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Old 04-24-2010, 11:02 AM   #1
scoobydoo666
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Member#: 132099
Join Date: Nov 2006
Chapter/Region: E. Canada
Location: Canada
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2012 sti limited
rally blue

Default Totaled 2006 WRX repair project ''DIY style'' Journal with pics

So a year ago, I did a body restoration on a 04 ts that had 12000$ damage done by hail. Came out amazing, so I decided to go on with another project.

THE CAR: a 2006 WRX TR with 18 000 miles on the clock. Bought it at IAAI live auction form insurance company. Came from North Carolina to my home in Quebec, Canada on a truck. Good thing about it when it showed, driver's headlight was in the trunk, not intact but easily repairable. (550$new...)



The day it showed up at home (2 weeks ago):




THE DAMAGE:
Missing was the front bumper cover(broken), fog covers, passenger headlight (there but broken). The hood was kinked at 2 places, the 2 front fenders were damaged and one was kinked a bit so I replaced it. 2 doors: 1 repairable, 1 replaced.
The quarter panel had to be stretched back into place with the Uni-Spotter. The headlight brackets were bent so new ones will do.

My objective is to get it on the road by April 30th. I'm working on it a bit every week days.

THE BONUS AFTERMARKET PARTS!!!:
Came with Rota Torques in Falken good rubber, Rally Armor flaps, Kartboy short shifter and knob.
This stuff I did not know about: Prodrive springs, 22mm sway bars with link kit, stainless braided brakes lines.




CAN SOMEONE HELP ME IDENTIFY THE SWAY BARS AND LINK SET??




The bar is a light gold and nothing written on it. 22mm 3 holes adjustment in the rear only.

Last edited by scoobydoo666; 08-20-2010 at 04:01 PM.
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Old 04-24-2010, 11:23 AM   #2
scoobydoo666
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2012 sti limited
rally blue

Default Day two:

Removed door panels, taped a bit, buffed down to bare metal where damaged.


started repairing this fender but ended up replacing it.

Lot of hammer and dolly work on the hood since it was bent almost one inch. Fender also.

Quarter panel was almost 1 inch bent also. Doesn't show much in the photo but it was bad. The rear door all messed up. I started with a pry bar straightening the door but it was too much work since it is where the widebody starts and I didn't want a door full of bondo. For 150$, I got another used one in the same color.


Front door was restored successfully with hammer and pry bar.
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Old 04-24-2010, 11:34 AM   #3
scoobydoo666
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2012 sti limited
rally blue

Default Day 3:

Door replaced and original window put in.


Quarter panel repair with UniSpotter. This welds small nails in order to pull the sheet metal. Then I cut and buff the nails.




Starting filler and sanding on fender.


Filler on front door. Sanding it after for a smooth and even panel.
Looks like a lot but only a realy small amount will remain.


small ding repaired on rear door since it was a used one.
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Old 04-24-2010, 11:27 AM   #4
99subi
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05 Legacy

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i cant believe they totaled that car..........
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Old 04-24-2010, 11:29 AM   #5
scrape
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Is there any frame damage?
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Old 04-24-2010, 11:35 AM   #6
scoobydoo666
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rally blue

Default

Quote:
Originally Posted by scrape View Post
Is there any frame damage?
ZERO frame damage.
all body panels are now straight btw. I'm writting about it this morning.
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Old 04-24-2010, 11:45 AM   #7
scoobydoo666
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2012 sti limited
rally blue

Default Day 4:

Quarter panel was back in place 24 welds later, so I began the filler and sanding work to shape back the original form. This is the hardest part because this is a complex shape with lots of angles and edges.




Received my other light and bumper cover. Test fitting the front panels. Realized my left headlight bracket was bent it did not fit good. Bracket ordered.




See the fender tip? here come the hammer again to raise it flush. The hood has to come down a bit also.

sanding halfway done. my wrists hurt... haha!
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Old 04-24-2010, 11:52 AM   #8
JeffrWRX
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Location: Murrieta, CA + SAN DIEGO
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2002 PSM WAGON Stg2
FORTUNE/RPF1-17x9/2354017

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I wish I had the tools, space, knowledge, and skills to do something like this.

Looks awesome
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Old 04-24-2010, 12:01 PM   #9
scoobydoo666
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2012 sti limited
rally blue

Default

Quote:
Originally Posted by JeffrWRX View Post
I wish I had the tools, space, knowledge, and skills to do something like this.

Looks awesome
Thank you. you know what? 2 years ago, I had no tools, space or knowledge. I learn while doing it!
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Old 04-24-2010, 12:22 PM   #10
scoobydoo666
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2012 sti limited
rally blue

Default Day 5:

fender reshaping and finishing work.


Look how flush it is now with the door. not perfect but getting there.



The hood was 1\4 of an inch too high compared to the fender on the edge since the hood was bent a bit. I took a 2x10 wood piece to pry the hood down with my 200lbs fully on it. That was scary but it did the job!

I drilled a hole from behind to push the dent out. I put mono inside to joint the sheet metal together. The filler won't crack that way. Plugged the hole.


filler applied on hood.



action shot!!


doing progress on the hood. not perfect.
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Old 04-24-2010, 12:22 PM   #11
scoobydoo666
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rally blue

Default

day 5 continued:

fender now straight.


door finished sanding. body panels all sanded with 320 grit for primer.




hood now perfect, ready for primer
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Old 04-24-2010, 12:29 PM   #12
scoobydoo666
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2012 sti limited
rally blue

Default day 6

after test fitting the bumper, hammering the fender a lot, a chose to replace the fender because fitment wasn't 100% perfect.



body work on the used fender with test fitment again.

took the car out for cleaning the garage.
friday pm cleaning

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Old 04-24-2010, 12:21 PM   #13
JDM_OBP
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'05 HTA68'd WRX
327/310

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coming along nicely. Wish I had the patience for something like this
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Old 04-24-2010, 12:37 PM   #14
Rexxin
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'03 Swap'd Wrx
'95 drift e36

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looks great ... are you keeping the car ... or selling it if you dont mind me asking ...
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Old 04-24-2010, 03:03 PM   #15
scoobydoo666
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Default

Quote:
Originally Posted by Rexxin View Post
looks great ... are you keeping the car ... or selling it if you dont mind me asking ...
I bought it for selling it. But after seeing all those aftermarket parts on it, and no frame damage and all, I think Im gonna keep it.
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Old 04-24-2010, 12:57 PM   #16
dowroa
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No More Subarus :(
Only a truck, for now. ;)

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Bump for a car from my home state!

- dow
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Old 04-24-2010, 12:59 PM   #17
IGoCode3
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Default

Hope you don't mind me asking this, but how much did you purchase the car for? Looks like you are getting an awesome deal for it considering you are doing all the labor, and if you got it for a great price.

Awesome job, can't wait to see the end result!
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Old 04-24-2010, 03:01 PM   #18
scoobydoo666
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Default

Quote:
Originally Posted by IGoCode3 View Post
Hope you don't mind me asking this, but how much did you purchase the car for? Looks like you are getting an awesome deal for it considering you are doing all the labor, and if you got it for a great price.

Awesome job, can't wait to see the end result!
the price was 9000$ us approx. here in Canada with dutys shipping and taxes, it was 12000. With that mileage, a car like that here is around 20 000$.
I save money doing it myself.

I'm getting ready to shoot 4 coats of primer now.
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Old 04-24-2010, 01:56 PM   #19
Ptero
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I've always wondered what the purpose of the nails were. That's awesome. Great DIY job!
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Old 04-24-2010, 03:01 PM   #20
blakkboxer
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black & gold is pimpin'

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that's very impressive work

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Old 04-24-2010, 03:14 PM   #21
The Database
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^^^^ You should, great find.
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Old 04-24-2010, 03:14 PM   #22
04wrexsti
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'00 RS race car

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nice work man! i just had to repair my old black 04 sti which had similar damage and red mud flaps haha except my damage on the passenger side doors was alot worse, but it was the only spot on the car that had anything wrong.
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Old 04-24-2010, 03:26 PM   #23
Mr_Hox
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I just went from
six to midnight...

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Great work!

Gonna paint it a different color, or keep it black?
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Old 04-24-2010, 03:52 PM   #24
PCrowlz
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PSM

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Very nice work. I will do one of these projects someday when im out of college.
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Old 04-24-2010, 04:57 PM   #25
scoobydoo666
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Quote:
Originally Posted by Mr_Hox View Post
Great work!

Gonna paint it a different color, or keep it black?
I keep it black since I'll paint only the damaged panels.
No need to paint the entire car. plus, paint is $$$
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