Hopefully the end be all to a 2nd gen Legacy build by the builder of Rumble (Scott Wrona)

[98Outbackdream]

Hello everyone, I've been a long time lurker, and member of SL-i.net but I'm ready to finally make some posts to document my newest build, and possibly will update past builds on details I do not believe have been covered anywhere else for the 2nd gen chassis.

This is my newest project (err.. haven't got a name yet)
It is an old postal service vehicle. A 1998 Ruby Mica pearl Red RHD wagon that Is getting a HUGE taste of JDM parts thrown its way.

Plans in the works include a FULL 04/05 Sti drivetrain and harness merge utilizing an 05 STi DCCD 5x114 complete mechanical drivetrain and a v7 spec C front crossmember and steering rack and a DBW 32BIT non-immobilized 04 Sti parts car. I will be utilizing the Sti tank and wiring
And maintaining all of the fuel evaporative emissions

Parts installed
Jdm GC ver3 i/c spray bottle
Jdm GC ver3 coolant overflow tank
Jdm sti cherry blossom red stainless pedal set
04 sti dbw pedal and gt-b tt pedal assembly
05 Sti 6 speed with axles,hubs knuckles, brembos, stoptech rotors
Stainless steel braided brake lines
Kw v3 coilovers
05 Sti BBS wheels


Parts on standby
JDM GT-b Limited Front bumper with both sets of fogs
JDM Gt-b Rear bumper with crash beam
JDM Gt hood with Zerosports splitter
JDM L7 grill
JDM projector headlights
Ganador Super mirrors
Aeromagic sideskirts
Aeromagic rear lip
JDM smoked tail lights MINTY
Full JDM seat set from with built in rear cup holders
JDM door panels to match seats with facelift window switches
JDM slate grey switches
JDM Sti 240kmh cluster with v3 STi DCCD board swap and L.E.Ds with
3rd gen illuminated needles being worked into it
Front cusco brace with integrated brake master cylinder brace
Rear cusco strut brace
Garage doghouse rear roof bar
EDM center console switch panel with 6 switch holders
EDM shifter surround for auto with card holder and pocket
EDM radio bezel woodgrain and clock panel
Jdm 3rd gen black ring MOMO wheel with sportshift buttons
Ej257 longblock
Aps sr57 turbo
AMR 3" hard turbo inlet pipe
04 sti koyorad
Jdm BG front radiator support
Company 23 EBCS
Iag AOS street series
Gr chassis clutch master cylinder and hardline
Ver 2 Impreza Sti type Ra 1 1/16" bore brake master cylinder
04 Lhd Sti brake booster flipped upside down
Heated seat elements and wiring, heated seat switches with l.e.ds
EDM cruise control switch
I/c spray switches
Dccd snyder Pro
04 sti fuel tank and 99 outback limited hoses and emissions parts
Jdm clear fender markers
V8 long runner manifold powdercoated black
Parallel fuel rail mod with full spectrum fuel rails and a Marshall for
15+ Sti tmic with grimmspeed hoses

Parts needed to purchase yet

Tribeca power steering reservoir and cooler
Dbc to dbw throttle body adapter
Phenolic intake manifold spacers


Here are a couple photos of when I first got the RHD wagon
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[Tylerhartman]

This pleases the nut

[grayguy]

Yesssszz

[98Outbackdream]

And the NUT shall be pleased

[98Outbackdream]

This car had a rough life ( as most postal service vehicles do ) I purchased it for $1200 USD with a "no spark issue" that was quickly diagnosed as a timing belt that had the teeth ripped directly off, however this didn't matter since the vehicle is being swapped anyway. However, I grew up in Pennsylvania, and this car being a Texas car its entire life IS SUPER RUST FREE all around (atleast the chassis is )
Here are a couple photos of damage the chassis has
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Here you can see that the radiator support was jacked up by some previous owner, which is fine because i have a JDM core support to swap in which allows me to fit a GD fitment radiator in, this way I can utilize my 04 STi Koyorad, there will be pictures posted later to showcase the fitment of that!
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[98Outbackdream]

Here are some pictures of the underside of the wagon prior to the DCCD swap
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Here is the 05 Sti rear diff and subframe, the STi is from California, and actually has minor surface rust, the Legacy although 7 years older has less rust
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This is literally just a quick pressure wash of the Legacy components
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[98Outbackdream]

Here are some pictures of the Underside of the body after pressure washing THIS THING IS MINT

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[98Outbackdream]

Here is a KW V3 coilover installed, these are worth almost 3x what I paid for the entire car :sign3: also unsure why its sideways, maybe I'll fix it, maybe I won't
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Here is what the rear 05 STi aluminum rear lateral links looked like prior to polishing them
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Rear end installed WOO, however the rear calipers are not installed yet, due to this wagon originally having drum rear brakes and the Parking brake lines are different on the end so I'll be installing OEM rear disc brake, factory parking brake cables in order to utilize the STi parking brake assembly and rotors properly
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I had an issue and Fubar'd the rear differential outrigger mounting bolt hole, as of today I'm still uncertain if these brace has different dimensions between the STi and the Legacy but even with the use of a ratchet strap i could not get it to line up easily, I ended up tapping it to a larger size (m14x1.50) and ordering new bolts from Mccaster Carr. I need to drop the rear end again, to swap the STi fuel tank in as i decided to use all the STi emissions and tank stuff, so i will address the issue again later.
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Here is an image of the autotragic 4eat getting removed
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[98Outbackdream]

I'm trying to backdate this build from the beginning, so i'm updating most of it in the chronological order that I accomplished them/received them, around this time I received my GT-b Limited bumper with both sets of minty fogs and the mesh, don't mind it not being 100% to shape, it was heat gunned and folded to be shipped from Russia from Ruslan Sibby c:
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Here is the JDM v7 STi crossmember and rack installed, I was wrong and it's not a Spec C rack (FE550) it's just a Rev A STi rack FE200, still better than stock
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Here is a picture of the front suspension/brake set up, KW V3 05 Sti coilovers and 5x114 Brembo brakes with GD aluminum arms and Stainless steel braided brake lines
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Here's a trick for when you're working on an incline, and you don't have a transmission jack or friends available and you're installing a 6mt, just wrap a ratchet strap around the pitch mount bolt, hook one end to the transmission and the other to the front tow hook, and ratchet away and use a jack to support the rear of the transmission
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Here is the 6mt 05 STi DCCD Transmission installed, the Driveshaft is the original Automatic Legacy driveshaft with the r160 yoke installed into the R180 differential
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[98Outbackdream]

Finally, the car was sitting on the Full 05 STi drivetrain, this was the biggest moment of excitement in this build so far, however IT IS FAR FROM DONE
Being a man who does literally everything to his projects car's himself, this was one of the easier things I get to do c:
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Here i was testing fitment of the stock TT Legacy BG5 Hydraulic clutch master cylinder and hard lines, to me, the lines were atrocious so I ended up selling them to another RHD Legacy enthusiast doing a manual swap and opted to pay EVEN more to purchase an 08-14 GR chassis RHD clutch master and hard line to simplify things.
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R.I.P Rumble, although he is currently driven daily by another enthusiast, this picture was one of the last times the cars were together.
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Here i placed the 04 STi ebrake boot cover onto the Legacy parking brake mount, and then ordered a leather bottom portion i believe from a Forester, to complete the look I wanted, I do believe there is an OEM parking brake assembly similar to this that will mount on our chassis, but it was cheaper and simpler for me to do this, I'm also not a fan of the chrome plastic button on the STi, update, just noticed the Forester lower portion isn't on at this point haha
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Here is the parking brake handle, ready to be installed, however just sitting in my room currently
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[98Outbackdream]

Here is where things on this build get different than most builds, I'm not using a JDM v7 ej207 or a RHD chassis harness at all to get what I want ( Why the hell would anybody overcomplicate their build to make it harder on themselves)? Welcome to the world of being me and having to do things never done or one off, or having one reason to necessitate a full 32bit non-immobilized swap, instead of just going the far easier route.

Here in this picture is an example of the 16bit RHD V7 ECU harness connector, and the 32 bit LHD 04 STi harness connector. I went out of the way to get a v7 STi harness local to me in hopes that I could simply depin, and repin the wires I knew would be too short, but were also of MAJOR importance such as the cam, crank, knock, MAF, EGT, EBCS, and the AVCS wiring. These wires are mostly shielded and therefor can not simply just be extended unless you want interference and improper data to your ECU, but, I will make due with the RHD shielded wires, and only solder/splice/merge directly out of the ECU connections prior to the wires' shielding in an effort to have the best of both worlds.
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I will not be sharing too many images of the wiring merge due to it being tedious, repetitive and somewhat overbearing characteristics. So, moving on to other cool things

I got this EDM Radio/ash tray bezel because it has the headlight leveler switch location and a clock pod, I have intentions to mount a Zeitronix LCD display where the OEM clock would be mounted, but have not free'd up enough funds to purchase it yet. however, the DCCD roller switch does fit perfectly where the headlight leveler switch was ( 04 STi roller switch fits the center console switch trim, but the notch only allows it to be placed in upside down, the 05 STi switch will fit properly, but I believe wires will need to be repinned, more on that in the future when I actually install the DCCD wiring).
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This project is going to have almost every creature comfort offered for this chassis, this is to include heated seats, heated windshield, cruise control, both sets of Limited fog lights, etc. so this is a quick mock up on an EDM switch panel, this is not what the final results will be as i have revised plans and need to get a custom part 3d printed to house more switches.
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I made my own I/C spray button by removing the cover from the STi switch, and trimming it with an x-acto knife and placing it into an OEM switch housing, the rear portion of the switch can be modified by removing an opaque plastic piece, and the OEM STi intercooler switch wiring, will plug directly into place as if 100% factory.
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Here is all i trimmed to place onto the 2nd gen switch, every single switch has an l.e.d swapped into them and the green transparent portion will be removed from the switches in the future.
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[98Outbackdream]

Here is the JDM radiator core support with an 04 STi Koyorad with OEM WRX fans (plug and play for harness and radiator), It fits exceptionally well and will require hardly any modification to fit directly in place
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The alignment pins line up directly into the core support, the only thing necessary will be to grind off a few mounts from the radiator
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[98Outbackdream]

Next thing I purchased for the wagon was the mintiest set of JDM smoked tails I've ever laid eyes on to make it to the States, there is not a blemish, stress crack or sort of imperfection ANYWHERE on these taillights, they're stored safely in my closet for now, also notice the 15+STI Tmic I picked up with Grimmspeed hoses
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Here is a comparison of a v4 DCCD cluster piece, vs the OEM 2nd Legacy JDM STi cluster PRND321 Stack, I was incorrectly informed that this would fit in my cluster, and i tried hard to make it fit, and ended up wasting the entire investment I spent on the v4 STi cluster.. LEARN FROM MY MISTAKES
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NOTE, IT WILL NOT FIT PROPERLY, here is a picture of the WRONG cluster to purchase .
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THIS IS THE CORRECT CLUSTER IF YOU WANT TO HAVE THE MOST OEM DCCD DISPLAY IN A 2ND GEN CLUSTER, it is a v3 STi cluster. I will share more pictures of the cluster DCCD portion swapping later
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[98Outbackdream]

I Received my V3 STi intercooler spray tank WOOHOO, next up installing it in the car, I got lucky as my postal doesn't have ABS from the factory, however removing the ABS system is quite easy with our cars, barring the hard part of finding a donor car with the lines.
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The bracket to mount it under the airbox is ever slightly off, but with two pairs of pliers I was able to bend it to allow it to fit perfectly.
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Our chassis does not have the mounting holes to properly bolt the intercooler spray bottle to it, so I purchased an Astro pnuematic Riv Nut installer tool with stainless steel riv nuts. IT HAS BEEN ONE OF MY BEST TOOL PURCHASES IN YEARS!!! I can not emphasize it enough, it has helped tremendously .
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Here is the Riv nuts installed with some random Honda paint color match that looked close, but wasn't
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Here is the Intercooler spray tank fully mounted c:
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[98Outbackdream]

This is the 2nd gen cluster Prnd321 stack up against the V3 STi DCCD stack, they're extremely close, with cutting the top portion off of the v3 sti, and cutting the PRND321 stack off the 2nd gen, and some super glue, you can make it look VERY OEM, I opted to get rid of the color template, as I replaced all the bulbs with LEDs
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Around this time I entirely stripped a 99 Outback limited I purchased to fix the front end on Rumble, and to use all the creature comforts such as rear tweeters, door courtesy lights, heated mirrors, and also the heated windshield, all the switches, the heated seat elements, the rear power socket, and also the harness, which i'll be using for the rear, to add the wiring pins for features missing, and to prewire the chassis for heated and power folding mirrors, I have pictures of it, but won't share it since i cut the car to pieces and posting all these pictures takes a long time xD

So here is my JDM STi pedal sets, i have an auto set behind the APS Sr57 Turbo, The nut is very pleased with this
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Shortly after purchasing the outback limited, and had intentions to use the leather seats temporarily until I found a good deal on my dream seats/interior.... I actually stumbled across a really good deal on the majority of the interior and jumped on it, so now I have leather seats and door cards just chilling.
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The seats have the rear net dividers, and a fold down center armrest with built in rear cupholders, and i also have the USDM rear cup holder! I'm currently looking for JDM facelift rear seat belts and the hardware for the nets if you're reading this
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[98Outbackdream]

The JDM door panels do not have the central locking switch for "Lock/unlock" like the 97+USDM door panels do, so with some extra careful precise cuts with an xacto knife, and tons of patience I transferred them over from the original Postal door panels, which have the central locking switch separate from the switch panel, unlike the locking switch on the 99 model outback i had which the switch is directly molded into the same panel as the window switches.
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Here is a picture demonstrating the different types of switch assemblies for the doors, The top door panel is the JDM door panel, the left is the 98 Postal door panel, and the right is a 99 Outback limited
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It's a very tedious process, very carefully having to remove melted plastic caps off the plastic studs which are locked in by a washer of sorts with little tabs that dig into the plastic to resist it slipping off, once all the little washers off it just slides out, then i cut the vinyl off around the panel fastener that holds the door panel to the door, all the way into the lip where the window switch rests, laid it over the jdm door panel and very carefully cut the same hole into the jdm panel and transferred the switch over.
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[Tylerhartman]

gibs me that door fabric

[ryu_haneda]

Looking forward to seeing more progress on this!