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Old 03-28-2012, 12:56 PM   #76
Bad Wagon
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Okay update time. Its a big one. With not much time and with what time I did have and Nasioc being down, progress pics have piled up.

Moving on with the interior I added a couple pieces to the cage and welded in some bolts to mount my harnesses directly to the cage:









Next it was one to some fab work. I got these tie rod links online. They are from a nissan 240sx. Right size, right thread pitch and perfect to fine tune adjustments.





Although you can't tell from this pic they are about 1" shorter then the stock links and can't be used to fit the hub in the stock location. But thats not why I got them...

Started making my own quick steer kit. By moving the tie rod location in closer to the hub you get an increased steering rate. This will allow me to corner in Auto X without having to go hand over hand as much and help lower run times. Yes it will feel a bit heavier and it will put a slightly high amount of strain on the pump but the pros still greatly outweigh the cons.

Started by cutting out my upper and lower pices..

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Old 03-28-2012, 01:04 PM   #77
Bad Wagon
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The a couple cuting discs and a hours later they look like this.







Once the A-arms are in I can set the angle of the steering rods. I will need to spacer them down to match them.

Next I finally got my tires mounted. Yokahama S Drives 275/40/17 to commuting to the track and for non-slick use.



These things are huge. (next to some 245/40/18s)





Installed on the rear:



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Old 03-28-2012, 01:13 PM   #78
Bad Wagon
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Next up it was A-Arm time. Gots these crazy arms from Willaim at TSS-Fab. These were a colaberation between the two of us and this is the first prototype set.



These arms have spherical joints both ends so the first thing I had to make was some new ball joints that could fit them. I took some Whiteline Roll Center joints that my freind cross threaded and cut them apart..



Next I got a huge 7/8"x5" bolt to fit inside the body. First I had to grind the head to get it to fit.



Here is it next to the original before welding. Its long long because I want the ball joint to not be seating in threads so this will be cut down. The oringinal Whiteline one looks so wimpy.. haha



Couple welding pics...



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Old 03-28-2012, 01:23 PM   #79
Bad Wagon
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Here it is shaved down w/ spacers installed with the new arm..





Then the front wheel went on to check the fit.





And lastly before I got I did get a couple more parts in... Got in my pair of aftermarket front fenders. A little cutting and fitting in here is a couple teaser shots of whats to come. They are mounted 1.5" lower then the OE flare to tuck the rear tire for better air flow. These will be bolted on and I will be modifying the door to bring the original flare farther forward. They will be bolted on but they are metal so they are strong.





Anyways hope this will hold you guys over for a few days while I puck top get the GC8 finished up to get painted.

Johann
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Old 03-29-2012, 11:23 AM   #80
Bad Wagon
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Here are some daylight pics of the rear flares.







I really think the wheels I picked fit perfectly with the style of this Forester.

Anywho, I ordered a couple gas doors from some wreaked foresters to extend the original doors flare. Should be here in a week with the hardware I bought to bolt them to the body. In the meantime I will be finished up the A-Arm install and making the tabs for the front endlinks. With all custom jobs many changes need to be made. Because I moved the tire rods inboard, the sway bar needs to be ran forward so the links are in front of the tie rods. Not a big deal just need to make custom tabs to weld to the A-Arms before powder. So when these are done they will look slightly different then the once that will be offered by William in the future.

I hope to maybe get started on the turbo and header fabrication later tonight as well. On Monday the GC8 project is going back to the body shop to finish up the paint so I will have a week or 2 to puch hard on the Foz and get it going. My first Auto X even is April 15th so the is a very slim chance I will have it done by then but its not out but I will make the May event for sure. It may not be painted but it will be there haha. Going to order the fittings and internals for the motor next week and put me close to the home stretch.

Johann
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Old 04-03-2012, 11:56 AM   #81
Bad Wagon
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Hey its update time!!!

I'll start off with the pics of it on the ground and the ride height pretty much set.











Sat there and looked at it for a while and then it was back on the jack stands...

First thing I tackled was making some modifications to my quick steer brakets. Because the TSS-FAB front crossmemeber has a 2nd higher mounting point for the A-Arm to allow a stock height suspension angle but with the car lowered 3-4" the tie rod were no longer at the same angle and the as the wheel traveled up and down it was towing in and out.



So I lowered its mouting point to match the arm and now the tire stays strait. Everything is welded together to make it as stong as possible and I also added a few extra pieces to make it stronger where it mounts to the hub.
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Old 04-03-2012, 11:58 AM   #82
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So my shop is getting pretty cluttered with parts. GC8 parts, ForeSTAR parts, Corollarussan parts etc so I had to make some space and install the fuel cell. I really wanted to use the stock fuel level gauge so I didn't have a unworking gauge in my cluster. So first I removed the fuel pump carrier and shortened it to the fuel cells hieght.



Then I cut the mounting flange out of a spare OEM fuel tank and then installed it into the cell.



Made a couple carrier pieces and done... Mounted it just behind the sway bar on the passenger side to help with the weight distribution.





The new filler point. I have a flush mount filler cap that will be installed in the corner in the lexan looks pretty good.

Next I finished up the tranny crossmeber by adding in the 2 rear mount points for the tranny.



and then to finish yesterday out I cut and modified the header to fit my forward mount turbo kit. This is an un-equal length twin scroll setup so it should sound pretty interesting to say the least. Removed 2 90deg bends and only added about 2" of pipe so flow is much better and with how much that will be removed from the up-pipe it will be a vast improvment over the stock location.





Stay tuned I'll have more updates tomorrow. I have a crapload of parts coming into me this week and with the GC8 gone for 2-3 weeks a lot of time to make up some ground.

Johann
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Old 04-03-2012, 06:09 PM   #83
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Fricken awesome. Everything is.
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Old 04-03-2012, 10:22 PM   #84
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pure envy!
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Old 04-03-2012, 11:15 PM   #85
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sign me up
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Old 04-04-2012, 12:39 AM   #86
Bad Wagon
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Hey I got a bunch of parts in today. Driveshaft, brake line clamps, nutcerts and ss screws. I'll be mounting the bumper for good. Relocating the radiator a little lower and maybe locating the turbo tomorrow. Just a few more parts still to come in to do some of the bigger stuff but I have plenty to work with this week.
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Old 04-06-2012, 10:58 AM   #87
Bad Wagon
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Hey guys its update time!!! YAAAAY!!!!

ahem... Okay so we last left off with the header but I couldn't mount the turbo untill the coupler that I orderd arived so I started working on the bumper. Drilled out some holes and use an aluminum plate to hold the 2 halfs together.





I'll use a tiny bit of filler or a trim pirce to help fill the gap a little but it came out looking pretty good. Then my hose coupler arived!!

Mounted and intercooler and turbo.





It fits in there pretty good with about 3" to spare when the tire is at full look at ride hieght. Im not to worried about burning the tire because it not like I am going to be racing at full lock so...

Then I fabed up the new up-pipe.



This is what was lefter over from the original header after I was done.



Thats about 17" of pipe. I added 10" to is what was actually removed was 7" or roughly 16.83 cu/in. Any reduction in the length/ volume of the up-pipe will increase spool so I think will be a pretty good improvment.

Lastly I finished out the day but fabricating the lower bumper and radiator mount.



Because the bumper hangs alot lower the the original I had to drop the radiator about 3" so I had to cut out the lower core support. This piece is a bolt on so it can be removed fix or gain extra room for removing the engine. The middle brace will be next along with the ducting to force all the incoming air into the v-mount's intercooler and radiator as well as locate the upper bumper mount.

Next up I'll be doing the downpipe and I really want to make a custom strut bar so I'm going to heat to the metal yard and rummage through their scrap. More parts arive every day so the updates will keep coming.

Johann
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Old 04-07-2012, 12:43 AM   #88
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great work Johann, i love watching your build , cheers mate.
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Old 04-07-2012, 12:47 PM   #89
Bad Wagon
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Hey all time for another update.

Started the day by cutting off the front fender rear flares to modify the door. If you can remember from earlier pics the fenders flare and the doors flare did not match. The door flare curved down into the new fenders flare and looked funny.



So I spent a good part of the day trying to fix that... First I cut off the flare from being tacked on the car.



Then i grabbed my ace up my sleave. Bought 2 of these from a wreaking yard. 98-01 Forester gas filler doors.



Then cut the front part of the doors flare off.



Trimmed up the filler door. I bet you guys can see where this is going....



and tada! Fixed.



I was going to bolt the flares on but upon attempting that I realized is didn't look like I wanted to so I am going to weld them on. I can't finish them untill I cut out the quarters for the wheels so I will try to get that done early next week and get the flares on for good. Dispite that I was kinda irritated that the bolt on idea was a flop so I finished off the day by adding some awsome to the front end...



grrrrrr



Well thats all I got for now. More soon.
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Old 04-08-2012, 02:25 PM   #90
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One unique forester. Love it. Wish I had the time And cash to build a rally foz.
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Old 04-09-2012, 03:28 AM   #91
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Love it, mine only gets sti struts
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Old 04-09-2012, 10:46 AM   #92
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Keep up the great work!
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Old 04-10-2012, 03:06 PM   #93
Bad Wagon
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Its that time again. Got lots of pics for this one.

Started the day off the the UPS guy.

Got this racing heater/ blower motor setup. This little guy weighs 5lbs vs the stock combined 47lbs of the heater and blower assy. Should be enough to defrost my windows...



Then I got my little cute braille battery. 21lbs not the lightest they sell but it was what they recomended for a car with 10:0:1 comp. Still much lighter then an OE one.



Then it was back to that rear flare. After deciding to weld it on I took it back off the cut the quarter panel out. Made sure there was plenty of room for that tire not to rub.



Then I tacked the flare on for the last time and cut it at the door line so it would open. Next was getting the harware install to hold it closed. Used some M6 nuts w/ a stainless thin walled pipe to make the little spacers.



And then use some M6 tapered screws and made them flush mount in the door.



Next I was getting a little bored so I broke out my new saw and started fabbing my down pipe.



Nice closeup of the collecter for the wastegate. No screamer pipe on this car...




Fits with plenty of room to spare. Pretty strait as far as down pipes go.



And plenty of ground clearence as well.

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Old 04-10-2012, 03:07 PM   #94
Bad Wagon
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I also finished removing all the window urethane and cleaned all the window flanges to get ready for the lexan. Made a mess. So this moring I rolled her outside for the first time since she went in for a little spring cleaning. Thought it would be a good idea to take some nice glamor shots.. Enjoy!



















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Old 04-10-2012, 03:08 PM   #95
Bad Wagon
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Well thats all for now. Going to try and finish up the exhaust and cage today.

Johann
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Old 04-10-2012, 11:04 PM   #96
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shaping up nicely Johann
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Old 04-11-2012, 09:28 AM   #97
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bosss
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Old 04-11-2012, 01:03 PM   #98
Bad Wagon
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Its that time again. Didn't get as much done yesterday as I wanted I was feeling a little under the weather. However I did get the muffler and exhaust pretty much finished.

Started by mounting the muffler..



The reason for it exiting here is ground clearence. With how low the car is running the pipe under the rear CV would only leave about 2" of clearence so thats no good. I mounted the muffler tip a little higher then where I originally wanted it because I didn't want to have to stick the pipe 4-5" out to avoid burning up the paint on the side of the door. I'm going to make an aluminum heat sheid for around the muffler but I can still open and close the door without taking it out for maintanence.







Then I ran the rest of the exhaust. I have at least 4" of ground clearence along the entire underside of the car cept for the front bumper which is 3"



Made a little cut here to curve in a little faster to leave room for the aluminum 1pc driveshaft.



and finally the rear of the exhaust



The hole in the floor as well as the exposed exhaust/ muffler is getting covered in an aluminum firewall as well as getting wrapped. I'll be getting the aluminum for the floor pieces later today to start fabrication on them tomorrow.

Johann
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Old 04-13-2012, 11:42 AM   #99
Bad Wagon
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Hey all. Got some more work done. Yesterday I spent most of the day getting a bunch of mock up pieces made from cardboard.

Firewall...



Rear floor panel...



I have a couple other but they are not worth showing yet. Next I spent some time and cleaned up the remainder of the sound crap off the interior to get it ready to paint once I finish the rest of the bits.



Then I started work on fitting the dash. Just getting rid of the bits...





Some of the more experienced know but when doing a dash swap from GC8 to WRX there is this really ugly gap at the door jam. This Forester actually had a GC8 dash in it from factory so the WRX swap is essensially the same. However... I know few tricks to eliminate that gap.. Fits like factory.





Yesterday I worked from 8am to 1am and got a bunch done. Time consuming but every hour is an hour closer to finishing. I was contimplating what to do with the forward floor panal and it hit me so I started getting that all taken care of.

First I started with the framing.



Then I made the upper cover plate.



Unfortunetly at this time it was about 7:00 and getting to dark for good pics but I finished cutting up a bunch of pieces to finish it. I still need to get a bit more aluminum sheeting for the muffler cover but tomorrow when I post my update you'll get a another look at one of my super mega funtime special ideas...

More soon today is going to be abother productive day.

Johann
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Old 04-13-2012, 11:53 AM   #100
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Are you just covering the firewall, or replacing it?

Looks good, I really like that fuel cell idea and am really curious how well the stock pump/sender works out for ya.

Are you only going to run the top half of the dash?
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