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Old 04-13-2012, 12:32 PM   #101
Bad Wagon
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Covering it. My class doesnt allow me to replace it.

It's a walbro intake pump and the per-filter is touching the cells floor. The surge tank will hold all the fuel I need while turning hard.

I'll be running the dash, center piece, and glove box. Need to get the dash flocked though..

Johann
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Old 04-14-2012, 11:55 AM   #102
Bad Wagon
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Damn, you're pretty good...

Update time!!!!!!

Started my day off on the right foot with gift from the UPS guy. FITTINGS!!!



Still missing a few that were back orderd but this is going to make working and fixing this beast a breeze. No more crappy hose clamps or torn hoses from barb fittings. All of the hoses have been consolodated to 4 sizes: Vacuum lines, -6an (3/8), -8an (1/2), and -10 (5/8). These are push lock style fittings so trackside replacing of hoses will be a snap and minimal tools will be required. I have an array of steel and aluminum weld bungs to convert the verious barb fittings over. Mapping out hoses and figuring out the required fittings is a pain in the ass but these guys had them all and the pricing was great. They even have the an/ metric fittings to replace bango or tapped holes in the block and manifold. Great place for one stop shopping when needing fittings. I have to have a few of my tanks rewelded with the new bungs so these will have to wait a bit before I can install them all. I am going to try and prep them this week along with the modifications I need to do to my intake manifold and intercooler.

Anyways back to some progress pics. Finished up the forward floor panel.



Super seceret cubby...





The battery fuse boxes and bulk of the harness will go here. Great for weight distribution. All on the passenger side by the axle and same level as the floor to lower the center of gravity. Still need to finish a few things up and paint the steel but I'll do all that once the cage interior is ready for paint. The battery itself is actually bolted to the steel square tubing on resting on the floor. Don't want my battery falling out from under the car... Still a ways to go yet.

Got the firewall piece cut and just set it in the there for now.



I'll be finishing this up and mounting all my crap to it today.



and finally the rear piece. I have a couple little things to finish up here as well. Going to make a couple cover panels that will cover the fillter next and sender unit to protect them if something lands on them. I should be able to run all the interior lines soon as well once I finish the firewall for the muffler.

I still have a crap load of stuff to do but I'd say progress is going well. I am hoping to have everything fabbed and ready to be puilled for paint, and powdercoating before the end of the month so fingers crossed.

Johann
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Old 04-14-2012, 05:11 PM   #103
kcrossman
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completely love this build!
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Old 04-14-2012, 10:04 PM   #104
leonbmx
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I am soooo going to do that to my spare tire well too!!! What thickness sheet did you end up using? And it's just riveted in place, right?
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Old 04-14-2012, 10:18 PM   #105
Bad Wagon
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The fuel cell or batt?
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Old 04-15-2012, 08:58 AM   #106
leonbmx
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oh sorry, the spare tire well cover
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Old 04-15-2012, 11:32 AM   #107
Bad Wagon
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It's just 16 gauge. You'll want to put some supports otherwise it will rattle.
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Old 04-15-2012, 11:58 AM   #108
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Quote:
Originally Posted by Bad Wagon View Post
It's just 16 gauge. You'll want to put some supports otherwise it will rattle.
because race car!
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Old 04-15-2012, 06:17 PM   #109
nategr8ns
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Wow, you've done so much to this car since the last time I checked. The bumper and fenders look great! And amazing work on all the exhaust bits.
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Old 04-15-2012, 08:45 PM   #110
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this is all just pure awesome.. when youre done with this car im gonna have to have a kid so I can sell it and buy it off you haha.

keep up the great work! I cant wait to see it done!
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Old 04-18-2012, 01:43 PM   #111
Bad Wagon
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Hey all iiiiiiiiiiiits UPDATE TIME!!!!

Started the day getting everything that needs TIG welding ready to go. My buddy is going to TIG them for me since I don't have a welder (yet) while I finish up other things.

I got this Throttle body flange from my buddy Mike at PIA. Just had it laying around... I start with him whenever I need a strange part lol.



Finished up modifying the crappy replica manifold to get it over to the win side. I use an aluminum spool gun to tack the parts in place so they could be TIGed. Welds are ugly but they hold.



Then moved onto the coldside intercooler pipe...



BOV has a home now.



Nice full shot. Look at how short my piping whooo doggy!!



After that all the parts came off and I dropped them off at my buddies. Other parts that joined them were my P/S and coolant tank (getting JIC fittings welded in), and my coolant manifold (getting a filler port for the v-mount installed)

So with those parts off and gone it was time to keep busy with everything else. I started off by shaving my alternator braket down. Because racecar, it only needs to hold the alternator.





My P/S pump with new converted fittings gets installed...



and the rest of my day was used up running the brake/ clutch lines. Not using ABS on this car so I have a non-ABS pump and bias block. Installed them nice and clean like....



and finally the clutch line. Originally it runs on the firewall but I need the room for other crap so I ran a new line..



Well thats all I got for now. More soon I still have plenty to do...

Johann
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Old 04-22-2012, 12:30 PM   #112
subieguy87
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Car looks amazing!

The ej205 I got off you is now mated to the new tranny & my gc is all set up for it now!
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Old 05-07-2012, 02:53 AM   #113
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I can't keep my eyes off of this thread, but i am saddened that you have not had any updates on the progress in a while!!!!!
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Old 05-07-2012, 05:33 PM   #114
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Quote:
Originally Posted by Immoreradthanu View Post
I can't keep my eyes off of this thread, but i am saddened that you have not had any updates on the progress in a while!!!!!
hear hear!
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Old 05-09-2012, 12:51 PM   #115
Bad Wagon
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Hey guys sorry about that. I had to put the Foz on the back burner for a week so I could get a few quick $$ makin jobs to pay the bills. However I did manage to get some time in this last week and weekend on the Foz before another job showed back up.

While I was taking a break on the Foz a buddy of mine TIGed up some parts for me since I don't have a tig. My P/S rez, coolant tank, radiator, and my coolant manifold. I ended up welding the intercooler and intake manifold myself with my spool gun. Welds were ugly but they had good penetration so I just grinded them down.

BOV and intercooler pipe finished up and installed..



Next was starting on getting all my lines finished. For my lines I have welded on AN adapters with puch-lock fittings to make maintainance easier. So I started with mounting all my crap.



For the coolant manifold because I have a V-Mount and the radiator is so low I welded in a fillter cap into it. This is just a threaded cap not a pressyre cap the coolant tank has that. Its like an 02 wrx setup.



Got some of the lines for the turbo figured out..



And stepped back for a nice engine shot..



Last I got a good amount of the fuel lines and pieces mounted for the fuel delivery system.



So the GC8 project I have been working on is back from what was sopposed to be getting painted but its taking too long to I told them to give it back after it was jammed so I could finish it and get paid. I'll be working on that most of the week but I will still be putting in the weekends on the Foz to keep it moving along. Once the GC is done I'll have the time and most importantly the money to get the engine built and order the last few parts I need to actually finish this thing.
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Old 05-14-2012, 01:24 PM   #116
Bad Wagon
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I got some work done over the weekend. Got my fuel lines pretty much ran. Ran a few of the coolant lines for the turbo but I am still waiting on a few fittings to come in to do the oil breather and oil cooler lines. SHould have those any day now. So I decided to start into the wiring a bit. First was to remove all the crap I wasn't going to need out of the harness.



ABS, Airbags, Heater/ Blower motor, Alarm, Keyless Entry, Fogs, Cruse Control, Door wiring (windows/ locks), and DCCD (my tranny dosen't have it.

There is about 10lbs of wiring right there. Next will be to drastically shorten the harness to fit everything on one consoldated location. I'll have one harness going to rear for taillights and fuel pump, one going forward for headlights and radiator fans. The ECU will go under the middle of the dash along with the OBD2 Plug and then foward to the engine. FInally I'll have one more strand going to the cluster. I should probubly get another 40lbs out of this thing easy and bot the engine and interior fuse boxes will be going in the box with the battery. So there is still a long way to go with this wiring.

Not a ton of stuff left I am on the last page of my To-Do list... It was 5 pages long when I started... The GC8 is coming together well so I'll be back on this project full time soon.

Johann

Last edited by Bad Wagon; 05-14-2012 at 01:32 PM.
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Old 05-24-2012, 10:25 AM   #117
Bad Wagon
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Hey all. Work on the GC8 has slowed the progress of the Fozz but I am pulling double shifts and working late into the night to get stuff done.

Last night I was up till 2 finishing up the rest of routing the hoses.

Oil Cooler:



I was going to weld steal bungs to each breather but it was going to be kinda chunky so I fabed this up to inegrate them together.



Welded the bung on the oil return for the turbo..



Re-instralled the valve covers after sanding down the breather fitting thing...



Here is what the bay looks like with about 90% of the hosing ran. Pretty clean I think.



I also managed to install the flex pipe and the last vband in my turboback exhaust and get everything welded up. Tomorrow my spare STi block is going to be machined so get ready for all new fancy internals so while its gone I will be tearing the engine bay down for paint/ powder/ and finish welding. The next update I'll be finishing up the sheet metal in the engine bay and over the muffler as well as fabrication on a rear diffuser and trailor hitch attachment as well as new aluminum bumper beams, ducting for the v-mount, cutting out the lexan etc.... Stay tuned.

Johann
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Old 05-24-2012, 10:25 AM   #118
Bad Wagon
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So I was up late last night working again and I got some more done. Started to finish up the front end.

Made some little brackets:



Then installed my thick walled 1.5"x3" piece of aluminum square tubing as my new beam..



Its mounted a little higher because the car is so low. I'll be adding some strength to frame rails to tie them together. Only 4.5lbs for the complete beam. I'll be able to mount the middle of the bumper to it as well as my front plate, tow hook, and v-mount ducting.

and thats what I started next. I managed to get the two lower side pieces for the ducting finished up.





I'll be adding nutzerts to it to mount the aluminum sheet to finish it off. I also got about 70% of the piece to make my rear strut bar done so I can get that in and start finishing the interior welding for paint.

Johann
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Old 05-24-2012, 10:37 AM   #119
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Nice fab work. Id love to see this car in person one day
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Old 06-10-2012, 03:08 PM   #120
gutie04
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Amazing work. I hope you've been tinkering with this more this past couple weeks.
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Old 06-11-2012, 08:56 AM   #121
prochucker
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Subaru Stars Amazing...

Beautiful work here, I can't wait to see the finished project. This is also a reference thread for many. Thanks for all the updates.
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Old 06-19-2012, 01:21 PM   #122
Bad Wagon
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Hey all. Got a good update. Just been super busy and haven't found time to get on the comp to post up.

Got the Driver side cash bar in and finished welding up the cage... Finally!!



Then moved on to making my rear strut bar.



After that I finished tacking up the driver side fender flare. Still have to a couple more things to it before finish welding both sides so I can get some body filler on it but that probubly wont be till next week.



Once the flares were on both sides I finally got to remove the rear bumper and that 52lbs rear bumper beam. I have officially pulled all the weight I can out of these beast. Cut the bumper out to make way for my new aluminum bumper beam, and rear diffuser/ underspoiler.



Then the UPS guy came by and brought me many things. New lugs, hood pins, hood dampers, tow hooks, and all the way from Japan.... My new grill. The one I got came with the headlights and it was trimmed on the sides and it was really buging me and I figure if I am going to paint this with good paint I might as well paint all the parts I actually want on it once..

So Sexy





And lastly another pic of her rolled out with her new wares.



Next up:

I'll be finishing the rear diffuser and getting the wing mounted. Mounting the heater and finishing off the inerior sheet metal so I can get everything inside painted. From there all the parts to be ether, finish welded, painted, or powdercoated will be coming off as well as the engine to make way for its new forged 10:1 comp shortblock and bodywork and paint will commence. GC8 is like 95% finished so I have been working hard to hopfully have both cars as the Big NW Meet on the 14th of next month.

Johann
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Old 06-20-2012, 09:04 PM   #123
Bratcher15 FOZ
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Hey I have a 1999 forester L and I want to put a new hood on it with a scoop what would fit that?
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Old 06-21-2012, 11:53 AM   #124
Bad Wagon
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You can buy a jdm hood which has a scoop in it. You can also fit a wrx/ sti scoop by modifying it a bit and drilling holes into your stock hood.

Johann
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Old 06-24-2012, 03:51 PM   #125
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This project is really awesome!

Can you provide some details on your rear diffuser and wing on your next update?

I'm interested in what angle you decide to put on both.
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