Subaru Impreza GC8 & RS Forum & Community banner

1 - 20 of 160 Posts

·
Registered
1998 GF8, 2003 BH9
Joined
·
155 Posts
Discussion Starter #1 (Edited)
This is the story of my Rev D 2.5 manual 2003 Outback BH5. It has 423,000km and looks the part.

This car will take over daily duties from my GF8 so I can repair the rear end damage.

My parents bought this car second hand in roughly 2006 to replace an old Mazda 626 wagon. It had about 100,000-130,000km on it. Since them they've put another 300,000km on it. In the 13 years of ownership the only mechanical failure was the clutch at 300,000km. This car has had battles with several kangaroos and wombats and lived to see another day. It has hauled cows, sheep and alpacas and much more in the boot. It burns oil like a 2 stroke and it still won't die.

As it has reached 423,000km it has been retired into my hands.

Mod List

Engine
  • Twin Scroll Equal Length Headers (Unknown Brand)(Wrapped in Heatwrap Tape)
  • Twin Scroll to Single Up-pipe (Unknown Brand)(Wrapped in Heatwrap Tape)
  • 57mm (2.25 inch) Intercooler Piping
  • Front Mount (65mm x 180mm x 550mm)(2.5" x 7" x 21.5")
  • TD04 off a 2004 WRX Sedan (EJ205)(Using 5-6 PSI Wastegate)
  • New Age Alternator Cover
  • Custom 2.5" exhaust
Handling
  • Front Sway Bar off a GC8 WRX Wagon
  • Front Sway Bar off a GC8 WRX Wagon
  • 316mm 2 Pot Front Brakes off a 2007 Spec B H6 Wagon
  • Koni Front and Rear Adjustable Struts
  • Gen 4 GT Springs
  • B4 Rear Sway Bar
  • Liberty (Legacy) Rear Bumpstops
Internal
  • Black Leather Front Seats off a 2000 Liberty Sedan
  • Black Leather Rear Seats off a 2000 Outback Limited (Not Originally from that Car)
  • Leather Armrest off a 2000 Outback Limited
  • Leather Door Cards off a 2000 Outback Limited
  • Sony XAV-AX100 Head Unit
External
  • GT-B Legacy Hatch and Wing
  • Rev D Turbo Bonnet
  • Front and Rear Spats
  • JDM Legacy Center Garnish
  • Custom Outback Grill
  • OEM Rain Guards
Wheels
  • Advan RG1's 17x7.5 +45
  • Bridgestone RE003 235/45R17
Engine Management/Support
  • Project Lambda
  • Bosch 3 Bar Map Sensor
  • AEM Air/Fuel Gauge 30-4110
  • Aem Boost Gauge 30-4406
-------------------------------------------

Stock Options Equipped

Engine
  • EJ251
  • 5 Speed Manual Low Range Gearbox
Exterior
  • JDM Headlights
  • Front Fender Indicators
  • Clear Rear Indicators
  • AUDM Bumpers, Wheel Arches, Sideskirts and Door Panels (All slightly different from the USDM ones for reasons I guess)
-------------------------------------------

Components Replaced. Either as Listed Above or Due to bad Condition
  • Front Bumper
  • Front Seats
  • Rear Seats
  • Glove Box Cover- Radio Trim
  • Rear Cup Holders
  • Door Cards
  • Boot Scuff Panels
  • Spare Wheel Cover
  • Mirrors
  • Rear Tailgate
  • Tailgate Center Garnish
  • Drivers Fog Light
  • Subframe
  • Steering Rack
  • Radiator Cap
  • AC Tensioner
  • Drivers Sun Visor
  • Carpet






Luke :)
 

Attachments

·
Registered
1998 GF8, 2003 BH9
Joined
·
155 Posts
Discussion Starter #2 (Edited)
So here it is. Stock as a rock. The Interior is filthy and the exterior isn't much better. But it has no rust, hasn't ever been in an accident and has a clean title. So to start this off I figured I should show some of the abuse it was put under for its 13 years of service.



Here is the condition as of my takeover.

The bonnet is wrecked (thanks to a combination of me and a kargaroo), the boot-lid is dented from a tow-ball, both mirrors are held in place by silicon, and the clear-coat is non existent on the passenger side (it doesn't look as bad in picture due to the rain).









Hopefully when I'm done it'll look much better than this.

Luke :)
 

·
Registered
1998 GF8, 2003 BH9
Joined
·
155 Posts
Discussion Starter #3 (Edited)
So this all started as a what if. And it really started to evolved into reality after I ran into a set of 4 pots and 2 pots at the wreckers yard. I originally bought them for my GF8 but soon changed my mind as I couldn't be bothered the bleed the brakes again.

As purchased ($84 for the 4 Pots) ($108 for the 2 Pots)





Before and after a repaint.


All painted and pins cleaned.




Then it started to snowball as the parts started to pile up,

First the smaller parts. Leather armrest as an upgrade and the others to replace broken parts. A new 'Limited' as mine had fallen of. It's important to note I still didn't have the car at this point.



Then the larger items came. Leather door-card are included in this I just forgot to take pictures.

Leather Front Seats with SRS Airbags ($130)




Leather Rear Seats ($60)




Cheers, Luke
 

·
Registered
1998 GF8, 2003 BH9
Joined
·
155 Posts
Discussion Starter #4 (Edited)
So when you have a car that's interior has been inhabited by the likes of alpaca, sheep and cows the best thing to do it just replace everything. So that's was it did.

Armed with new front and rear Seats, new door cards, radio shroud, armrest, and boot scuff panels that was the past weekends mission.

So to answer the question, "can you fit and outback interior into your GF8?" yes but I wouldn't recommend it.



I started with the boot as it seemed the easiest. Here's a before and after, sorry about the blurry picture.

While the panels where out I decide to clean the years of dust from the local road. Left is dirty and right is clean.




Here's the carpet are the clean. I didn't dare to take a picture of before as it was horrifying.




The pile of parts not needed anymore.




Various clips, nuts, bolts and screws collected from the old panels.




The old seats and door cards. For the fact they'd maybe been cleaned 5 times in as many years they weren't too bad. Dog being the dog.




The dog being more approving of the new interior.




Better shot of the new seats. I have a new steering wheel outer, just needs to be restitched






And from the back. Gotta keep the cargo nets.




All in all the new interior cost $323 AUD. There's still one or two pieces to get but not bad tbh.

And that brings this journal up to date. Progress with probably be intermittent as the car is at my parents 2 hours away, but hopefully not to slow.

Cheers for the read, Luke :)
 

·
Registered
1998 GF8, 2003 BH9
Joined
·
155 Posts
Discussion Starter #5 (Edited)
So over the holidays my work has a shutdown period. This left me with some time to get to work.

First I moved the outback into a location out of the way, but still able to be worked on easily.



Once that was located we had to get a photo of all the cars together. As you can see we have a theme going.



Engine bay pre tear-down.



Then the tear down of the engine began. This is all being done so that I can replace the sub-frame with a turbo version.





The engine ready to lift. This was two days before the engine was actually pulled as I couldn't get the nut undone on the lower bellhousing.



The engine finally out. Overall it was easy just a long process as it was all new to me. That being said it's not something I'd like to do frequently.



Heavy duty degreaser is a beautiful thing. Engine looks clean(ish) now.



The engine is now in storage until the sub-frame is replaced. This is how you make a Porsche right?



Engine bay needs a clean. I'd like to paint it but I don't think I have the skill level to remove everything out for paint. I'm going to speak to a spray painter up the road and see what he thinks.



The causalities of the engine removal. I have a bad habit of breaking the A/C tensioner as I did it in my first GC8 a couple of years back. Not bad all things considered.



I also picked up a new gear shifter trim as the old ones leather was destroyed.



That's all for now. This is a huge step for me as it always felt like the unachievable goal and now its done it kind of feels like I know what I'm doing.

Luke :)
 

·
Registered
1998 GF8, 2003 BH9
Joined
·
155 Posts
Discussion Starter #6 (Edited)
So a bit more progress. The weather has been so erratic meaning getting anything done on the car was a pain, and I'm back at work now so I can only work on it on weekends.

I was dragged along to Melbourne (9 hour drive) by my dad so he didn't have to be the only driver and while I was down there I picked up a 99 WRX subframe with steering rack and sway bar for $150. By sheer luck the steering rack just bolts up to the steering column so yay.



The mess of the car with stuff being stored under it



Dog tax as always



Started cleaning the engine bay as prepping for paint. I spoke with the spray painter down the road and he said just to paint it satin black so that's the plan. He also said he'll paint the car for free in his booth if I do the prep work so that's awesome.

Also question for people who've painted the engine bay, is it worth removing all the brake lines and booster or is masking sufficient. I'm currently at a crossroads with what to do.



Some before and afters of the engine bay.





I'm hoping to getting the engine bay degreased and masked ready for paint this weekend. I'm stoked that the WRX rack has the same spline as the outback as I've heard the horror stories of the difference splines for them.

Also anyone know what the fitment of the GD WRX exhaust is like on the BH chassis as I have my eye on a few but want to confirm it fits.

Cheers, Luke :)
 

·
Registered
Joined
·
103 Posts
hey mate nice project you got going on. I'm actually doing something similar (slowly getting there...) But instead of changing the crossmember i'm using a 2.5i exhaust manifold, changing the sump and will make a custo up and down pipe setup.

How are you going to run the injectors? Project lambda ecu or piggy-back?

PS isn't that car a BH9 model?? Looks identical to mine..
 

·
Registered
1998 GF8, 2003 BH9
Joined
·
155 Posts
Discussion Starter #9
How are you going to run the injectors? Project lambda ecu or piggy-back?
I haven't actually though about that yet. I'm hoping I won't need the injectors but I'm not sure yet. I'd really like to be able to run on the stock ecu/without a piggy-back as wiring isn't something I'm very good at.

PS isn't that car a BH9 model?? Looks identical to mine..
Fixed. I started the journal before I'd looked at the vin plate. I've had a quick look only and BH5 seems to be turbo whereas BH9 is NA.

Does that make NA-T BH7 as it's in the middle?

nice work so far!
Cheers mate. You shave a ton of knowledge with NA-T so any hints or tricks?
 

·
Registered
Joined
·
103 Posts
haha BH7 sound logical!

I have already put a 3bar map sensor on my motor months ago and it is running really good, i used the project lambda software to change the settings. It would be pretty dicey not doing any ECU mods. I've got the standard injectors pretty much maxed out on my current motor (delta 1500 cams and some other work), so i doubt it would handle much boost at all without running lean. the other route is adding a 5th injector on sort sort of controller. I once had a microtech microfueler on a VL turbo motor adding fuel above 10psi..
 

·
Registered
1998 GF8, 2003 BH9
Joined
·
155 Posts
Discussion Starter #11
so i doubt it would handle much boost at all without running lean.
I figured that to be the case. I've been looking into rrfpr and voltage clamps as they seem to be what a lot of people are running on the Facebook NA-T groups.

I had a quick look at the Project Lambda website and to my understanding its a ECU reflash project. How hard is it to run.
 

·
Registered
Joined
·
103 Posts
The project lambda stuff is easy to setup and get running. But learning how the software works is what takes a lot of time (like any other tuning software though). I have had it for a while and still have hardly any idea of what does what.. access to a dyno would help a lot!

For the basic upgrading of the MAP sensor and injectors though, it looks easy.. I'm about to install the blue 550cc injectors and check the settings, plus check it with a proper O2 sensor. Fingers crossed
 

·
Registered
1998 GF8, 2003 BH9
Joined
·
155 Posts
Discussion Starter #14 (Edited)
crjohnson I'm seriously considering Project Lambda now. Engine management seems like a good idea haha.

So last weekend I started by stripping the front bumper, crash bar off and fenders. There was one missing and one rounded bolt on the crash bar, and one of the fender bolts on the pinch weld broke but nothing major.

I found a little more damage from the wombat that hit the drivers side but it was only the small brackets and nothing a hammer couldn't fix.



Next I removed the brake booster and lines. I was expecting this to be a nightmare but it was pretty easy once I realised that the brake lines weren't connected to the booster. You can also see to ac condenser moved out of the core support for access.



I then proceed to wet sand it all with 320 grit. That was last weekend consumed.



During the week I decided to modify the crash support bar to allow for a front mount. Unknown to me at the time was that I was basically turning in into the Legacy/Liberty version which was thinner.

The was just achieved with an angle grinder and a spot weld drill. Only grinding the stitch welds and whats shown in the second photo.





Today (friday) I did a half-day at work and then traveled to my parents for the Australia Day long weekend. My aim for today was to clean with wax and grease remover, and mask of everything for painting.

Everything clean and masked for paint. I finished this at about 3:30-4ish in the afternoon.



When this was done it was 38 degrees and it was a dry heat so I decided to paint. I used an acrylic satin black and the end result looks great. All for less than $35 too.



Masking removed and closer photos.







The results turned out better than expected. The plan for the weekend is to install the WRX sub-frame and steering rack, and slowing reinstall everything else.

Thanks for reading, Luke :)
 

·
Registered
1998 GF8, 2003 BH9
Joined
·
155 Posts
Discussion Starter #17 (Edited)
fantastic update. engine bay looks great!
nice work!
Cheers guys, I've had a bad experience with cars and rattle cans before so it was nice that nothing went wrong.

You can download the project lambda software for free, have a look and see what you think
I was just doing that before writing this. They don't have a basemap for 2003 but they do for the year before so I think that will work.

Well here's what it looked like at the end of the next day. Nothing to exciting but its getting there. All the wiring and brake lines in place as well as a few other things.



To clear the incoming front mount I flipped the temp sensor on the bracket. No cutting required.



Before replacing the sub-frame I got some rubberised underliner to redo the wheel wells. I'll do more coats when I replace the brakes and suspension. Before and after.

Subframe in. This was fun as I couldn't get to to balance on the jack.



When I went to bolt the swaybar link on to the control arm I noticed that I couldn't steer at all. Turns out it was upside down. No idea why???



The other fender and crash bar back on. The crash bar will be getting painted, I just was to get the intercooler fitted first so I don't have to paint it multiple times.



Bumper back on. Taken from the same angle somehow.



Front end back together. It's a bit disheartening when it looks like this when you've put so much work into it.



Replaced fog light. It took the brunt of collision with wombat and the bracket is bent to shit. It also has a hole in it so a new one was in order.



And what it looks like at the end of the weekend. This makes it all worth it and, although I'm biased I think it looks great.



This was how it was left on Sunday and nothing else was really done on Monday (public holiday) except for measuring for the front mount and working out how to route the piping.

Next step is to get the engine back in. I'm planning on getting it running as stock first so I can troubleshoot anything that isn't working before adding the complexity of a turbo.

That's all for now, so thanks for reading
Luke :)
 

·
Registered
Joined
·
103 Posts
Do you have a pic of your ECU? There's a fair chance it'll be the same as mine which the 2002 map in Project Lambda was created for.
 

·
Registered
1998 GF8, 2003 BH9
Joined
·
155 Posts
Discussion Starter #19
I don't have one currently. I'll try and grab a photo tomorrow. If it isn't I should be able to swap it for a 2002 ECU anyway.
 

·
Registered
1998 GF8, 2003 BH9
Joined
·
155 Posts
Discussion Starter #20 (Edited)
Well as we all know with working on cars, some days everything goes right, and other it doesn't. This weekend a few think went wrong and it just makes you feel like shit. But that's working of cars, or any project to be honest.

So when researching for images of an outback with a turbo hood I found this image, and it pretty much shows the end goal/looks/stance for this project. Don't know whether to go with a turbo hood though.



Image source:
(VIC) Subaru Gen3 Outback, Bilsteins, BBS's, Leather, Twin Sunroof etc.

So progress this weekend was alright but I wish I got more done. I started with getting the rest of the stuff back in the engine bay like the cruise control unit and such.

Then was the fun of the power steering. As you can see below the ports between the Outback and the WRX are slightly different. To fix this I just bent the top hose as it was pretty malleable.






I also managed to pick up another piece of the turbo puzzle. A TD04. I already had a seized one that I got for $20 but the shaft broke so I got another. The bonus is that I now have a waste-gate for the 5-6 psi range and the 7-8 psi range as they changed from one to another in about 2004-2005.

Later I found that the TD04 was the only useful piece in this photo



Seized turbo on the left with the 5-6 psi waste-gate



Next I went to fit the headers to the engine and they wouldn't fix. I had ignored the part about the water pump outlet being in the way as I didn't want to deal with it. I was pretty annoyed with myself on that as it was stupid of me to do.



Then I found I couldn't even fix the up-pipe because of the cat hitting the back of the head. This was really annoying.



Then up-pipe broke at the flex joint. I was over it all at this point and it was 37 degrees which didn't help.



So I decided to get the engine back in the car and then call it for the day.



It needs a good clean but before I got the chance it started to rain so that was the end of the work for the weekend.

So to sum up the weekend, I got none of the exhaust fitted, some of it broke, I didn't achieve my goal of getting the engine started, I was tired as shit, and to finish up I managed to have the bonnet fall on my head. The drive home was a pretty solemn one.

On Monday I decided the solution to my problem was to throw money at it. Kidding, but I was looking for a new up-pipe and found a set of Equal length, sort of twin scroll headers and matching up-pipe that should clear the water pump and the head. So I parted ways with $250 of my Australian dollarydoos and it was mine. Should arrive sometime next week.



Being that this will arrive next week and that I haven't taken a weekend off from working on the car this year I'm not going to work on it this weekend. I need a break and its a good chance to get some other parts like a dump pipe and maybe a new door for the GF8 as one is dinged.

So that's all for a little while, hopefully next time I update this the engine will be running, who knows.

Luke :)
 
1 - 20 of 160 Posts
Top