So it was definitely the pump. I rode down to IAG on Saturday and picked up a Walbro 255...then I sat out in my car with a space heater in 15*F weather and installed it.
Started right up like nothing ever happened. Hopefully the Walbro lasts.....I don't think I'll try another DW pump.
Here's the two pumps for comparison....they look almost the same (minus the logo):
Here are the finished alternator brackets...for now. I wanted to paint them, but it was just too cold. Once it gets warm I'll shave more off and paint them.
I can't re-use my alternator cover because the ej22 P/S bracket and the ej205 P/S bracket are slightly different. The bolt to tension the alternator is moved slightly to the side and it won't line up with the cover I made. So I'm using no cover for now:
I replaced the heatshield that's between the exhaust and driveshaft....it's been rattling, probably since I bought the car.
The one corner was rusted off so I couldn't secure it. I bought a brand new one through Subaru so it would be in perfect condition and cause no rattles.
Of course one of the bolts broke taking the old one out.....so....self tapper to the rescue!
I also caved in and got some rumble. Since I wanted a quiet catback, there's not many lightweight options....I went with the Invidia q300 because I was told it was quieter than the Cobb. It's only 7 lbs lighter than the OEM wrx catback.
Fitment is meh....but so was the WRX one. It hits the rear diff bracing/shield and doesn't line up with the middle hanger....but with a little convincing from zip ties and Kartboy hangers it doesn't rattle.
It's louder than I wanted, but atleast it sounds good. The tip isn't a huge barrel, so it's kinda stealthy. Even though it's a 3" flange, it actually bolts up pretty well to my Cobb downpipe (2.5" at the end).
You can see how close the exhaust is to the underside here: