Subaru Forester Modz for a Light Expedition Rig

[MountainBiker]

While a Subaru Forester is not the usual choice for an Expedition Rig, it has been a good compromise vehicle for our needs. I started out exploring 4wd roads with the car when it was stock, and I quickly realized it was a lot of fun, but obviously had some weak points when offroading. Even so, I could tell that it was quite capable to get me to most of the backcountry areas I want to visit, while still being economical to own and maintain. Besides, if the road gets too tough, I can always park the Subie and hop on my bike!

The plan is to make the Subie as capable as possible, without getting into major suspension modifications like grafting on parts from other vehicles.

Updated on September 12th, 2007
Modz so far, in approximate order of completion:
-Start with a 2002 Subaru Forester, Automatic Trans (the auto provides a little bit of a low range for ascents, but of course doesn’t help too much on descents!)
-Aluminum Sump Guard from SubaXtreme (http://www.subaxtreme.com.au/)
to replace the OEM plastic splash shield. It ain't steel, but this isn't a rockcrawler either!
-Center Diff Lock (Sort-of). Wired up a switch to override the electronic control of the center transfer clutch. This gives me the ability to get maximum power to the rear wheels, essentially “locking” the front and rear drive shafts. This is a fairly common mod for Subarus with the automatic transmission (stick shift Subies have a mechanical center differential with a Viscous LS unit, except for the Rally inspired STI!).
-Larger tires: Pirelli Scorpion ST 215/65-16, which are as tall as you can go on an ’02 Forester due to strut clearance. ’03 and up have a little more clearance for larger tires.
-40 mm lift, using strut top lift blocks from SubaXtreme (http://www.subaxtreme.com.au/). Lifts everything further off the ground, including the diffs, but at the cost of increased driveshaft angles.
-Offroad Front Bumper from SubaXtreme (http://www.subaxtreme.com.au/), provides a lot more approach angle!
-Sway bar quick disconnects of my own design.
-Custom rear bumper, incorporating a 2” receiver. Also replaced the stock muffler with a smaller unit, tucked up higher (axle-back), to get an incredible improvement in departure angle! To make it look halfway decent, I cut the bottom off the stock plastic bumper cover and re-installed it.
-Removed Bullbar section of the offroad front bumper (http://www.expeditionportal.com/forum/showpost.php?p=107620&postcount=11)
-Cargo Restraint system: using the 6' pickup truck net from www.cargonets.com.
-All Terrains: General Grabber AT2 (http://www.generaltire.com/generator/www/us/en/generaltire/automobile/themes/van/all_terrain/grabber_at2/master_en.html), 215/65-16. I’ve got six matching wheels and tires so I can do rotations with all six. By doing so, all six tires will be similar sized so that the AWD system doesn’t get damaged. As probably many EP members know, the hidden cost of full-time AWD is that one failed tire can mean that you have to replace all four due to the difference in tire circumference!

Here is a picture from Valley of Fire, Nevada State Park in November 2006: http://img233.imageshack.us/img233/8276/subiezt5.jpg (http://imageshack.us)

To Do in the Near Future:
-Quaife torsen style limited slip rear differential to replace the useless Viscous unit. Sitting in box, waiting for install!
-Fabricate tranmission pan impact protection
-Fabricate gas tank impact protection
-Transmission and diff breather extensions for water crossings
-Re-design sway bar quick disconnects for easier use and more durability
-Install switch to turn off radiator fans for water crossings (currently I just pull the fuse)
-Install switch to turn off ABS when on certain types of gravel and snow (currently I just pull the fuse)

Further down the road:
-I’m looking at all the cool cargo drawer systems on this site! Hopefully I'll be inspired enough to build a set.
-50 mm body lift (to add to the current 40 mm strut lift) from Scorpion Subaru ( http://scorpionsubaru.com/product.htm)

I plan to update this first post by moving things into the “completed” list as it occurs. And to add new stuff to the wish list!

[MountainBiker]

Some stats as it currently sits with the 40mm strut lift and 215/65-16 tires.

Ground Clearance = 9.4" to the lowest point (exhaust pipe), 10.4" or more to everything else.

RTI Scores, with homemade 20 degree ramp, and 36psi in the tires:
-400 with sway bars connected
-460 with sway bars disconnnected

[Bergger]

That's awesome! I've always loved subarus and it's nice to see someone using one in that capacity. Now you need to strap a roof top tent and a snorkel on that bad boy!

[jim65wagon]

That's awesome! I've always loved subarus and it's nice to see someone using one in that capacity. Now you need to strap a roof top tent and a snorkel on that bad boy!

Don't forget your expo decal!

[DaveInDenver]

That's so cool. A lifted, semi-locked Subie with a bull bar. That's more capable and does more than most mall terrain Rovers, Toyotas, etc. ever will. Awesome.

[TeleScooby]

Hey MountainBiker -
My X is exceedingly jealous of yours! But you knew that from the Forester forum...

Anyway, I'm using yours as a blueprint for what I want to do to mine, the problem is, SubaXtreme is gone and I have an '06...so no bullbars/bumpers out there for me...I'll do the Scorpion lift when money allows, and I'm due for new rubber in a couple of months.


Keep it up! I need somewhere to look for ideas...

My ride, pretty much stock except for the rack:

http://i81.photobucket.com/albums/j230/jessekelber/ForesterBox3.jpg

[MountainBiker]

That's awesome! I've always loved subarus and it's nice to see someone using one in that capacity. Now you need to strap a roof top tent and a snorkel on that bad boy!
Thanks! I really like the roof top tents, but I'm trying to keep the overall weight to a minimum.


Don't forget your expo decal!
Yep, gotta get one of those!


Hey MountainBiker -
My X is exceedingly jealous of yours! But you knew that from the Forester forum...

Anyway, I'm using yours as a blueprint for what I want to do to mine, the problem is, SubaXtreme is gone and I have an '06...so no bullbars/bumpers out there for me...I'll do the Scorpion lift when money allows, and I'm due for new rubber in a couple of months.
Thanks! You are in luck, because it looks like Hi-Rise Subaru (http://www.funonwheels.net/hirisesubaru/pages/home.htm) is doing a 50mm strut top lift for all Foresters! Check out the OffroadSubarus group buy (http://offroadsubarus.com/index.php?option=com_forum&Itemid=46&page=viewtopic&t=2852&start=30) going on.

[Martinjmpr]

How much does that bull bar weigh? I would think it would have some adverse effects on your front end (not to mention approach angle) to have that big hunk of iron hanging off your front end.

I've seen a lot of photos of modded Subarus in Australia, I guess it's something of an art form there. I enjoyed my Outback Wagon, even though it was not a serious "off roader" it certainly got me to places a more ordinary vehicle would not have been able to get to.

[MountainBiker]

How much does that bull bar weigh? I would think it would have some adverse effects on your front end (not to mention approach angle) to have that big hunk of iron hanging off your front end.
I didn't weigh it weigh it during the install, but it is close to the weight of the stock parts. Everything you see has no iron it, just Aluminium! There is a steel reinforcement beam behind the aluminum though. I'll be taking it off in the near future for some maintenance work, so I'll try to remember to weigh it. I still have the stock parts, so I can compare the difference.

[Toozeetoo]

Great post on your mods and plans, you may recognize me from SF.org, but I spend sooo much more time over here just drooling over everyones setups.
My 98 is still pretty much stock, with the exception of a pair of Hella 500's I mounted in front of the grille, I've had my Ironman lift springs sitting here since November of last year, I just can't find the time to install them!

While my Forester won't be used for extensive expeditions, I will be using it primarily as a camping base, to get me to greater spots than your regular park and camp sites.

[MountainBiker]

How much does that bull bar weigh? I would think it would have some adverse effects on your front end (not to mention approach angle) to have that big hunk of iron hanging off your front end.
I didn't weigh it weigh it during the install, but it is close to the weight of the stock parts. Everything you see has no iron it, just Aluminium! There is a steel reinforcement beam behind the aluminum though. I'll be taking it off in the near future for some maintenance work, so I'll try to remember to weigh it. I still have the stock parts, so I can compare the difference.
I weighed all the parts:

30 lbs = Stock bumper parts
55 lbs = complete offroad bumper/bullbar as seen in photos
40 lbs = offroad bumper with the "bullbar" loop removed

I had to do this because I noticed the bullbar had started shaking a lot over bumps. After pulling the bumper off, I could see that the unibody was had some cracks near where the bumper mounts up. I'm certain this was primarily due to a poor collision repair job that was completed years ago, before the offroad bumper/bullbar was installed. I had a local frame & body shop weld on new front unibody frame plates for less than $300. I don't want it to happen again, and I can't think of any real "need" to have the "bullbar" section in place, so it is now removed to put less weight on the mounts.

I also plan to build some supports to better stabilize the bumper, especially on those fast washboard roads!

[Superu]

I'll be having some custom fab work done shortly to shore up the FRH on Superu and I'd love to get a look at what's been done on yours to strengthen support for that bumper. Thx.

[MountainBiker]

I'll be having some custom fab work done shortly to shore up the FRH on Superu and I'd love to get a look at what's been done on yours to strengthen support for that bumper. Thx.
The original frame/unibody mounting was damaged in a crash (still had the stock bumper at the time) and the unibody repair was done poorly. This time around, I took it to a different autobody frame shop, and they just repaired it properly. They got new frame plates from Subaru, cut off the damaged parts and welded the replacements into position. Since this was just bringing it back to stock condition, I didn't take any pictures.

I wanted the frame shop to do some reinforcement, but they weren't interested, since they would be modifying "crumple zones", airbag actuation, yadda yadda yadda. In other words, they are afraid of lawyers, and I can't blame them!

[Starscream]

Very cool. I love Subaru's!

[Scott Brady]

Any updates on your project?

[MountainBiker]

Not too many updates or mods have been added, but the Subaru is still surviving! I'm heading out tomorrow for 1.5 weeks in Northern Arizona and 4 corners, so I'll have to send an update after the trip.

[MountainBiker]

Well, it is time to move on. I just purchased a 2000 4Runner LTD, which will replace the mighty Fozz.

It has been a great vehicle, introducing me to a slower pace off the highway (compared to my countless thousands of miles "off highway" on motorcycles), giving me time to enjoy the scenery.

If anyone wants any parts from the Subie, let me know. The lift will come off soon when I replace the struts, and the front and rear bumpers are available for trade, as I no longer have the original bumpers.

[Applejack]

Interesting......... I am looking to get out of a 3rd gen limited and into a Fozz. Why did you decide to make the switch?

[Bdiddy11]

What kinda MPG were you getting with the lift/tires?

I've been looking at a more fuel efficient light off-roader...namely the Forester (needs to be modded to look remotely decent), Impreza Wagon (lifted), Jeep Patriot and weighing other options for AWD vehicles...

My wife and I aren't hard core and we've got a 16 month old baby we bring along so nothing too crazy. But it'd be nice to actually be able to travel distances without getting bent over at the pump every time.

[MountainBiker]

I hate to be the one to tell you, but if you get a Subaru of the 2002 era, here is what you get:
-put on some decent A/T tires, 215/65-16 are the largest that fit
-add a 40 mm lift
-make sure you have an auto transmission, because the 5 speed cannot cope with steep offroad terrain (and the open center diff of the 5-speed is worthless offroad, while with the auto trans you can "lock" the center clutch pack by doing some wiring modifications)
>>> you will get below 20 mpg city, and 25 mph on the freeway (best case), if you keep it at 65 or below

[MountainBiker]

Main reasons for switching to the 4Runner:
- Subaru gas mileage wasn't great (see above)
- Lack of a locking front or rear diff, and poor articulation (even without anti-sway bars) means that you get diagonal wheel spin quite easily
- My Forester, and others of the same era, have undersized radiators, so it overheats when climbing a steep dirt road in the summer. Add a turbo and it gets worse, because Subaru doesn't upsize the rad for the turbo model...
- no easy way to protect the vulnerable auto trans pan (and the 5-speed manual just doesn't work offroad, unless you are only interested in smooth dirt roads)
>> keep in mind that I have heavily modified the front and rear bumpers to improve clearance. Combine this with the locking center clutch pack mod and the lift, and the Forester is quite good on moderate offroad trails, until a tire lifts in the air.

I don't want to mislead people, this car has been great for getting me offroad without using a motorcycle. In the car, I went slower, and enjoyed the same areas I had taken my motorcycle, but or course at a much slower pace. This was great, since the lower speeds helped me to appreciate new things. And I liked being able to plenty of carry camping gear so I can camp wherever, and enjoy the solitude.

The stock 4runner has similar ground clearance to my modified Forester (measured from the lowest point), has a little more space, but it has way more articulation AND the locking rear diff. The gas mileage so far is about the same around town, and ~15% lower on the freeway. It will get worse once I add some A/T tires, but it is still quite close while providing a lot more capability.

YMMV

[Ozarker]

WOW, a Fozzy owner flips on us in mid thread! LOL I took my stock 04 out on a fire road and went slow, it was fine and comfortable. I'd like the mods of the OP but not sure if sinking more money in it will turn out to be the vehicle I expect. No rock crawling, but getting over a ditch wouldbe nice. Two things I don't like, running out of gas just below the half tank mark and weak fan on A/C with the climate control, almost nothing in 100+ degree heat. Other than that it can make me smile.

[aerozeta]

That's plenty of awesome, I've been wanting a Forester, but still unsure about its offroad capability.

[ducktapeguy]

Say it isn't so! You still had one of the best modded foresters I've seen. We'll have to do another trip one of these days.

[MountainBiker]

Thanks DTG! The Subaru took me a lot of great places, but it was time to get something a little more capable. I've been wanting to do the Mojave Road again, and there are many, many other places on my "to do" list, so yes, lets do another trip sometime!