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Discussion Starter #421
Re: BlueScooby's 06 STI - Underbody Panels Phase 4 (rear diffuser)

so I have got a strange clunk coming from, what sound like, the front right suspension/wheel area. It only happens when turning right, it only happens if its a harder turn, and I think it only happens under power (although that could be wrong).

I just crawled under the car again, during lunch all the bolts seem to be tight, nothing is loose or moveable (by hand) there are no visible signs of any scraping/things touching/movement...

It kinda sounds like something hitting sheet metal (fender) but the fender is clean/dent free/etc.

I suppose it could be the CV joint, but it doesn't sound anything like the CV joint noise I'm used to hearing... The axel nut appeared to be tight, the pinch was still in the slot.

Brakes arent loose or anything. It could be one of the bushings I guess, but nothing is moving when I push on it (although I guess that doesnt eliminate that possibility since its only hard turns that produce the noise...).

I'm really at a loss for what to look at next...:confused:

any suggestions?
 

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Re: BlueScooby's 06 STI - Underbody Panels Phase 4 (rear diffuser)

endlinks and swaybars?

Check the top nut on the strut as well, it might not make noise until it's unloaded/loaded.
 

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Discussion Starter #423
Re: BlueScooby's 06 STI - Underbody Panels Phase 4 (rear diffuser)

I will check those, but Ive actually had both happen to me before and Im doubtful thats the source of the noise :(

Any other ideas?

After leafing through the multitude of "clunking" threads, the nut/bolt through the rear LCA joint (where my ALK is) could be loose...
 

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Re: BlueScooby's 06 STI - Underbody Panels Phase 4 (rear diffuser)

I had the exact same thing and it ended up being an end link.
 

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Re: BlueScooby's 06 STI - Underbody Panels Phase 4 (rear diffuser)

Welp, I had a similar issue. I thought it was a bad axle as I had a boot torn but it turned out to be a blown strut. I've had to have a strut rebuilt on numerous occasions now and am pretty in tune with the noise now. I hope it's something that's just loose but anything's possible.
 

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Discussion Starter #426
Re: BlueScooby's 06 STI - Underbody Panels Phase 4 (rear diffuser)

Welp, I had a similar issue. I thought it was a bad axle as I had a boot torn but it turned out to be a blown strut. I've had to have a strut rebuilt on numerous occasions now and am pretty in tune with the noise now. I hope it's something that's just loose but anything's possible.
its funny that you say that, because the strut in that corner is the only one that doesnt have a Feal Revalve... I had to replace the revalved one in a pinch and just put a used factory strut on there... I wonder if thats my issue.
 

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Re: BlueScooby's 06 STI - Underbody Panels Phase 4 (rear diffuser)

its funny that you say that, because the strut in that corner is the only one that doesnt have a Feal Revalve... I had to replace the revalved one in a pinch and just put a used factory strut on there... I wonder if thats my issue.
If I we're a betting man...
 

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Discussion Starter #428
Re: BlueScooby's 06 STI - Underbody Panels Phase 4 (rear diffuser)

i had been meaning to do something about that strut, in terms of getting a "matching" one installed, for about two years now. After this latest clunking, I figured I'd finally do it. I called Feal this morning, and they actually had two front cores in stock! Pretty sure they don't normally have ANY cores in stock, so that is awesome. I was going to just get the one, but Odi recommended I do all 4, or at least in pairs, so I'm getting a "new" set of front struts from them :)

I had wondered if it was possible that the noise was related to the engine mounts (which is unlikely) but this past week, I've noticed the engine shaking a bit more on startup and making some clunks like the engine is shifting/bouncing on startup... So I ordered some Group N engine mounts and a Kartboy Pitchstop :) I was going to go with the Group N Pitchstop but apparently its not really a worthwhile upgrade.

Between the two, of these, i better not have any more unwanted noises up front...
 

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Discussion Starter #429
Re: BlueScooby's 06 STI - Underbody Panels Phase 4 (rear diffuser)

A lot of news!

Installed Group N engine mounts and a Kartboy Pitchstop. Things are much firmer/connected, which is great, but man those engine mounts are noisy! Pitchstop made basically no NVH difference though.

I have been plauged with coolant leak issues with my upper/lower radiator hoses on and off for the past year or two, so I bought some Mishimoto T-bolt clamps thinking that was the solution. Little did I know that T-bolts don't work well in smaller sizes. I had dropped the car off at the shop to do the engine mounts because I didnt want to mess with them and asked them to swap out the T-bolt while they were there. They found my water pump discharge elbow had corrosion/pitting so they replaced that. In the process they found the timing cover was loose and missing bolts. So they pulled that apart to fix, and found my timing belt tensioner and one or two pulleys needing to be replaced, and potentially never were (even though I paid the dealer to do that...). And my timing belt was off a tooth on one of the cam gears.

I'm glad they found all that, but the cost of my "little" trip to the shop was now quadrupled... :(

Now back to the fun stuff.

I pulled the rear diffuser off and the "phase 3" panels to trim about an inch off the right side. Ever since Ben noticed it wasn't even, it has been driving me nuts! It's not perfectly even, but now its much closer and not noticeable. I also hit the two end-fences with some black spray paint so they don't look so crazy driving down the road.

I still need to cut the two middle strakes and get everything welded up...
 

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Discussion Starter #430 (Edited)
Re: BlueScooby's 06 STI - Underbody Panels Phase 4 (rear diffuser)

Heres a couple of pics of this weekends work. Its harder to see the end-fences now that they are black :tup:


I'm not sure if you can tell or not, but the width of each side is MUCH more even now. I think I might not have been directly behind the center of the car though, as it still looks a little skewed in this pic though...


I still need to cut out those middle strakes. One of these days.... lol
 

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Discussion Starter #431 (Edited)
Re: BlueScooby's 06 STI - Underbody Panels Phase 4 (rear diffuser)

Happy Thanksgiving guys!

Cut out a mesh screen for my hood scoop and epoxied it in yesterday. Reinstalled it today after it had fully cured. No more ish sitting on my TMIC :)









Now I need to swap my front struts out... Already got "new" ones in from FEAL waiting to go on.
 

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Re: BlueScooby's 06 STI - Underbody Panels Phase 4 (rear diffuser)

I really love the looks of the Diffusor already! Maybe it looks still a bit off because of the Muffler. Optical illusion maybe? It looks good, especially in that picture from the side :)

Good idea with the mesh in the hoodscoop.
At least the mail man won't put any letters in there again when the car is parked outside :D

I aim for Group N Mounts too.
Might buy them when I'm in Oregon next year and bring them over like I did with the Buddy Club Seat Consoles.

Keep up the good work :tup:
 

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Discussion Starter #433
Re: BlueScooby's 06 STI - Underbody Panels Phase 4 (rear diffuser)

Thanks! Yeah i dont know why I cant take a picture that looks square, but I swear it looks even in person... The exhaust certainly doesn't help anything... lol
 

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Discussion Starter #434 (Edited)
Re: BlueScooby's 06 STI - Rear Diffuser Complete(ish)!

So I finally spent some more time on the rear diffuser this yesterday and today. Cut out the two middle strakes, got them bolted up, and finished painting the whole thing flat black. The only missing piece now is to have the whole thing welded up. The L-brackets I used to support everything will come off once the welds are in place and the whole thing will be much sleeker. Although at this point you probably won't be able to tell a difference from now to then... Either way, I'm REALLY pleased with how this has come out!

Also, notice the rubber sheeting I put down outside of the phase 3 panels and the beginning of the rear diffuser. This enables me to have my "end fences" much closer to the ground without sacrificing being able to go over speed bumps and such. :tup:















In other news, I have a fresh set of front struts that will be going on next, as well as new brake rotors and brake pads. Upgraded to DBA T3 rotors (got a deal at KNS) and stuck with the Ferrodo DS2500s. :cool:
 

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Re: BlueScooby's 06 STI - Rear Diffuser Complete(ish)!

That looks more race-car-ish than most aftermarket diffusors! :)
 

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Re: BlueScooby's 06 STI - Rear Diffuser Complete(ish)!

Are you going to cover the outside edges under the rear bumper?
 
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