklace, she'd been eyeballing it, I bought it for her, earned some major brownie points that I can't make use of for a while still.


OCT-DEC2013: Thought I had scored a super deal ($115 shipped) on BNIB ‘04/05 Impreza tail-lights from a seller on eBay, but the shithead seller decided they wouldn’t ship. When I filed a dispute they immediately refunded the money, though I said I wanted the lights, not the money. Worked out though, as a week after getting the refund I won the bidding on another set of BNIB tails, got them for a little over $220 shipped, so about as much as a used set.

OCT2013-FEB2014: Bought a few other things for the build during this time:
• TSS Weld-on strut mounts
• Second set of ’06 STi struts (for a future revalve)
• Armrest extenson
• Replacement oil cap (billet Aluminum piece with STi engraved)
• Replacement fuel door (replace that silly CF covered one)
• Grp N Front top hats
• 2004 STi owner’s manual case (looks better than the ones on other years, has a pretty CBR STi logo too)
• Tigwerks engine mounts (w/60A bushings)
• Perrin turbo heatshield
• 60mm Defi BF Oil temp. gauge (goes with the Defi-link setup)
• 3mm Phenolic spacers
• GrimmSpeed High-lift hood struts (will replace the Sokie-tech set)
• KartBoy Pitch-stop
• TSS Trailing arm mounts (stock & 1” longer mounting positions) – Lime Green
• Borla Hush CBE
• JDM Hazard Light Switch
• TSS Trailing Arms (adjustable from stock to 1” longer) – Lime Green
• DBA 4/2 Pot Rotors for 5x114.3 hubs (STi fitment)
• Perrin Stiffies (2 more to finish the spoiler)
• Tigwerks Oil return fitting & Power Steering pump fitting
• Offensive Power fender braces
 

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Discussion Starter #4 (Edited)
This is the overall plan behind that Borla Hush I bought (also got that JDM hazard light switch in the same deal); it’s used and is leaking at the slip fitting, so that will be getting welded up. I figured this exhaust would be perfect for my plans as I was planning on building something similar, this ended up cheaper ($250 shipped for exhaust and the hazard switch). On to the plan though; this is a rough Paint job of what I want as a result:


It's a rough illustration (think I made the tips a little smaller looking than they really are), but basically there is a way to run exhaust up a little higher in the bumper (little bit of metal removal required, and mounting point changes will be required), and make a little CF lip (the gray oval in the picture) around the exhaust. I'll also have to do some plastic welding to close up the bump on the bottom, but it will remove the exhaust from hitting out on the trail (plus I dig the look after seeing another GD STi with a single tip exiting in the same way - mjfubar on IWSTi).

This should illustrate how much metal will be cut out (and braced):


I'm figuring I should be able to chop out at least 6-10" above (to that spot pointed to in the pic, maybe a little higher; I'd weld a brace across the bottom of the hole (and weld shut the cut if there is more than one layer anywhere)). If it comes down to removal of the bumper bar, I'll make a tube replacement (I was considering making one anyways).

And some parts pics to hold off the pic-hungry, until I can put said parts in:
Braid Wheels:


Killer B Oil Pan, Pickup and Baffle:


TSS Weld-on Strut Mounts and Trailing Arms/TA Mounts:


And a collage of some of the other bigger (read pricier) components:
 

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I've been lucky with eBay so far (about 50 purchases). I do take the time to read the seller's feedback, regardless of his % score. If I see that there's too many issues with shipping or with the item I'm interested in, I pass. It's just too bad we can't see the feedback only for the item we want to buy, it would make it faster. I guess eBay knows that would kill sales for some of its users.

By the way, that roof vent almost looks like a big truck's side sleeper vent! :lol: It'll do the job though, it'll do... :)

Keep it up! :tup:
 

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Discussion Starter #10
I've been lucky with eBay so far (about 50 purchases). I do take the time to read the seller's feedback, regardless of his % score. If I see that there's too many issues with shipping or with the item I'm interested in, I pass. It's just too bad we can't see the feedback only for the item we want to buy, it would make it faster. I guess eBay knows that would kill sales for some of its users.
That wouldn't of helped in this case. It was seller with all of maybe 120 sales, and a 99.7% positive rating. My negative experience just dropped them into the 98% area, but my lights were the last thing they had for sale, and they haven't put them back up yet, if they do I'm going to call them out on it. Fucking scumbags.
By the way, that roof vent almost looks like a big truck's side sleeper vent! :lol: It'll do the job though, it'll do... :)
That's exactly what it is. Link Lol, good eye.
Keep it up! :tup:
Thanks, I can't wait to be home and start installing everything! I have to get a few more supplementary parts for some of the installs (rotors, pads and lines for the 4/2 pots; springs for my struts, and get said struts revalved), but I'll have a busy time when I start doing all of it combined with time with the wifey. :cool:
 

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Discussion Starter #11 (Edited)
^Oh, and Jay, to be fair, that's only the second issue I've ever had on eBay. The first time was some seller claiming to be selling those Orsen (or whatever that company is) ball vacuum cleaner. Thought we could catch it cheap. Turned out being some horseshit scam to sell listings. EBay pretty promptly refunded me, and banned the scammer group.

Good news as far as this transaction though, it has actually shipped. I'll have to ask our mail snatcher (wife's female friend who's house checking & mail/package grabbing while I'm deployed) to open the box when it comes. So a couple days then.
 

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Discussion Starter #12 (Edited)
My wife got back to El Paso on the 1st, for anyone who follows along, since she'd been in VA since May or June (I left in April), to see friends and spend time with her Mom. I got her to open the boxes for the taillights (came in the OEM packaging, mostly), the one that was opened for pictures was missing any protection beyond the box for the lens, so there is scuffs all along the "corner" of the lens, but no cracks. The micro scratching should buff-out though, and I sure as hell am not sending them back at this point.

Also had the wife open up a few of my other packages to confirm lack of damage from shipping, but only made it about a quarter way through the stack (6 or 7 packages) before the internet here got crappy again. Maybe I'll just ask her to lay out all the boxes and open the rest for me, and then take pics of the items. Or maybe not, as she is rather pissed about the mass of packages that were waiting in the house when she got back (~30 packages overall). I just know that I'm going to have plenty of car stuff to keep me busy for a good while this summer, it'll just suck working in my garage closed (no auto work in the garages by housing rules, I say **** that, I got a garage baby!). Maybe I can get my buddy to let me come over and work there since he has no such rules, or didn't when I left.

I just made a list of everything I purchased and was delivered while I've been gone, some to her parents place (5 or 6 packages) the rest were all to our house. By my count it is 35 packages, some of which are small things (like an '80's or '90's style Subaru badge, hollow between the stars, but same star layout as currently), little pamphlets of some vinyl for my tool box, couple are hoodies (another DirtyImpreza hoody and a ScoobiesForBoobies Hoody), and there are a few larger ones (struts, tail-lights, turbo heat shield), and 2 yet to be delivered. This is over a 9 month period, so it's not that ridiculous.
 

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Got my wife to open the boxes for the taillights (came in the OEM packaging, mostly), the one that was opened for pictures was missing any protection beyond the box for the lens, so there is scuffs all along the "corner" of the lens, but no cracks. The micro scratching should buff-out though, and I sure as hell am not sending them back at this point.

Also had the wife open up a few of my other packages to confirm lack of damage from shipping, but only made it about a quarter way through the stack (about 10 packages) before the internet here got crappy again. Maybe I'll just ask her to lay out all the boxes and open the rest for me, and then take pics of the items. Or maybe not, as she is rather pissed about the mass of packages that were waiting in the house when she got back (~40 packages overall). I just know that I'm going to have plenty of car stuff to keep me busy for a good while this summer, it'll just suck working in my garage closed (no auto work in the garages by housing rules, I say fuck that, I got a garage baby!). Maybe I can get my buddy to let me come over and work there since he has no such rules, or didn't when I left.
Yeah i guess it's kinda normal that your wife isn't all too pleased with 40 boxes of parts when she knows it probably isn't 5$/package :lol:

If you ever get the chance -> post some pics of all those boxes with parts :D

What exactly do you mean by "working in my garage closed" and "no auto work in the garage"? Your not allowed to work on your car inside the garage? Well that's ridiculous :p

Small tip: the journal would be easier on the eyes with pics to complement the mods you describe :)
 

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Discussion Starter #14 (Edited)
Yeah i guess it's kinda normal that your wife isn't all too pleased with 40 boxes of parts when she knows it probably isn't 5$/package :lol:

If you ever get the chance -> post some pics of all those boxes with parts :D
Yeah, I'm not surprised by her ire, especially cause I spent more (not all on parts, a lot was extra stuff around base here) than I was saving. Granted, I HAVE been saving and paying off my car with double payments at the same time. I'll try and get her to send me a picture of the stack. They aren't all big packages, so it's not as impressive looking as it sounds, if they were stacked like a tree on the box my struts came in, it'd make a 3 or 4 foot tall tree of cardboard.
What exactly do you mean by "working in my garage closed" and "no auto work in the garage"? Your not allowed to work on your car inside the garage? Well that's ridiculous :p
Exactly what it sounds like. Base housing is regulated and maintained by a civilian housing company in El Paso, and because I live in the base housing, I have to appear to follow their rules. One of the rules is no vehicle maintenance in the housing areas. Garage gets up to almost 200* in the summer at times, so I'll be buying fans to do any work out there, and cracking the door to blow out heat. :mad: I've got a buddy who has a bigger garage (2.5 car to my 1 car), and was letting me do work over there too, stuff he's done and he assists.
Small tip: the journal would be easier on the eyes with pics to complement the mods you describe :)
That'd be easy if I wasn't across the globe. I got surprise deployment orders 2 months or so after getting the car, and was more interested in getting as much done on the car, and spending time with the wife than getting pics. Hence all the things I forgot to take pictures of; stripped interior, kick plates, triangle brace, gauges, etc.... Just a few more months though and I'llget this thread back alive. Pretty sure I posted pics of most of what I've purchased (the bigger things) a few post back though. If not, I'll copy/pasta them in from my build on anther site.
 

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They aren't all big packages, so it's not as impressive looking as it sounds, if they were stacked like a tree on the box my struts came in, it'd make a 3 or 4 foot tall tree of cardboard.
Still better than a real Xmas tree IMO! :D

Exactly what it sounds like. Base housing is regulated and maintained by a civilian housing company in El Paso, and because I live in the base housing, I have to appear to follow their rules. One of the rules is no vehicle maintenance in the housing areas. Garage gets up to almost 200* in the summer at times
Meh, that sucks. Sounds more like Hell Paso to me... :rolleyes:

I'll copy/pasta them
Try it alla bolognese, you'll love it! ;)
 

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Discussion Starter #16 (Edited)
Still better than a real Xmas tree IMO! :D
Agreed, though the wife doesn't I'm sure.
Meh, that sucks. Sounds more like Hell Paso to me... :rolleyes:
And agreed again, long ago (look at my location).
Try it alla bolognese, you'll love it! ;)
:lol:
Moved to post#3

Oh, and apparently this was my post #420, I feel like I should celebrate, but I haven't touched that stuff in years.
I'll try and make an album of pics of all of these later on, and link it.
 

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Alright, scored a leaking Borla Hush exhaust (leaking from a slip joint, easy fix will be welding it shut at the leak) and a JDM Hazard switch, all for ~$250 shipped. Have a plan for the exhaust, as I want to modify it anyways, and it's cheaper to snag the Borla setup than buy everything and build it from scratch (either way I need to snag myself a decent MIG). But here is the idea:
[URL=http://i1108.photobucket.com/albums/h410/gregroot198521/BumperExhaustExit.jpg]Image Link
[/URL]
It's a rough photochop (think I made the tips a little smaller looking than they really are), but basically there is a way to run exhaust up a little higher in the bumper (little bit of metal removal required, and mounting point changes will be required), and make a little CF lip (the gray oval in the picture) around the exhaust. I'll also have to do some plastic welding to close up the bump on the bottom, but it will remove the exhaust from hitting out on the trail (plus I dig the look after seeing another GD STi with a single tip exiting in the same way - mjfubar on here).
Why run it all the way, just make a side exit :lol:
 

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Because I want it quieter. I'm up before my neighbors, and I prefer not having the MPs called on me.
Oh, so it's that kind of housing district... That brings memories! My family used to stay on base housings as well when my father was in the air force and was stationed at a cold war radar base. We could see the radar domes from our house. Here's a digitized slide pic:



Top right in the pic! :)

I loved that place. Lots of nature and adventure for a kid like me. Man, this was a lifetime ago...
 

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Discussion Starter #20 (Edited)
Oh, so it's that kind of housing district... That brings memories! My family used to stay on base housings as well when my father was in the air force and was stationed at a cold war radar base. We could see the radar domes from our house. Here's a digitized slide pic:

Image Link


Top right in the pic! :)

I loved that place. Lots of nature and adventure for a kid like me. Man, this was a lifetime ago...
It's not as bad as that sounded, but I prefer not risking things.
 
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