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Old 10-24-2011, 02:16 PM   #1
girodisc
Former Vendor
 
Member#: 177674
Join Date: Apr 2008
Chapter/Region: NWIC
Location: B-ham WA
Default Swapped GC Build.

Hey all. I know have a couple build threads going on right now but I figure I would share this one as well since there is so much love for the GCs.

This project is a compliation of me and a few of my friends coming together to rebuild a car that was lost by my buddy. A freind of his rolled it. Originally this car was owned by a member on this forum that was attempting to do an EZ30r swap to it. After taking it to a few shops and getting hosed he decided to give up on the project and sold it to my buddy over at PIA. I bought a car from a freind of mine that need to get rid of it because he needed cash to buy a new car. It was a 2002 RS that I converted into a stock WRX. I traded this car to get the GC because I wanted the EZ30r for the Legacy.

Held onto the car for a long time while I was waiting for time to start the EZ swap and my freind (the one that got his car wrecked) bought his old car back from insurence and was looking for a good 4dr shell to rebuild the car. I sold him this car w/o the EZ and this is where this build starts.

All these first pics are from him while he was stripping the car down at my shop. He stipped all the drivetrain out of this car and out of the Forester I just bought (the ForeSTAR build thread car) because I sold some parts off it for the GC. His original car had a Ver 7 STi swap but he was worried that because of the rollover there could have been some internal dammage to the motor so he gave the engine to another good freind of mine for a rebuild. The tranny is also getting a once over by my buddy Mike at PIA so this car is getting worked on from all fronts all at the same time by a small team of misfits.

Okay lets start off with the mods list.

Engine:
JDM EJ20 STi

Engine Mods:
Balanced internals (crank pulley to flywheel)
ACL racing bearings
Port and polished cylinder heads
ARP head studs
Rotated Intake Manifold
850cc Injectors

Engine Management:
Hydra EMS ECU
Innovative wideband
Turbo timer (integrated with alarm system)
Tune from Maxwell Power Services

Turbo:
16G EVO

Turbo Mods:
Port and polished
Tial 38mm wastegate
Custom Rotated uppipe, downpipe, and screamer pipe
Greddy Ti-C catback
OBX FMIC with custom piping

Transmission/Drivetrain:
Custom build 5 speed
PPG semi-straight cut gear set
Spec Stage 3 clutch (6 puck)
ACT lightweight flywheel
2004 STi R180 Raer Diff/ Hubs/ Brake Swap

Brakes:
2004 STi Brembo's custom painted
Girodisc slotted rotors
Girodisc stainless brake lines
Girodisc Magic Pads

[b]Wheels/Tires[b]
Rota SVN-R 18x10, +30 offset
255/35/18 G-force KDW's
15mm hub-centric wheel spacers

Suspension:
Tein SS coil-overs -TEMPORARY LOL
Perrin sway bars (front/rear)
Whiteline anti-lift kit
Cusco strut tower bars (front/rear)

Interior:
2004 WRX dash assembly
2004 WRX Pedal set
2007 STi gauge cluster
2005 STi Seats, Carpet, Steering wheel
Defi boost, Oil Press, Fuel Pressure gauges in ATI dash pod
Custom painted door panels, headliner
Custom door cards wrapped in blue fabric
Custom Modded 6 point roll cage
Corbeau harnesses


Exterior:
Por-15 undercarriage/ engine bay
Vis racing side skirts
Seibon CW carbon fiber front lip
JUN S-13 replica fender flares
3M carbon fiber wrap (hood, roof, trunk
2.5RS front bumper
Depo smoked headlamps, corner lights, turn signals (bumper and fender)
JDM v6 front grill
JDM v6 fog light covers
JDM v6 tail lamps
Hood latch/vertical beam mount delete
Sparco hood pins

Heres the car the day he bouight the car from me:





Shortly after he started cleaning out the inside and getting all the interior gutted. It was tan. Its getting dropped off at my buddy's shop so it can get painted black.



A week latre he had the drivetrain all dropped out:



Then I spent a night and stripped all the parts out of the engine bay and removed all the dash wiring to get access to the firewall.

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Old 10-24-2011, 02:19 PM   #2
PseudoKirby
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Member#: 203835
Join Date: Feb 2009
Chapter/Region: BAIC
Location: California
Vehicle:
2000 2.5RS
Aspen White

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this is going to be a beast
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Old 10-24-2011, 02:26 PM   #3
ArSoN9
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Member#: 285777
Join Date: Jun 2011
Chapter/Region: MWSOC
Location: Milwaukee, WI
Vehicle:
2004 STi-

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Good to see another GC being pulled from the junk yard and given the love it needs...

Cant wait to see this together
GLWYB
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Old 10-24-2011, 02:31 PM   #4
girodisc
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Member#: 177674
Join Date: Apr 2008
Chapter/Region: NWIC
Location: B-ham WA
Default

Once that was done he wanted to touch up a couple little rust spots on the chassis so I cleaned the underside and then coated it in POR15 and some undercoating.

Before:



After:



The next day after it was all dry he swapped in the rearend and front assy from the Forester.





Suspension and wheels in and back on the ground:



In another location that same night my buddy with the engine was getting started on his rebuild.





Should be finished in a week or so.

While the engine and tranny are getting loved I got busy with my portion of the project:

WRX Wiring Conversion
WRX Dash Swap
Custom Modded 6pt Roll Cage
Smoothed Engine Bay
Relocated Battery, Fuse Box
Relocated ABS w/ Custom Brake Lines
Bolt On Fender Flares w/ Herra Frush but functional stance (Like the Lego)

Got Started on the Dash Swap. I was happy I got to do this one right way because the windshield needs to be swapped so I got to pull it. Tonight I will make the holes for the Blower and Heater in the Firewall and plug all the un-used holes along with removal and addign metal to start the smoothed out engine bay. Once the Dash and wiring are in for good I am going to make some nice custom trim pieces that cover the gap on the sides from the dash swap so it will be cleaner. I'll be doing it from laser cut acrylic and then having it panted to match.



This project is on the fast track so stay tuned for updates. Once I run out of work and I am waiting for parts back from other places I will be back onthe ForeSTAR project to check that one out too its also going to be a good one.

Johann @ Girodisc
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Old 10-24-2011, 03:33 PM   #5
Matt515
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Member#: 241492
Join Date: Mar 2010
Chapter/Region: NESIC
Location: Bristol CT
Vehicle:
2006 Forester, RBP
Tuned by M@ at WI!

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as long as i find them, i will always subscribe to your build threads. you are truly inspirational
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Old 10-24-2011, 05:13 PM   #6
i_adz
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Member#: 281829
Join Date: May 2011
Location: western mass
Vehicle:
04 wrx
02 ts DD

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awesome build
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Old 10-24-2011, 05:34 PM   #7
alwazsidwaz
Scooby Newbie
 
Member#: 133454
Join Date: Nov 2006
Location: Allentown
Vehicle:
2004 Forester
AW

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Tuned in. I want a white sedan.
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Old 10-26-2011, 11:41 AM   #8
girodisc
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Member#: 177674
Join Date: Apr 2008
Chapter/Region: NWIC
Location: B-ham WA
Default

Got some more work done last night.

Started by finishing my modifications to the cage. I'm not going to finish it for good until the interior panels are back in to make sure there is enough clearance.



Removed some parts off the engine bay to get ready to smooth it out.



mocked up the cover pieces to be redone in metal and welded on. However by the time I was ready to cut metal it was to late to make that much noise.



Also got the ABS Pump Relocated. Had to order some tools last night for mounting the fender flares, I needed to get a new flaring tool. Also ordered up some parts, Wire, Nutzerts, so while I am waiting for those things I am going to install the heater and blower so I can get the holes cut in the wall and start smoothing everything out. Also I have to de-loom all the wiring so I can relocate the fuse box and crap. More pics soon.

Johann @ Girodisc
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Old 10-31-2011, 03:26 PM   #9
girodisc
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Join Date: Apr 2008
Chapter/Region: NWIC
Location: B-ham WA
Default

Got another update. Got a good amount of work done this weekend.

I started the day but getting the FMIC Mounted.



Then I got the Header Core and Blower Motor from the WRX Fitted. Got the Fire Wall All ready to go. Plugged a couple unused holes to make it look a little cleaner. I have one more to plug but I need to finish the wiring to figure out with one I am going to keep.



Next I pushed her outside and cleaned the engine bay all out so I could start prepping the bay for the metal pieces I need to make and for the All-metal filler. Used a product calls Scuff It. Its a mild abrasive past that has a cleaning detergent it. One red scuff pad and this stuff will clean your bay down super easy its really great stuff.



Next it was the rear fender flares. Got my nifty nutzert tool and hardware in so I got the rear flares mounted. I need to Jonny to drop the bumper off so I can fit it and trim it for the intercooler and get the front flares on. 15mm spacers and extended studs already on the way.





To finish out my weekend I got the harnesses ready for some custom work. The wire isn't here yet so I have to wait before I can cut any wire.





For the wiring there are a couple things that need to be done just to get it to fit nicely in the GC with the converted dash. Next will all have to do with the wire tuck. Fuse box wiring will be reversed and extended to mount next to the battery in the trunk. All the wiring for the engine bay is going to come out of the wire wall in one spot just above the tranny so its all clean and consolidated. Wiper motor, and passenger side ABS wires are going to go out through the inside of the fender and poke into the engine bay in a unnoticeable spot. My new brake line flaring tool came in so I will be able to start fab work on the new lines for the relocated ABS pump in a couple days.

More updates with the motor and tranny should be soon to follow.

Johann @ Girodisc
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Old 10-31-2011, 05:10 PM   #10
1VIPWRX
Scooby Specialist
 
Member#: 107554
Join Date: Feb 2006
Chapter/Region: Tri-State
Location: some where in washingtonville
Vehicle:
03 03/07
yellow

Default

wow..
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Old 10-31-2011, 07:32 PM   #11
boostdprotegelx
Scooby Specialist
 
Member#: 139996
Join Date: Feb 2007
Chapter/Region: MAIC
Location: Essex, MD
Vehicle:
2004 Subaru WRX STi
PSM

Default

subbing. badass.
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Old 10-31-2011, 07:57 PM   #12
chrisbolton
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Member#: 216597
Join Date: Jul 2009
Chapter/Region: Tri-State
Location: Kennett Square, PA
Vehicle:
2003 WRX
PSM

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This build looks like amazing can't wait to see the progress!
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Old 10-31-2011, 10:18 PM   #13
Ferg
"Tekeli-li! Tekeli-li!"
Moderator
 
Member#: 14145
Join Date: Jan 2002
Chapter/Region: NWIC
Location: Top Scoob HQ
Vehicle:
'02 WRX
'10 4Runner

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aaand subscribed
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Old 10-31-2011, 10:40 PM   #14
BeBop86
Scooby Guru
 
Member#: 147776
Join Date: May 2007
Chapter/Region: NWIC
Location: Bellingham, WA
Vehicle:
'02 Impreza WRX
'85 Toyota Corolla

Default

Hey, that first pic of the wiring harness look familar...



Oh now I remember
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Old 11-01-2011, 01:41 AM   #15
|Rev|
Scooby Specialist
 
Member#: 100651
Join Date: Nov 2005
Chapter/Region: RMIC
Location: Longmont, CO
Vehicle:
2010 STI
OBP

Default

awesome work man, I wish I had half the knowledge and experience you have on rebuilding cars.
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Old 11-01-2011, 04:45 AM   #16
Rice Devil
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Member#: 51164
Join Date: Dec 2003
Chapter/Region: International
Location: UK - F&F mag 06
Vehicle:
Jap Jp mag 09
Ti mag 09 (cover)

Default

Superb work, have to say you are the king of scooby work!!

Ricey
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Old 11-01-2011, 12:08 PM   #17
girodisc
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Member#: 177674
Join Date: Apr 2008
Chapter/Region: NWIC
Location: B-ham WA
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King? No. Maybe like a exuberant henchman. Or like a mad scientist. lol Id have to give the King of scooby work to say a shop owner or something. Dom, the guy that owns Ebishu and Team Orange, one of the cosworth or prodrive desginers, etc..

My shop is more like a freak show. haha

So the car is going into paint on the 14th so I had the bumper and lip dropped off so I could finish the exterior work and get that all ready. I am going to finish up the engine bay this week as well while I am still waiting for the materials to do the wire tuck. While the car is at paint I will be getting both the motor and the tranny back so I can work on reversing the manifold. Its also going to give me some time to make some headway on the ForeSTAR. Once I get the GC back I'll start throwing parts at it and it should be on course to finish before the end of the month. I'll have some good updates in a couple days.

Johann @ Girodisc
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Old 11-01-2011, 03:41 PM   #18
Run Forester Run
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Member#: 89594
Join Date: Jun 2005
Chapter/Region: NWIC
Vehicle:
2007 STi
OBP

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Quote:
Originally Posted by girodisc View Post
King? No. Maybe like a exuberant henchman. Or like a mad scientist. lol Id have to give the King of scooby work to say a shop owner or something. Dom, the guy that owns Ebishu and Team Orange, one of the cosworth or prodrive desginers, etc..

My shop is more like a freak show. haha

Johann @ Girodisc
Definitely mad scientist! The harebrained ideas that you come up with leave no doubt that you are the Dr. Frankenstein of Subarus.
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Old 11-01-2011, 04:04 PM   #19
girodisc
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Member#: 177674
Join Date: Apr 2008
Chapter/Region: NWIC
Location: B-ham WA
Default

Yeah true. I have been the 1st to do a lot of things probably because I am the only one dumb enough to actually attempt them.

This build I'd say is going to be one of the only normalish builds I have done. Couple custom things but all been done before by me or others on the forum. The Forester, Legacy, Explorer, and Subreal Atom (Coming Soon) are getting all the crazy ideas I have floating around in my head.

Johann @ Girodisc
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Old 11-01-2011, 06:14 PM   #20
skierc16
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Member#: 299693
Join Date: Nov 2011
Chapter/Region: SCIC
Location: Newport, CA
Vehicle:
2007 STI
OPB

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oooooo flares! looks good so far man!
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Old 11-01-2011, 06:26 PM   #21
Jose Bonilla WRX
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Member#: 250987
Join Date: Jul 2010
Chapter/Region: International
Location: Miami,FL 33126
Vehicle:
2003 JDM WRX STI
Grey

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Niceee proyect.... Good luck
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Old 11-03-2011, 11:42 AM   #22
girodisc
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Member#: 177674
Join Date: Apr 2008
Chapter/Region: NWIC
Location: B-ham WA
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Update Time:

Had to take a day off work so I could get my fireplace fixed. So... I got a whole day in the shop.

Started by trimming the front bumper to fit the FMIC and getting the front fender flares bolted on.



Bumper is sagging in the middle so I fitted the headlights and grill so I can make a new custom bumper support.



Then, I moved on to some wiring. Fitted the WRX Dash harness, heater and blower motor so I could setup the wires to do the custom tuck.



I consolidated all the engine bay wiring to one point on the firewall. Wiper and Passenger ABS will poke through where the rear brake lines used to go. The brown and grey engine harness wires that connect by the fuse box will also be joining these wires so not only will it look super clean but all the wiring will be in one spot so disconnecting the engine for removal will be easier and take less time.



Last a pic of the car at a distance. Its getting there.



Next up will be finishing the engine bay sheet metal and body work, then a coat of gloss black paint. Next will be fab work on the custom bumper support, fitting the lip, side skirts, and rear spats. Then cutting out the fenders and quarters, and finally modification to the harness for the wire tuck and relocated fuse box. Then the car is off the paint for a couple weeks and I'll get some time to work on the ForeSTAR project and get the tranny and engine here. Once it comes back it will be a nice sprint to the finish installing everything, fitting the custom rotated turbo kit, and reversed manifold and sending it on its marry way. Next update will be Monday to show the fruits of my weekend labor.

Johann @ Girodisc
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Old 11-07-2011, 11:31 AM   #23
girodisc
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Join Date: Apr 2008
Chapter/Region: NWIC
Location: B-ham WA
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Got some work done over the weekend. Mainly little tedious stuff to get the car ready for paint. I did however get some pics of the bumper beam I made so the bumper would fit correctly.





Tonight and tomorrow I will be getting the rear spats and side skirts fitted as well as finish cutting out and modifying the rear quarter panels

Johann @ Girodisc
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Old 11-07-2011, 12:30 PM   #24
frayz
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Member#: 106909
Join Date: Feb 2006
Location: Essex-England-United Kingdom
Vehicle:
2002 V7 STi Prodrive
Edition... Black!

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Loving this.

Your threads are always a great read Giro, well done

frayz
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Old 11-07-2011, 12:47 PM   #25
evoklr101
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Member#: 139159
Join Date: Jan 2007
Chapter/Region: NWIC
Location: mill creek
Vehicle:
0207 did i hurt your
feelings? grow a pair

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I claim you to be the king of this stuff man!
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