Sleezer1533's 2005 Impreza 2.5RS GC

Ok so here we are with pics

Noticed that much of the fitment problem at the header outlet/HFCP inlet was due to the 2.5" piping at the inlet sticking past the flange and hitting the smaller flange at the outlet of the header
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So I filled the gap with metal filler and then ground it down
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Then I painted it with High Temp paint after prepping the surface with a scotch brite
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And started the headers
First I filled the gaps with metal filler and ground the pipe edges down a bit
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Then added liberal amounts of metal filler and let er dry
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Then ground it all to a smooth angle
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Not sure how the metal filler is going to hold up to the high temps but it is supposed to harden to metal strength, I mean this stuff was just as tough to grind down as the metal was. Anyway it was better than leaving it and worth the try to see what happens.

Ill paint the headers tomorrow probably and order wrap later tonight
 
Last Little update before bed:
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Regretting not taking as much time to scuff the surface of the header before painting, as I was taking it off the hanger the hooked aprt snapped from me spinning it earlier as I was painting it ... my thumb grabbed part of the painted area to keep it from falling and slipped a big spot of paint right off

Maybe Ill see how much I can force off and re-do them while I wait for the wrap to get here ... *shakes head at stupid-ness of cutting corners*
 
Quick test fit with the paint dired for a couple days and wow such a better fit. Not sure why they thought it was ok to send the pipe/flange out like that but w/e
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And the whole shot
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Haha, high flow cat yes

And yes there are inspections but as a NYS inspector myself I learned...

As long as there visually is a cat and there are no emissions codes you are all set. We don't do the exhaust sniffer stuff cali and other states do.
 
You've been on the forum long enough to know that someone is now going to ask what happened so why didn't you include it in the original post? lol but seriously, I'm sorry to see that. I hope you get it fixed soon and not out of your pocket.
 
Def. coming out of my pocket

Karma b**** slapped me in the face for trying to show off in front of my coworkers and I found out Imprezas are pretty good at obliterating mailboxes attached to 4x4s

Also found out Impreza fenders ... impossible to find!
 
Got one step closer to getting the exhaust finished
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To order or not to order wrap coating spray...

You an also see my wrap estimation skills leave something to be desired
 
the wrap looks great. dont be afraid to toss high temp paint on it. and that sucks about the fender. use a heat gun to head up the dent around the area affected and slowly work to the inside. go to the store and get compressed air duster. once the area is hot, turn the air duster upsidedown and do the same motion. the contracting of the metal can cause the dent to pop right out. you can also tap the back with a hammer while you do this to nudge it in the right direction. then use polishing compound to get the paint off.
 
Its kinda more than just a dent, It pushed the metal in and then slid along the fender about 6 inches flattening the flare. Skeptical about how effective the hot/cold trick will work although I have used that method several times.
I was thinking of pulling off the fender and using a hammer wrapped in a cloth to slowly work it back into rough shape and then wrapping it like the protege was, only thinking camo this time like protegeAK's instead of CF
 
remember you got rid of the protege for this car and we both know you want to do this car right, keep that in mind.
 
Tis true, but apparently they dont make replacement fenders for imprezas lol, none on ebay, roackauto doesnt have em...
 
Not so much my style, Id kinda like to stay OEM and a bit pricey just for fenders, fitment will probs be off in areas

On the other hand there is tad of weight savings with duraflex/CF fenders
 
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