Restoring my 2005 STI - ScoobyNet.com - Subaru Enthusiast Forum



Projects For Serious DIY Car Projects

Restoring my 2005 STI

Reply
 
 
 
Thread Tools Search this Thread
Old 13 January 2018, 10:14 PM   #1
Angus0413
Scooby Regular
Thread Starter
 
Join Date: Oct 2017
Location: orbit
Posts: 36
Default Restoring my 2005 STI

Hi everyone!

I wanted to share the restoration of my STI 2005 with the community.

First to Introduce myself, I am a nearly 33yo french dude working as a motorsport engineer in UK (I let you imagine the abuse I get...)

In 2017 it was really time for me to get a proper car (Wont tell you what was my daily drive so far but my colleagues pushed me to add a mattress and a roll of duct tape in the back... just to complete the look).

Compared to France, great cars are so cheap here in UK. So when I realized I could afford a nice Porsche for <15kGBP, I thought I knew what to get.
But one day a colleague showed me what else I could get for that price: a Subaru Impreza... WOW... I did not think about it. In France they are very rare, but anytime I had seen one I felt attracted. It always remind me about Colin Mcrae, and the playstation games I spent hours on.

By the way, the french Highway Police has been using WRXs from 2006 to 2011.




So after learning about the different models, my preference was going for a BlobEye. I hesitated a bit about the Color, but at the end: "An Impreza has to be Blue" I would say. It does not prevent me to appreciate ones in black or white but Blue is a classic.

So here is the one.
Almost Standard, 2005, Wide Track, DCCD, Prodrive Perf Pack. 75K Miles at sell time.







When I went to see it I had a quick look underneath and noticed some rust on suspension part but arch wheels were fine.



My test drive was a bit short but this is my fault. I said the guy I was a bit nervous to drive a 305hp car RH drive for the first time in a city center so he took it out, we swapped and I came back to the garage with it.

Few days later when I picked it up, on the way back home I noticed the steering wheel had to be few deg left to keep it drive straight...
Also the rear axle felt loose... I had zero confidence to push. In fact I would still be quicker we the other car than this one...

I took it for tracking and there I understood a bit what was going on...
I had some Toe Out on the rear....



So those guys tried to fix the rear toe, but they did not manage to correct it, and actually they even made it slightly worst...?
One guy explained me the bushings were probably too worn to make the adjustment effective...

When they went to correct the front toe, nuts were too rusty to crack them loose. No adjustment possible.

From there I knew I was going to have quite a lot of work on the car. I actually have descent skills and experience for that but all my tools are in France.
So I inspected the car and tried the best I could to list all that needed a replacement. The work would be done during Christmas holidays and with no other car available it was crucial to have everything I needed before to start.

Indeed the bushings were foocked!
Have a look here:

I bought a lot of parts from www.importcarparts.co.uk, http://www.carparts-pros.com/page_1_3.php#oeformo and local Subaru dealers.

Back in France! here is my workshop.




I started by measuring the Toe variation on the Rear Left wheel: about 4mm!!



Then taking parts off, terrible surface rust on them...



All this goes off easily with a small hammer...


Here is another example with the canister bracket


I removed tons of this!


This is like 2mm thick. Hopefully I did not remove 2mm of metal from parts. Its just that the rust expands.


CV joints


Rear Hub...


Rear Bumper brackets were foocked.
One day I shut the boot and a chunk of rust came off the car.... Pretty sure it was coming from there.
Hopefully the body is absolutely fine here.






Rear Subframe.
For info, mine does not have bushings to connect to the chassis. Apparently they started to do it around 2005.


Same things, a lot of the rust goes off with a hammer...


Then I sandblasted some parts myself. This operation is quite messy...


But the result is nice!


Then Hammerite paint


The one on the right is as coming out of the dish washer after being sand blasted. This made it rust again but actually as the Hammerite paint I was using was "Direct to rust" so adhesion was much better this way.


Looking good now!


Same for CV joints and drive shafts.


New boots and fresh grease!


After so much efforts, it is nice to see this:


About the rear diff, I had the common Whining sound (not much). I was worried the bearing was going off.
I did read somewhere that the Whining sound was coming from a too big backlash.
I measured about 0.33mm, tolerance is between 0.10 and 0.20.
After just cleaning and reassembling with correct torque on bolts I had about 0.15mm.
Whining sound is still there in 5th, 6th gear but I stopped worrying...



For the bushings I wanted to use PowerFlex.
When I get them I was a bit worried about the play between the insert and the bolts.




But actually Subaru bushings have the same play.
Then I realized the clamping force was made to block it anyway. Torque on the bolt that connect side links to upright is 140N.m, which equals to several tons of clamping force!

By the way I get those from my mate Max @ https://www.mmrperformance.co.uk/
Website build is in progress, his facebook page: https://www.facebook.com/MMRPerformanceUK/

Muffler was about to give up...




I fixed it with some welding and some Holts Gun Gum

After that, I also had to treat the chassis, which is much less affected.
It looks bad like this but rust is very thin here.
Treating rust by working underneath the car is a pain!





Here I used this. It puts I thing rubbery layer which look nice.



The only pic I have to show the result is here. I only put 1 layer. Should put much more.
One can goes quite far... I bought six for a very good price on ebay.

Note that I removed the plastic covers there. They are like bucket for stones, water and ****. What do you think?




Be careful when using a metallic brush on a drill...



This is not recommended but I used oven cleaner inside my rims. Did not work enough... maybe this one was not that strong.


And finally reset rear toe using the TrackAce of a colleague. Thanks Paul



Before



After




I had my Front and Rear ARB sand blasted and powder coated by a pro. 50gbp, no bill (Cash is king )

Now the Rear Left Wheel Toe Change:

Notice that here I am really forcing on it, you can see the tyre moving on the rim.

I did not remeasure the rim displacement but for sure it is much less.

Driving is much better now. And the wheel does not have to be steered as much as before to make the car go straight. I would says the rear fixed the front by 75%

Later I will go to a tracking shop to get all Adjusted.


What you see above took me like 10hrs/day for 14days.

I still have a lot to do:
- Do basically the same for the front, replacing steering rods, treat front subframe and UCradle...
- Rebuild calipers, brake lines.
- Replace all fluids, Power Steering, Brake fluid, Gearbox oil, Coolant...
- Clean Engine bay
- ...

This will happen for my next holidays in France.

I will update the thread then.

What do you guys think?
Do you think I bought too quickly? Should I have stay away from it because of the rust?

Engine seems healthy, will go on a Dyno later to check it.
Gears are a bit difficult to downshift when its cold. Fresh oil may fix that.

Also I want to take the opportunity to take my hat off to FMJ.
This guy is a legend for me. He started a massive project while working on a parking lot!
https://www.scoobynet.com/projects-4...m-scratch.html

Last edited by Angus0413; 14 January 2018 at 10:09 AM.
Angus0413 is offline   Reply With Quote
Old 13 January 2018, 10:30 PM   #2
johned
Scooby Regular
 
Join Date: Jan 2010
Location: derbyshire
Posts: 1,767
Default

Great stuff keep it up.
johned is offline   Reply With Quote
Old 14 January 2018, 12:54 AM   #3
poffer1
Scooby Regular
 
Join Date: Mar 2016
Location: Surrey
Posts: 109
Default

Brilliant job. Glad to see the rust didnít run too deep.

Maybe the car was used in a coastal area?
poffer1 is offline   Reply With Quote
Old 14 January 2018, 01:08 AM   #4
Angus0413
Scooby Regular
Thread Starter
 
Join Date: Oct 2017
Location: orbit
Posts: 36
Default

Thanks guys,

No I think it always lived in the Northamptonshire.
Angus0413 is offline   Reply With Quote
Old 14 January 2018, 10:29 AM   #5
sivo
If in doubt loose weight.
iTrader: (30)
 
sivo's Avatar
 
Join Date: Jul 2009
Location: Over the hill
Posts: 1,825
Default

Great work Angus

Keep it up

Siv
sivo is offline   Reply With Quote
Old 14 January 2018, 11:37 AM   #6
fpan
Scooby Regular
iTrader: (10)
 
Join Date: Jan 2007
Location: UK
Posts: 2,654
Default

Great work , keep it up!
fpan is offline   Reply With Quote
Old 14 January 2018, 05:11 PM   #7
Angus0413
Scooby Regular
Thread Starter
 
Join Date: Oct 2017
Location: orbit
Posts: 36
Default

Cheers Guys!

Thanks Sivo, I really like yours.

I wish mine to be that clean soon.
Angus0413 is offline   Reply With Quote
Old 14 January 2018, 07:07 PM   #8
sivo
If in doubt loose weight.
iTrader: (30)
 
sivo's Avatar
 
Join Date: Jul 2009
Location: Over the hill
Posts: 1,825
Default

Quote:
Originally Posted by Angus0413 View Post
Cheers Guys!

Thanks Sivo, I really like yours.

I wish mine to be that clean soon.
Iím sure it will be, Iím looking forward to seeing your progress.

Siv
sivo is offline   Reply With Quote
 
 
Reply

Related Topics
Thread Thread Starter Forum Replies Last Post
restoring paint MattN Non Scooby Related 9 11 December 2003 07:50 PM
Restoring my brickdrive Tiggs DIY 5 12 May 2003 11:35 AM
Restoring user profiles InvisibleMan Computer & Technology Related 7 15 December 2002 04:05 PM
Restoring Torque mrp Drivetrain 12 04 March 2002 03:19 PM
Restoring paint with tree sap issues!!! VKL723 Scotland 5 18 December 2001 06:26 PM


Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

Forum Jump


All times are GMT +1. The time now is 01:30 PM.


We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.
 
  • Ask a Question
    Get answers from community experts
Question Title:
Description:
Your question will be posted in: