kpluiten's Build Thread: A Tale of Procrastination

[mc06STI]

Originally Posted by kpluiten

Thanks. It's not the best write up, but I hope it's somewhat interesting.

this is a great write up and its interesting to read. i personally dont like reading long paragraphs. but this stuff is Great!

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[Z0rr0]

Originally Posted by kpluiten

Also make sure to coat the pinch bolt in anti-seize as well. These bolts are notorious for rusting like crazy and becoming one with the knuckle resulting in a snapped bolt when you try to remove it.

This +1
But the good news is the bolt that breaks is only like $2 from CSS.. i bought 2 just in case I had to have my passenger bolt removed by a machine shop, after it broke, i didn't even bother with the driver's side.

[kpluiten]

Originally Posted by Z0rr0

This +1
But the good news is the bolt that breaks is only like $2 from CSS.. i bought 2 just in case I had to have my passenger bolt removed by a machine shop, after it broke, i didn't even bother with the driver's side.

Yeah, I usually buy new ones for any car I work on that is even slightly rusted. A $2 bolt and a bit of anti-seize beats the hell out of $40-60 machine shop visit... and another $2 bolt.

This is where experience pays off. I can feel when that bolt is going to snap now and I jump straight to the torch and hammer rather than just turn it harder.

[blkscooby]

Good work Ken. Leave no stone unturned... We could use you at Mike's house to finish the GN.

[Stick8373]

Originally Posted by kpluiten

Gah! I got rear-ended this weekend and forgot all about calling you. Damnit. I'll take a few bucks off for making you wait so long. I'll be in Tucson for the holidays (Thursday on) so we'll get something going! Sorry again! Thanks for the patience.

Got it!! Thanks for the shipment. Build looks sick!! Great work ...

[madmax_087]

Glad this thread is living up to its name...

Where is this wagon at Ken?

You still have it?

I dont think you do!

I think you sold the wagon, and are photoshopping old pictures every once in a while until you find a built one to buy that you can say you did yourself!

My whole life is a LIEEEEEE

[kpluiten]

Originally Posted by madmax_087

Glad this thread is living up to its name...

Where is this wagon at Ken?

You still have it?

I dont think you do!

I think you sold the wagon, and are photoshopping old pictures every once in a while until you find a built one to buy that you can say you did yourself!

My whole life is a LIEEEEEE

I have a clutch to do in a customer's car this weekend, but I should have some good time tonight and on Sunday to make some good progress. I hope to get the following done:

-Front suspension assembled and installed
-Rear hubs assembled
-Bushing installed on rear hubs and lateral links
-Rear subframe assembly assembled
-R180 assembled
-Fuel tank put back into the car

Tall order, but hopefully it will work out.

[kpluiten]

Well... I was WAY less productive this weekend because the clutch and other things took way longer than expected. I did get some stuff done though.

The first thing I did was take care of the bushings that needed to be pressed into the lateral links. I decided to go with Group-N bushings in every location I could for the car over poly bushings for a variety of reasons. One issue with the Group-N bushings is that they are not a two piece design like most of the aftermarket solutions and as such, they are hard to install, especially given their much higher durometer (firmer rubber).

Initially, I tried to lube up the lateral links and bushings with the Energy Suspension silicon grease, but I still couldn't manage to get the bushings into the arm. I would get them in there about 75% of the way, but then they would bulge to the point I felt I would damage them if I continued to press them.

In response, I made a couple of "funnels" that went from the bushings unloaded diameter to a couple thousandths smaller than the lateral link hold diameter. The funnels has a very slight angle of taper; in the case of the lateral links, it went from ~35mm to 33mm in a 1.5° taper. I also put a radius on the leading edge to prevent and bushing cutting. Armed with this tool, installation went way smoother. This tool is very similar to the Subaru special tool shown in the service manual.

First I lubed the funnel slightly and inserted the bushing needed (there are three different types of lat link bushings and they must be installed in the right lat links for proper performance.


Next I used the press to push the bushing into the funnel, usually about halfway down.


After that I carefully align the tool hole with the hole in the lateral link. They must be concentric to prevent any cutting/slicing/damage to the bushing being pressed. I then clamped the entire assembly to the press block with a ball joint press. This was chosen because it has a hole in the end which can be pressed through. I had to clamp the tool down to keep it from lifting off of the lat link while the bushing was making the transition from the tool to the link. If it lifted, the bushing would extrude out between the two and become damaged. At $10 a pop, that could get expensive very fast. I used an impact socket to give the press some extra reach.


Next I pressed the bushing into the link until I felt it bottom out on the press block.


With the clamp and tool removed, I was left with this:


Then it is just a matter of pressing it the rest of the way in. You usually have to press the bushing through until it looks like it is just about to start going through the link the other way. You do this to make sure the bushing flange pops out on the other side. Then you turn the link over and push the bushing back until it's centered. I had to go back and forth a couple of times to get it right.

[kpluiten]

Next I did the Group-N trailing arm lower bushings in the rear hubs. The process was very similar to the lateral links and again I used a funnel tool. I had the hub apart already so there was plenty of room to work. Others have made tools to do the install while the hub is assembled or on the car. My funnel tool went from 45.5mm to 40mm over a 4° taper.

[kpluiten]

Finished lateral links:

[kpluiten]

The other good news is that the powder coater finished the rest of my parts last week and I got a chance to pick them up yesterday evening. The results speak for themselves. If you are considering powder coating, I would go see:

Lou @ Section 8 Powder Coating
5346 S. Desert View Dr. Building #10
Apache Junction, AZ 85120
(480) 734-8372
http://www.section8powdercoating.com/

Tell him that you saw his work on my car.

I didn't get many good pictures, only some quick cell phone shots, but here it is:

BEFORE (I only had a shot of the rear of the caliper):


AFTER (the logo is powder too):



And here is the wheel color with a quick setup:




The brakes were done in a color called "Sweetpea Green" and the wheels were done "Super Black Chrome II" over a silver metallic base.

The wheels are a bit darker than expected, but they look really neat in the light. They are more gray when the light hits the silver base than they look in the above picture. I think it should look good on the car.

[02blkwagn19]

I like it man. Good call on the lime green.

Keep it up man! If you keep up with this heated pace you should be done within the next 2-3 years!

[KP]

Originally Posted by 02blkwagn19

you should be done within the next 2-3 years!

I wouldn't hold your breath.

[madmax_087]

Originally Posted by KP

I wouldn't hold your breath.

Uh, sarcasm?

Ken that color combo looks EFFING sick son. Effing sick. Im gonna come over to your house and hump your leg later.

[mc06STI]

ken! That green is CRAZY. i love it. good choice!

[Battousai311]

Originally Posted by mc06STI

ken! That green is CRAZY. i love it. good choice!

+1, sick looking as hell

[kpluiten]

[amroof]

im gonna come steal all your parts and put them on my wagon they look sick!

[05bluesti]

ken, wish i woulda had my wheels powder coated with yours, if ya want to trade, im open to it haha

[TwinscrollGT35R]

kpluiten spotted... driving down Bell rd

[kpluiten]

Originally Posted by TwinscrollGT35R

kpluiten spotted... driving down Bell rd

It ain't easy being green.

[madmax_087]

Originally Posted by kpluiten

Oh man that is so sick! I wish my stove had four burners... What color is that? Taffeta White? I mean you are a really brave guy to get your entire stove powdercoated. Looking good dude, cant wait to see that thing in the back of the wagon.

[kpluiten]

Originally Posted by madmax_087

Oh man that is so sick! I wish my stove had four burners... What color is that? Taffeta White? I mean you are a really brave guy to get your entire stove powdercoated. Looking good dude, cant wait to see that thing in the back of the wagon.

****in' Max.

[Evil Imports]

Originally Posted by madmax_087

Oh man that is so sick! I wish my stove had four burners... What color is that? Taffeta White? I mean you are a really brave guy to get your entire stove powdercoated. Looking good dude, cant wait to see that thing in the back of the wagon.

You are a dick to everyone

****ing retarded

[Z0rr0]

Originally Posted by madmax_087

Oh man that is so sick! I wish my stove had four burners... What color is that? Taffeta White? I mean you are a really brave guy to get your entire stove powdercoated. Looking good dude, cant wait to see that thing in the back of the wagon.