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2001 Impreza 2.5RS Sedan
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643 Posts
Discussion Starter #1 (Edited)
Update (07-05-2017): Apologies for the missing pictures, Photobucket decided they wanted $400 per year to link images... If there is something specific you are hoping to see, please let me know and I'll see if I can find it. I just don't have the time at the moment to redo all of them.

Time to start the "build" thread I suppose. Been tinkering with the car for a few years now and just about on the brink of going RS-t (yes, little "t" = little turbo = TD04). I have a bunch of pictures and little mods/changes to detail so it's going to take me a little bit to catalog it all.

A year ago I had everything collected to turbo... then ended up selling most of it to pay bills and whatnot. Now I'm back with a simpler plan after another year of research.

Current Plans/Tasks:
Mock up the turbo install, goal it to be able to install in a day with no surprises.
Going to go with a TD04 (5psi) and custom up/down pipes (to retain my UEL) and a stock STi rear cat.
I'm going with no intercooler (gasp!)...
Thinking of building a custom funnel from the hood scoop to direct airflow over the turbo.
I've got a J&S Safeguard on the way to manage knock so I don't kill my engine on day one
I have a UEGO wideband, but after reading more about the stock front 02 sensor (which is a wideband) I think it can use that with DashCommand for iOS hooked up, just need to relocate about 6" behind the turbo in the downpipe. Hoping to get things mocked up when the wife returns from running errands this afternoon.


Drivetrain Mods
Chassis Mods
Interior Mods
Exterior Mods
Adventures/Workhorse

When I first got her from a family member, she had kissed a concrete embankment at 35mph in the slush, messed up the front corner a little



Aug 2015



Oct 2015





Feb 2016




 

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2001 Impreza 2.5RS Sedan
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643 Posts
Discussion Starter #2 (Edited)
Reserved for drivetrain

Current:
Rotated airbox to use hood scoop for intake <- Original Post
eBay UEL headers
Stomung midpipe with 18" resonator welded in
WRX axleback
Delicious Stage 2 Tune
Cruise control relocated to passenger fender <-Link to thread
Washer fluid bottle relocated to trunk

Future plans:
TD04
Custom up/down pipe from RS25 member
J&S Safeguard


Current engine bay (as of 02.20.2016)


Previous N/A engine bay



As detailed in another thread linked above, took the back of the stock airbox, rotated it and with a 45 degree silicon elbow you can go fresh air from hood scoop. If you are wondering about the details of the elbow, it was a 2.75"-3.00" 45 degree silicon elbow (Throttle body is 2.75" and Airbox is 3")




I wanted to have a scoop splitter without buying one so I made one.


Went through many cutting wheels on the dremel to get it cut out.


Creative cutting and bending for a splitter, then coated with a rubberized paint.




Little bit of weather stripping for a good seal.




Valve covers vent to atmosphere.



I wanted more space in the engine bay so I moved the washer fluid reservoir to the trunk
Honestly pretty easy to run the hose and power line to the back along the trim.


Ran into an issue where under hard breaking the fluid in the line to the trunk would bubble out the sprayers and make a mess on the hood.
So I installed a 12v valve to open when the fluid pump is powered and close when off, works great.



Exhaust:
Comparing '02 WRX catback with '01 RS catback


Made a few exhaust adapters to match up 02-07 WRX/STi catbacks to NA midpipes
DIY Exhaust Adaptor
 

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2001 Impreza 2.5RS Sedan
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643 Posts
Discussion Starter #3 (Edited)
Chassis

Mods:
Carbon fiber front strut bar
Paranoid Front braces
AGX Struts w/ 2002 WRX SPT Springs <-Original Thread
Group N engine mounts and transmission mount
TiC shift linkage
Kartboy Outrigger bushings
Beatrush Rear Dif Brace
22-24mm adjustable rear swaybar
Audi rear swaybar end links


Managed to replace the engine mounts in less than two hours. Just unhooked the header from the track pipe, unhooked the dog bone (tranny brace), and unbolted the engine mounts from the frame (5 bolts in total). Then carefully jacked up the engine 2-3" with a hydraulic jack and a board under the oil pan. Then it was relatively easy to undo the four bolts holding the engine mounts to the engine. Didn't need an engine hoist or to remove the headers...


Beatrush rear diff brace
Less clunk, looks pretty, here to stay.


Paranoid fender braces before and after.
Absolutely worth it, much better turn in on hard corners




Stock suspension was about shot after 130k+ miles
Found some AGXs on eBay (returned but brand new) for $130, '02 WRX SPT springs for $100...
I usually run the AGXs on 3 front/6 rear








SPT Springs compared to stock RS springs


Ride height w/ Rear spacers to balance front and rear


Ride height in front
 

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2001 Impreza 2.5RS Sedan
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643 Posts
Discussion Starter #4 (Edited)
Current Interior
'04 WRX front seats (Drove from KY to PA for work and stopped in MD to grab them)
v8 Momo Impreza steering wheel
Zebra/Ebony hvac/stereo trim (thanks JDM Gary)
Black vents and shift surround (thanks JDM Gary and SubiGami)
Dash hood w/ gauges (Volt, vacuum/boost, oil temp) -Volt to likely be replaced by oil pressure
Kartboy Short Shifter (shortened 1")
1lb round shift knob
Shift boot w/ matching e-brake boot from Zealous Interiors (thanks Andrew)
Pioneer double-din touch screen
Voltmeter in place of 12v socket
USB/Aux extension fit into coin holder
'06 wiper stalk (yea intermittent wipers)
Blue LEDs in instrument cluster and HVAC
WRX Pedals

Current State (Nov 2015)







Details of gauges in dash hood.
Glowshift gauges (yeah, I know... But I have four kids to feed)
Glowshift "1-Din" staggered insert
Some dremel work and epoxy
I say "1-din" because there is no way to actually put a 52mm gauge in that space, but there is extra room in the hood.




I like making things reversible in case I change my mind, so I picked up both male and female stereo connectors so I could build a bridge to wire the gauges.
 

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2001 Impreza 2.5RS Sedan
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Discussion Starter #5 (Edited)
Exterior

Mods:
JDM v6 Grill
JDM clear tail lights
EDM clear corners
clear bumper lights
clear fender lights
Hella horns
Hella 500FF driving lights
Australian(?) door trim (thanks JDM Gary) <- Original Thread
OEM rear splash guards
Graphic Gray painted 6-spokes


Details:
Picked up some Hella 500FF driving lights from Amazon for cheap, didn't want to pay almost the same amount for the Kartboy brackets so I made my own from $4 of metal parts from Lowes.






They are rock solid, no movement in the last year; light output is awesome, more than doubles my low beams



Door trim from JDM Gary, have only ever seen one other set and haven't figured out exactly where it's from but I love it.

Pulled off the old trim (it can be done from the outside if done carefully)


Sealed the holes with aluminum tape


3M heavy duty double sided trim adhesive tape


All done on this side


Matches the color of the side skirts and goes well my wheel color in my opinion



I tried black chrome headlights for a couple months, but decided I liked clear better


v6 grill (from the UK), I really like how it balances the front with the overhang on the bumper
 

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2001 Impreza 2.5RS Sedan
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643 Posts
Discussion Starter #7
Trying to figure out the best way to turbo...

I have a set of custom up/down pipes that I was going to use with my UEL headers, but my headers are not quite bent right and it pushes the TD04 up too high and in the wrong place. After fighting with it all weekend, I've decided that I'm going to go down a different road for this. I'm going to go with one of the turbo headers and notch my cross member. Looking at the different designs/styles on eBay, I found three distinct types.

The 1-pc design with a flex portion.


The 2-pc design with a separate up-pipe


Another 2-pc design that routes the passenger side pipes a little differently


I'm not planning to change my water pump, it only has 30k miles on it. Another trend I'm seeing on these headers is a slide/adjustment for the driver side pipes, trying to figure out if I need to weld or seal that once I get it adjusted correctly.

Any thoughts or experience with one over another?
 

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As far as I know, you will have to change your waterpump to run one of those oem location headers. Anyone feel free to correct me if im wrong...

I LOVE that black door trim though. Very 90's and old school :)
 

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2001 Impreza 2.5RS Sedan
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643 Posts
Discussion Starter #11
As far as I know, you will have to change your waterpump to run one of those oem location headers. Anyone feel free to correct me if im wrong...
I had read in multiple places that the stock manifold won't clear, but the aftermarket headers clear in many/most cases... I hope they are right.


I LOVE that black door trim though. Very 90's and old school :)
Thanks, it's one of my favorite exterior mods. :-D
 

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2001 Impreza 2.5RS Sedan
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643 Posts
Discussion Starter #14
how much NVH did the beatrush rear diff brace add?
Practically none that I noticed. The most NVH I think of all the things I've done is the GroupN engine mounts, most of the rest of the stiffening very little effect from what I can tell. The rear diff brace definitely helps reduce the shudder in deceleration or transitions between accel/decel.
 

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2001 Impreza 2.5RS Sedan
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643 Posts
Discussion Starter #15
*sigh* Still trying to figure out if I should "adjust" (w/ propane torch) my poor fitting UELs and run the turbo that way, notch/replace the crossmember and go that route, or to just throw in the towel and look for a 4.44 tranny/diff and stay NA.

Found the boot on the driver's side of the steering rack is torn so I have to deal with that first...
 

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2001 Impreza 2.5RS Sedan
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Discussion Starter #16
"Adjust" UEL headers

After thinking about it for a while, I came up with this setup to attempt to adjust my Tsudo UELs. The bend for the driver's side is too tight and it pulls the flange/connector for the cat/track pipe section too close to the car (rattle). I realized my over engineered workbench should work nicely for leverage :)

I bolted the header to the bench and once I find my head for my propane torch will try to heat the bend a little and get it to move a few degrees which should help move the end 1-2" down where I need it.



 

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Discussion Starter #17
More slow progress...
John P from J&S Electronics still had the file from 10+ years ago for the face plate of Ultra Safeguard that I have. Was kind enough to laser a new one for me. Going to install it soon as it should be just fine even still NA.


Drilled and installed the oil drain in a spare valve cover, capped it so I can replace at the next oil change in a week or so and just be ready for turbo install day.


 

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2001 Impreza 2.5RS Sedan
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Discussion Starter #18
Swapped out the OEM vent with the new vent scoop today.





Got it from http://stores.ebay.com/JT-PERFORMANCE-SUBARU
HT Autos stopped making theirs, so I tried another UK shop.
Fitment is pretty good, could be a bit deeper, but there is no terrible gaps.
Would do it again :)

Now to find the time to put the turbo in so that it actually has a purpose to feed cold air...
 
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