Was wondering if anyone has tried to increase the gap in between the bracket that connects onto to hub/spindle assembly? Is it possible to make the gap bigger to fit the 05 STi hubs without any damage to the original welds? BTW I'm doing a 5X114 conversion on my RSTi and the coilovers are Megan Racing. I bought the BC brackets thinking that since Megan products are made by them it should fit, turns out that there is a difference in diameter and so the way they are designed won't fit my coilovers. Red circle in image is what I'm trying to open up so that the STi hubs will fit.
The only way you are going to do it and not compromise it's integrity is to cut it off and re-weld it back on in the proper size. To do it right you would need a jig of some sort, otherwise the bracket will not be exactly where it needs to be, and you would have too much variability between each strut body. So, short answer is no.
So should I take this to a shop to modify or does anyone on the forum have enough expertise to help modify and reweld it?
Like I said, unless you already have a jig set up for manufacturing coilovers, it is going to be really hard to get it right. You are better off selling them and buying the proper set for your application.
I never thought it be this hard to do a 5x114 conversion, LOL. Guess they'll be up for sale then and they've only been on the car for about 3K miles.