Front Suspension & Brakes

Done and done!

I also got a replacement for the cracked timing cover on the left side. While we were in there, we inspected all of the belts and they more or less looked nearly new. I have new belts and timing kit for this project, but I think I will save them for later or perhaps for one of our other cars. Also, we did a compression test, 130 on all cylinders. We have a nice clean version 8 ej207; thanks JDM Racing Motors!  Part of me relishes the idea of doing a monster motor build, perhaps a 2.1 stroker, or perhaps bore out the block to use 100mm pistons and machine the heads, but the more practical part of me would feel sad breaking down a perfectly health motor. Besides, the version 8 should be built enough to run roughly 400 whp which should be fine if I run our Steam STX 67 turbo in twin scroll. If I go with our Steam STX 71 turbo, I may be pushing it. In any case, I will rebuild the motor whenever it comes to that.

Leftovers

We have some of the original 2001 RS leftovers that need a good home.  Need some parts?

Brakes for all four corners.

Front and rear subframes, suspensions, wheel carriers, axels, rear diff, etc.

Complete fuel tank.

And...some JDM STI bits.

Labor Day Progress

Next we separated the engine from the transmission.  Fun fact: you must undo the clutch's release leaver by removing it's shaft before the transmission and engine will separate (6MT only).  This is basically how we took the car apart.  Given that the car is on jackstands, and there isn't a lot of room to push the engine and tranny from underneath, it is safer to install them one at a time.

Next, we installed the control arms, and coilovers.  We didn't install the wheel carrier today because we still needed to install the ball joint.  We have new Whiteline upgrades, but needs the aluminum arm shims which still need to be pressed out.  Once the wheel carries are in, we will have a rolling chassis again.  Then we will be able to roll this baby out to power wash it clean.

Front Subframe.

Here is the front subframe all setup.  It has a 2005 USDM STI rack and Whiteline swaybar and tie rod ends.

Now bolted up to the car shell.

Rear Brakes Are In!

The rear breaks are in!  JDM STI Brembro 2-pot and 2007 USDM rotors for 5x114 are setup in the rear.

This is what it looks with wheel and tire combo with the corner loaded with the floor jack.

Here is the side angle.  It is a little too hella flush for my tastes, but remember the suspension hasn't actually been configured yet; still, I think we will be rolling this finder to the max to minimize rubbing.

The Rear Is Coming Together

It is fun to to figure out how to put things back together when parts come for several different years and models.  Subarus are like Lego bricks...except when they are not.

We got the tank back in.  It is from a 2002 WRX, but it has a fuel pump assembly from a 2005 STI.

We pressed out some old subframe and rear dif bushings and added some new Whiteline parts.  We swapped the RS' old rear subframe for a JDM version 7 STI subframe that came complete with sway bars, lateral links, etc.  Who knew that a JDM version 7 STI rear suspension looked like a 05 WRX's?  Not me.  Also the version 7's lateral links are longer that the RS'?  Me neither.  Not realizing that version 7 rear suspension looked like the 05 WRX and not the 05 STI, wanted to use USDM 05 STI style suspension parts, so I swapped out lateral links for Whiteline parts.  This allowed me to use 05 USDM STI style endlinks from Perrin and swaybars from Whiteline.

Next I wanted to go 114 hubs/bearings, so I have spindles and trailing arms from a 07 USDM STI.

If you are moving to 5x114.4 hubs, ideally you use GC8 style rear coilovers for the tophats, and 2005-2007 STI style front coilovers because you need the larger receiving bracket.