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Old 04-02-2014, 01:42 AM   #76
B-85
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All went well with the first power up ! Will keep working . Also found the Factory manual has some problems with colors! It does not match the car my parts came from ? Oh well ,just adds more time.

I have made a choice on replacment shocks. I went with AGX for the Impreza. The travel is only 1/2"+- less than that of the Forester. But will lose almost 2" over all in the rear and a 1" in the front. I will keep the front spacer at the motor tray. Still need to work out the 2 1/2" springs for the car ? Thinking 300 # front and 250# rear ? Thinking about using Zero-Rate Helper Spring for the droop ? With the ability to address ride height and the ability to adjust springs feel I can make this work ? Not as far off the ground as the stock Forester may helps ?

Randy
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Old 04-02-2014, 10:18 AM   #77
BrockP
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One of the things I've been curious about is if the zero-rate springs do anything besides keep everything on the perches. After feeling how soft a 1.5 kgf/mm (84#/in) helper spring is, I'm not sure anything softer would be able to extend the shocks and overcome bushing friction. They would keep the overall spring rate linear over a longer range though.
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Old 04-02-2014, 11:09 AM   #78
Preludecris
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dam that is an old yale forklift.... if you ever need help with forklift repairs or looking to get a new one hit me up 602 454 6712 ask for seth
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Old 04-02-2014, 10:43 PM   #79
B-85
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Originally Posted by Preludecris View Post
dam that is an old yale forklift.... if you ever need help with forklift repairs or looking to get a new one hit me up 602 454 6712 ask for seth
Hay ! Whats with the hait? LOL She runs and works well!

Brock, I think that and thing under ,say 15 Lbs is Zero to them ?



More wires today. This is getting OLD!

Running lights /
Parking lights/
Brake lights/
Fog Lights/
Wipers,all speeds,washers /
Hazards /
Head lights (only HI ? ) will work on that. Oh,and the dash light work.
Parking brake / and the dash light works!
Fuel gauge /


For now the ECU / PCM is unpluged. Didn't want to short it out ! All the testing.

Played with the Ground Control coil-overs on the dead struts. Looks like I can go 6" ( alittle on the short side ) all the way up to 10".?? Was also thinking about the KYB warrenty ? may need to leave the spring perch on and not cut them down ?

Photo is tieing the old with the newer or JDM to Forester.



Randy
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Old 04-03-2014, 01:53 AM   #80
B-85
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Quote:
Originally Posted by BrockP View Post
One of the things I've been curious about is if the zero-rate springs do anything besides keep everything on the perches. After feeling how soft a 1.5 kgf/mm (84#/in) helper spring is, I'm not sure anything softer would be able to extend the shocks and overcome bushing friction. They would keep the overall spring rate linear over a longer range though.
Brock, (thanks for posting )I have been thinking about this and maybe it would be better anserwed by putting the car on scales ? Then pull the Zero-spring and see?

After looking at the old struts and getting the spec. from KYB, you would need to use a very short spring ? I'm feeling that it would be more needed for a lowered / road car ? It would acked more to keep things together.

I think,for me I would like to have a full spring or a two spring system for Rally X / Rally ? Maybe a two stage spring.

My thinking is the car would use the first 1" to 1 1/2" just to hold it to ride height. That would only leave 8 1/2" for bump +- bump stop. This is from the total travel of the KYB (6.5" +-) ? Also if I got this right their would be no droop, only the unloading of the spring. The 1" to 1 1/2" ? Ok,that is droop but the spring (10") would never,not be under load. A 8" or 7" or 6" make me think I would be short on load carrying ? But would need a helper to keep things seated .

I'm thinking the strut,at ride height is about 10% down in its stroke ? That would leave about 6" +- for bump. .5 +_ for droop. What is a good droop number for a Rally car?

Having said all of that , the struts are to short ! But stock is stock and that is what I'm willing to spend now. The AGX will let me get a idea of what is going on and then maybe I will go to the $$$$+ stuff. And the stuff on the car is leaking anyways.

This is making my head hurt . Think I will go back to the wiring!

Randy
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Old 04-03-2014, 04:25 PM   #81
BrockP
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I'm not sure what a scale would tell you about helper springs since the car will still weigh the same.

With just 300 lb/in springs, you should have at least 2.3"F/1.6"R static compression under the car's weight. I definitely used to get the rear of mine off the ground (using 300 lb/in springs), which is why I started using 1.5k helper springs for more droop (basically becomes a 2-stage spring, usually 300 lb/in, but drops to ~66 lb/in when the helper starts to unload).

Using a zero-rate spring with the Ground Control perches will be nice because it lets you adjust ride height without messing around with preload.

You're right about needing a spring longer than 8". I originally had 7" springs, but the front would bind. Didn't feel good and probably wasn't great for handling.

I'm not sure exactly how much droop the rally guys use, but it's a lot. Odi at Feal Suspension told me he usually shoots for ~30% of the shock travel.
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Old 04-04-2014, 01:56 AM   #82
B-85
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No,it was more , what differance it will make in the spring length, the total. I don't know what I was trying to say with the scale comment ? My bad. As you remember, I will only have 10" in the front and 11" in the rear for springs. Maybe a 12' x 275# under 2" of preload ? But it binds at 4.057" and the shock is on the bump stop at 3.375"
Randy
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Old 04-06-2014, 01:22 AM   #83
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CPU/ECM is in and now will start the motor install.

Does anyone know if the Main relay and the Fuel pump relay ,only work with the motor installed ? Can't seem to get them to click. Think it may have something to do with the link to the motor and the ECM ?

Had to mod the mount,like everything in this build! I den't take a photo with the cover. Will do that later.

Randy

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Old 04-06-2014, 07:37 PM   #84
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Things I learned today.
Impreza parts that are just going to fit installed, well not somuch! Need to do some sloting.
My motor/tranX stand needs more down angle at the rear. Got around the problem with a jack.
Pulled all the old front end parts and broke all the bolts lose. Think it would be harder just laying on the ground ? Will put spairs into storage.











Still need to plug the motor in to see if it then will run the main relay and the fuel pump ??
Long day. Randy
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Old 04-07-2014, 10:38 AM   #85
BrockP
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Quote:
Originally Posted by B-85 View Post
Does anyone know if the Main relay and the Fuel pump relay ,only work with the motor installed ? Can't seem to get them to click. Think it may have something to do with the link to the motor and the ECM ?
Mine clicked on without the motor ground... but didn't shut off. The car caught fire for a few seconds and probably would have burned to the ground if I tightened the battery (yanked the -lead as soon as I realized pulling the key didn't shut off the fuel, then ran into the house and got the fire extinguisher).
I do dumb things sometimes.
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Old 04-07-2014, 09:22 PM   #86
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I hate "FIRE" ! But love my nomex !

For today I pulled the motor, rapped the exhaust (lost the top cover when I cut the pipe!) with temp cover and 3 layers of Alum. rap. Didn't want to melt the P/S hoses. Cut down the stand rear leg by 1 3/8". Reinstalled the motor (stand worked just fine now) ! Pulled the exhaust header and reinstalled come clamps missing from inside the heat cover.Installed the drive shaft and covers. And also started installing the front A frames.

The new shocks got here and 2 are good and 2 are the wrong ones ! Its always the ones I need ! Going to do a mock up with pvc tubing to get the weights at the coners and then order springs.

I will install the rear struts and the maybe plug the motor into the harness and see what works ? Hope things go well ??











Maybe I will start work on a catback ?

Randy
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Old 04-09-2014, 12:05 AM   #87
B-85
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Today, installed the steering wheel. (makes it way-easer to steer).I installed the clutch cylinder . Started on the struts.

Also tested ride height? Looks like I can make it work with a 12" x 2 1/2" spring of 300# ? What do you think ? The gray is the stand-in spring. Its 2 1/2" Electric PVC. Also helps with the scaling of the chassis. When your as cheep as me. Trying to keep the spring I can't use down. LOL

Struts are Impreza AGX. Lots of mods to make them work.

Randy





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Old 04-10-2014, 11:39 PM   #88
B-85
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For today I installed the T cable,Fuel lines,Vap line,pulled all the Sti A/C stuff on the motor and installed a A/C system from my old 1994 Impreza 1.8 FWD car. I love how things work out! The Sti. pump would not take the Forester lines. Need a good condenser ( the one in the car,not so good!) then I will pull a vacum and see if it leaks? But it all fit! Need to install the heater hoses also, That is more the reason for getting the A/C closed up. Then the Rad and ??

Been asked to build a tool for the shop,so I may not get to try a start untill Sat ??

So close!

Randy
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Old 04-11-2014, 10:16 PM   #89
B-85
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Still have some things to finish but looks like a test start Sat. ? Need to build a P/S cooler. And the other shocks got here today. All I need are the springs. Monday?



Maybe its time to start looking for some Sti. stickers ?
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Old 04-12-2014, 10:18 PM   #90
B-85
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Old 04-15-2014, 09:44 PM   #91
B-85
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Worked on the P/S cooler and wired up the horns. Cooler is from a Ford S/D, $15 at the junk yard. Had to weld up the bracket.

Springs will be here Wed. but? Then back to the struts.

Would like to go to the upcomeing RallyX but?? will see?
Oh,and still have the front brakes to do. And a cat back exhaust. Don't think I could stand the cat only,man can you hear the turbo!

No hood,lights (front) grill. Can I run ? maybe I just need to keep working on the Forester. LOL







Randy
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Old 04-17-2014, 12:34 AM   #92
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Good and bad day.
The 12" springs will not work. So on to the 10".

Found the very small turbo oil leak . And why the main fan will not come on. You need to plug it in all the way in.

Also started work on the air intake box.

So, no rally X for me. Bad me.

And I will be needing the hood,headlight assy, and trim soon. Hint,hint.

Last edited by B-85; 04-17-2014 at 01:03 AM.
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Old 04-17-2014, 03:57 PM   #93
B-85
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Work on the air box,still need the 2 1/2" pipe to link to the filter box.
Will drill the lower corner for a water drain.
Also working on using the fog light opening for a little ram air ! LOL



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Old 04-17-2014, 10:40 PM   #94
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Some work on the air/box. What a pain . The HF on the welder is not on all the time, makes Alum. alot of work. Need to do more thin stuff,that I hate!











The shape of things to come ! LOL
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Old 04-18-2014, 02:20 PM   #95
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installed,and how it looks installed.





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Old 04-21-2014, 06:11 PM   #96
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Finished the intake box and started clean up on the front brakes.

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Old 04-23-2014, 10:18 PM   #97
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Good day !
Springs are here and in ! Think this will work.



Cut the spring ring off. Just to close.





It sits just about the way I think it should ?







Also the LSD works just fine! Open diff up front.





So a good day. Will reinstall front brakes Thus. Almost a driver? And looks to have good POWER!
Randy

Also got the co-drivers seat in.

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Old 04-24-2014, 01:00 AM   #98
yman
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what it looks like


what it feels like
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Old 04-24-2014, 02:14 AM   #99
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Good job man, looking real good! This is a build right here.... dirt, guts and glory.
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Old 04-24-2014, 06:29 PM   #100
LESSthanDan
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I'm so stoked to see this thing get all finished up.
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