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Old 11-20-2013, 04:46 PM   #26
Digitalwave
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In for updates.
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Old 11-29-2013, 09:06 AM   #27
BagRidersJohn
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Finally! Shots of Tubbing / Notching / Other "Get low" cutting! PART 1
These shots show the process of removing material. I will upload shots of everything welded up this weekend, pending completion!


Here's the passenger side. You can see the wheel arch is gone and a hole has been drilled for the axle notch. The control arm notch (previously outlined in red) is done as well!


Here's a better shot of how I tucked the big harness in the driver side wheel well. I removed the fender braces so the harness could be routed up and above the red line which highlights the top of the wheel well.


The notch for now. Haven't welded in any pipe to seal it up yet because I want to ensure the vehicle drops low enough first!


Passenger side


Passenger side


Driver Side


Driver Side (view from where the headlight would be)

Happy Thanksgiving all! Hope these help someone
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Old 11-29-2013, 09:21 AM   #28
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nice write up of the air bag setup in the back. thats how im going to do mine, but more showy.
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Old 11-29-2013, 09:27 AM   #29
BagRidersJohn
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Quote:
Originally Posted by magus2222 View Post
nice write up of the air bag setup in the back. thats how im going to do mine, but more showy.
Thanks man! I wanted to keep everything tucked in the spare tire well, so aesthetics weren't my top priority but I think it still looks pretty good I may add some hard lines for some "bling" at some point, but for now the setup is very functional, looks clean and otherwise serves its purpose flawlessly!
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Old 11-29-2013, 04:18 PM   #30
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This is awesome!
That compressor set up is very well done.
And that is a HUGE operation just to get the last half inch!
Keep up the good work
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Old 12-02-2013, 10:51 AM   #31
BagRidersJohn
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Quote:
Originally Posted by CanadianSTi View Post
This is awesome!
That compressor set up is very well done.
And that is a HUGE operation just to get the last half inch!
Keep up the good work
Thanks a bunch!

Got the wheel arches tacked back in and set the car down to test fitment. Everything is looking good and should kiss fender to lip perfectly once I'm done


Driver Side


Passenger Side


Here you can see that the wheel arch was raised to be flat with the chassis. The gap in the bottom shows just how much room was created, which should allow me to roll very low and even turn the wheel without rubbing at all

Should have everything done this week. I'm waiting for some stuff to arrive before I hack apart the rear quarters and start grafting in some wide body goodness
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Old 12-04-2013, 08:32 AM   #32
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Alright! Finished up with the tubbing! The driver side is hard to see as it is blocked by the fuse box and my coolant reservoir, but here is the passenger side. Welded up the old hole for the intake box as well, once I have some time to do some wire tucking I will shave the hole for that boost solenoid harness as well. You can see along the bottom how much the wheel well was lifted, but it is probably more obvious in previous shots.


Annnnnd crappy shot of engine bay. Need to order a black coupler for the TB. Since I'm flipping the IM over the winter I'll be redoing all of my charge piping anyhow. I'm hoping to shave ABS and move the turbo up front as well, along with fabbing an EL header, EWG uppipe and a down pipe that runs along side the passenger side head. That's really my only concern with relocating the turbo, it will make servicing that head and spark plugs a total pain in the butt!


Should be doing more stuff this weekend. Cheers folks!
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Old 12-05-2013, 01:17 AM   #33
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Hey john, I'm curious how you went about dyeing your interior plastics. I would really love to do the same thing!
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Old 12-05-2013, 02:27 AM   #34
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mmmmmmmmmmm, very interesting project! Good luck!
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Old 12-05-2013, 08:29 AM   #35
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Quote:
Originally Posted by TTyphoon View Post
Hey john, I'm curious how you went about dyeing your interior plastics. I would really love to do the same thing!
I used SEM Black Trim paint. The most important part of the process, like with any painting, is the prep work. I removed all interior plastics and gave them a very thorough hand wash with soap and water, then hit them with a quick 600-800 grit sand and fresh scotch bright and a rinse. With the surface clean and scuffed, I followed up with a degreaser (I used DX330 I had lying around but any degreaser would be fine), another rinse, then a plastic adhesion promotion product before painting. The paint was laid down in about 4-5 light coats, allowing ample flash time between each coat. Remember there is no rushing a good paint job!

With careful prep work you'll have a set of painted plastics that are much more resilient to light scratches, fading and cracking compared to your typical quick rattle can jobs I daily drove my vehicle all summer, most frequently with my girlfriend riding shotgun and all of my plastic pieces are still perfectly black. Not to mention, I pull my interior out a LOT

The plastic adhesion promoter I used is here:


For doing stuff like the seatbelt holder plastic (that the belt slides though) or the little plastic things that your sunvisors clip into... or really anything that has to hold up to lots of abrasion, you need to actually penetrate the plastic which involves using a chemical dye. This is pretty common in the RC car world, so there are plenty of tutorials on YouTube. I did my sunvisor clips and seatbelt clips using Rit Dye and they are holding up great!! For the interior plastics though, careful prep is the key to preventing cracks or otherwise bogus looking paint. Plenty of folks have ridiculed me for "spending so much on the genuine S204 trim set" before I tell them its a DIY I take that as a compliment!

Quote:
Originally Posted by ag_1 View Post
mmmmmmmmmmm, very interesting project! Good luck!
Thanks!
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Old 12-17-2013, 02:08 PM   #36
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Well... just went and bought a donor sedan half-chassis (for only $700, delivered to our shop!!) to use for the quarter panel conversion. I'll be cutting out the quarters from the donor chassis hopefully later this week depending on when the junkyard gets around to cutting it up and hauling it over here... it was -5 today here in VT, so not going to hold it against them for waiting a couple days for some slightly warmer weather

I'll share some photos of cutting up the donor chassis and how I intend on doing the conversion on my wagon. There are a few threads out there, but as the saying goes "there's more than one way to skin a cat" so I figure it couldn't hurt to share my own experience I probably won't get around to cutting up my WRX quarters until after the holiday, but we shall see
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Old 12-17-2013, 02:16 PM   #37
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I love cutting! Or should I say, when you're cutting!
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Old 12-17-2013, 02:28 PM   #38
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Nice! This is going to be sitting so nice once it is all said and done. Can't wait!
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Old 12-17-2013, 02:59 PM   #39
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Man. My car isn't even that low (BARELY tucking tire) and I already hit frame with the axle.
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Old 12-17-2013, 10:51 PM   #40
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That sedan conversion is going to look amazing! You and Kevin have VT's cleanest Subarus!
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Old 12-18-2013, 08:54 AM   #41
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in for the sedan conversion!
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Old 12-20-2013, 09:55 AM   #42
BagRidersJohn
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This showed up today I am SO EXCITED!!!


Quote:
Originally Posted by emazz104 View Post
That sedan conversion is going to look amazing! You and Kevin have VT's cleanest Subarus!
Thanks Eric! Hope all is well over at your shop!

Quote:
Originally Posted by _adam View Post
Man. My car isn't even that low (BARELY tucking tire) and I already hit frame with the axle.
There's a little pinch weld you can cut for a little more drop, but after that you have to do a subframe notch for the axle. If you plan on doing a subframe notch, I wouldn't cut the pinch weld quite yet as it is really helpful to use as an anchor to guide the drill!

Quote:
Originally Posted by 25rsti View Post
I love cutting! Or should I say, when you're cutting!
Haha thanks dude

Quote:
Originally Posted by ocdpvw View Post
Nice! This is going to be sitting so nice once it is all said and done. Can't wait!
Thanks Corey! Happy Holidays man!

Quote:
Originally Posted by Honest Bob View Post
in for the sedan conversion!
I'll be sure to include plenty of pictures! I won't be getting started until after the holiday, but I really can't wait!

---

Happy Holidays all, thanks for the kind words and support. I've wanted to do this conversion ever since I first widened the front end on my last wagon and saw what looked incomplete to me. Finally having the donor chassis in my possession is making this dream of mine seem much more like a reality. I think reality will REALLY kick in once I take the cutoff wheel to my WRX's panels :P I can't wait to get cutting so I can have the car painted and ready for shows come spring time

I have to give a shout out to the beater I picked up for the winter. This AWD '95 Impreza L 1.8L may be a bit rusty, but despite the 291k miles on the engine she still runs like a champion and shifts smooth like butter. I used some leftover decals from our SEMA build for a tongue-in-cheek sticker bomb on the driver door :P "Because Racecar"




Have a safe and happy holiday everyone!
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Old 01-03-2014, 08:32 PM   #43
BagRidersJohn
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Update! Happy New Year Everyone!

Quarter panels are cut off the donor chassis!


I also just ordered a bunch of P&P goodies from GrimmSpeed to use when reversing my intake manifold. The parts should arrive late next week so I hope to get started the week after!

Cheers,
John
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Old 01-05-2014, 07:28 PM   #44
BagRidersJohn
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Update! Quarter panels are cut off my WRX and test fit a sedan door! Haven't swapped the glass out yet.


Now it's a real harlequin! :P


No going back now....

Can't wait to progress further on this project. I'm going to pull the intake manifold in preparation for the P&P parts arriving from GrimmSpeed, hopefully soon. Also got some other stuff coming in that I'll put pictures up when it arrives.

While I have stuff apart, I'm considering deleting the ABS pump since I broke two rear reluctor rings (which require pulling the hub to replace, ugh) and have since had the fuse pulled with no issues. I'm also going to see if I can tuck the fuse box neatly into the fender well and I've been contemplating moving the battery out of the bay as well... With all that stuff out of the way, whenever I pull the engine next I would weld up a bunch of holes and paint the bay for at least a clean look, but far from "shaved". So many decisions to make!

Hope everyone had a great weekend!
John
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Old 01-05-2014, 07:36 PM   #45
AnthonyWang
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loving the time and dedication put into this. Keep doing what you are doing.
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Old 01-06-2014, 01:35 PM   #46
BagRidersJohn
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Quote:
Originally Posted by AnthonyWang View Post
loving the time and dedication put into this. Keep doing what you are doing.
Thanks so much, that means a lot!

Hopefully more updates this week, figuring out what to do with the upper body line and the tail light.
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Old 01-09-2014, 05:40 PM   #47
BagRidersJohn
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More cutting and test fitting... should be able to start welding tomorrow if all goes well.
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Old 01-09-2014, 05:49 PM   #48
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Nice! what size wheels and tires? im very excited to see an aggressive wheel fitment on a true wide body wagon.
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Old 01-10-2014, 07:05 AM   #49
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love it!
I adore the wagons with the widebody.
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Old 01-10-2014, 09:33 AM   #50
BagRidersJohn
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Quote:
Originally Posted by Dr. Ill View Post
Nice! what size wheels and tires? im very excited to see an aggressive wheel fitment on a true wide body wagon.
Thanks! Right now, they're 17x10 with 225/45's. When I converted the front end last year, I had to use a 30mm spacer to fill the space created by the fenders, since running a staggered setup isn't really a good idea. Last night I did some fitment testing in the rear with a quarter mocked up and about 25mm of spacing put the wheel where I want it. Therefore, I'll be adding an inch of lip all around and shouldn't have to run any spacers, perfect!

Quote:
Originally Posted by Mr.Veryfast View Post
love it!
I adore the wagons with the widebody.
Thanks a lot! I appreciate the kind words

UPDATES!!

Here's the driver side inner wheel well pretty much finished. You can see the seam of where the sedan inner well was welded in, and from there you can kind of determine how much additional space was created, just by the angle of the outer arch.


Passenger side is all mocked up!


Annnnd the moment of truth! This is a 17x10 wheel with 30mm of spacing in the rear. It fits just how I want, I'm so excited! Now just to rebuild the wheels


Since I'll obviously be painting the quarters and will have some bondo'ing to do (not that much, though), I'm going to do a somewhat aggressive pull, and an EXTREMELY aggressive roll. I'm going to cut slits along the inner seam so that the quarter can be pressed perfectly flat without warping the outer quarter, then hit with some seam sealer to avoid the rust pocket that fender/quarter rolling typically creates.

Side note: My wagon lived in Cali for the majority of its life and is therefore extremely clean and rust free... one of main reasons I bought it Before putting all of the interior back together, I'm going to spray some sealer along the inner quarters (once everything is welded back together) using a flex extension to really keep any moisture and gunk out of there. This is a good practice whenever entire body panels are replaced! I learned this trick when we did the quarter panels on our SEMA 335i build:



Our SEMA build is for sale if anyone is interested! http://bagriders.com/modlab/pages/e92.html
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