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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
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291 Posts
Discussion Starter #1 (Edited)
Raszaron's MY04 Forester XT Modding Journal

Hello to my Journal of how I have been modding my 2004 Subaru Forester XT. My plan has been to surpass stock STI performance levels while not going to aggressive in any one area of the build.

How the story begins:

I purchased the FXT on 09JAN2010 near Washington D.C. The FXT had 82,650 miles at time of purchase, and at that time was completely stock!

By the numbers:

2004 Stock: (Multiple sources)
BHP: 210 @ 5400rpm
- Converted for 18% drivetrain loss: (172awhp)
TQ: 235 @ 3600rpm
- Converted for 18% drivetrain loss: (193ftlbs awtq)
Redline: 6500 rpm
Curb Weight: 3210 lbs.
0-60: est. 6.5 seconds (one test had it at 5.3 secs)
1/4: est. 14.6 seconds (one test had it at 13.9 secs)
Boost: 11.6 lbs

TD04 w/ stock TMIC w/Cobb Stage2 OTS Map:
Mileage: 95,000
EST Flywheel: 270 @ 5600 (Estimates from Cobb - Stage 1 = [email protected])
- Converted for 18% drivetrain loss to Est. AWHP: 221awhp
EST Flywheel: 285 @ 3400 (Estimated from Cobb - Stage 1 = [email protected])
- Converted for 18% drivetrain loss to Est. TQ: 234ftlbs
Redline: 6500 rpm
Curbweight: 3210 lbs.
0-60: 5.4 secs (Measured on Cobb Accessport v.2)
1/4: 14.477 @ 96.64 mph (06May2011 at MIR)
Boost: 14 lbs

With my current mods:
Current Mileage: 100,000
AWHP: 310 @ 5400 rpm (100awhp more than stock claimed 210BHP)
- converted for 18% drivetrain loss to BHP: 366bhp
AWTQ: 333 @ 4500 rpm (300ftlbs @ 3600 to compare with stock 193ftlbs)
- converted for 18% drivetrain loss to BTQ: 393ftlbs
Redline: 7000 rpm (increased 500rpm for AutoX)
Curb Weight 3210
0-60: 4.9 secs (Measured on Cobb Accessport v.2)
1/4: 13.45 secs @ 104 mph (12August2011 - MIR)
Boost: 20.4 lbs

Update UPdate UpDate!!!!!
Mileage: 115537
2005 STI Drivetrain/Brembos/Steering Rack/Subframes swapped in (STI mileage: approx. 95K)


Listed below is what I have currently done, or taken off (in red). Enjoy my journal and let me know what you think, good, bad, both, I don't get offended.

INSTALLED MODIFICATIONS:
Power / Drivetrain Mods:
1. TurboXS TBE 3"(Catted) - Forester Specific
2. Cobb Accessport V.2 (for Forester) (Cobb OTS VF39 TMIC 91octane) Made (245whp/235lbft tq)
2a. Agile Automotive Pro-Tune Made (310whp/333lbft tq)
3. Perrin TMIC Y-Pipe Kit
4. 07 Limited STi VF43 Turbo
5. 07 Limited STi TMIC
6. Downloaded OTS Cobb VF39 (91&93) Maps for Forester
7. Grimmspeed Ceramic Coated Up-pipe
8. Grimmspeed Ceramic Coated Manifolds and Crosspipe
9. Grimmspeed AOS
10. Grimmspeed 3port EBCS (in 2 port configuration)
11. Walbro 255lph fuel pump
12. Perrin Turbo Inlet Tube
13. NGK IX-Series Iridium (LFR7AIX) {1step colder plugs}
14. SPEC Stage 2+
15. Spec Flywheel
16. STI Braided Clutch Line
17. STI Group N Transmission Mount
18. STI Group N Pitch Mount
19. Kartboy Short Shifter with Front and Rear Bushings
20. Koyo Racing Radiator (VH13026) SG specific
21. Samco Silicone Radiator Hoses (TCS351/C)
22. Grimmspeed 160 Thermostat
23. Second Radiator Cap (Moshimoto 1.3bar)
24. K&N Panel Air Filter (Stock Air Box w/Silencer Delete)
25. Go Fast Bits Deceptor Pro (almost always run it full recirc)
26. Gates Racing Timing Belt, Pulleys, Waterpump
27. Gates Racing Ancillary Belts
28. Cobb lightened Crankshaft Pulley - Blue
29. STI 11mm Oil Pump
30. 06 STI Oil Pan
31. Killer B Oil Pickup Tube and Baffle
32. Group N Engine Mounts
33. New Clutch Master Cylinder
34. New Clutch Slave Cylinder
35. 2005 STI 6spd Manual/R180/DCCD/Axles/Driveshaft/etc/etc
36. DCCD Pro
37. Uncle Scotty's Cocktail

Non-Power Mods:
1. Kartboy special edition (Pink) exhaust hangers
2. AEM EGT, and Oil Pressure
3. Subtle Ashtray Gauge Mount
4. Perring Adjustable Gauge Mount
5. Subtle Hood Dampers
6. Subaru OEM rear spoiler (painted)
7. Rear Cargo area mat and Subaru Nets
8. Importology Front Lip
9. Perrin Gauge Pod Inserts (52mm) (should have come with gauge pod)
10. Subtle Solutions Hood Scoop Splitter
11. MRT 04-05 STI Hood Scoop
12. Fire Extinguisher - mounted
13. 3M Window Tint (Florida Legal)
14. AEM Digital Wideband Gauge w/ sensor
15. AEM Digital Boost Gauge
16. Yakima Load Warrior Basket, Crossbars, Mounts, Locks
17. Mishomoto Magnetic Oil Pan Drain Plug
18. 2011 Black STI front seats (leather and alcantara w/ red STI stitching) ($700.00 with proper rails)
19. Custom Black Suede Headliner with red stitching and Subaru designs ($1,200.00 - Lions Automotive Upholstery)

Suspension / Handling Mods:
1. BC BR Coilovers Forester specific with Swift Spring (8K-F/6K-R) upgrade (adapted for STI on the front) (WINTER USE)
2. FEAL 441 Coilovers with Swift Springs (Brand new, waiting for SUMMER USE only)
3. Subtle 1/4" saggy butt spacers
4. Whiteline 24mm Sway Bars Front/Rear
5. Whiteline HD Rear Sway Bar Mounts
6. Whiteline Adjustable Lateral Links
7. Kartboy Endlinks (Front) Kartboy Endlinks (Rear)
8. DBA Slotted Rotors (Front/Rear)
9. Hawk HPS Ceramic Pads (Front/Rear) - for Brembos
10. Goodrich SS Braided Lines
11. Dot4 Racing Brake Fluid... currently have their yellow racing fluid
12. Grimmspeed Brake Brace
13. 2010 STI Limited Wheels 18x8.5 (SUMMER USE)
14. Michelin Pilot Super Sport (225/45ZR18/XL 95Y) {These are the best tires I have ever used!}
13. 2013 STI Enkei Wheels 18x8.5 (WINTER USE)
14. Continental Extreme DWS (245/45ZR18/XL 96Y)
15. Whiteline Strut Tower Bar (Rear) with quick release
16. 2005 STI steering rack with whiteline bushings
17. 2005 STI front U-shaped subframe
18. Grimmspeed Ceramic Coated Turbo Heat Shield
19. 2005 STI Brembos (front and back) - retained the hill assist

HOW MUCH DOES IT COST TO BUILD A FORESTER STI?
So, some people have been asking me how much it would cost them to build their own Forester to be like mine. So I thought I would give the ballpark figure on how much have I spent on this Forester without adding normal maintenance costs, labor, or taxes. I am also leaving out parts that I have since removed from converting to STI. So here's a little break down:

2004 Forester XT purchased January 2010 with ~83K miles = 11,400.00
Current parts on the car = 10,248.79
Parts sitting in boxes to go on the car = 1,600.00
Parts I don't have the receipts for = ???
Dyno tuned by Agile = 500.00
2005 STI drivetrain swap = $7,500.00

GRAND TOTAL = $31,248.79+???


Shout out to Vendors and Companies I have used and I like:
1. Agile Automotive Performance- Great people and great work. Check them out if you are looking to have work done on your vehicle and you are in the Baltimore/DC area!
2. Oakos Automotive - Great selection of products for our Foresters! A+ rating on customer service as well!
3. Grimmspeed - Great products and customer service as well! I have a hard time passing up products that they produce.
4. Subtle Solutions - Great quality products and fitment has never been an issue with anything that I have used from them.
5. TurboXS - Their exhaust products are tops! Great fitment. Great sound.
6. Annapolis Subaru (Jackie) Parts and Service Departments. I have never had a bad experience with them!
7. Jim Keras Subaru (Dama) Service and Parts - straight forward and great people, quality service.
8. Allpro Subaru - Great people who provide excellent customer service and services. They help out in every way they can!
9. RallySportDirect - Great customer service and products! Website is awesome on what fits which car with added reviews and customer questions!


Stay tuned.....:new_multi:

09January 2010 - Purchased
28 January 2010 - updated:
07 April 2011 - wow, but finally updated:
15 April 2011 - bought more stuff!
12 May 2011 - Got more stuff done to the FXT
13-15 May 2011 - VF43 Turbo swap and more Complete
27 May 2011 - Tuning Update (Agile Automotive - 310.2whp/333.5lbft)
30 August 2011 - Updated
07 January 2012 - Updated (Happy New Year!!!)
30 July 2012 - Updated, now living in the Memphis area...
1 August 2012 - Ordered Spec Stage 2+ clutch and Spec steel Flywheel
14 December 2012 - Spec Stage 2+ clutch and flywheel have approx. 4,000 miles on them, added the Whiteline rear endlinks to the outside (they clear the rear caliper banjo bolt, and today just replaced the Goodyear Eagle GTs with Michelin Pilot Super Sports)
27 February 2013 - Went nuts buying and installing stuff! I need to get my addiction under control! LOL
19 March 2013 - Installed the new clutch master cylinder and slave cylinder.
26 July 2013 - Updated....
21 October 2013 - We have gone STI drivetrain and brakes + more....
6 August 2014 - What could possibly better than one Forester XT (now STI) in the driveway? How about 2 Forester XTs in the driveway!!!
19 June 2015- Updated...
08 January 2016 - Happy New Year! Now to sell the Forester STI Clone, or not to sell the Forester STI clone?! That is the question!
 

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Administrator
2007 Forester Sports XT 4EAT
Joined
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36,334 Posts
Always good to see another member starting their MODding Journal! Have fun & I'll be looking forward to watching your progress. :cool:

Bobby...

My MODding Journal
 

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Pleiads' biggest leghumper
04's 2 FXT's.
Joined
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9,325 Posts
I would say you some how bought a CANADA 04 Forester XT. Canada had 04 Xt's with leather & sunroof. Is your drivers seat power?


joe r
 

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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
Joined
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291 Posts
Discussion Starter #5
I would say you some how bought a CANADA 04 Forester XT. Canada had 04 Xt's with leather & sunroof. Is your drivers seat power?


joe r
Interesting... but no my driver's seat is not powered. Do have seat warmers though, and those have been coming in handy lately!

Updating page today.
 

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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
Joined
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291 Posts
Discussion Starter #6 (Edited)
TurboXS TBE 3" w/ Kartboy Hangers

TurboXS 3" TBE w/ catted Downpipe and Kartboy Special Edition Hangers. Cobb Accessport v2 w/ Stage2 93octane tune installed.

Great Exhaust! Perfect Fitment, Great Sound, Still Strong!
 

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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
Joined
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291 Posts
Discussion Starter #7 (Edited)
Forester Swift Springs and Prodrive GT1 Wheels

Love the Swifts, great ride! And the Prodrive Wheels are nice plus brand new and not questionable like used 04 STi Gold BBS...

Also in these pictures are:
Subaru Factory Rear Spoiler
Importology Front Lip
MRT 04-05 STi Style Hood Scoop
 

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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
Joined
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291 Posts
Discussion Starter #8 (Edited)
ACT Clutch Install

ACT HD00 Clutch with Streetlite Flywheel and STI Braided Clutch Line:

At first was a harsh shuttery engagement, but have about 3,000 miles on it now, and it is significantly better. Mostly depends on temperatures now.

My fourth gear grinds a little when shifting above 3K rpms... maybe time for a PPG gearbox!!!
 

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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
Joined
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291 Posts
Discussion Starter #9 (Edited)
Gauge Install Pics

Perrin Gauge Mount... it should have come with the silicone 52mm inserts, rather than having to pay extra for them after receiving the pod and seeing that they don't! But it works well.

Megan Racing V2 gauges... worked for about 6 months, now they work off and on, which to me means they are junk! I had Defi in my STI, expensive but never had an issue with them, hence, you get what you pay for.

Subtle Solutions Ashtray Gauge Mount... simply awesome, relocated the cigarette lighter to the passenger side of the center console:
 

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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
Joined
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291 Posts
Discussion Starter #12
How did you fit that scoop? I want that style but I don't want the fiberglass knockoff's.
Purchased it from MRT, it's for the 02-03 WRX but it fits our hood as well. Had to bore out the holes on the Forester hood to get it to fit snuggly in the location, and I used larger washers when fastening it.

The bad part is it's expensive and shipping is as well to the US from Australia.
 

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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
Joined
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291 Posts
Discussion Starter #14 (Edited)
Brake system tinkering

APRIL 15, 2011

Upgraded the Stock Rotors to Racing Brake Slotted rotors
Upgraded pads to Hawk HPS Ceramic Pads
Upgraded stock brake lines to Goodrich SS Lines
Upgraded fluid to DOT 4 Racing Fluid Super Blue
Cleaned and Painted the Stock Calipers


APRIL 16, 2011

Added the Grimmspeed Brake Brace
also added the Walbro 255lph Fuel Pump and new Fuel Filter
 

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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
Joined
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291 Posts
Discussion Starter #15
Coming up shortly

In the next couple of weeks, if my schedule allows, I plan on doing the following:

Once I get the Koyo Radiator in; (planning for April 29th)
Installing Radiator, Samco Silicone Radiator Hoses and Ancillary Hoses, Grimmspeed T-stat, Vibrant T-clamps, STi Radiator Cap and Moshimoto Radiator Cap, and Redline Water Wetter to Prestone 50/50 Antifreeze.

Then the swap will occur; (planning for April 30th)
07 STI Limited VF43 Turbo
07 STI Limited TMIC
Samco Silicone Intercooler Inlet Hose and after MAF hose
Perrin Turbo Silicone Inlet Hose and After Intercooler Hoses
Grimmspeed Coated Heat Shield
Grimmspeed Coated Exhaust Manifolds and Crosspipe
Grimmspeed Coated Up-pipe
Grimmspeed 3port EBCS
NGK IX Iridium one step colder plugs
STi Group 'N' Pitch Stop
K&N Panel Filter
All new gaskets from Downpipe to the manifolds
Install the VF39 Stage 2 map until I can get a pro tune
 

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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
Joined
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291 Posts
Discussion Starter #16
I can't say I like the gauge mount on the dash, but everything else sure looks fun! :) Awesome job so far, keep it up!
I looked all over the place where to put that, and that ended up being the only place where it wasn't in the way of something else. I wish there was something nice like the ATI pod for the STI's that goes where the clock is located.

Or a matching pillar pod...
 

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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
Joined
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291 Posts
Discussion Starter #17
Added a poll to get everyones opinion on their most import mod area.
 

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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
Joined
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291 Posts
Discussion Starter #18
Koyo Radiator Install

Installed the Koyo Racing Radiator (VH13026) and Samco silicone radiator hoses (TCS351/C) and a few of the ancillary hoses (TSC135/C).

Install was pretty easy, was worried that there might have been a leak due to the smell of burning antifreeze, but after a day of driving around, no issues - no leaks - no smell - no fluid level drop. Must have been some residual antifreeze that needed to burn off.
 

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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
Joined
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291 Posts
Discussion Starter #19
Kartboy Shifter Bushings

So the beginning of a good day got bad as soon as I heard something go....

"SNAP"

Well, I sheared a bolt off... the one that holds the forward shifter bushings! So I spent the next 3 hours fabbing up a piece to temporarily work until I can get a replacement...
 

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Super Subie Fan
2004 Forester XT 6spd MT (2005 STI)
Joined
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291 Posts
Discussion Starter #20
Whiteline Suspension Components

Add the 24mm Front and Rear Adjustable Sway Bars
Added the HD rear mounts
Added the Adjustable Lateral Links
Added Kartboy Endlinks Front and Rear

*Problems I ran into:
1. Taking the Lateral Links off the Passenger side. Corrosion was holding the bushings onto the long bolt that goes through them. I had to use a press and deep well socket in order to break the bushing free from the bolt. All in all the driver side took about an hour to complete, the passenger side with the problem about 3 hours...

2. It is nearly impossible to get the endlinks straight up and down due to having them on the inside. Having them on the outside can cause the endlink bolt to hit the caliper banjo bolt. No issues with handling setup like this.

3. Do yourself a favor, as I have learned this before, remove the front subframes and then replace the swaybar, makes it 100x easier!
 

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