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Premium Member
2018 X3 M40i / 2016 X3 xDrive35i
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1,632 Posts
Discussion Starter · #1 · (Edited)
Backstory: Was riding the interwaves looking for an 04-08 Forester XT with a stick. Not easy to find for the right price and right condition. I checked cars.com one last time on a Saturday evening before dinner and saw a newly listed 2004 Forester XT 5MT, Silver, 1 owner, 120k miles in Little Rock that popped up that day and happened to be about 4500 below what every other forester of similar age/mileage/condition was listed at.

Sweet. Called them up, just got it on trade that day, needed inspection. Told them to let me know what turns up. They called back Monday morning indicating it was likely going to be wholesaled. Needed body work and there was a check engine light that concerned them. I told them to wholesale to me. They agreed, I got another 2 grand off.

Booked a flight that night, picked it up the next morning and drove back to Kansas City.

It was a great deal.

Got better. Was able to get the phone number of the past owner. At ~104k miles, the engine needed rebuilt due to turbo failure introducing metal into the oil. Owner opted to drop the car off with Cobb Tuning of Plano for a full rebuild including forged pistons.

!!!!!

let the fun begin.











As it stands right now, pretty much any/everything that needed to be refreshed to look like new has been.

Mod list is as follows:

Engine:
Cobb Tuning rebuilt block with 100mm CP pistons
VF48
09 STI TMIC
10 STI Uppipe
Invidia Catless Downpipe
STI Catback
Cobb V3 AP

Engine Pending:
Perrin Inlet
ID 1000 CC injectors
DW200 fuel pump
Tune

Drivetrain:
Group N Pitch Mount
Group N Motor Mounts
Group N Transmission Mounts
Kartboy Crossmember Bushings
TiC 5MT Narrow Pivot Bushings

Interior:
13 WRX Shift Knob
05 STI Wheel
05 WRX Airbag
05 WRX Heated Seats
Weathertech Digitalfit liners
 

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Premium Member
2018 X3 M40i / 2016 X3 xDrive35i
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1,632 Posts
Discussion Starter · #2 ·
Shift knob replaced with '13 WRX




Missing armrest replaced with junkyard takeoff




Broken rear cupholder replaced with junkyard takeoff




Failed clearcoat on exterior c-pillar trim replaced with junkyard takeoff






Cleaning up 2009 STI Intercooler




Old and busted vs. New. Went with 05 which were just slightly different in color and design




Busted Rear wiper needed replaced




Front end almost done, needs a few clips that broke to continue


Rear bumper completed and installed


STI Steering wheel

Stay tuned...
 

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Premium Member
2018 X3 M40i / 2016 X3 xDrive35i
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1,632 Posts
Discussion Starter · #3 ·
STI vs. Stock Axleback


STI vs. Stock Midpipe


TD04 vs. VF48


VF48 vs. TD04 hotside


Stock Catted uppipe vs. STI Catless


2005 WRX Heated Seats




 

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Premium Member
2018 X3 M40i / 2016 X3 xDrive35i
Joined
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1,632 Posts
Discussion Starter · #9 ·
I've sucked at updating this thread. Sorry guys.

Progress: She's nearly done mechanically. VF48, STI TMIC, Invidia V2 catless DP, ID1000cc injectors, DW200 fp, VERY mild tune of only 16.5 psi (stock clutch won't take much more). Made 265hp, 320 ft lbs...has probably 350/400 in it if when I get a new clutch.

VF48 I bought was a shoddy rebuild so I had to get a new CHRA for it due to oil leaking out the hot side and smoking pretty bad. The SD tune from MKC needs a few kinks worked out so it will go back to them sometime soon then it's onto making the rest of the car look presentable.

Crap CHRA:



New CHRA:







 

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Premium Member
2018 X3 M40i / 2016 X3 xDrive35i
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1,632 Posts
Discussion Starter · #10 ·
Been fighting a stumble in the powerband for the last couple weeks, about to tear my hair out over it it's been pissing me off so bad.

Finally narrowed it down to a dampening problem. Ordered two dampers and adapter setup to connect to the input side of each fuel rail to get rid of the stumble.

This is the same issue that plagues most GRs. Surprised the forester got bit by the problem...but I guess that's what happens with giant *** injectors.

https://www.youtube.com/watch?v=sSyut7D1A_c
 

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Premium Member
2018 X3 M40i / 2016 X3 xDrive35i
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1,632 Posts
Discussion Starter · #11 ·
Dampening is fixed!

Sounds different, idles different, revs different.

drives SO much better. No stumbling at all through the RPM range now. Fuel corrections are a little wonky now though as the original tune was performed on the car with erratic fuel pressure so MKC had to adjust and try and compensate for it. Now that it's got rock solid fuel it'll need to be re-tweaked. Pulls considerably stronger too. Bet it would put down an extra 10-20 whp.

https://www.youtube.com/watch?v=zJEuVPcGjT0

Here's the damper setup that resolved the issue:



[ame]http://www.amazon.com/gp/product/B00...?ie=UTF8&psc=1[/ame]
[ame]http://www.amazon.com/gp/product/B00...?ie=UTF8&psc=1[/ame]
[ame]http://www.amazon.com/gp/product/B00...?ie=UTF8&psc=1[/ame]

Fuel Pump > 06 STI inlet damper > 2 ft of Injector Dynamics braided inlet line > Amazon Damper setup right on the inlet side of the rail > Amazon Damper setup right on the inlet side of the other rail > FPR > OEM Damper on return line.
 

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Premium Member
2018 X3 M40i / 2016 X3 xDrive35i
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1,632 Posts
Discussion Starter · #16 ·
Nice find on the car, and great photos of all your work! What's been your scoop splitter solution, since you are running a big IC with the original scoop?
Thank you! For the scoop splitter I got the OEM forester/WRX height splitter from process west. The splitter is designed for the process west intercooler so it lines up front and sides well, but the back goes beyond the intercooler. To remedy I took a 2x4 and used it as leverage on the inside of the back portion of the splitter and then hammered forward the back. Was able to keep all the sealing that way and it looks the same, with a minor bend in the back. Now it seals perfectly with the back of the intercooler.

Looks great! :icon_biggrin:

What %'s did you go with? I got my XS in the same color tinted a couple weeks back and it makes the car look so much better. How nervy was the drilling for the spoiler? I've ordered one from Jackie and it'll be in next week.
Thank you! It's 20% all around. Drilling for the spoiler wasn't bad at all, except that the template is NOT correct. I had it lined up 100% and drilled exactly where I should have but there are variances in the spoiler itself on the two inner most bolts. As a result I had to drill each side more towards the middle and made more of an oval than a circle. I used a rust stopping paste on the holes and then tightened her up and she fit like a glove.
 

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Premium Member
2018 X3 M40i / 2016 X3 xDrive35i
Joined
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1,632 Posts
Discussion Starter · #17 ·
I'm in the middle of detailing it now. The pictures don't show it but there was absolutely terrible reflection on the parts of the body I didn't have repainted.

Using surbuf pads, flex 3401, M100 and M205 and so far the hood has come out absolutely beautifully. I'm giving up for the evening and will resume tomorrow, then follow up with opti-coat. She's going to look like a new car when she's done.
 

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Premium Member
2018 X3 M40i / 2016 X3 xDrive35i
Joined
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1,632 Posts
Discussion Starter · #20 ·
Steering wheel is a bit of a hybrid...it's an 05-07 STI wheel, with an 05 WRX airbag.

airbags can be found easy/cheap from LKQ online. The steering wheels are bit harder to find in good condition for a low price.
 
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