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Old 12-15-2011, 01:46 AM   #1
kaos200
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Impreza GC8 Project Phoenix. 2.5RSTi Rises From The Ashes.

I had a whole story about my love affair for GC’s written up. But that will have to wait for my other RS’s thread . This is the latest project to be taken on in my garage.

About 4 weeks ago, another forum member was forced to sell his 1999 RBP 2.5RSTi, due to an unfortunate engine bay fire. While tracking the car at Infineon in NorCal, a power steering line burst setting fire to the back passenger’s side of the engine bay. It was apparently put out really quickly, but not before taking out the wiring harness with it. Lucky for me I do wiring mergers all the time



My friend and I decided we couldn’t pass this up. We wanted another project and this one was so familiar to me that we had to jump on it. Only a few days later on a Thursday morning we left with the trailer and made a non-stop trek to Sacramento to pick her up, trying to time it so that I could be back in time for work on Friday morning.
Due to getting there late in the evening, the owner of the shop where the car was stored couldn’t be there. He had pushed the car outside and left her out there for us to pick up.



Funny thing happens when you are looking at a car with flashlights, in the middle of the night, outside of a shop….






The policemen was nice, he asked if it was ours “nope, we just bought it”
“Actually… we haven’t paid for it yet”
“And the owner is meeting us later… yeah…”

Fast forward to after the DL and plate checks, and speaking to the shop owner on the phone, he believed our wacked out story and let us go.
Not until AFTER saying he wouldn’t help us push the car into the trailer OR take a photo with the car so we could post it up on here.

But I snuck the photo above anyways

He did take a photo of US with the car however…




Here came the most aggravating hour or two I’ve ever had working on cars.
Imagine two guys, pushing an RS, down a rough beat up road, UP ramps, UP the back of the trailer, and into it. I don’t want to talk about it. I get upset….



So! We were off. We met the owner, paid him for the car, removed some parts he wanted and headed home.


And here she is all safe and sound in our garage.

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Last edited by kaos200; 12-31-2011 at 08:53 PM.
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Old 12-15-2011, 01:46 AM   #2
kaos200
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The fun begins


We could have simply cleaned her up, fixed the wiring, and run the car. We do NOT operate that way. If she's getting done, she's getting done right.
  • Engine will be coming out for a refresh and check up.
  • Trans as well.
  • Engine bay will be sanded down to metal basically and painted black.
  • Wiring will ALL be redone.
  • Car will be put to CARB specification, and receive its CARB approval tag. (We live in Nazi Kalifornia...).
  • Brakes, suspension and interior will get checked out and some little bits updated as well.



The bastard power steering line that caused this all.














Granted, the wiring in the engine bsy was crispy, but the wiring on the whole for the swap, was absolutely atrocious.
I've been doing swaps and wiring mergers for years now, and seeing this made me upset.

I started cutting.... (I'll add pics of the wiring horror later)

Engine is coming apart for a refresh, even though she looked good inside



A little dirty on the outside. That will all change soon.



Last edited by kaos200; 01-22-2012 at 04:00 PM.
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Old 12-15-2011, 01:46 AM   #3
kaos200
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Hmmm so fresh and so clean clean.
We had the heads checked, cleaned, valve job, resurfaced etc.











Last edited by kaos200; 01-07-2012 at 11:12 PM.
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Old 12-15-2011, 01:47 AM   #4
kaos200
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Transmission was pulled, cleaned, opened up the bottom (pan) and inspected, and had new seals installed.


All new pullies, tensioner, etc.




As I said, the wiring in this thing was horrible.




All out, feels so much better just having the crap all out.


I want a tetanus booster after touching this.


MUCH BETTER!




Last edited by kaos200; 01-07-2012 at 11:14 PM.
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Old 12-15-2011, 01:47 AM   #5
kaos200
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Engine bay stripped down and getting sanded down.






We sanded it further, cleaned it, dried it, acetoned everything, dried it again.
Then, primer:







Quick Ratio steering rack

Crossmember painted




Last edited by kaos200; 01-14-2012 at 05:26 PM.
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Old 12-15-2011, 01:47 AM   #6
kaos200
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A big thank you to Aaron at Saab & Subaru Parts for getting me a pristine condition harness and other little goodies to get this baby on the road.







Last edited by kaos200; 03-30-2012 at 12:20 AM.
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Old 12-15-2011, 04:13 AM   #7
turbochrgdRICE
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Ahh, this is the reason why he stopped responding in his for sale thread, haha. Great platform to start with, can't wait to see how she turns out.

Since you're the new owner, I guess I have to ask you, so let me know if you're willing to sell the rear pass through seat that it has =D
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Old 12-15-2011, 11:48 PM   #8
kaos200
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Haha no sorry that's a really clean part of the car I like, they fully fold down and are matched to the STi front seats.
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Old 12-16-2011, 12:47 AM   #9
boostdprotegelx
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and sub. love build threads!
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Old 12-16-2011, 09:17 AM   #10
20wrx05
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Looks great! Looks just like mine!

I have a 04 sti swap, just getting mine done, had to do it right like you say'd, which was make it fast! haha
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Old 12-16-2011, 09:44 AM   #11
TheHoboMan
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cool thread keep us updated!
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Old 12-16-2011, 10:26 AM   #12
ILoveLamp
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lol, that's the S.O. I work for. Glad to hear one of my co-workers was cool about things.
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Old 12-26-2011, 07:44 PM   #13
kaos200
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Engine assembly has progressed quite well.
ARP headstuds used instead of oem
all new gaskets and seals of course.
Almost every rubber hose has been replaced.
Photos in post #3


Just about to head out and get some hose clamps and other bits to call it a day.
Waiting on new timing belt parts for the front end of the motor and gotta find a good turbo to throw on it

Last edited by kaos200; 12-31-2011 at 08:54 PM.
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Old 12-26-2011, 09:46 PM   #14
kaos200
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Quote:
Originally Posted by 20wrx05 View Post
Looks great! Looks just like mine!

I have a 04 sti swap, just getting mine done, had to do it right like you say'd, which was make it fast! haha
Nice RBP RSTi's ftw haha
Or just RSTi's in general. Amazing little cars. I'm addicted.

Is it done yet?
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Old 12-26-2011, 10:05 PM   #15
KINGSKY
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so ur teh HO who bought it... ja ja
looks like an awesome project...
keep up teh great work...


RANDi
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Old 12-31-2011, 08:58 PM   #16
kaos200
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Got quite a bit done in a few short hours today.
Removed all the wiring harness
Sanded and painted the dash beam
Removed brake booster, lines and abs pump
Progress made on sanding the engine bay down.



Thanks Randi. It's a lot of work but really rewarding to see her come back together.
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Old 01-01-2012, 12:12 AM   #17
Smoke
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Looks like another Project Phoenix we saw on here (John's2.5RS)!

I like projects like these!
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Old 01-01-2012, 10:29 AM   #18
shadowmd
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liking this thread! nice work
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Old 01-01-2012, 12:14 PM   #19
ShiftGear
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Saved. I love this thread! Keep on going
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Old 01-01-2012, 12:22 PM   #20
renegadeSTi
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The RBP coupe RS is becoming a rare breed. I love my swapped RBP RS as well.

Here is mine

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Old 01-01-2012, 12:51 PM   #21
kevosnowsti
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Ah, so you're the one who bought this! Glad to see you are fixing it all up the right way.
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Old 01-07-2012, 11:17 PM   #22
kaos200
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Quote:
Originally Posted by Da-Risin-Smoke View Post
Looks like another Project Phoenix we saw on here (John's2.5RS)!

I like projects like these!
I'll check it out
Thanks

Quote:
Originally Posted by shadowmd View Post
liking this thread! nice work
Thank you !
Quote:
Originally Posted by ShiftGear View Post
Saved. I love this thread! Keep on going
Updates are above!
Quote:
Originally Posted by renegadeSTi View Post
The RBP coupe RS is becoming a rare breed. I love my swapped RBP RS as well.

Here is mine
Nice Yeah, I really enjoy them. What's next for yours?

Quote:
Originally Posted by kevosnowsti View Post
Ah, so you're the one who bought this! Glad to see you are fixing it all up the right way.
Yupp, thanks for the compliments everyone.
I've updated post #5 above with the engine bay progress. Possibly spray a couple top coats tomorrow.

Last edited by kaos200; 01-22-2012 at 04:04 PM.
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Old 01-07-2012, 11:54 PM   #23
Misterjew
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Awesome nice build
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Old 01-08-2012, 05:42 AM   #24
pheonix991
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Keep up the good work man.
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Old 01-13-2012, 09:00 PM   #25
kaos200
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Quote:
Originally Posted by Misterjew View Post
Awesome nice build
Quote:
Originally Posted by pheonix991 View Post
Keep up the good work man.
Thanks guys
Updates above.

Last edited by kaos200; 01-22-2012 at 04:04 PM.
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