SG forester budget build

[loweredexpectations4x4]

So I moved to San fransisco a couple years ago and had to get rid of my jeep and my camping gear. I’ve recently been itching to get back out on the trails so I’ve begun my rebuilding. My new overlander of choice (or convenience) is a 2004 Subaru forester 2.5X base model. I got it for free from a customer who bought it new and didn’t feel it was worth fixing after nearly 20 years and 200k. It had a blown head gasket and was generally worn out from use as a family wagon.

 

[loweredexpectations4x4]

So I set to work fixing the head gasket and replacing the dirty cloth seats and carpet with a second hand black leather interior from a XT. The heated seats have been an amazing upgrade.

 

[loweredexpectations4x4]

Set my sights next on gaining some altitude. After a weeks of research and endless arguments and opposing views on the forums on lift and tire size limits I decided to go with 3” lift and 205/85 R16 tires to get maximum ground clearance. I decided to use a 3” strut spacer lift without dropping the subframe, I removed the sway bars to encourage as much travel as I can with the independent suspension. While I had the suspension apart I swapped the rear drums for disc breaks off the same XT that gave me the interior. For tires I went with a wired size, 205/85R16 Achilles M/T. These wound up being about the same width as the original tires but as tall as 235/75 r15 tires on original steel rims. Keeping the width down allowed me to (barely) clear the lower spring perches without wheel spacers. Removed the mud flab’s and trimmed the fender liner and body seam. It still rubs at full lock but that’s the price you pay for ground clearance.

 

[loweredexpectations4x4]

Then time for it’s first test! Took a day trip out to a water Hole I know close to me. Mostly just fire roads but got to test it on some small hill climbs, rutted out side trails, and more than a few water crossings. Coming from a well built jeep im pretty impressed with how well it handled off road.

 

[benmmc]

Oh man that looks like fun! We bought a 2003 on eBay back in 2011 – same color as yours. Had low miles, but I think it was used as a delivery vehicle or something because it has many issues and was really beat up. I fixed it up and we drove it for years. Never bought another car on eBay though, that's for sure.

Good luck with it, already looks cool with the MTs!

 

[loweredexpectations4x4]

Oh man that looks like fun! We bought a 2003 on eBay back in 2011 – same color as yours. Had low miles, but I think it was used as a delivery vehicle or something because it has many issues and was really beat up. I fixed it up and we drove it for years. Never bought another car on eBay though, that's for sure.

Good luck with it, already looks cool with the MTs!

Thanks!!! Even though mine is really high millage the previous owner took really good care of it mechanically. I’ve got the records on it from my shop going back to 2007. It was a well loved and well used vehicle.

 

[loweredexpectations4x4]

Today took the forester in to the shop to give it an inspection before heading on a three day off road trip over the forth of July. While I was I. The shop I installed a modification I’ve been working. It’s a couple relays and a resistor that take control of the AWD duty solenoid to lock the center diff while giving the TCM the dummy load so it doesn’t get mad and light up my dash. I’ll see how well it works on this trip and make a more permanent circuit board for it.

 

[loweredexpectations4x4]

Took the forester out on its first off road camping trip! Three days in the sierras! It handled really well a for a first real off road trip! Did wind up breaking the front bumper off but that just means it’s time for some armor.

 

[El-Dracho]

Awesome. Looks like a great trip and a lot of fun with the Subi. Thanks for sharing.

 

[SJ Dave]

How’s your subi holding up??

 

[Wildcat-01]

This is a fun, approachable build. I wish that I'd read about the 205/85R16 option before I shelled out for my 215/70R16s! Oh well, next time.
Our builds have similar trajectories, it seems. I'm building up a bit of a worn 2004 BH Outback. Doing the 3" coil spacer lift and brakes and CDL mod. I've finally gotten the suspension cleaned up enough and new bearings in that I finally feel like I'm starting off from a clean enough starting point.
Keep on wrenching and wheeling! I hope to see you on the trail someday!

 

[DintDobbs]

@loweredexpectations4x4 Nice rig! Most vehicles with even the simplest of AWD configurations can tackle more than they will ever see, given a half-decent driver behind the wheel.

I sort of laugh in the face of built Jeeps, since I've seen a lot of self-righteous folks who buy them for their off-road capabilities without bothering to install the appropriate driver mods.

Subaru is no slouch in the off-road scene, but its limit is reached where low range is required. Exceptionally versatile vehicles, otherwise!

 

[loweredexpectations4x4]

after a long fall and winter started back on the forester. I picked my parts and upgrades with some specific trails and camping spots in mind. I replaced the old worn CV axels with some high travel ones. I added a front “skid plate” made from some shop scrap. I’ll upgrade this later to one with better coverage but needed some protection for an up coming trip. I did add a Primitive transmission skid and a rear skid as well. The rear diff needed a reseal so while it was apart I added a lunchbox locker. Now with the center diff lock mod and the rear locker it should be pretty capable. Knowing that I like to play in the desert I added a hood from an XT to help get hot air out and an auxiliary transmission cooler. I got tired of the saggy broken front bumper so I used some scrap shelving bits to make a bumper. It’s surprisingly light and strong, but mostly a cosmetic filler. Once again I plan on upgrading to a winch bumper in the near future.

 

[SJ Dave]

after a long fall and winter started back on the forester. I picked my parts and upgrades with some specific trails and camping spots in mind. I replaced the old worn CV axels with some high travel ones. I added a front “skid plate” made from some shop scrap. I’ll upgrade this later to one with better coverage but needed some protection for an up coming trip. I did add a Primitive transmission skid and a rear skid as well. The rear diff needed a reseal so while it was apart I added a lunchbox locker. Now with the center diff lock mod and the rear locker it should be pretty capable. Knowing that I like to play in the desert I added a hood from an XT to help get hot air out and an auxiliary transmission cooler. I got tired of the saggy broken front bumper so I used some scrap shelving bits to make a bumper. It’s surprisingly light and strong, but mostly a cosmetic filler. Once again I plan on upgrading to a winch bumper in the near future. View attachment 278899View attachment 278900View attachment 278901View attachment 278902View attachment 278909

Nice! I also saw your post on Reddit. Haha

 

[Dogbite]

Where did you source CV axles?

 

[Wayne AKA Jugbutt]

So I moved to San fransisco a couple years ago and had to get rid of my jeep and my camping gear. I’ve recently been itching to get back out on the trails so I’ve begun my rebuilding. My new overlander of choice (or convenience) is a 2004 Subaru forester 2.5X base model. I got it for free from a customer who bought it new and didn’t feel it was worth fixing after nearly 20 years and 200k. It had a blown head gasket and was generally worn out from use as a family wagon.

That is so nice. You going to lift it or what's your plans. Very interested

 

[Wayne AKA Jugbutt]

Took the forester out on its first off road camping trip! Three days in the sierras! It handled really well a for a first real off road trip! Did wind up breaking the front bumper off but that just means it’s time for some armor.

That sure isn't any Louisiana camping. That is a beautiful place there

 

[Wildcat-01]

Where did you source CV axles?

Napa has long-travel front CVs. A pair is about the same price as one OE axle. When my $60 emergency axle finally dies, I'll be getting a set for my own beater Subi.

 

[loweredexpectations4x4]

Where did you source CV axles?

oreillys auto parts. I've got a commercial account with them for my shop so i get a bit of a discount.

 

[loweredexpectations4x4]

That is so nice. You going to lift it or what's your plans. Very interested

its got a 3" strut spacer lift on it. most of it is amazon stuff but ive gone through and found the individual spacers for the struts and the rear trailing arms as none of the full kits in my price range seemed heavy duty enough to handle what i want to do with it. ive got some heavy rear springs on it to help carry the load of camping gear i fill it with, when i install them ill do a full wright up on the suspension mods.