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Stew's 98RS

144K views 718 replies 81 participants last post by  Combat Chuck 
#1 · (Edited)
The time has finally come for me to organize a members journal! Ive been a member here since I purchased my 98 2.5RS in late December of 2005. My car, not unlike myself, has been through a lot since then and made many changes. And now, upon organizing parts and information for my swap, I though I should get the cars history laid out so I can properly journal its future :D

Current Photos:










Current Mod List 3/13/2023

Engine / Exhaust / Fuel System

Version 9 EJ207
Injector Dynamics 1050X Injectors
IAG Competition series oil pan / baffle / pickup
IAG polyurethane engine mounts
KSTech DBW throttle adapter
2007 2.5i DBW Throttle Body
Roger Clark Motorsports Downpipe
Roger Clark Motorsports Group N turbo-inlet
Roger Clark Motorsports Alloy Cam Gears (Exhaust Side)
IAG V3 competition AOS
HKS Kevlar timing belt
Roger Clark Motorsports timing belt guide
PTP Turbo Blanket
Grimmspeed Turbo Heat Shield
ETS Top Mount Intercooler
Samco intercooler elbow
Tial Q BOV w/Torque Solutions Adapter
Forge BOV
Aluminati Expansion Tank
CSF Oil Cooler (#8119)
RCM Black Series Oil Sandwich Plate
CSF Aluminum Radiator
Spal 12" fan
Samco radiator hoses
iWire radiator shroud
Cobb overflow bottle w/iWire bracket
K&N Filter w/ 3" Vibrant velocity stack & custom inlet adapter
Fuelab low-pressure lift pump
Radium Venturi transfer pump
Radium Surge Tank w/Walbro 255
Radium In-line fuel filter
Continental Flex Fuel Sensor



Drivetrain
Kotouc (KAPS) R4 Sequential Transmission (P2 ratios 3.33 / 2.38 / 1.80 / 1.37 / 1.06 / 0.84 )
Version 9 Sti 6MT transmission TY856WB8KA
Version 9 R180 rear diff
ACT StreetLite flywheel
Exedy Stage 1 Organic HD Clutch
OEM Exedy Clutch
Goodrich Stainless Braided Clutch Line
Torque solutions transmissions mount (poly)
Torque solutions solid carrier bearing bushings (Aluminum)
Kartboy transmission crossmember bushings
Whiteline front and rear shifter bushings
Torque solutions solid shifter u-joint
Whiteline rear diff bushings (rear crossmember)
Whiteline T-frame bushings
IAG Competition pitch stop


Suspension / Steering
V9 STI 5x114 hubs
V9 STi subframes (front/rear)
V9 STi sway bars (front / rear)
Feal 441+ Coilovers w/Swift springs (10k/8k) (9k/8k)
Swift Helper Springs
Professional Awesome 777 Bumpstops
JDM GC8 STi Aluminum control arms
Whiteline ALK
Whiteline roll center kit
Whiteline control arm bushings
Whiteline lateral link bushings
Whiteline trailing arm bushings
Whiteline rear endlinks
Whitleine rear sway-bar mounts
Whiteline 22mm adjustable rear sway bar
Whiteline 22mm adjustable front sway bar
SwayAway front endlinks (for 2015 STi)
2015 STi Steering Rack
L&E Rack steering shaft adapter
Whiteline steering rack bushings
Chasebays power steering reservoir
Mooresport power steering pump adapter
IAG -6an PS high pressure line, custom -6an return line, custom -8an suction line


Brakes
C6 Z06 Corvette 6 piston front calipers w/12.8" STI Rotors
STi Brembo rear calipers
Stoptech Stainless Braided Brake Lines
G-LOC R12 / R10 Brake pads
Centric blank front rotors
Brembo blank rear rotors
CompBrake brake servo
Nameless performance 18" Hydro Handbrake

Wheels/Tires
Enkei PF05 17x8.5 +48
WedsSport TC105X 17x8.5 +43
Falken Azenis RT660 235/40/17
ARP Extended wheel studs

Interior / Safety
Sparco Sprint seat on custom fabricated mounts
Sparco steering wheel
Snap-off R1000 quick release
Custom roll cage built to SCCA GCR specs (1.5"x0.120" DOM)
Schroth Profi 3x2 FIA Harnesses
Renscott Harness Collars
6OC lightweight door panels
181stleader Carbon fuel tank access covers
Custom central switch panel
6OC Drivers floor plate
iWire DBW pedal adaptor
Flocked Dash
Rennline/Rennscot fire extinguisher mount w/Maxout 2.5lb extinguisher


Exterior
Aerosim Research carbon fiber race roof
V6 / RS front bumper w/Fog light covers
JDM Smooth rear bumper
JDM Lightweight bumper beams
JDM Rear spats
JDM Taillights
JDM Clear Corner Lights
Clear side markers
L'aunsport S5 WRC style Rear wing
Bakemono 22B Hood Vents
Bakemono Carbon S201 Mirrors
Shaved side moldings
Shaved trunk
Custom Pearl Blue paint
30% Ceramic window tint
RPG Carbon WRC Mirrors
RPG Carbon Exhaust Shroud
V5/6 Replica front lip

Electronics
Haltech Nexus R5 VCU
Haltech PD16 Power Distribution Module
Haltech 15 Button CAN Keypad
Haltech 8 Button CAN Keypad
Haltech TCA-8 CAN Thermocouple Module w/Prospeed connector brace
Haltech CAN Hub
Haltech TMS-4
ECU Master Dual H-Bridge module
Plex SDM700 Digital Dash Logger
Custom motorsport wire harness
MAPDCCD Center Diff controller
MSEL Solid state battery isolator
Odyssey PC680 Battery
2006+ WRX DBW Pedal / Throttle Body
KA NTC2 Fast motorsports IAT sensor (Intake Manifold)
RIFE IAT charge cooler temp sensor (Intercooler)
Lowdoller Motorsports oil pressure sensor
Lowdoller Motorsport oil temp sensor
Delphi Flex Fuel Sensor w/Raceart Mount
MAC 3port EBCS w/Raceart Mount
AIM Sport 2k PSI brake pressure sensors
Hella Sharptones Horn




Introduction
My name is Steven and this is my long-standing journal documenting the path of my 1998 2.5RS from purchase, daily driving, to now many years later restoration and transition into a dedicated track car. The most recent phase of this project has taken me roughly 6 years. 5 years, but I'm getting close to having a complete car, with the goal for a running driving car later this summer (2021). I'm at the point now where the car is so nearly road-worthy. I'm making a big push, and the goal now is to have it track ready by July 2022. I've now been using and enjoying the car from the summer of 2022. A project like this is never "complete" but its in some version of done. I'll continue to update this as it continues to evolve.

Original Intro from 2005
Heres my Introduction and story for how I got my car:
My name is Steven Stewart and I'm from lower West Michigan. When I was a freshman in college I was in the market for a new car after crashing my first car, a 95 Nissan Altima, into a telephone pole in the snow. Im not exactly sure what sparked my interest in Subarus but It was pretty quickly that I decided I wanted an impreza.

I browsed Ebay, autotrader, craigs list, news papers and such for a couple weeks looking for a new car. One session on ebay, I clicked on a link for this wrecked blue 98 coupe but just glanced at it and moved on. Later, I returned to that link and realized it was about 40min from my house! So the next day I went and looked at it, drove it around the parking lot (it was salvaged title, thats all I could do :( ) and immediately fell in love. They wanted $5500 for it off the lot and that was way too much so I decided to bid on it on Ebay. I Lost the auction to a sniper and it went for $3600 :( I was pretty sad I didnt get it. Anyways, two days later i found it listed again on Ebay! I called them right away, offered $3600 cash and picked it up the next day!

12-21-2005 Purchase!
Heres two pictures the dealer used on the ebay auction




And here she is at the body shop I worked at the day I brought it home




After this, I began the process of rebuilding my new purchase.
 

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#36 ·
It has been quite some time since Ive updated this...
Ill have more this evening after I get home from class but Im going to post pics from this summers autocross adventures and some more details on the car.

One thing I will say is I had it over a scale this weekend and it came in at 2750...Woot!
 
#37 ·
Okay, delayed but....Autocross pics from this past summer...








I found myself very outclassed in SM with my basically stock EJ20G. I was still somewhat competitive however, and would typically finish middle of the pack.

I just changed up my winter setup so Ill to post of some pics of that soon.

Also, Sno Drift Rally in 2 weeks...My RS will be making the pilgrimage.

-Steven
 
#38 ·
wicked subie

Great thread, a classic tale of a boy and his subie... What a life your little RS has had eh, and she's a beast now! Good work on the ride and the thread! Hope your enjoying having your car back in the snow. Love the monkey using the spoiler as a holy shit handle.
 
#40 ·
Alright, So I realized I never posted some of the finished pics from my swap. These are almost a year old now, but for consistency with my journal Ill post them now.

Dash Apart


Cluster wiring


Wiring splices at the ECU


Where the wiring was run through the drivers side fender grommet


Engine harness run through fender


I had to move the alarm speaker because the intake got in the way of where it was before. I bolted it to the passenger side strut tower


Detail of how I ran the coolant lines from the header tank to the overflow. I ended up ditching this setup after the header tank broke. I now just run a hose from the crossover pipe to the turbo (Ala Supermoose style).



And finally a "finished" engine bay shot. It has changed slightly since then.


-Steven
 
#41 · (Edited)
Some other changes include 02 WRX coil pack conversion. All but ONE of the stock EJ20G coil packs were cracked and fell apart under the boot when I inspected them. Since converting, Ive noticed a lot of improvement.

I also installed two prosport gauges, boost and oil press. I used a OEM gauge pod with a custom carbon fiber gauges plate I made myself.





Ive been chasing a couple other issues with the swap. I had to modify the brake booster vacuum line out. With the way it was on the stock RS booster, the hard line comes out and makes a 45* bend to the right, putting the line directly under intercooler. This caused problems with the hose being cut by the intercooler, or getting kinked from the tight bend. I simply cut the hard line at the bend so It comes out strait. Voila! Fixed.

It recently has been going in and out of limp mode at random. Im going to do some regular maintenance tomorrow (plugs, clean maf, new air filter) and see if that helps. The only code Ive had is a MAF code...we'll see what happens.

Anyways, Ill post Winter setup pics ASAP. Im REALLY happy with how my winter look has come together.

VictoryLap...Thank you SO much! I really appreciate your kind words. This car has certainly been a journey and I have loved and hated a lot of it. It is ridiculous how attached I have become to this machine, but I feel very connected and very close to the car. It has become a part of who I am and defines who I am. Im at a point in my life now when im finishing my college career in may and will be off into the real world of work. Im very much excited for My beloved RS to help take me into the next chapter of my life.

-Steven
 
#44 · (Edited)
Stew,

This was a great thread! It really brought me back to being 17 and doing my first swap. It was pretty much the same ordeal, me and my buddies,trial and error. I still remember how great it felt to have it start and run for the first time! After watching your Videos and seeing your pics, it put a huge grin on my face. Good for you guys! Congrats! You guys really made me remember why I loved doing Subaru conversions, and even got into this game.
-Paul @ ECS
 
#45 ·
Thanx Paul! You actually sold me the motor...dunno if you remember. It was a great experience and I definitely had some great help from my friends. I also spent several weeks studying the diagrams and reading threads. Rob also was a big help, so much thanx to him too. But yeah, It was a great feeling and I love it.

I just need to remember that when I get frustrated with it. I keep chasing down little issues with it. IT likes to randomly go in and out of limp mode. I take care of one code, it throws another. really, really frustrating.

-Steven
 
#48 · (Edited)
Wow ! So its been almost 3 years since I've updated this...Or even been active on RS25. I've got a renewed interest in working more on my RS, so I've re-upped my premium membership and returned to the forum.

In the last 3 years my life has changed considerably, most notably that I've graduated with my bachelors, moved now to the east side of Michigan and started working full time for a major automotive OEM.

In this time, my RS has sort of been on the back burner - Due mostly to time, not having space to work on it (apartment living), and not having my tools at my new home (again, no room). Little fix-it items had started to become more and more frequent with the RS, so since working full time (and having a little more cash) and needing reliable transportation, I picked up this little guy about 2 years ago...

When I Picked up:


2004 STi:
Engine
K&N typhoon Intake
Godspeed Top mount
Grimmspeed ceramic coated crossover
Megan turbo-back exhaust
MBC
Mishimoto radiator
Samco rad hoses
Gates racing timing belt
Pro-tune

Trans
ACT Street-lite flywheel
Exedy stage 2 clutch
TIC Holy shift kit

Suspension/Brake
RCE Yellow Springs
Whiteline steering rack bushings
Hawk HPS pads
Slotted rotors (front, not sure brand)

Interior
Agency power shift knob
Greddy Oil pressure gauge

Exterior
Carbon fiber front lip
JDM tail light mod
De-badged front grille
Cleared headlights

Wheel/tire
OZ Racing 17x8 Ultruleggera
Nitto NT-05 - 255x40x17

Recent Photos:


Winters



/\ This /\ Is a wonderful machine, and I'm really lucky to have it. It makes a phenomenal DD and is a complete riot to drive. It lacks however the character my RS has always had. I've been busy with work, other hobbies, life, and just have sort of let my RS sit parked in front of my apartment, forgotten.

But now is the time, and although I don't yet have a garage (Yet...) I've started gathering parts to fix some little things, improve others, and get my RS back to daily driver+ status - This I'll begin to document on the following posts/pages.

Thanks for reading, it feels good to be back on RS25.

-Steven
 
#49 ·
First things first:

Items to fix that keep me from driving the car:
Leaky, broken intercooler piping. Anyone who's familiar with older JDM swaps, particularly the V2 ej20g, knows that any plastic components aren't long for this world. I've struggled with the intercooler piping - charge tube - It tore at the flex joint, I've patched it, and fiddled with it, but it just needed to be replaced. It would boost leak like crazy And eventually the TB coupler dried up and the intercooler would fall off.

I ordered a Samco IC hose kit for V1-2 WRX. This set required you to cut the stock tube back and slide on the new unit. You can see it installed below. I cut the stock piece about 1/4" in front of the first hose clamp. Its a good fit - and so nice and flexible and should be able to be installed and removed several times without breaking.


I haven't yet installed it on the car, but I'll be sure to update when I do.

Next up - intermittent limp home mode due to suspected bad MAP sensor.

This bastard - New from Subaru is ~$350 :eek:mg:

I've got a used one on the way from a member on NASIOC. Will update when installed.
 
#50 ·
Gauges

I had previously posted my gauge setup. Both sensors - boost and oil pressure - failed. They didn't last long at all really. I'll never buy cheap gauges again. It's so depressing getting in the car for a drive and these two useless, glowing gauges staring you in the face to remind you how broken your car is.

Not for long!


:banana:
Greddy electronic boost and oil pressure. Really nice quality, small sensors (can fit the oil press. sensor in the dummy light sensor position), doesn't cost a million dollars, doesn't require a controller and reliable. The Greddy oil pressure gauge in my STi is going strong for almost 2 years. They are, however, discontinued so these were hard to find. Oil pressure gauge is still in transit. I'll update when installed.

I also made a new gauge face plate, as the old one was warped and broken.


Hoping to install soon - !
 
#52 · (Edited)
Samco Sport IC hose set installed:



This solved a lot of drivability issues, including the MAP code I thought was a bad MAP/vacuum sensor. The car now makes full boost (11-12 psi) and holds it, no limp in mode.

New boost gauge is installed. Again, GReddy gauge quality is fantastic. The sender is really robust and comes with a nice mount. All sheathed wiring with a weather-pack connector at the sensor - really makes install easy. Just have to connect power/ground/ign/illum. in the cabin for the meter itself. Its a shame they're discontinued.




The gauge face itself is a perfect match for the stock 98 cluster. The amber backlight doesn't really match at all, but no big deal for me. Only have this daytime shot now, will upload more and day/night photos when the oil pressure gauge arrives and I have a chance to install it.



Tried to fix a couple other issues today as well - blown out bushing on the wiper motor with Autozone wiper repair kit. Also trying to repair the windshield sprayer - seems as if there's no power at the connector. Was a little too cold today to finish these though.

One other issue - driving around Monday I got a CEL. Checked it out - Code 22 - Knock sensor. The current one is cracked in two places. Resistance through the connector to ground is also really high, according to my FSM. Will try to get a new one tomorrow at dealer.

More tomorrow, I hope.
 
#54 ·
Thanks ! I already feel really good about the progress, even just this week.


Called my local dealer this morning - no knock sensor. :( ordered it online, hopefully have it in a couple days
 
#57 ·


OEM knock sensor came in. I found the old one had cracks in two places. Was setting code 22 and giving a lot of knock retard. Popped this new guy on and power has improved - car pulls pretty good now.

I've been sick the last week so I haven't been able to work on the car, BUT! my oil pressure gauge came in and I got time (now that I'm feeling better) to install it tonight.

I figured out with these GReddy V2 gauges that if you just wire the red to switched 12v, the gauge does an opening sweep on start-up. So after re-wiring that circuit, I added in the oil pressure wiring and mounted it up.




again, the black face, white font and red needle match the 98 cluster perfectly. I just wish they were back-lit Green!

My favorite part about the GReddy gauges is that the pressure sensor is small enough to fit in the dummy switch position. Just unplug the dummy switch, pull that bastard out and screw the pressure sensor in.

Alternator out


Sensor installed. Use Tef-tape. I think my PS pump is leaking :D


Alternator back in - You can see the sensor peeking out there.


Ran the wire through, connected and done. Voila.



Again, lighting doesn't match but they're quality, Japanese made pieces and I got them both for about $300. Since they're discontinued, a lot of places are blowing them out.



All done for now. I've got some fresh Rotella-T to change oil this weekend, otherwise she's ready for the ~700 miles We'll cover going to Sno*Drift 2013. :D

Until next time...
 
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