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#1 2017-10-11 16:02:41

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

05 desrt silver aero work horse

I recently purchased a 2005 aero locally that needed a motor.
https://i.imgur.com/WIOnTtr.jpg
I've spent some time and money fixing it up.
https://i.imgur.com/FuCMRcN.jpg
05 JDM EJ205 instelled
https://i.imgur.com/OqhsbmC.jpg
https://i.imgur.com/N267PrR.jpg
https://i.imgur.com/ysQvEJm.jpg
https://i.imgur.com/Eob21ZT.jpg
https://i.imgur.com/os4cu0e.jpg


AEM wideband air/fuel gauge added, steering wheel swapped. The steering wheel is off my black rescue project, it isn't perfect but better than the one that came on the car.
https://i.imgur.com/1p7cC1t.jpg
Sitting on my old O.Z Superleggeras and Continental DWS and a fresh set of KYB Excel G struts and an old set of usdm wagon pinks I had stashed away for some time.
https://i.imgur.com/v29bxsC.jpg

Prodrive oval
https://i.imgur.com/jUkXdwa.jpg
It is a work in progress project as of now, I have a jdm wrx ecu to run it, avcs will be enabled. It'll just be a basic stage 2 setup, Cobb catted down pipe, Stromung 2.5" intermediate pipe, Prodrive oval axleback, Cobb 3 port boost controller. Tuning duties will be by Mr. Stephen Clark from IA Performance. Once I install the avcs wire kit, finish the wide band wiring and register the vehicle the tuning process will begin.
Details:
JDM 2005 EJ205 39,000 miles claimed by vendor.
JDM wrx ecu
IA Performance AVCS wire kit
New oem rear main seal
New oem valve cover related gaskets and half moons
New Gates timing belt kit
New oem thermostat
New oem accessory belts
Mishimoto radiator
Mishimoto radiator hoses
Resurfaced original flywheel
New excedy klutch kit
New oem front 02 sensor
New oem coilpacks
Low miles like new cross pipe
New exhaust manifold heat shields
New oem exhaust gaskets and hardware all around
Cobb up pipe
Cobb catted down pipe
Stromung 2.5� intermediate pipe
Prodrive oval axleback
Cobb 3 port boost controller
New oem inner front cv axle boots
New oem shift linkage
Low miles KYB Excel G struts
Usdm wagon pink lowering springs
New 6mm saggy butt spacers
Fresh set of wrx brake calipers all around
O.Z Ultraleggera 17x8 48+
Continental extreme contact 235/45/17
Gorilla splined lug nuts
AEM air fuel wideband gauge
Subaru all season floor mats
Team Dynamics Pro Race 1.2 17x8 48+ winter wheels
Yokohama iceguard 235/45/17 winter tires
Steering wheel off my black rescue project, not perfect but better condition than original.
Swapped a spare set of HID headlights, no more plans to retrofit original halogens
Installed a rust free low mile rear sway bar, sway bar mounts and new oem endlinks

Items on to do list:
Polish head lights and install better bulbs. I do have a spare set of factory hid headlights but I may keep them as spares and eventually do a retrofit source HID projectors.
Some kind of navigation head unit.

Last edited by Rodman (2019-08-03 01:27:22)


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#2 2017-10-11 23:22:19

crisco
saabaru x2
Supporter
From: skyline dr, va
Registered: 2006-12-26
User Number: 1721
Posts: 751

Re: 05 desrt silver aero work horse

Awesome.  Your plans were better than my plans were, and youve gotten way more done than i would have by now.  And done it nicer.

Its great seeing another cool project. Now if i could only find a good two for one deal i could start another project...


2 many saabarus

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#3 2017-10-11 23:40:05

juicebox
I'm Rod and I like to party
From: St. George, Utah
Registered: 2011-01-17
User Number: 5151
Posts: 600

Re: 05 desrt silver aero work horse

crisco wrote:

Now if i could only find a good two for one deal i could start another project...

That made me laugh so hard!  lol


Black 2005 Aero 5MT - Sold
Red 2005 Aero 5MT - Sold

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#4 2017-10-11 23:57:49

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

Thank you, Im hoping to drive this car for a couple of years when I dont want to drive my black aero. The black aero is a rust free car, want to keep it that way. Hey I have two 05 Aeros, the right offer can take them home.


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#5 2017-10-12 10:28:46

Pyromancy5
))<>(( Back and forth. Forever.
Supporter
From: Bexley, OH
Registered: 2009-02-23
User Number: 3538
Posts: 6017

Re: 05 desrt silver aero work horse

juicebox wrote:

crisco wrote:

Now if i could only find a good two for one deal i could start another project...

That made me laugh so hard!  lol

Me too lol lol lol


2005 Linear, 5mt, Satin Gray Metallic, moonroof, ixizsclutch, ixizhood, FHI 21 mm rear sway bar, rear dif guard
2014 Nissan Leaf SL, Glacier White, Bose
1981 Yamaha SR500

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#6 2017-10-20 03:33:12

Dunnington
Member
Registered: 2017-10-09
User Number: 42624
Posts: 1

Re: 05 desrt silver aero work horse

I like what you did with the car, Rodman. Thanks for sharing your project with us.

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#7 2017-10-20 08:11:45

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

Thank you Dunnington, best first post ever ✌️
AVCS is now wired, JDM ecu in place.
Having an issue with the new Denso 02 sensor I purchased on Ebay, I know better, OE only. Waiting on OE sensor to arrive, signed up for etuning with IA Performance, sent stock jdm wrx rom, waiting on first map.


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#8 2017-10-23 23:49:29

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

Installed new OEM o2 sensor tonight, no more codes. Took the car for a gentle spin around the neighborhood on the JDM ECU. Kept off boost, the AVCS equipped JDM EJ205 felt very smooth, really nice.


https://i.imgur.com/vasH5G5.jpg
https://i.imgur.com/wsofxUa.jpg

Last edited by Rodman (2019-08-03 01:39:55)


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#9 2017-10-28 00:59:29

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

The car is now insured and registered.
Flashed first IAP maps to both USDM and JDM ECU's, Logged idle and logged driving around on the JDM ECU. Felt Excellent.

Last edited by Rodman (2017-10-28 01:03:33)


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#10 2017-10-28 14:31:37

snowphun
Member
From: Central CT
Registered: 2005-11-09
User Number: 890
Posts: 599

Re: 05 desrt silver aero work horse

Is that a wideband you have installed at the top of the DP?

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#11 2017-10-28 15:09:23

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

Yes it is, not the ideal location for the sensor but that's where Cobb places the bung.


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#12 2017-10-28 19:43:17

myzislow
Member
Registered: 2012-11-10
User Number: 7861
Posts: 336

Re: 05 desrt silver aero work horse

I've run my AEM wideband sensor there for years and have never had an issue, I read many reports that it's too close to the Turbo, too hot blah blah blah but never had an issue over here.

Looking good, congrats on getting it running so quickly!

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#13 2017-10-29 09:12:01

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

Thats good to know, I do wish Cobb placed the bung further down the stream. I sold the evil sedan and gave the outback to my wife, the new aero will be my winter driver. Im loving the jdm ej205, the TD04L and AVCS make for a wonderful combination of instant responsiveness when pushing the gas pedal. My other car is no where near as responsive.


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#14 2017-11-05 21:50:40

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

Car has been running well, today I installed a hitch so I can hookup my bicycle rack and fixed the driver side heated seat switch. All that was  needed was the micro bulb replaced in order for it to start working again.
Radio Shack 272-1092 #7219 12v 60ma


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#15 2017-11-17 20:25:34

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

Tune done.
4 wheel alignment done.
Car feels great, happy.


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#16 2017-12-16 22:27:53

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

Winter mode, car feels great.
https://imgur.com/a/5lLu8

Last edited by Rodman (2017-12-18 13:56:23)


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#17 2018-10-16 20:27:53

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

Well, the work horse developed a fuel smell on the back side of the car. Sunday I had a chance to lift the car and observe around. Mother fucker, the gas tank is leaking all around the seam due to rust. The gas tank needs replacing, the entire rear end has to come out to remove the tank. I started the job but gave up after facing too many rusted bolts for me to take on. Had to flat bed the car to my friend's shop, its going to be an expensive repair. Found a complete gas tank with pump assembly and filler neck that is rust free on ebay for $344 shipped. Labor cost will be ugly and I'm probably going to take the opportunity to replace bushings and rusted bolts.


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#18 2018-10-16 20:36:01

snowphun
Member
From: Central CT
Registered: 2005-11-09
User Number: 890
Posts: 599

Re: 05 desrt silver aero work horse

Man that is a properly rusted car for the tank seam to rust. I replaced a WRX tank years ago as it was dented in an accident, at least that car was new enough that none of the bolts were rusted. I'm surprised you can find someone willing to ship a tank, if there's any chance of flammable vapors it gets hit with some hefty fees, and it's hard to make a used tank not stink of gas. I ended up sourcing my replacement locally.

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#19 2018-10-16 21:34:02

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

Fedex is the carrier, its coming from California, it is in transit, should have it Friday. I'm surprised my friend Alex agreed to do the job, he may not want to be my friend any more when all said and done. I'm his bicycle shop guy, he likes his bikes rolling proper, he needs me, lol.


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#20 2018-10-16 21:39:47

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

Just removing the fuel line quick disconnect was a nightmare.
https://i.imgur.com/7sTt20R.jpg
https://i.imgur.com/Sloxb5V.jpg


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#21 2018-10-17 07:33:54

snowphun
Member
From: Central CT
Registered: 2005-11-09
User Number: 890
Posts: 599

Re: 05 desrt silver aero work horse

I had a lot of trouble with the quick connects when I swapped my fuel pump, it was even harder getting them back on as they wouldn't lock in place. The orange inner plastic clip is replaceable and was cheap, may be good to have them on hand. 

All that rust is such a bummer.

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#22 2018-10-27 15:24:29

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

New to my car gas tank in progress.
https://i.imgur.com/OfRknIC.jpg

Last edited by Rodman (2018-10-27 15:26:47)


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#23 2019-08-03 00:49:46

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

Update on my workhorse:
Replacement tank and filler neck all working well. Installed a new in tank filter and new Walbro fuel pump while at it
I’ve been struggling with an exhaust leak where the up pipe meets the exhaust manifold. Installed extra thick GrimmSpeed gaskets but issue persist. Good news is that it stops leaking once all up to operating temperature. I’m going to go at it again but I’m going to losen the brackets at the top by the turbo flange before tightening the bolts at the bottom of the up pipe junction.
I’m actually planning on installing a brand new Blouch 16gxt and dark blue STi injectors soon.
Tackled the hatch door handle, there’s a metal plate that has to be reused. Mine was very rusted and required wire wheel brushing all the rust off and painting. I was lucky it was still good metal under all the rust. It looked really bad when I looked at it at first.
I have rear strut tower rust, have to make time to pull the interior and asses the situation. I don’t think it’s too bad but shall see.
I think at some point might move the motor to the project bugeye.
https://i.imgur.com/qK2cumP.jpg
https://i.imgur.com/rNPOWUe.jpg
https://i.imgur.com/x4ygCXN.jpg
https://i.imgur.com/0oAs8GD.jpg
https://i.imgur.com/bIr8JmY.jpg
https://i.imgur.com/Zyt6LGf.jpg
Last winter mode
https://i.imgur.com/vchlNMa.jpg
https://i.imgur.com/AFs4Uct.jpg

Last edited by Rodman (2019-08-03 15:04:36)


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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#24 2019-08-04 13:40:14

snowphun
Member
From: Central CT
Registered: 2005-11-09
User Number: 890
Posts: 599

Re: 05 desrt silver aero work horse

I also did 16G and dark blue injectors, if I was to do it again I'd get bigger ones as I am definitely fuel limited. 305/300 on a Mustang dyno though mine is an IAG hybrid.

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#25 2019-08-04 17:43:44

Rodman
Member
From: Long Island
Registered: 2006-03-01
User Number: 1046
Posts: 2527

Re: 05 desrt silver aero work horse

2.5L is a totally different animal. I’m getting it tuned for 91oct fuel for when I travel to the Midwest and can’t find 93.   sadbanana


2005 satin gray metalic aero, sold. 06 wrx, adios!
2005 black aero, rescue project, jdm STi ver 7 drivetrain.
2005 desert silver aero, work horse JDM EJ205 AVCS
2002 bugeye, sedan :-( new project

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