('03-'05) AusCan 05 XT & RS Impreza - Subaru Forester Owners Forum
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post #1 of 323 (permalink) Old 04-10-2015, 03:03 PM Thread Starter
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Join Date: Dec 2014
Location: Vancouver, BC
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Car Year: 04
Car Model: JBP XT & STI
Transmission: 5MT & 6MT
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Thumbs up AusCan 05 XT & RS Impreza

Howdy Guys,
I've decided to have a crack creating a Subie Journal.
I've been a fan of Subaru's for a number of years but didn't get a chance to own one whilst living in Oz.

I recently sold my daily driver an 05 XT 4EAT and I'm now daily driving a 04 XT 5MT which I completely rebuilt.

Oh yes my wife drives a RS Impreza - which I plan to do a turbo engine swap in the near future.

We love our Subies



Here is a few pics of my old 98 Foz - this was sold back in December 2014.


New Forester 05 XT 4EAT which is my daily driver - this was sold recently December 2016.


My best mate is really happy riding around in the XT - this was sold recently December 2016.


Just finished detailing the wife's RS now onto the XT - this was sold recently December 2016.

Oh yes the old carport needs some TLC lol.


Last edited by AusCan; 12-22-2016 at 08:58 PM.
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post #2 of 323 (permalink) Old 04-10-2015, 07:52 PM Thread Starter
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Join Date: Dec 2014
Location: Vancouver, BC
Posts: 462
Car Year: 04
Car Model: JBP XT & STI
Transmission: 5MT & 6MT
Garage
Feedback Score: 2 reviews
Previously our cars had been serviced via a dealership. After purchasing the XT and reading numerous threads I've decided that I will undertake future services on our Subies :)
With that I built myself a set of ramps:
--> plenty clearance for oil changes



Last edited by AusCan; 12-22-2016 at 08:59 PM.
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post #3 of 323 (permalink) Old 04-10-2015, 08:39 PM Thread Starter
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Join Date: Dec 2014
Location: Vancouver, BC
Posts: 462
Car Year: 04
Car Model: JBP XT & STI
Transmission: 5MT & 6MT
Garage
Feedback Score: 2 reviews
1st Service: Oil change, replaced plugs & filter:

Here is the resultant plugs removed. Not too difficult if one takes there time.
I was very careful in not crossing treading the new plugs.


Old and new filter:


Last edited by AusCan; 12-22-2016 at 08:59 PM.
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post #4 of 323 (permalink) Old 04-10-2015, 09:39 PM
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good start.
don't forget to check
boy i'm i ever jealous of your garage/workspace. you even have two spaces! I might have to borrow your garage for a future engine swap.

come check out my journal of custom stuff!!
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post #5 of 323 (permalink) Old 04-12-2015, 11:26 AM Thread Starter
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Join Date: Dec 2014
Location: Vancouver, BC
Posts: 462
Car Year: 04
Car Model: JBP XT & STI
Transmission: 5MT & 6MT
Garage
Feedback Score: 2 reviews
Sure I'm down for that
Got a third spot as well which my neighbour doesn't use.


Quote:
Originally Posted by atlasunit22 View Post
good start.
don't forget to check
boy i'm i ever jealous of your garage/workspace. you even have two spaces! I might have to borrow your garage for a future engine swap.
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post #6 of 323 (permalink) Old 05-10-2016, 09:17 PM Thread Starter
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Join Date: Dec 2014
Location: Vancouver, BC
Posts: 462
Car Year: 04
Car Model: JBP XT & STI
Transmission: 5MT & 6MT
Garage
Feedback Score: 2 reviews
It has been sometime since the last Journal post. Okay here we go --> heaps of progress since my last post way back.
Purchased the 04 XT 5MT back in June 2015.

It is in need of a fair bit of TLC - which I'm up for the challenge.
Oh yes it required a tow which one of my mates kindly helped me out.



Here is a quick engine bay pic - b/f commencing the removal of the engine and undertaking much needed rust restoration.



In order to pull the engine I needed to source a engine hoist - found a great deal on CL (as you do) which I snapped up. Hoist looks a little lonely don't it - well not for long.

Last edited by AusCan; 12-22-2016 at 08:56 PM.
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post #7 of 323 (permalink) Old 05-10-2016, 09:57 PM Thread Starter
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Join Date: Dec 2014
Location: Vancouver, BC
Posts: 462
Car Year: 04
Car Model: JBP XT & STI
Transmission: 5MT & 6MT
Garage
Feedback Score: 2 reviews
The plan is to undertake the following:-
- engine rebuild (blown head gasket), go with Forged Pistons, new bearings (basically new block)
- remove & replace rusty front cross member
- tackle rust underneath body & interior

Last edited by AusCan; 05-13-2016 at 06:52 PM.
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post #8 of 323 (permalink) Old 05-11-2016, 08:05 PM Thread Starter
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Join Date: Dec 2014
Location: Vancouver, BC
Posts: 462
Car Year: 04
Car Model: JBP XT & STI
Transmission: 5MT & 6MT
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Engine Pulled. Not that difficult and there are number threads on this topic..... so no need for me to replicate etc.
Good progress and now have more room for the major job.... that being rust repairs. Alot of cut knuckles and fingers lol. More on that later.

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post #9 of 323 (permalink) Old 05-11-2016, 08:27 PM Thread Starter
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Join Date: Dec 2014
Location: Vancouver, BC
Posts: 462
Car Year: 04
Car Model: JBP XT & STI
Transmission: 5MT & 6MT
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Feedback Score: 2 reviews
Red face

Rusty Front Crossmember - this is toast and needs replacing badly. See below:-
Oh yes some pics are a little blurry apologies...



Now that is some major rust ha....


Another view of engine out and crossmember that needs replacing.


Crossmember removed and now off to the local wreckers to source replacement part




Found myself a replacement crossmember at the wreckers... had some minor surface rust. Nothing major - gave is a good surface clean and painted. Happy with the final result - see below:-

Now just need to install - will show the end result later


Here is the new crossmember installed and awaiting the engine


Last edited by AusCan; 05-16-2016 at 08:42 PM.
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post #10 of 323 (permalink) Old 05-11-2016, 09:18 PM Thread Starter
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Join Date: Dec 2014
Location: Vancouver, BC
Posts: 462
Car Year: 04
Car Model: JBP XT & STI
Transmission: 5MT & 6MT
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Feedback Score: 2 reviews
Rust Restoration... what am I up against.... well it has taken me extensive hrs to tackle this rust. I was determined that I could restore this beauty back to show room condition - or as close as possible.
Here is a good pic showing the under body rust - XT previously resided Ontario. No surprises here - I knew what I would be up against hmm maybe lol.
The simple/easy solution would be to part it out... that be too easy lol. I have a DD 4EAT - so why not have a crack at restoring this beast.
See below:


I've spent many man-hours underneath this beast .... I will show in another post the completed work.


The wood you see is additional safety measure. There are six jack stands..... Oh yes I am very safety conscience it is a given in my field of work.
Additionally not shown in this pic I also used the wheels as an extra safety precaution.


Last edited by AusCan; 09-12-2016 at 08:07 PM.
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post #11 of 323 (permalink) Old 05-12-2016, 04:45 PM Thread Starter
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Join Date: Dec 2014
Location: Vancouver, BC
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Car Year: 04
Car Model: JBP XT & STI
Transmission: 5MT & 6MT
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So here how she current sits - after many long hrs grinding, sanding, drilling, heating & spray painting.
End result is major improvement!!!



Looking back at the creeper:






Last edited by AusCan; 05-16-2016 at 10:10 PM.
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post #12 of 323 (permalink) Old 05-13-2016, 03:09 PM Thread Starter
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Join Date: Dec 2014
Location: Vancouver, BC
Posts: 462
Car Year: 04
Car Model: JBP XT & STI
Transmission: 5MT & 6MT
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Feedback Score: 2 reviews
After tackle the majority of under body rust repairs - I moved onto the inside of the vehicle. The remaining exterior area that needs attention is the fuel filler piping area. A common area to watch out for rust development etc.

Okay here are some inside pics:-

--> looking from underneath the car - drain plug completed rusted.

--> just a little bit rusty ha






--> seats/carpets all removed. If you look closely over at the fuel release handle totally rusted lol.

--> oh yes here is a better pic of the super rusty release handle - wow ha









I've tackled all the areas where there was any glimmer of rust. All floor pan metal plugs were replaced









--> since I've undertaken this work I noticed some rust forming under the crossmember near the fuel handle. I tired my best to repair this but.... rust has since reappeared under the weld.
-->I knew it would have to be removed.... I've purchase new part already and will mig weld new section at same time as the fuel filling piping weld repair.

Last edited by AusCan; 05-13-2016 at 07:29 PM.
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post #13 of 323 (permalink) Old 05-13-2016, 07:16 PM Thread Starter
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Join Date: Dec 2014
Location: Vancouver, BC
Posts: 462
Car Year: 04
Car Model: JBP XT & STI
Transmission: 5MT & 6MT
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Feedback Score: 2 reviews
I've always liked the look of the Sti BBS Rims both on the Sti and XT. I'm always browsing and was very fortunate to come across a set of 04 BBS Rims in fantastic condition and good $$ - which I couldn't pass up. These are super rare and are the 5x100 bolt pattern.
Here is a quick pic - test fitting and basically seeing how she looks - sweet!!!!


Last edited by AusCan; 05-13-2016 at 07:42 PM.
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post #14 of 323 (permalink) Old 05-13-2016, 08:38 PM Thread Starter
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Join Date: Dec 2014
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Car Year: 04
Car Model: JBP XT & STI
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Next on my list to do was the rusty fuel filler piping rusty our rear wheel area - see below:-
Now that is toast and I will definitely need to mig weld a 18g sheet metal.



Removed the filler pipe - will replace with a new piece. I've check at RockAuto and they have good new pricing for this part. You can see that I cut it in order to make the removal much easer - part was toast so didn't matter etc.



Area cleaned up and prep for welding. Will do a final grind to remove any surface rust prior to welding.


Last edited by AusCan; 05-13-2016 at 08:50 PM.
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post #15 of 323 (permalink) Old 05-13-2016, 08:57 PM
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I am going to check there for the pipe too. I think mine needs to replaced too.


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