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Old 09-09-2012, 01:59 PM   #1
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

Default Bugeye Journey - future road/track car

Hi folks. For fun I've decided to create a log of my 2002 WRX project car. I'll be up front that I'm a bit of a noob mechanically so I'll be learning and screwing up before getting it right but that's ok, its the whole point. I always wanted to document a car's transformation and I've spent countless hours reading other's build threads so why not do my own? I know I'll be learning and perhaps others will get something useful out of it to boot.

On the upside, I have big plans and I will execute. I'm braver than I am smart I'll start off small, trying to rectify issues before leaping to performance enhancements. That will probably be boring initially but that's life.

The intent is to build a road/track machine. Feal, qrack, hybrid build, 6 speed, BBK, bushings, ALK, RCA, mounts, body work, paint etc.

But like I said first and foremost I've got to get the car mechanically sound again and get all the basics working. Luckily this isn't my daily, so tearing it apart and breaking it won't be an issue. The "R" will be my parts runner and the Bronco in case I need anything really big...

A brief history of the car:

Chassis 133,000
Motor 70,000 (claimed, no doc, but likely)
Megan Turbo Back Exhaust, no cats
AJW Stage 2 Tune
Cheap ass VTA BOV from EBay
Short throw shifter (I believe)

The good:
Pulls strong and sounds good doing it
Very clean body / underside
Motor dry, heads look good
tranny dry, no grinds
Decent Alpine aftermarket setup
Air conditioning works (owner claimed otherwise )
Its an Aspen Bugeye!

Problems:
Struts shot to ****
Driver's window not functioning
Leaking Steering Rack
Bad inner tie rods
Intermittent Cel (no codes)
Gas tank very difficult to fill
STI seats have more brown on the seat portion than blue
smells like dog
crappy wheels and tires
Depo headlights.. fitment and lens issues
Previous owner*

* nice guy in person, but hacked the car badly and doesn't return calls or text messages post sale. On the upside I no longer care as the more I find the more apparent it is he as nothing to contribute.

Here she is, taken today.
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Old 09-09-2012, 02:30 PM   #2
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

Default

Drivers Window - nasty first project...

I had the bad luck of having a dead motor with the window stuck in the up position. The window master switch was butchered by the pervious owner, but it still sort of works (replacement on its way). I was able to get a multimeter on it to validate the wires to the motor are functioning. Here is the situation, with all the previous owner's "handywork":



What does the window stuck in the up position mean? Its bad. Its bad because the procedure in the manual calls for the window removal to get the regulator out. You are supposed to lower it to get to the bolts! Its still possible of course, but takes some effort and planning so you don't lose your fingers in the process. A couple things I did to keep my fingers attached to my hand:

1. I left the pink plastic retainers and felt retainers in for friction to keep the window from crashing down at full rate of gravity.
2. I taped the window up with masking tape until I was ready to slowly lower it.

Unfortunately, my car has lots of old sound deadening on the doors which uses a black tar like adhesive that in the sun gets very nasty to work around (it liquifies in direct sunlight practically). Oh joy! It took about a half hour just to expose all the bolts that need removal. Here is a pic of that mess:



Here is a critical point I discovered doing this removal... the black window guide in the pic labeled "Guide 1" has to come out to get the regulator out. The reason is that the regulator once collapsed down straddles the guide. The window has to come out to get the guide out as well. Here was my sequence in the end:
1. Tape up the window as described above
2. Unbolt the lower slide bolts (the upper slide is attached to the window, the regulator scissors won't move until the lower slide bolts are freed)
Note there are only two bolts holding the window to the upper slide:
3. slowly push the window down to get the rightmost window bolt. (it will move when the lower slide is unbolted)
4. I was unable to access the left bolt in the service port because the window wouldn't go further than 2/3rds down, so I used a wrench and a mirror to find the bolt. Its not that hard.
5. Now the window is free from the regulator but still in the door. remove pink guides and felt guides.
6. Remove side mirror
7. pull window out. Notice all the damage to any tint you had Oops!
8. unbolt all 4 of the bolts holding the regulator assembly (labelled "Regulator Bolts(4)" in pic)
9. Unbolt and remove "Guide 1". Now the regulator assembly can come out.

In the next pic I've laid the regulator and the window out on the ground so you can see how the whole thing goes together. I wish I had this pic prior to starting the job, it would have made things much easier to envision. Working blind isn't that fun, even with a mirror as an aid.


In that pic "Guide 1" and "Guide 2" are the peices that slide into the black guides in the door. Some final thoughts on this job: Its not actually as hard as it looks. There are no cables or regulator wires or anything to destroy here. There are no moving parts that you can unintentionally screw up or bend easily really. The only caveat to that is the window motor. In the pic above if you remove the 3 screws that clock spring is going to push the rotating bracket away from the teeth. Its not that strong, I was able to force it back and reattach the motor.

So I'm still awaiting the new motor. Hopefully I'll have a working door by next weekend
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Old 09-09-2012, 02:38 PM   #3
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

Default

Quick (and Temporary) Trunk Release Fix


So apparently some of these cars are affected by a slack or stretched trunk release wire. I could hear my strike plate hitting the cancel switch but not hard enough for the trunk "bump up" spring to crack open the trunk. Well, I know folks have managed to put a spacer on the wire (a zip tie) to account for the stretch but that didn't work for me. Temporarily, I've taped a washer to the strike plate, effectively pushing it out a few mm. I'll take the assembly apart later and simply bend the bracket....

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Old 09-09-2012, 06:07 PM   #4
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

Default

EBay VTA BOV Removal

OK so in this pic it looks like the crappy BOV has the recirc hose wide open. I got a little surprise though... about 3 inches down the hose the pipe was plugged with this special device... very professionally installed

Also note the boost gauge hose is leaking...




All set now. Cleared the CEL again. Time will tell....

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Old 09-15-2012, 03:47 PM   #5
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

Default

Window Tint Removal

When I pulled the glass out I butchered the tint pretty badly. Seems inevitable. I wanted to get the tint removed prior to the the new window motor arriving. Pretty simple job really:
1. hold an iron about a half inch above the tint and hit it repeatedly with steam button.
2. Get a corner started with a razor blade, something to hold onto.
3. pull. heat. pull. heat. pull. heat. 5 minutes later you are done.


I'm probably going to retint the window once it is reinstalled. The car looks pretty good tinted.
Agree or should I remove it all?

Opinions???



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Old 09-15-2012, 04:19 PM   #6
VTSubieRS
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Member#: 90608
Join Date: Jul 2005
Chapter/Region: South East
Location: Vermont & St. Simons Georgia
Vehicle:
2005 STI, '08 3.0R
05 2.5RS, 92 Legacy L

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thanks god you got rid of the BOV. keep us updated with your progress. she looks pretty clean. Hopefully you don;t run into too many other hack jobs done by the previous owner.
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Old 09-20-2012, 07:30 PM   #7
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

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OK... who can GUESS what mod I have planned???
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Old 09-23-2012, 04:41 PM   #8
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

Default

Hey nobody guessed the mod... When it arrives I post a pic. Its significant.

Meanwhile back to the boring stuff... thanks to PMPAutoGroup I got a window motor, master switch and the harness section for the window. It went in pretty quickly today. I spent more time adjusting the window stops to get it to seal perfectly than I did putting it together. Its nice to have that job done. It wasn't easy (for me) but its done and done well.

So should I redo the tint on the driver's window to match everything else or strip the passenger window? The tint job is very well done but generally I'm not a big tint fan. If anyone is bothering to read this... I'm open to opinions.

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Old 09-23-2012, 06:16 PM   #9
TRinityMtrSprts
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Join Date: Sep 2003
Chapter/Region: SCIC
Location: Redondo Beach
Vehicle:
2002 mbp WRX
97 Ford Ranger on Bags

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i'm guessing STI steering rack?
personally I fish bowl it, but the sun in Cali does take a toll on fading your interior.
Maybe just peel the passenger window and call it a day?
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Old 09-23-2012, 06:31 PM   #10
MGigantelli44
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Member#: 234591
Join Date: Jan 2010
Chapter/Region: NWIC
Location: Vancouver, Wa
Vehicle:
2004 WRX STI JBP

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I really only like no tint or the same % tint all the way around. Just my opinion Good work on the motor too. I did that on an old car of mine once and it was a pita
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Old 09-23-2012, 08:01 PM   #11
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

Default

I thought about an STi rack. The 04's aren't very easy to find and go for a premium and in the end I'd probably end up doing inner rods and wanting new seals so... I decided to bite the bullet and order the holy grail from Canada. Coming from an Evo 15:1 just isn't going to cut it.

I'm leaning toward re-tint, but I'm going to wait on cosmetic until I'm done with the "while you are there" spending spree: After all why put those old bars back on? boy those stocker struts look like ***** and with stiffer bars I should get some Feals... and those rotors/calipers are looking pretty woeful... look at that shiny Wilwood kit...


What do people think of that Wilwood 6 pot front / 4 pot rear kit? I've driven a GC8 with the 6 pots brakes and thought they felt great. Please remember this bugeye is not a daily driver and the Wilwood rebuild looks comically easy (although a timesink I'm sure...).
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Old 09-25-2012, 02:27 PM   #12
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

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Cool Tool Time

A little lunchtime project today. I picked these up from Amazon the other day and they immediately became useful for cleaning up my steering rack mounting threads. The top threads on each bolt took a real beating due to the weather, oil, grease and dirt exposure where they poke above the rack mounts. The impact gun powered through it but the threads took a beating. First off, I hate guessing metric sizes so the thread checker keeps me from time at the "wall of boxes" at the hardware store. I used it on my power window project and now to check the thread size on the steering rack. No guessing when selecting the Gearwrench bits either. Anyway... self explanatory pictures. Threads are all nice and clean and smooth now The Gearwrench ratcheting handle rocks.




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Old 09-25-2012, 02:58 PM   #13
SG02WRX
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Location: South Gate
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Wow looking forward to seeing the rest of your build. I love it when a bugeye gets a second chance. Nice color also, not to many AW bugeye left.
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Old 09-27-2012, 08:25 PM   #14
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

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Thanks man. I love the bugeye and the whole GD series. I had an RS2.5 and I would have stuck with it but the aftermarket support wore me down. I've sort of grown to like the GR too, at least the 5-door. The new Impreza though... well...
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Old 09-27-2012, 11:14 PM   #15
treystoys
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Member#: 97436
Join Date: Oct 2005
Chapter/Region: South East
Location: Metairie, Louisiana
Vehicle:
03 WRX stage 2.2
white/w/ce28n's

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I'd ditch the tint all the way around...my 05 was tinted by the dealer as an add on and done very nicely. After about 6 years the rear window started to show some distorting or wavyness, so one day I stole the wifes steamer and went at it...30 minutes later I was de-tinted. As much as I liked the comfort aspect of having tint, the car just looks more suited to my 38 year old arse w/o it...lol. Brake wise I did 4/2 pots from a totaled 07 years ago...been pretty happy with them.

Looking forward to watching the build!

And hey if you need or have the want for a new cat back I have a g200 catback and injen sjs axle section that matches the invidia midpipe to go with it...shoot me a pm if interested.

Trey
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Old 09-28-2012, 06:50 AM   #16
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

Default

A steamer eh? That rear window scares me. Did you have to pull the headliner or pillar trims to get a corner started or did you just slice it somwhere to get started?

As far as the cat back I'm on hold sadly - but thank you. I've got some pretty spendy items coming in soon. My Paypal account has taken quite a flogging
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Old 09-28-2012, 06:41 PM   #17
treystoys
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Member#: 97436
Join Date: Oct 2005
Chapter/Region: South East
Location: Metairie, Louisiana
Vehicle:
03 WRX stage 2.2
white/w/ce28n's

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I used a new straight razor blade and peeled a small part of the corner while applying the steam...never removed anything to do it, just layed some towels on the rear deck lid to keep the excess water from getting all over.

I totally understand about the spending limits...I've surpassed mine and then some in the past.

ttyl

Trey
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Old 09-28-2012, 07:17 PM   #18
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

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I'm going to blow past the purchase price of the car by Haloween. I bought it in August lol.
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Old 10-06-2012, 11:25 AM   #19
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
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2014 STi Hatch
Crystal Black Silica

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OK the first real mod to the car - better stopping power! Test fitting Brembos. Got them for a good price from TAE Used AutoParts down in Tampa (http://www.taeusedautopartsfl.com/). Good people, they shipped a different set than I originally purchased due to a botched helicoil on one of the rears. They caught it prior to shipping.

Also, I've got the DBA 4000 conversion kit from Mach V / FastWrx (thanks Matt and Dan )

This is just a test fit. I'm not putting them on until the coilovers and wheels arrive. All bleeder valves are good, all mounting threads are good, no helicoils. I was going to paint them but the overall condition of the finish is too good to ignore...

I do have the Mach V Brembo rebuild kits to play with over the next few days...

3 Bananas

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Old 10-06-2012, 11:58 AM   #20
03boxer4
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Member#: 66622
Join Date: Jul 2004
Chapter/Region: MWSOC
Location: Springfield, MO
Vehicle:
2002 WRB wrx
BRZ in the works

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Looks great!!! I am hoping to park my bug wagon in the garage next year and give her a good makeover.
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Old 10-09-2012, 08:55 PM   #21
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

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^thanks man. I'm loving it. And I'm *really* loving that I don't have to stress to get it all back together since it isn't my dd...

Update: parts in... cash out...

More parts flowing in... RCE Tarmac 2's, Ground Control front camber plates and Cusco rears. A set of Awesomes! Man these things are light....





4 bananas!
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Old 10-09-2012, 09:14 PM   #22
scby rex
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Chapter/Region: TXIC
Location: copperas cove
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02 wrxbastardchild
aw, MPS 2.34 breaking in

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I like tint, did you order a Q-rack?
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Old 10-09-2012, 09:23 PM   #23
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

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Sure did. Just got notification that it shipped today. The Holy Grail of subi steering
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Old 10-09-2012, 09:34 PM   #24
SG02WRX
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Location: South Gate
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Wow!! Love it when a car comes together using quality and correct parts!
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Old 10-09-2012, 10:05 PM   #25
ToddMcF2002
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Member#: 135007
Join Date: Dec 2006
Location: Plymouth, MA
Vehicle:
2014 STi Hatch
Crystal Black Silica

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Thanks. Its unnerving how much I've spent already but I only want to do this once. I just hope I get a few sessions out of the car before the motor goes LOL
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