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Old 11-22-2015, 02:07 PM   #1
JVEC
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Default Burnup/L'Aunsport Bugeye WRC Conversion

Back in 2009, I found Scoob's post trying to find a new home for his L'Aunsport parts. He bought them on a visit to Japan and carried them back on the airplane, intending to install them on his car. Through accident or sale (don't remember which), the car would never get the treatment. He sat on the parts for some time, and a new owner was never found.

Summer 2013, I was flipping through some old posts and came across Scoob's thread. The parts are still available and very much for sale. A few phonecalls later and my buddy and I are on our way out to Ohio, meeting Sccob halfway between MD and Detroit. We met Scoob and his lady for lunch and had a look at the parts shortly after. They were well-cared for all that time, showing no signs of damage or age. After some conversation, I paid for the parts and loaded them in the truck. Before leaving, Scoob asked one thing of me....he made me promise that I would install the parts, not store them away and simply sell them later. The parts must be used. I gave my word, and I now understand how much these meant to him. We made the trip home the same day and the parts went into my workshop that night.

Now a full 2 years later and the build is almost complete. There have been numerous setbacks along the way, which I'll illustrate in coming posts. If you're looking for instant gratification and a simple photo showing the end result, I don't think this is the thread for you. I've documented in detail so that both Scoob and other builders can appreciate the time and effort that goes in to a modification like this. I learned a long time ago that you can do something quick or do it right, and this is absolutely worth doing it right.

Enjoy!
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Last edited by JVEC; 11-23-2015 at 03:01 PM.
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Old 11-22-2015, 02:39 PM   #2
JVEC
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To start, Scoob (Mark) sent me photos of the parts. The WRC bumper includes the covers and turn signals, along with hardware and wiring. Second are the headlights. They are dry carbon units, with FRP backing and include Hella halogen projection units.










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Old 11-22-2015, 02:40 PM   #3
JVEC
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Old 11-22-2015, 02:53 PM   #4
thrasher
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Ok, you've got my attention
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Old 11-22-2015, 03:24 PM   #5
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Excited!

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Old 11-22-2015, 03:53 PM   #6
JVEC
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Test fitting yielded some unexpected surprises. The stock bumper reinforcement is completely trashed; apparently a common problem with Impreza's. This is the biggest setback of the build. For months, I searched for another reinforcement and then the project got sidelined. It was an on again/off again search.




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Old 11-22-2015, 04:05 PM   #7
JVEC
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Support bar problems aside, it was time to see the parts mounted. The bumper mated well, though there would need to be supports added in key places to make sure it lasts. I was more concerned with what was exposed behind it. The bumper beam had some inherent problems (rust notwithstanding). There was just too much of it that could be seen. Even with some flat black paint, the eye is drawn to the "guts", not the surface. It also adds a tremendous amount of weight to the car.

Ultimately, replacing the stock bumper beam with another OEM unit is off the table. A custom bar will need to be made, and it will need to be crash-worthy.






There were also problems fitting the headlights. While mounting was straightforward, the fitment wasn't exact. Bolted in place, there are large gaps seen on the sides. These too would need to be modified.

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Old 11-22-2015, 08:00 PM   #8
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These need to join my collection lmk if u ever want to part with them I'm always looking to hoard more for backup
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Old 11-22-2015, 09:14 PM   #9
JVEC
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Will do. I have a Prodrive S7 rear spoiler looking for a new home. Needs a little repair work.
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Old 11-22-2015, 09:48 PM   #10
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Any pics I got a matching l'aunsport wing atm but always interested in cool parts I'm super jelly of how new an mint you pieces are my first bumper got damaged during shipping but the lights came with some sweet hids the second bumper needs some work on the bottom lights are normal like yours but got fenders with them
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Old 11-23-2015, 01:51 PM   #11
JVEC
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I have a few pictures that I can dig out. I do also have a genuine Prodive S7 hood. I'll pm the pics to you.
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Old 11-23-2015, 02:57 PM   #12
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After removing all the parts, the bumper went off to the body shop and I focused my attention on the headlights. In collaboration with Mark, I wanted to come up with a way to protect the carbon from road debris, but not detract from its visual appearance. A film from XPEL was the first option, but a lot of trimming would be necessary and it would give the carbon a gloss appearance. The second option is to coat them in Plastidip. A matte clear coating would be ideal and after learning that the coating can be peeled away if necessary, I was sold on the idea.

I made some marks on the headlights and began disassembly. I broke a few of the retaining clips and had to locate replacements. Hella doesn't carry the clips, but sent me to someone that does. They were not cheap but I really don't have any alternative. Once stripped, the light bezels are cleaned and prepped. Following the instructions, several coats are applied until the can is empty. Below are the lights before coating. I may have gotten carried away with the gratuitous carbon shots.




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Old 11-23-2015, 02:59 PM   #13
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Below are post application. You can barely make out the coating.



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Old 11-23-2015, 10:43 PM   #14
Shik
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Awesome!

More pics the better!
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Old 11-23-2015, 10:46 PM   #15
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This is awesome... I super excited to see how your build turns out! You are creating exactly what I've been dreaming about since I bought my bugeye from the stealership in 03. I literally have the AutoArt 1/18th scale model of Richard Burns #5 WRC car sitting in its permanent spot right here next to my keyboard. I love the S7/S8 WRC car in a fanatical (and probably unhealthy) sort of way.

In case there are other devotees following your thread I will mention that there's an abused JDM bumper cut with the L'Aunsport bumper on Ebay right now that looks a bit beat up, but IF the plastidip can be removed the WRB paint underneath might be ok.

http://www.ebay.com/itm/172000916697...%3AMEBIDX%3AIT

I don't know why I typed all this gibberish. All I meant to do was subscribe to the thread..
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Old 11-23-2015, 10:54 PM   #16
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Quote:
Originally Posted by JVEC View Post
Will do. I have a Prodrive S7 rear spoiler looking for a new home. Needs a little repair work.
Could you PM those pics/info to me too please? This wouldn't be the same wing you posted about 10 years ago would it?

http://forums.nasioc.com/forums/showthread.php?t=486226
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Old 11-23-2015, 11:05 PM   #17
JVEC
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Man, that was a long time ago. No, this is the one that was mounted on my car. My guy at Prodrive was in touch one day with an absolute blowout of S7/S8 parts, and the wing was one of those. If memory serves, he had 3 wings of varying condition along with some of the carbon headlights, front fenders and bumpers. Problem was (still is) shipping, and fitment of the actual WRC front pieces was difficult as they were much wider than stock. The wing I have is FRP, not carbon, and was much more expensive as it was new. He said it came off a Solberg show car. But I'll forward you the pics. The hood and wing both need some repair work.
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Old 11-23-2015, 11:47 PM   #18
NordiX
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I wish I had the money and was connected to you back then. I would have done terrible and wonderful things to my car.
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Old 11-24-2015, 11:16 PM   #19
Scoob
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Awesome stuff Jeremy! Glad to see it all come together! Thank you for keeping your promise, you sure made my day when I saw these parts all done on your car! Super jealous now!

All the best!

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Old 11-25-2015, 12:10 PM   #20
JVEC
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I'm so glad! I think it turned out beautifully. I'll let it unfold here so folks can see.
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Old 11-25-2015, 06:43 PM   #21
JVEC
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I moved on to protection of the Hella glass housings. I picked up some Xpel film from Amazon in the thickest size available. I had never worked with films such as these, but they were really pretty user friendly if you follow the directions. The film was pre-cut for some other car, but more than large enough for what I need. A water/alcohol mix in a spray bottle along with a heat gun and razor blade is all you need. The adhesive is incredibly sticky so I had to make sure I had the film where I wanted before clearing the liquid. I was happy with the results.

Before:


First application:


Most of the liquid pushed out:


Heat applied. Remaining liquid is eliminated and forming of the film begins


Dries clear and sides tapered into place





After trimming
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Old 12-02-2015, 11:57 AM   #22
JVEC
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After talking with a few fabricators, I found one willing to make the front support bar for me. We went back and forth on what the material should be, ultimately landing on chromoly. The chromoly available was slightly smaller in diameter than the mild steel option, but it had better strength quality than the mild. His concern was if there was an impact, the mild steel would be more receptive to straightening, where the chromoly would not. If it gets hit, it's going in the scrap bin, and another would be made. I was happy with the finished product, and the holes were positioned correctly.




One of the only things I didn't like about the parts was the chicken wire mesh grille. The holes were far too large for my taste and I could see my a/c condenser getting thrashed by road debris. I searched for awhile and decided to contact Grillcraft for the pieces. I had one of the lower grills for my OEM bumper from these guys and was happy with the quality. The question would be whether they would cut my custom sizes for both an upper and lower grille. They helped me out and shipped them asap. Below you can see the Burnup mesh vs the Grillcraft.

Now everything is headed to the powdercoater.

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Old 12-02-2015, 01:35 PM   #23
JVEC
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Turning to the headlights now, I began working with the passenger side as it needed the most work. First is to get the fitment right. I don't know whether it was a layup issue or because the Burnup parts are intended for the Japanese market (somehow different on RHD cars), but they didn't fit properly. Determining the passenger side would need to be shimmed at the top mount, I used a plastic sleeve from stock and cut to length, affixing with good ol' JB Weld. My apologies for the cloudy pictures. I needed to clean the lens on my phone but didn't notice until later.







Last edited by JVEC; 12-02-2015 at 01:45 PM.
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Old 12-02-2015, 01:58 PM   #24
JVEC
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The drivers side needed more modification than expected. In addition to minor shimming, the mounting holes would need adjusted. There was a noticeable upward tension stemming from the mount on top of the unit, fastening to the upper core support. To get the lower two holes to line up would require an amount of downward force, putting stress on the housing. Opening these holes would offer the necessary relief.






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Old 12-02-2015, 02:05 PM   #25
NordiX
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Nice! Those are looking awesome!

How's the fitment between the backs of the housings of the outside Hellas and the inside supports of the fenders? I'm referring to that part of the fender that the OEM headlights clip into with that little post.. how much gap do you see back there?
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