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2008 XT Sport Build Thread

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57K views 187 replies 48 participants last post by  SlyFXT  
#1 · (Edited)
This will be my tale of taking my 2008 Forester XT Sports from a pretty much stock car too a STI forester (in my eyes)

Mods that will be going into the car (as of right now 10/5)

Motor:
Built SB (balanced crank,balanced Manley rods, Manley pistons, King race bearing)
JDM Twin scroll Header/up-pipe
Kinugawa 18g billet wheel Twin Scroll turbo
HOA 3 port boost solenoid
Walbro fuel pump
ARP Head studs
ID1000s
Walbro 255 pump
Coswoorth timing belt guide
Gates racing timing belt/kit
2011 STI TMIC
SPT turbo heat shield (if it works over the TS setup)
Kartboy Crank pulley
Mishimoto Alum radiator (wrx/sti spec)
Mishimoto Slim Fans
Mishimoto Radiator Hoses
Mishimoto TMIC Hoses
Megan Racing/Group-N Engine mounts
Moroso Oil pick-up tube
Motive Autowerks TGV deletes
Perrin Turbo Inlet (worst fitting thing on my car)
Kinugawa/Invidia custom Twin scroll Downpipe (Done by Kent at Precision Chassis Works)
Custom Catback exhaust with a 5" round Magnaflow muffler in midpipe and 18" oval Magnaflow, with all V-band clamps (Done by Kent at Precision Chassis Works)

Drivetrain/Brakes:
2007 STI 6 speed trans
Motul Gear 300 (Trans)
Subaru Extra-S (Rear)
TiC Trans crossmember bushings
5x114 hubs (Completely rebuilt)
ARP extended Studs
Muteki SR48 Open Lugnuts
STI axles (rebuilt)
R180 (cleaned up)
Kartboy/TIC shifter and all the bushings for the shift
Kartboy Pitch Mount
STI Brembos Calipers (Completely rebuilt)
STI Master Cylinder and brake booster
Grimmspeed Master cylinder brace
Clutch Slave w/ Dampener Valve Delete
FXT frame spacer deletes

Suspension/Steering:
KW V3 with rear linear spring conversion
MSI front camber plates
Custom made Fender braces (Done by Kent at Precision Chassis Works)
2007 STI Front Subframe
2007 STI Steering Rack
Flat 4 Motorsport Power steering line kit (High and low)
2005 STi Rear Subframe
TiC Diff mount bushings
Whiteline Lateral Links
Whiteline Roll center kit
Whiteline Steering Rack Bushings
STi Aluminum Control Arms
Cobb 25mm Sway bars
Kartboy Endlinks
TiC Front and rear Trailing arm bushings
Kartboy out rigger bushings (comfort)

Exterior:
2010 STI Mirrors
Ravspec Carbon Fiber front lip
2005 Forester Tail lights

Interior:
2010 STI airbag
GT Spec D shape steering wheel (blue stitching)
2006 STI front seats
Sea-scooby Sub box
Alpine 8" Type R sub
Alpine sub amp
soundstream 4 channel amp

Misc:
19x8.5 Prodrive GC-014i
Bridgestone RE11s 245-35-19
Open end Lug nuts
Lots of powder coating

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#3 ·
Some block pics, block was already at the machine shop, was bored and honed with the torque plate, here is a few pics of me getting ready to gap the rings, will post more pics when i start assembling the block/motor

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#5 ·
10-10-12 My buddy Ken and I drilled out 2 broken bolts on my brembos and put Helicoils all the mounting holes so i will not have to worry about the bolts getting stuck again (since it seems to happen a lot)

Brembo Mounting holes
Front M12x1.5
Rear M10x1.5

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#6 ·
10-24-12
i decided to do my Viper alarm/remote start,

Points if you are going to do this on your own car
1 - Get a proper wiring diagram.
2 - Get some tools - cutters, el. tape , etc.
3 - READ INSTRUCTIONS !!!!!!!
4 - Multimeter (if you really understand what you are looking at, you can use a test light)

Viper 5901 Wiring into my 2008 Forester XT (5 speed) (DO NOT USE THIS WIRING FOR ANOTHER CAR)

H3 harness (10 pin connector)
Pink – Ignition – to Black (key side) or Green (car side) wire on ignition switch
Red/White – 12+ constant – to Black/White stripe (key side) or white (car side) at ignition switch
Orange – Accessory 1 – to Black/Blue (key side) or Yellow (car side) at ignition switch
Red – 12+ constant – to Black/White stripe (key side) or white (car side) at ignition switch
Pink/White – Ignition 2 – to Pin 85 of Relay
Red/Black - 12v constant – to Black/White stripe (key side) or white (car side) at ignition switch
Starter wire you need to Cut
Violet – Starter 1 – to KEY Side of Black/Yellow (key side) or White/blue (car side)
Green - Starter 1 - to STARTER Side of Black/Yellow (key side) or White/blue (car side)

Relay to bypass clutch during remote start only

Wire Pin 85 of Relay to Pink/White – Ignition 2 (see above in H3 harness)
Wire Pin 86 of Relay to Ground
Wire Pin 30 of Relay to Clutch wire A (Clutch wires are above the clutch pedal) White plug
Wire Pin 87 of Relay to Clutch wire B (Clutch wires are above the clutch pedal) White plug

H1 harness (12 pin connector)

Red – To 12+ constant
Brown - To + on Siren
Black – To chassis ground
Green - Door Trigger input - (diode isolate if you have multiple door triggers) (Drivers door trigger blue/orange at BIU, all other doors yellow at BIU in gray 20 pin plug)
White – Parking light output – (Orange/black wire at parking light switch)

H2 harness (18 pin connector)
Violet/white - Tachometer input (Green wire in 24 pin plug above fuse box)
Dark Blue - (Blue wire from 556u bypass)
Grey - Hood pin ( Mount hood pin and connect)
Brown - Brake shutdown (White/black at brake switch)
Black/White - Neutral Safety Wire ( Green/black at ECU in 35 pin plug) (this is so your car will NOT start if left in gear)

Door lock harness (3 pin)
Blue - Unlock output (Yellow/Red at BIU in gray 20 pin plug)
Green - Lock output (Red/White at BIU in gray 20 pin plug)

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#7 ·
Rear Gate trim smoothing

10-27-12

I like the look of the 03-05 Foresters gate trim because it doesn't have the badge, I did test fit a trim from a 04 forester and even tho it fit on the car, it was a little shorter in height

You can see in the first pic that it has the badge, it is also 2 pieces for whatever reason

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Now you can see it apart and that the piece is NOT flat, it is shaped like the badge

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First i filled the back side with resin, so when grinding it flat i would have a backing

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Next i had to grind the front to be more even, you can see how much would have been a whole in the plastic

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Next filled the front side indent with resin (and sanded)

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Next i used the resin between the 2 pieces and then on the line between the 2

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Lots of sanding

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First light coat of body filler to smooth it out a little, and then sanding (did 2 coats of body filler)

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Primer, first coat, (did 2 so far) will still need to sand the primer and will most likely paint it body color when i paint some stuff for a buddy in like 2 week

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Overall very happy with it so far
 
#20 ·
Quick pic of the trim mounted, just did a test fit to see how it looks, Color seems like it is a little off (tiny bit on the light side), so i need to decide if i want to repaint it or i might have it wrapped in real carbon fiber

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#26 ·
also just ordered a full 2007 sti 6 speed swap, so my 05 swap with be up for sale in about 2 weeks once everything gets here, happened to find a good deal on a 07 setup so i decided to get it so i have the longer gears
 
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