Jump to content
LegacyGT.com

Zero1's JDM Legacy S402 clone USDM 2008 spec.B


Zero1

Recommended Posts

I think it's about time to start this build thread lol. I bought her brand new on January 15th, 2009 with 804 test driven miles from the local Subaru dealership. Oil consumption started to become an issue after ~50k miles so a motor build was needed. Now after 15 years of ownership, it's very nearly complete and so much fun to drive! Enjoy my journey from the beginning to the end :spin: 

 

 

Mods (>^.^)>

 

Exterior:

 

20% tint all around

18x8.5" +38 Volk RE30 custom polished and powder coated wheels with 245/35-R18 Michelin Pilot Sport 4S tires

H&R 5mm wheel spacers with extended studs (front only)

JDM STi rear lip spoiler

JDM rev D-F spec B front bumper w/ FMIC mod (secondary/spare)

JDM STi front lip spoiler with STi rubber lip spoiler skirt (secondary/spare)

JDM rev D-F spec B grille (secondary/spare)

JDM rev D-F spec B front bumper w/ FMIC mod and custom fog lamp brackets (show only)

JDM multi-chrome fog lamps (show only)

S402 carbon fiber front lip spoiler (#?/402) with Arai Motorsport rubber lip spoiler skirt (show only)

JDM rev D-F spec B/STi power leveling bixenon HID headlamps

S402 grille with Zero Sports badge (from BP #54/400)

S402 front fenders (from BL #112?/402)

Customized front wheel liners to fit S402 fenders

JDM rev D-F spec B rear bumper w/ dual brake lamp fogs

JDM aero splash guards

JDM aero strakes

JDM power folding mirrors with Liberal 3-function grampus winkers

S402 rear badge (from BP #54/400)

Liberal blue carbon rear STi emblem

STi polished stainless steel fuel cap cover

DRL delete

Diode Dynamics LED turn signal and brake lamps

PIAA halogen high beam, halogen fog lamp, and LED city lamp bulbs

Zero Sports oil cap

Zero Sports radiator shroud

Zero Sports alternator shroud

Zero Sports V-Earthing/Effector kit

Zero Sports 1.3 bar silver radiator caps

IAG silver billet aluminum cap and dipstick set

Hella Supertones hidden

JDM Subaru OEM Window Visors

Redline Racing SS Hood Struts

 

Interior

 

JDM Blue LED floor lighting kit

LED interior and trunk lamps

JDM OEM option plush trunk mat

Canadian 2008/09MY spec B floor mats

S402 shift knob (from BP #54/402)

S402 door sills (from BL #241/402)

Redline custom alcantara/leather parking brake and shifter boots

EDM/JDM/USDM center console w/ red illuminated cup holders

JDM dual console box w/ OEM alcantara arm rest

DAMD carbon fiber D-shape steering wheel with custom painted trim pieces

STi airbag horn

Custom molded triple pod A-pillar

Pillars wrapped in perforated black alcantara

JDM/Custom black suede headliner and components

One-off Liberal carbon fiber interior trim set

Liberal carbon fiber parking brake handle

Defi Advance CR boost and oil pressure gauges

Zeitronix ZR-2 combo gauge

McIntosh secondary tweeters

EDM LHD double DIN conversion [retaining factory AUX, SWC, & NAV - @SVXdc]

Pioneer Headunit

JL front and JBL rear speakers

Backup camera in factory location w/ OEM NAV integration

Hardwire Garmin dash cam

 

Steering, Suspension and Brakes

 

STi 6MT short throw shifter kit

Cobb adjustable short throw shifter

Perrin front shifter bushings

STi rear shifter stay bushing

Kartboy pitch stop mount

Cusco power steering rack brace

P&L Motorsports stainless steel braided high pressure power steering line

Off The Line Motorsports insulated low pressure power steering line

Whiteline power steering rack bushings

Whiteline outer tie rod ends

Whiteline rear diff bushings

Whiteline front lower ball joints

Whiteline rear upper control arm camber eccentric bushings

S402/STi flexible front strut tower bar

S402 BL rear strut tower bar (from BL #194/402)

STi Group N motor mounts

STi Group N trans mount

SPT lower front chassis brace

Cusco Zero2e coilovers with dampening control

Cobb front and adjustable rear sway bars

Cobb rear sway bar stout mounts

Perrin front and rear endlinks

S402 Brembo 6-pot front calipers with custom paint (from BL #241/402)

STi Brembo 2-pot rear calipers with custom paint

KNS Brakes rear Brembo caliper adapters

Zero Sports SS braided brake lines

Grimmspeed brake master cylinder brace

ITS brake pedal firewall brace

Goodridge SS clutch line

Custom parking brake shoes via Unclemat @ LegacyGT.com

S402 front rotor top hats with Endless slotted replacement discs

DBA 4000 slotted rear rotors

Endless brake pads front/rear

Yperion titanium brake pad shims front/rear

Yperion titanium brake caliper crossover bolts and pad pins front/rear

STi rear pillow ball lateral links

Lots and lots of SS hardware lol

 

Engine/Power

 

BNM Performance/Modified by KC custom T3 flange twin scroll header, up-pipe, and 2-piece downpipe black ceramic coated

Strömung quad-tip cat back exhaust

Kartboy urethane exhaust hanger bushings

Garage Tuning T3/T4 Garrett Gen1 GT3582R 1.06a/r twin scroll turbo

Twin Turbosmart 40mm EWG

AWDTuning assembled longblock:

    - EJ257 case halves honed with OEM EJ25D SAVCS heads

    - Heat-treated STi crankshaft

    - King Race bearings

    - JE FSR pistons

    - Pauter X-Beam rods

    - Killer B pickup/baffle/oil pan

    - Custom aged ARP head studs

    - Kelford 272/268 cams

    - Beehive valve springs/retainers

    - Fluidamper crank pulley

Gates timing belt/water pump kit

Radium Engineering top-feed fuel rails with fuel pulse dampeners

2000cc Injector Dynamics injectors

Custom Fragola -6AN PTFE feed, return and parallel fuel lines

Aeromotive A1000 FPR

Radium Engineering twin hanger in-tank pump kit with twin AEM 320 lph ethanol pumps

Hobbs switched twin fuel pump hardwire kit

Custom Cobb prototype flex fuel setup with inline pressure and ethanol sensors

ACT 6-puck ceramic clutch

STi 6MT flywheel

3.5 bar Zeitronix MAP sensor

AEM IAT sensor

Cobb Access Port V3

AVO front mount intercooler

Cosworth intake manifold

Modified by KC ceramic coated custom aluminum FMIC piping with Vibrant HD clamps

IAG 76mm big bore throttle body customized with Vibrant HD fitting

Tial Q BOV

Cosworth air pump delete plates

IAG billet TGV deletes

IAG Competition recirculating AOS system

Koyo radiator

Zero Sports radiator hoses

Zero Sports magnetic oil drain plug

Mishimoto SS coolant overflow tank

Killer B turbo coolant decompression tank

Vibrant custom coolant/vacuum silicone hoses

Neoplot lightweight alternator and power steering pump pulleys

Custom trunk battery relocation kit

Mele Design battery box with ATX-30 lithium restartable battery

Semi-wire tuck in engine bay and heat proofed engine main wiring harness

 

She makes some pretty good power :spin:

IMG_0091.thumb.JPG.0b52aef97c614f4fa952497dd6c4f4c4.JPG

IMG_0092.thumb.JPG.4a2c1e80cad418c45bef2b7f23934647.JPG

IMG_0966.thumb.jpg.8851a58e8922223c8100d48fe3dfd74b.jpg

IMG_0960.thumb.jpg.481329bed1cc73842b0dc9c733d27113.jpg

IMG_0972.thumb.jpg.62af6fe9b9a31bcf2cb43ab7ad294f79.jpg

Edited by Zero1
Too many parts
  • Like 1
Link to comment
Share on other sites

Alright, starting from the beginning...

 

First week of owning the lady she got tint. At this point I was extremely happy I had not purchased the 2009 OBP WRX Premium sedan I had been looking to buy. I ended up spending the same on the spec.B as I would have on the WRX (lots of rebates lol). I had intended on modding the piss out of a WRX but when I got the spec.B I was so giddy about it I honestly didn't want to modify it. That didn't last long at all...

 

Three months and I installed a Volt HID kit, then a few months later it was Volk RE30 wheels with Limited Edition Formula center caps (hard as hell to find and glad they found a great home Catalyst :) ), Cobb catted TBE (stock exhaust was rusted all to heck and back!), STi 6MT STS with Perrin front and STi rear bushings, SPT front lower chassis brace, Cobb radiator shroud (scooby2.5's now :) ), Cobb battery tie down, SPT intake with heat shield, STi aluminum strut tower bar, SPT oil cap, and an Optima red top.

 

Still had the TMIC off the car when I took the engine pick lol. It was at this point that the muffler tips not only shot flames between hard shifts but also melted the bumper a little :spin:

IMG_1469.thumb.jpg.a8cc3c7e788017a49597f6df3fac62cf.jpg

IMG_1472.thumb.jpg.bad545383b6d481dc5ecb721b0460a1f.jpg

IMG_1475.thumb.jpg.247a070c89382381bee0bb572c6141d6.jpg

IMG_0918.thumb.jpg.825607a50279f8b517dd76048e230f39.jpg

IMG_1489.thumb.jpg.bf3cee447d190756fa3cd95a9edfcbc4.jpg

IMG_1510.thumb.jpg.6c354e33a016761999b09028d27fe3a3.jpg

IMG_1491.thumb.jpg.2dfd431415483f3be4fc89eb75a0bac6.jpg

IMG_1508.thumb.jpg.51587edede6cb6486d4dae3dd1ea0b14.jpg

IMG_1513.thumb.jpg.035b0d9d84aa39e1067243dd23c5b74c.jpg

Link to comment
Share on other sites

This one will be a little shorter... Couple weeks later and the rest of the suspension bits came :)

 

Tein Flex coilovers with solid aluminum pillow ball upper mounts, Perrin front and rear endlinks, and Cobb front and adjustable rear sways. At this point of putting stuff on it was becoming VERY apparent not a whole lot of SS hardware was used from the factory so I started upgrading... all of it lol. And voila! No more monster wheel gap!!!

 

Time to order JDM goodies right? A LOT of them :wub:

IMG_1687.thumb.jpg.7b86ec04723aed907f3957761fc29bc9.jpg

IMG_1700.thumb.jpg.1898fcd2ed7dc558a741595f225878f6.jpg

IMG_1711.thumb.jpg.65166116184df7f7a5bf13a59a753afb.jpg

IMG_1695.thumb.jpg.5867b24150bcb1a0d9211b8e37bc8168.jpg

IMG_1698.thumb.JPG.b4b0d20636dda64efb668a58d6e37df1.JPG

Link to comment
Share on other sites

The first wave from Japan came in the form of the GTB-STi front end that sat in boxes and traveled half-way across the US with me when I moved to Ohio from Oz. I want to point out that no one knew anything about what was needed at this time summer of 2009 so it was one heck of a learning experience lol. Took a while to figure out that I needed JDM fenders as well lol.

 

Oh and a super rare set of gen 3(?) JDM Legacy STi wheels that i dearly miss... At least they went to a good home :rolleyes:

 

Gotta have that plush trunk mat too! And I can always dream about what it will look like eventually...

IMG_1760.thumb.jpg.4ebf60b6005212c38d69d38591341833.jpg

IMG_1761.thumb.jpg.5eb1984f679024945654f49007d33725.jpg

IMG_1862.thumb.jpg.bb6e17db857117dc10db3d3749c028a8.jpg

IMG_1780.thumb.jpg.75ec99d458498a4d823748dce0ab99a3.jpg

IMG_1798.thumb.jpg.4dbcc330c09853ebcf881aace4e2bae7.jpg

IMG_4162.thumb.jpg.f033d05ded44430150439f6a992ba63f.jpg

2133294299_LegacySTi.thumb.jpg.928b0f3aebdac6d4ee74432b201d6781.jpg

Edited by Zero1
Link to comment
Share on other sites

The second most fun I have had modifying her was doing the brakes. My buddy's wife was not a happy camper when I kept them up til the wee hours of the morning using their garage the night before they had to work lol. The fronts were super free and easy while the rears were a PITA. Little bit of modification necessary lol.

 

Bought brand new (at my cost ;) ) 2004 Impreza STi Brembo calipers and hardware, DBA 2-piece front and single piece rear slotted rotors 2004 Impreza STi fitment, FastWRX.com rear adapters, unclemat's custom extra thick parking brake shoes, Hawk HPS pads (love to have some EBC Red Stuff now...), Goodridge SS lines, and ATE Super Blue fluid.

 

Gold on gold never looked so fine!!!

IMG_1812.thumb.jpg.a8150eb2d27517960802bbfb037cef72.jpg

IMG_1813.thumb.jpg.c8148715d62baf79f896054c1dcef187.jpg

IMG_1814.thumb.jpg.834ebf4e58c9cc932c3f43c80f2cac3b.jpg

IMG_1817.thumb.jpg.9712a6b195e6f397e23d01405dfa5795.jpg

IMG_1827.thumb.jpg.4bb19e7bf90b0e933fc897427dd956a6.jpg

IMG_1819.thumb.jpg.02cd33cffd94deaacb313513829f2cc1.jpg

IMG_1816.thumb.jpg.5e5a84ba0d0f4bdc7faa00ab3879b13d.jpg

IMG_1823.thumb.jpg.a199e2c33aa7f3cbfac43ce8decb128d.jpg

IMG_1824.thumb.jpg.85a92720109bedd6dba44a98cdd11e12.jpg

Link to comment
Share on other sites

Winter 2009/2010 was a blast but led to curbing one of the goldies and had to let them go (was told it was unrepairable :( ). 2010 was a LOT of goodies...

 

TRUNK MONKEY FOR THE WIN!!!

 

Instead of hole filling, got a new OEM trunk lid to go along with the STi lip spoiler and had them paint-matched along with the license plate trim piece to the rest of her. Thought it would be cool to jazz it up a little so picked up some STi badges and bolted them to the front mats, stuck them in place of the SI-Drive badge, and an OEM Legacy STi trunk badge from Japan. Then had a triple pod A-pillar piece designed for 04-07 Impreza STi fitment custom molded onto my A-pillar and then had all my pillar pieces wrapped in black perforated alcantara matching the rest of the interior. I left all the trim pieces alone as I think the contrast still looks good and man that would have been a nightmare plasti-dipping all those small pieces...

 

I also found a JDM blue interior lighting kit :) The plug and play connections were not compatible with the USDM wiring so it took a little bit of custom wiring/searching/test-lighting but no air bags were deployed and it was very helpful I already had the pillars taken off. And yes, they are OEM pieces so they come with the timer relay so they shut off a few seconds after the dome lights do ;)

IMG_1945.thumb.jpg.e1fa829a738604d631259c6d2a63201d.jpg

IMG_3871.thumb.jpg.3112fa81fe0da858fe802c1d09310630.jpg

IMG_3868.thumb.jpg.f1c0fade9162322cdd1a6d3fb980d24d.jpg

IMG00014-20100727-2153.thumb.jpg.53d5eda502fc0bb30c18424bb11739df.jpg

IMG_3864.thumb.jpg.231d046e8737fea608a2be7d266c973b.jpg

IMG_3888.thumb.jpg.ddaaf9561be4a61c8f6043d9e2012244.jpg

IMG_3232.thumb.jpg.f9cb2d9d6e4ac28426c11afa272b9a82.jpg

IMG_3867.thumb.jpg.eb4e43228f394e6010cd1cf3c15b9b01.jpg

IMG_4157.thumb.jpg.ba980be8440c83f6b64e6a70b351dc53.jpg

IMG_4152.thumb.jpg.8f742d26d2e2fd9da826a49185995243.jpg

Link to comment
Share on other sites

The best part of 2010 I'll save for next time so here's a few good ones to leave you with for winter 2009/2010 and spring/early summer 2010 :)

 

My buddy devxtech in his 2008 QSM spec.B is in a couple of those :spin:

IMG_3881.thumb.jpg.52c7b42311943cc6cc16d25ace168aa7.jpg

IMG00031-20091116-1202.thumb.jpg.e49e85af6bb67dfb25e4822cae921da6.jpg

IMG00040-20091224-2201.thumb.jpg.0cbbe6abfa1d474cdb5d1495e0a86a6d.jpg

170738163_TwinspecBs2.thumb.jpg.7d00905dad9a442a0cc5e82e8448fa9b.jpg

1061254853_TwinspecBs.thumb.jpg.e4360b95a8a52830235b90b627fa0f0f.jpg

1586618943_IMG_3751e.thumb.jpg.dbece742facbeff632f11a6a019b170a.jpg

IMG_3857.thumb.jpg.77f60d7510785f2cda6e5a40acff181c.jpg

1393264638_IMG_3754e.thumb.jpg.ffd2081b83a8f7851bd218e36625f27f.jpg

Link to comment
Share on other sites

I see you lost your wing in that first pic. Wingless FTW.

 

Still got the stock trunk with the wing on it in storage lol. That pic it's hard to see but the STi lip spoiler is lurking there ;)

Link to comment
Share on other sites

The end of summer and fall of 2010 was the most fun I've had working on her. At this point I thought I could do the front end conversion as well... Before I found out that I needed the JDM fenders as well LOLOLOL!!!

 

Time for the go fast bits! at 17k miles on the clock she got an AVO450, AVO FMIC, AVO BOV, AVO inlet pipe, AVO CAI, AVO SS flex UP, DW 850cc top feeds, AVO 245 lph fuel pump, all exhaust and intake Grimmspeed gaskets, Grimmspeed 8mm phenolic spacers, TGV deletes, removed the entire air pump system and performed m_sprank's APS mod on the driver's side solenoid, Cosworth air pump delete plates, CF Braille race battery (same specs as OEM battery just 21lbs!), 05-07 LGT oil fill neck, Cobb oil cap, Zero Sports radiator shroud, Prodrive 3-port EBCS, new A/C condensor (damn shitty hardware breaking and poking holes in things...), Hella horns, Xtreme HID kit, Grimmspeed AOS, removed the oil screen in the passenger side banjo bolt, STi radiator caps, removed/hacked a bunch of useless metal bits around the engine bay, and LOTS LOTS LOTS of SS hardware and SS T-bolt hose clamps lol.

 

It seemed like every day I looked at her for the month and a half she was sitting on jack stands it was another set back, hence the length of time lol. Put one thing on and find out I needed another, this, that, and the other thing. The real fun came when I started on the JDM STi conversion...

 

After hacking off the harnesses from the USDM headlamps and using them to wire the JDM lights for perfect OEM style plug-and-play use, I test fitted the JDM front end only to find out the issue with the fenders. Shit. So then I had to make my own harnesses for not only the USDM's so I could put them back on but also the JDM's for later on lol. I went ahead and cleared the headlamps while I was at it too. Then, instead of hacking up the JDM front bumper, I had to hack up the USDM bumper for FMIC clearance (quite a bit of other trimming was necessary as well). At this point, since I was unable to use the JDM bumper beam, I ditched it and the USDM bumper beam and mounted the HID ballasts on the "subframe rails" end caps (perfect spot for them if you are unable to use your bumper beam :) ).

 

After putting it all back together, I went ahead and put some icing on the cake in the form of (only ones in the country?) JDM Legacy/Liberty GTB-STi 10 spoke 18x7.5" Enkei wheels ;) I got 5 just in case of an accident and being stuck with an incomplete set so one sits in the trunk as a spare :)

 

I had Calvin Dotson at Cobb Tuning Plano, TX send me a couple e-tunes so I could limp it down there from KC. When I got down there I had him pro-tune it for me on their Mustang dyno and put down 279whp and 279wtq. Later come to find out the turbo is mis-matched with the stock EJ255 but that would later be fixed, sort of...

 

At 20k miles on the clock I noticed the oil burning issue in full effect... I'm guessing she had this problem most of her life :( Leak down test showed nothing out of the ordinary, compression test showed 140psi in three cylinders and 145psi in one cylinder, oil was black and smelled like fuel, and oil was being consumed at about a quart every 1k miles :confused:

 

I have a TON more pics but only 10 per post LOL!

 

 

Almost there... two more years and a lot more to it yet!

IMG_3911.thumb.jpg.45b07020048bde09122c1736bd025046.jpg

IMG_3941.thumb.jpg.0aec92cb2efa69c89c4f9b2e85a45428.jpg

IMG_3942.thumb.jpg.21f52154215a632a1d4991e372c0fce1.jpg

IMG_3987.thumb.jpg.856affac9e5da6dd5854c9fd03321348.jpg

IMG_3991.thumb.jpg.e4ad3de9561010efd6b87625e9e28512.jpg

IMG_4012.thumb.jpg.c5a0513d77c05fedd7b363cf6be78fff.jpg

IMAG0236.thumb.jpg.014cd88e4ca679b45616617e0a99b0b3.jpg

IMAG0243.thumb.jpg.6453b6ddb251f5faadde50cf46d718eb.jpg

Edited by Zero1
Link to comment
Share on other sites

Winter 2010/2011 involved A LOT of fun in the snow! devxtech joined in on the fun too haha!

 

Just a few more adds for the summer of 2011 including Mishimoto radiator and fans/shroud, Zero Sports radiator hoses, Evans NPG+C coolant, Grimmspeed pnp exhaust manifolds (sent mine in since I already had a EGT sensor tapped in) with oversize flex crosspipe all ceramic coated, wrapped all the exhaust in DEI titanium wrap, DEI turbo blanket, Grimmspeed turbo heat shield, and then... Also picked up a Subtle Solutions SS alternator cover and had to modify it a little for fitment with the radiator hose.

 

Went back to Cobb Tuning Plano but this time to figure out why I wasn't getting the power I should have been... Went ahead and swapped out the AVO450 for a Tomioka TD-05 20G 8cm hot side turbo and changed out the Grimmspeed AOS for a V2 Crawford recirculating catch can AOS to (hopefully but not so much success) reduce oil consumption lol. When back on the dyno she put down 324whp 335wtq with the shop at 113 degrees (so guessing add 10whp/wtq in fair weather?). Who would have thought a smaller turbo would make more power? Again, back to the mismatch :( I also saw scooby2.5's OBXT waiting for his new motor while I was down there!

 

When I got back to KC this time I noticed the car running rough and stumbling. Well due to turbo fitment issues, the inlet pipe had slid off the turbo and was letting post-MAF air flow in. LOTS of hours and frustration went into taking it all apart, fixing it the best I could, and putting it all back together.

 

That would just about wrap up 2011... just a few more bits and some recent pics soon to come!!!

IMAG0025.thumb.jpg.c63fd5e6b964c1b405425670657ce0a0.jpg

IMAG0061.thumb.jpg.017d323059139cb9e9518066133564c1.jpg

IMAG0062.thumb.jpg.e4b9b4653a9177c2cc07ebd3a3490116.jpg

IMAG0136.thumb.jpg.45e184e0a8705af7f0f8a2b355f4dd53.jpg

IMAG0143.thumb.jpg.c0029fce4df35880123e3aef2ec83295.jpg

IMAG0174.thumb.jpg.db73022ba46b4f3134cd1cf9542be0af.jpg

IMAG0173.thumb.jpg.29e3f14f8eb27dbac5877451ac81a9cc.jpg

IMAG0249.thumb.jpg.1acdd8d37960fd9edf5fa313bafa5b74.jpg

IMAG0167.thumb.jpg.52adbf5376f13339355c6869e11ab2f0.jpg

Link to comment
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
×
×
  • Create New...

Important Information

Terms of Use