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Old 10-17-2011, 01:48 PM   #1
girodisc
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Location: B-ham WA
Default The ForeSTAR Build thread.

Hey all. Starting another project....

The car used to be a buddies of mine. About 5 years ago after my wagon was killed. I bought an 03 Wagon to rebuild it. Since I still had all the go fast bits out of my wagon I sold and installed all the parts into this Forester. My buddy drove it around for a long time trouble free and it was very dependable. Recently he decided it was time for him to swap up to an STi. He wanted something stock and fast so I offered to buy his Forester to use as my dedicated Auto X/ Track Car.

I had been Auto Xing the Legacy for a while now and it was performing great but the ride was a bit hard, the gearing was way to low for good freeway runs and yes is was fast and relatively comfortable it wasn't really what I envisioned the car to be. So this winter the Forester is going to get the full race car treatment and parts will be coming off the Legacy so I can soften the Legacy back up so its a better hwy cruiser/ dd.

So on to the build. The Class I like to Auto X in is C1 FP an for track use I will probably start by just doing club days. Here is the current parts list that I have.

Engine:

STI Long Block
CP 9:1 Pistons
Manley Rods
Killer Bee Oil Pickup
Killer Bee Oil Baffle
Unorthodox Crank Pulley
Unorthodox Alternator Pulley
Unorthodox P/S Pulley
Custom Modded Tomei Replica Manifold
Modded WRX 800cc Injectors

Turbo/ Exhaust
20g XT 7cm w/ 3" Inlet
Custom Forward Facing Turbo Setup
Custom V-Mount Intercooler Setup
Custom Side Exit Exhaust

Drivetrain/ Brakes:
Ver 7 RA Spec-C Non-Dccd 6mt
05 STi 5x114.3 Hubs
ACT Prolite Flywheel
Exedi Certametallic Clutch
Agency Power Short Shifter
ACPT Carbon Driveshaft
STi Brembo Brake Calipers
Girodisc 2pc Front Rotors
Girodisc 2pc Rear Rotors
Girodisc SS Lines
Girodisc Maxi Pads
Custom Relocated ABS Pump
Custom Brake Lines

Suspension:
Stance XR Coilovers
Perrin PSRS
Perrin Rear Stuff Sway Bar Mounts
TSS Fab Custom Front Crossmemeber
TSS Fab Custom A-Arms
TSS Fab Custom Tranny X-Member
TSS Fab Custom Rear T-Bar
TSS Fab Custom Rear X Member
TSS Fab Adjustable Control Arms
TSS Fab Adjustable Lateral Links
Custom Stitch Welded Chassis
Custom Smooth Bottom Paneling
Whiteline Roll Center Kit
Whiteline Steering Rack Bushings
Whiteline 24mm Front Sway Bar
Whiteline 27mm Rear Sway Bar
Kartboy Front Endlinks
Kartboy Rear Endlinks
Kartboy Shifter Bushings
Kartboy Subframe Lock Nuts

Wheels/ Tires:
Daily: XXR 527 18x9.75 on 245/40/18 Hankook RS-3
Race: XXR 527 19x9.75 on 275/35/18 Hankook Z214

Exterior/ Weight Reduction/ Safety:
Lexan Windows
Aluminum Roof
Gutted Front Doors
Bolt On Rear Door Skins
Gutted Hatch
VIS Carbon Fiber 02 Forester Tracer Hood
Liberal Replica FRP Front Bumper
Custom Aluminum Rear Diffuser
Custom Carbon Rear Spoiler
Custom FRP Fender Flares

6pt Roll Cage
Netami Carbon Bucket Seats
STi Dash
Shaved Harness
Fusebox/ Battery/ ABS Pump Located in Cabin

etc....

So I started the Project Yesterday by starting the tear down. Many of the original parts are going to be sold off and some of it already is. What I don't sell I will use the replace the Auto X parts coming off the Legacy.

Here is what She looked like before I started:







And 2 hours Later...








So this week I will continue to strip the car down to just a shell. Once I am done with that I am going to set it on its side and remove all the undercoating and then stitch welded the car and coat it. Then I'll put it back on its floor and working on installing the cage and wiring. I'll be working on this in tandem with 2 other projects to progress will be a little slow for a few weeks and then I will be on this for the rest of the year. Going to talk to TSS fab and get the Chassis parts done and sent so I can make it roller again after the Lego is stripped.. Stay tuned.. I

ts no Celaru but this is going to be a good one..

Johann @ Girodisc
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Old 10-18-2011, 11:31 AM   #2
girodisc
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Hey all. Got some more work done last night. Engine is ready to pull, suspension is ready to come out and I got some more work done on the interior.



Here's a pic of the shop. The car next to it is getting a few parts of the fozzy to help pay for the initial cost of buying it and then its getting a nice helping of Johann flare.

Smooth Engine Bay
Tucked Brake Lines
Tucked Wiring
Custom Roll Cage
Full WRX Wiring Swap
Full WRX Dash Conversion
Ver 7 JDM STi Motor Swap
05 STi Brembo Brake Conversion
Custom Fender Flares
18x10 Rota SVNr w/ 255/35/18



I'll post up some pics when its closer to getting put back together.

Johann @ Girodisc
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Old 10-19-2011, 07:48 PM   #3
bFreed
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Very cool build! Love this bodystyle Forester. What's the offset on those wheels?
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Old 10-19-2011, 10:28 PM   #4
Lazer84
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Don't see too many SF builds like this! Solid start and I'll be looking forward to seeing this come together!
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Old 10-20-2011, 11:14 AM   #5
girodisc
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Those are Rota SVNRs 18x10 +30 on 255/35/18s

The new setup will be ether 18x9.75 +20 on 275/35/18s or 18x10.5 +15 on 295/30/18s

I need to look at the rules of my class I think I am limited to a 10" wide wheel.

Johann @ Girodisc
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Old 10-22-2011, 01:45 PM   #6
Tuned200
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Nice to see a build with proper fitment for tires! I very much hate the new scene stretched look.

Props!
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Old 10-24-2011, 01:23 PM   #7
girodisc
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Got a bit of work done to the fozzy the last few days. Finished stripping it out and its ready to be put on her side so I can strip all the undercoating off and stitch weld it. I have to spend this week working on the GC sitting next to it but maybe this weekend I'll start stripping the underside down.







Yesterday took an 8hr drive in the Zombie Killa to go pick up some parts for her. Picked up an 05 STi engine, a full harness, gas tank, steering column, dash etc...

I'll be tearing into this harness in a week or so and taking all the covering off it so I can start cutting out all the crap I don't need.

Johann @ Girodisc
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Old 10-25-2011, 02:10 AM   #8
TSSFAB
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Killer project! You thinking about raising the front towers I could cut up plates for that
in my sleep. Because front packaging is really short and one inch could keep the front
from bouncing you can get more bump with out bottoming.

your a savage and cant wait to work with you and make some wicked custom parts.
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Old 10-25-2011, 11:32 AM   #9
mrpink1942
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cant wait to see what you do with this, the legacy was awesome.
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Old 10-25-2011, 11:35 AM   #10
girodisc
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Yeah I am allowed to use crossmembers made from scratch change location of the drivetrain as long as the firewall isn't altered heavily. I can also change any suspension points including moving the shock towers if necessary. I can also brace and notch frame rails.

Give me a call when you got time and we can talk it over. I want to get started on something with you soon so when I get all the stitch welding done I can start throwing parts in it to make it a roller again to I can drop the motor in and start fabricating all the turbo goodies.

Johann @ Girodisc
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Old 10-28-2011, 07:42 PM   #11
good dog
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What do you mean by stitch welding?
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Old 10-28-2011, 07:44 PM   #12
good dog
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And are you able to weld the floor-pans. I seem to recall a video of New England Sportscar building a streetable rally car and they tightened up some flex by welding the floor-pans.
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Old 10-31-2011, 11:12 AM   #13
girodisc
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Stitch welding is when you add additional welds to the underside of the chassis to strengthen it. The OE spot welds are good but for racing you can remove a lot of flex by doing it. I will have pics of the process in a couple weeks.

Update coming in a little bit.

Johann @ Girodisc
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Old 10-31-2011, 03:43 PM   #14
girodisc
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Hit a good stopping place on the GC on Sunday so I got to put in a few hours on the Fozzy.

Got my ol trusty hammer and big screw driver and got to work on the sound proofing.



Next wheel be taking a wire wheel to all of it and getting the remainder off. I'll do that once all the metal that I am going to remove is off so I am not wasting time cleaning parts I don't even plan to keep. After I finished I removed the windshield and side windows. This is the result of a couple hours of work...



After I finished I weighed the sound proofing and amazing I removed 49lbs of weight alone. The glass as another 55lbs so total for the day was 104lbs! Not to shabby.

Next I marked the 2 floor pieces that I am going to remove and replace with some much lighter aluminum. pieces. I am leaving the stock gas tank cradle strap points for now. I have my new spot-weld bits ordered up so I can get the pieces inside removed. I am confident I can pull another 100 or so pounds out of the chassis before I even start pulling off undercoating pieces out of the engine bay.





More updates once my bits come in.

Johann @ Girodisc
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Old 11-04-2011, 04:47 PM   #15
EGGS
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holy !!!!!
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Old 11-07-2011, 11:29 AM   #16
Nosogirl
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I dig it. I have the same body forester and I'm trying to take it down a similar road. Well, i might not go as far as lexan windows, she still has to be my winter hooptie, and ill be gutting my interior not so much for weight savings but more to remove that dog-owning-hippie-smell all used foresters seem to have lol. totally ill man!! i have a well earned respect for those who auto x their foresters.
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Old 11-07-2011, 11:41 AM   #17
girodisc
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Thank you.

Got a bit of work done this weekend. My buddy (the previous owner) said if he could help that he would so I cashed in on some volunteer work so I could work on the GC. Need to start removing all the undercoating from the underside and laying on my back is not very fun. So we made a poor-mans lift. The car actually balances at his angle but I strapped it to make sure. Soon i'll have pics of the stripped underside and I have been trying to keep all the debris so I can weigh it. They say its around 40-50lbs if you take it all off and I intend to so I guess we'll see. Then it will be stitch welding time!





I need to get the GC ready to head off to paint on the 14th but once that's done the Forester will get about 2 weeks of strait work so I can get the chassis done and hopefully painted so I can start making it a roller again. I have some parts ordered up and on there way so fabrication time will begin shortly after the GC is finished.

Johann @ Girodisc
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Old 11-22-2011, 12:32 PM   #18
Bad Wagon
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08 Lego 3.0R Flared

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So the GC8 Project is off to paint which is going to give me a couple weeks to give the forester some love. Spend about half the day after the GC left getting started on more chassis fun.

Started be removing some of the undercoating:





So far from what I have removed (about 30%) its about 8lbs. So when its all finished the removal of the undercoating will drop about 30lbs but the real reason for this is to get at the panels to stitch weld them. So a couple pounds added back in but for a rigid chassis its worth it.

I finished the day off by busting out my new spot weld removal bits and they work great. Got a few of the pieces off that I will not be neededing:



Just in this pile here is 19lbs of un-needed metal. I have at least another 20lbs to pull off the passenger side and then I will be removing their drivers side counterparts and with the addition of the pieces of the floor I marked for removal it should get me a total of around 80-110lbs dropped off the car. This does not include any of the front core support that has yet to be removed. Willain at TSS-Fab has started work on my cross-members. I will be getting the full monty of stronger lighter crossmembers so once those are here I can remove the suspsnsion and drivetrain pieces off the Legacy and get this back into a roller. By they time the GC will be back so I will be pushing hard to finished that so I can get a payday and start ordering more parts and materials.

More updates soon to follow.

Johann
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Old 11-24-2011, 10:34 PM   #19
dasboot
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Unreal man! Subscribed.
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Old 09-21-2013, 10:42 PM   #20
Doa672ug
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Unreal man! Subscribed.
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Old 12-01-2011, 08:27 PM   #21
Bad Wagon
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Okay I finally have time to get to this. So I got some more of the undercoating off.



Managed to cut out the pieces in the floor I wanted to remove.



So far we are at 86lbs for the scrap metal that has been removed off the chassis.



Tomorrow I am going to take as much off the Legacy as I can so next week when I get it back into a roller and off its side.

Johann
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Old 12-02-2011, 01:00 PM   #22
tehFish
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This is going to be awesome! I got my popcorn ready!
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Old 12-03-2011, 04:54 AM   #23
Kumachn
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Just in case you haven't finished taking the sound deadining out. It faster and and comes off cleaner if you use Dry Ice and leave in the spot your going to removes with a rag covering the area. Then when you whack the sound deading, it comes right off and leaves the paint less sticky.
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Old 12-03-2011, 01:15 PM   #24
Bad Wagon
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Ya I have used that technique before. Nice thing about Washington is that it already that cold here so 95% just chipped off. Once the underside is finish and it on the groundnuts right way I'll clean up the remainder on the interior.

Johann
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Old 12-05-2011, 11:56 AM   #25
Bad Wagon
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Hey all. So after a couple days of some of the most tedious work I will be doing on this project the underside has been stripped and the chassis stitch welded. A nice coat of gloss black paint finishes her off. Bring on the TSS- Fab Parts!







Johann
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