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Old 12-09-2011, 02:08 PM   #26
Bad Wagon
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Some high temp thick engine paint. It acts like sprayable POR15 and its what I use to paint most of my engine bays and engines with. Good stuff.

Okay update time. I have been having some problems with my photobucket account but it has been resloved so this will be a big update.

We'll start with the more lightening. The front doors w/ glass weighed in at 81lbs each. Very heavy. After some magic with the cuting disc and saw I managed to get that down to a respectable 20lbs a piece.



Hinges and latch still installed so tghey function as working doors. The rear doors and hatch are a different story. Because of my class the doors must function as doors but they do not need handles and latches so the can be bolted to the chassis. So I removed everything to make them a skin and just kept the mounting point for the hinges so once unbloted they could still swing open. The rear doors came in at 55lbs each stock. Dropped that to 7lbs a piece but I still need to add a pound of lexan.



The Hatch came in at 57lbs and I got that to 12lbs but this will get some lexan as well. So total weight savings give or take a pound after lexan will be around 259lbs total.





Not to shabby. Still have another 40-50lbs from the chassis to pull so it will be on a nice hefty diet. Not to mention everything thats going back in is getting the Atkins aswell. Wiring, dash, seats, battery, crossmembers, driveshaft, brakes, engine parts etc..

And she still looks pretty much stock... for now lol.



Johann
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Old 12-09-2011, 02:18 PM   #27
Bad Wagon
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Next I finally got to the point were I could do some fab work and get some parts in. First part on the list is the v-mount. Its a pretty nice bid of kit. Radiator comes with an oil cooler built into the bottom rows. It retains the lower radiator hose location and comes with an extention piece to modify the upper rad hose. Taped mounting brakets for the dual 12" fans and a nice assortment of mounting brackets. Also came with an aluminum overflow tank. Intercooler pipes are nice as well. Correct sizing and also comes with an intake pipe.











Now this was designed to bolt into a wrx/sti so obviously there is a little modding needed to fit the Forester so after drilling some holes and making a mounting tab it fit snug as a bug. Still have to do some more mounting and there will be some other modding too but it fits really nice.





Once I get my bumper in a week or 2 I can do the aluminum bumper support and air ducting. I'll be closing everything off so the air can't go anywhere but into the rad and intercooler with some nice streemline pieces. Much like I did for my old Ae86 v-mount...



So next I'll be doing some more tedious stuff while I wait for some parts to get here. Cleaning up the window flanges so I can get them ready for lexan. Removing the last pieces of metal out of the interior and cleaning it up to paint. Modding the firewall and tubing the front. Cutting out the rear for wider tires. Got the parts off the Legacy but most of them are going to powdercoat along with the TSS crossmembers. Once William has them done it will be a fast frenzy to get the car into a roller and have the suepsnion and drivetrain finished. So Hopfully before the new year the cars underside will be pretty much buttoned up and even more hopfully some of the parts I have for sale will sell so I can get some of the bigger items orded like the turbo setup so I can do all that fab work. The list is long, but I am determined to get this done before the end of Jan so long as funds are availible. If any of you are looking for parts check out me for sale threads or pm me if I don't have it I can find it. Keep the ForeSTAR build thread moving! lol

Johann
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Old 12-10-2011, 12:34 AM   #28
slickohio
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Really digging this build! I'm excited to see how this is turning out. You are also giving me some ideas for my sf

Cheers, Ben.
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Old 12-10-2011, 12:49 AM   #29
bmxkelowna
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who makes that vmount kit?
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Old 12-10-2011, 02:29 AM   #30
Bad Wagon
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I'll post a link up tomorrow. Got some more stuff done today. Cut out the sides if the engine bay out to get ready to fab the new aluminum tubbed replacements. Removed the pitch mount metal because it won't be needed with the solid motor/ tranny mounts. Removed the excess metal on the inside of the fire wall and a few more pieces out of the interior. Also cut out some of the core support to give more airflow to the v-mount.

Think I might have one of my wheelsets sold so I can order up a few more parts. I am excited it seems like everything is moving pretty quick. Just hope I can keep the parts coming in so I can keep up the pace.

Johann
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Old 12-15-2011, 11:35 AM   #31
STIdarkside
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Is the exterior fabrication all done? Was curious if you were going to flare the fenders?

You do great work, the legacy is a piece of art...
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Old 12-15-2011, 01:37 PM   #32
Bad Wagon
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No not yet I need to get the car in a roller with the wheels and tires on before I make any flares. Next up is interior and roll cage while my crossmembers and suspension components get powder coated.
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Old 12-16-2011, 04:12 AM   #33
forestersub
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WOW what alot of work you have ahead of you , doing this race mod. keep the pics coming as i like this.
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Old 12-16-2011, 11:38 PM   #34
Kumachn
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Sorry off subject, what was your screen name on club4ag or hachiroku.net? I also had a AE86 before getting my FXT.
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Old 12-17-2011, 02:36 AM   #35
NW2TONE
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hey dude i have the week off between christmas and new years. maybe i can come up and stay the night one night. tear in the foz and hit up baker as well.
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Old 12-17-2011, 04:05 AM   #36
Bad Wagon
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It's hatchi go.

In fortunately I'm waiting for a couple parts so the fozz is on the waiting list for a week or two. I have been holding those cvs and hubs for a certin car we were talking about. What's goin on with that?
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Old 12-18-2011, 06:50 PM   #37
NW2TONE
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who ****ing knows. the kids a rich flakey punk lol. if it happens it happens. dont hold anything im not worried bout it. I found a set of 5x114 hubs with ebrake cables for 600 on cl the other day. im not gonna get them but thats all i would need to have a complete swap.
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Old 12-18-2011, 09:10 PM   #38
Bad Wagon
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Well I have those parts so if you do get that car I'll give them to you was trade.
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Old 01-02-2012, 11:15 PM   #39
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18x10? That will be so sick! Can't wait to see the finished product.
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Old 01-03-2012, 07:27 PM   #40
Matt515
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bump for updates!
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Old 01-05-2012, 10:34 PM   #41
socal624
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Wow...
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Old 01-06-2012, 12:39 PM   #42
Bad Wagon
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It looks like the final wheel choice is going to be a 17x10.5 +21 on 285/40/17

Just got back from dropping all my suspension parts off as TSS so they can be powdercoated with the parts he made for me. Also while I was there, he bent me up a main hoop and som sweet side intrusion rails for my roll cage. I'll be starting on that next week. Sorry I haven't been updating much. Had to hammer down and get a few other cars done to get some extra funds for the holidays and more fozzy parts I'll be working on the cage and interior while my parts are at powdercoating and then it's full bore into getting as much as I can installed for fab work before paint.

Johann
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Old 01-12-2012, 01:54 PM   #43
gutie04
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This project is amazing. Can't wait for the updates.
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Old 01-12-2012, 10:08 PM   #44
BrysImpreza
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Is that an Isuzu Stylus?

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Old 01-13-2012, 01:36 PM   #45
1gnasty
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wow this build is insane that is lots of work
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Old 01-13-2012, 09:52 PM   #46
Bad Wagon
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Ya it was my buddies auto x car. We going to chump race it this year. I'll have an update tomorrow.
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Old 01-17-2012, 05:09 PM   #47
singincanary
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Well........
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Old 01-21-2012, 10:24 PM   #48
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Give it time, he'll update when he can.
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Old 01-23-2012, 04:10 PM   #49
Bad Wagon
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Okay so after a long delay I have a good sized update. I have been really busy with other cars, winter apocolypse and just no time to sit down at the computer to post. We last left off with the V-Mount and weight reduction. I finished up the last of the weight loss in the engine bay. Removing the pitch mount location, fender wells, and center of the core suport to give more air to the V-Mount.







The engine will be on some custom solid motor and tranny mounts so there is no need for the pitch mount. The fender wells I cut out because the car is going to be tubed but not in the way ots normally done. I have decided to try something new and take some large plastic barrels and cut the tube piece out of them. They will be bolted on. I'll do some strengthing to the frame and tower to make the lip for the tube to bolt to but there is very little flex now that its stitch welded. They will be light. Cheap to replace if they get torn out and best of all much quieter then a steal or aluminum tub.



Next it was roll cage and interior time. Upon my last visit to William at TSS-Fab to drop off the rest of my suspsion bits before my crossmember head to power he bent me up a few pieces of DOM pipe to make my cage.







Next was to clean off all the rements of the sound proofing. The last step before paint will be some carb cleaner and scuff. I'll be covering the floor pan with traction tape once the cage is finished and seat mounts are welded in.







Trimmed and fitted the hoop. Like a glove Willaim really knows his stuff.







Next was to install the side intrusion beams. Willaim had the idea of going on the outside of the B-pillar and welding it like the new Mini WRC car. So I started by notching the B-Pillar.



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Old 01-23-2012, 04:23 PM   #50
Bad Wagon
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Next up was notching the door so it would fit. I wanted the bar to be as high as it could so I cut and reworked the door latch. Took some work but it works like a charm. Just can lock the doors anymore...







Made a small based stud pipe for the front mount. It will later tie intop the dash support beam.







Front door notched and fits like a glove.













You can see that the bar takes up almost no interior space so the drive and passenger will have lots of room and distance between the seat and the bar.











This design is great because it not only give more space it also ties the b-pillar in to help with side impact on top of adding a ton of stiffness to the chassis.



Next up was the rear bars and the cross bar.







I'll be getting some smaller diameter pipe to make a harness bar, a welded rear strut tower/ x-brace, and a x-brace to tie the to rear bars. I don't need a cage for Auto-X but I want it for club days and track events. I weighs about 70lbs with the other pieces I havent installed included so its pretty light as well. Better safe then sorry.



X-members from TSS-Fab are done with some possible custom additions to come later. Suspension pieces are at powder with the TSS goodies. Wheels are ordered on on there way so I can make it al roller as soon as the suspension parts come back. I'll be ordering some seats probubly next week. Once the cage is done and the seats are hear I can finished the interior fab and paint interior and cage. Then it will be onto wiring and stripping the harness down. Dash install and all that and once the suspension pieces come in its full throttle to get the suspension, tranny, and engine in so I can get it into a roller to make the fender flares and turbo/ exhaust system. Its going to get hot in here in the next few weeks.



Stay tuned.



Johann
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