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Aren't all aluminum wheels these days CNC cut out of blocks? Or at least partially CNC milled?
I recall crash designs are also now including wheel strength based on how the wheel gets pressed back into the wheel well vs say shattering etc. Wheel design for sure is far more complex today than it use to be.
 
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New wheels and tires thanks to Discount Tire. Went with the Drag DR 62 and Continental Cross Contact tires. Dealer installed and reprogrammed TPMS sensors for free (had an "issue" with the service dept the other week so they have been willing to do a lot for nothing). Receipt stated cost would have been $165. I did pay $30 to have them balanced as I wanted to make sure they were fine as only 1 had weights on it when shipped. About 50 miles on the tires and they are much smoother and quieter than stock that came on car...they had 32,000 miles on them.
 

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Are any of the WRX or STI wheels forged?

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I know the 04-07 BBS wheels are forged (04 STI wheels won't fit as they are 5x100)and believe the optional BBS wheels offered since then are also forged. I believe the 'standard' WRX and STi wheels are all cast.
Aren't all aluminum wheels these days CNC cut out of blocks? Or at least partially CNC milled?
I recall crash designs are also now including wheel strength based on how the wheel gets pressed back into the wheel well vs say shattering etc. Wheel design for sure is far more complex today than it use to be.
No most wheels are still cast aluminum. The casting process has evolved a lot in the last 20 years but they are still cast. Some wheels are forged and wheels machined from billets are crazy expensive.
 
LP Aventure up in Canada runs 245/65R17 BFGoodrich All Terrain T/A KO2 on their newer outbacks. I'm looking to do this with their 2" lift kit and spacers if necessary. Looks like they used the Neo Motorsport spacer 17x8+15 final with a wheel that measures 17x8 Offset 45. Their instagram says: "because you have oem offset.. you can go 17x8+40 or 17x7+28 w/o problem (you have 17x7+55) go with 25mm w/o trim." I found a wheel that looks similar to theirs but the specs are 17x7.5 - offset 45.

My question is around the 7.5 width vs the 8. Can anyone tell me if this would pose a problem?

The wheel is the MSW Type 77 Matte Dark Grey 17".
 
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Looks great! How much clearance do you have between the strut and tire? The STI wheels are 8.5 inches wide with a 55 offset so that would put the wheel between 19.1mm closer to the strut than a stock 18" that is 7" wide with 55 offset.

Did you go with 245/55-18 size tires?
 
Looks great! How much clearance do you have between the strut and tire? The STI wheels are 8.5 inches wide with a 55 offset so that would put the wheel between 19.1mm closer to the strut than a stock 18" that is 7" wide with 55 offset.

Did you go with 245/55-18 size tires?
I have 2016 WRX Limited wheels on my Outback (same specs as STI wheels), and I swapped the stock tires over. Because the sidewall design of the stock Bridgestones are so rounded, they did come close to the strut, but still had about 3mm clearance. I plan to switch to 245/55-18 tires when the stock tires wear out, but the new tires should have a much straighter (less bulge/rounded) sidewall, so clearance shouldn't be a problem.

Custom wheels, wheel tire packages for your ride - RIMSnTIRES.com
 
My setup for 2016 Outback 3.6R Limited

My setup for 2016 Outback 3.6R Limited

(Current) 3-season: RWC SB40 GUNMETAL (18x8 ET48) with OEM tires

Winter: OEM wheels with Michelin X-Ice3
 

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