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Old 05-20-2013, 04:05 PM   #1
Bad Wagon
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Member#: 53022
Join Date: Jan 2004
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Location: B-ham WA
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1999 Top Scoob Lego
08 Lego 3.0R Flared

Default Last one: Project BATLFOZ

I decided to make a new thread so the Project ForeSTAR could just have its parts in there since this is technically a different Forester all together... Also I am tired of posting in threads that I started under the Girodisc SN. This will be my last big build for a few years. Moving to a smaller place so I am having one last hurra before my hiatus to make the baddest Foz out there. Project ForeSTAR is being sold to another member who plans to use the already prepped chassis to restore her to her former time attack ready glory and actually finish it.... So there will be 2 Foresters out there with My crazy stupidity behind them.. So with that. Lets get ready! I am mvong fast with one this she should be just about done by memorial day..

Hey all. So some of you may know that I had been building a pretty sick time attack/ autocross Forester over the last year and a half. Due to some changes in my life I can no longer really store a race car that I would only be able to use a handful of times a year. So I decided to change the direction of the build and go for a more practical offroad type Forester. Of course being me I can't just do anything a little but and since the chassis is already stitch welded I might as well go big. So I sold the suspension parts off the Foz to help pay for all the new goodies. I bought an 01 Forester to get the interior, un gutted doors, hood, and harness for the new and improved Foz so once my new foz is just aboue done I'll be rolling in the 01 to strip it of the parts I need and then have a yard sale.

Heres a pic of what she used to look like...



Okay so at least to start this isn’t much of an update. I have 3 cars in my shop because I am no longer allowed to have them stored outside so I am getting one of them finished this weekend and maybe even the other if all the planets align so the shop will just be Foz time by next week…

Here she is all stripped out of all her go fast road course goodies…



And yes thats supercharger is part of this project...

In a side room I have consolidated all of the parts I am going to re-use from the racecar project and a few new ones…



Got me the parts for all the joints for fabricating the suspension components…



In the back are ¾” Hyme joints with non tapered spacers for the upper and lower control arms. Next are 1” Uniball joints with non tapered spacers for the rear trailing arms. Going to use a 1”x5” bolt for these suckers they are major overkill but why not.. Next are 1” Uniball joints with ¾ tapered high misalignment spacers. These will be going in the knuckles. In front of them are 5/8” hyme joints with ½” tapered high misalignment spacers for the steering tie rods. I will be pulling the stock inner rod and replacing it with a bracket that will bolt onto the end of the rack so I can use a solid 3-piece link. And finally at the front are some little baby ½” Hyme joints with 3/8” tapered high misalignment joints to be used as the end links for a rear sway bar if I need to install one..

Next are the po-go sticks…



I’m pretty proud of these. FOA 2.5” Dual Rate Coilovers w/ remote reservoir, heat treated viton seals 10” of travel for the fronts 16” of travel for the rears.. The fronts are 28.5” extended and 18.5” compressed. Rears are 40.5” extended and 24.5” compressed. I won’t be ordering the springs till they are installed and I can get all the measurements down to get the correct rates.

Johann
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Old 05-20-2013, 04:06 PM   #2
Bad Wagon
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1999 Top Scoob Lego
08 Lego 3.0R Flared

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Here is the list of what I kept off the Race Foz and what bought to convert it into Baja Foz

Parts I have kept:

Engine:
STi Short Block (w/ High Comp Pistons, Forged rods yada yada)
All my JIC Fittings
Fuel Cell
Agency Power Crank Pulley
Unorthodox P/S Pulley
Unorthodox Alternator Pulley
Tomei Timing Belt Guide
Cosworth Oil Pan Baffle
PIA Special Burly Pickup Tube
Accusump
All My Pushlock Fittings

Drivetrain/ Suspension:
STi RA Spec C 6-speed (Tranny, Diff Axles)
Exedy Clutch
ACT Flywheel
Agency Power Short Shifter
Kartboy Front + Rear Bushings
STi 5x114.3 Bolt on Front Bearings

Exterior:
JDM Grill
JDM Corner Lights
Fenders
ForeSTAR Stitch Welded Shell

Interior:
Prosport EVO Gauges
Racing 5 Pane Mirror

I am keeping the shell of the ForeSTAR and using it to do all the fabrication for the new project. I can assemble my new motor and install it with the tranny and make it a full roller painted and ready to go. Once I am there I will take the 01 Foz I bought and use the:

Full Harness
Full Interior
Hood
Doors
Hatch
And some misc crap to finish the new project. The rest I’ll sell to recoup moneies.

Here is the new parts list:

Engine:
2008 Impreza SOHC Heads
Gates Racing Belt (SOHC)
ARP Headstuds (SOHC)
10mm Spark Plug Wires
WRX Top mount TGVs (w/ Delete)
WRX Stock Modified Injectors (800cc)
Perrin Fuel Rails (V1 w/ new pushlok fittings)
2004 Roush Mustang Eaton MP90 Supercharger
Universal 31”x16”x3.5” Radiator
X3 10” Electric Fans
OBX SS Header (N/A)
OBX 2.5 Exhaust
Universal 3” Snorkel Snout
150amp High Power Alternator
X2 Optima Batteries

Drivetrain/ Suspension/ Wheel & Tires:
Stock STi Driveshaft
X8 1” Uniball Bearing Joints
X83/4” Hyme Joints
X4 5/8” Hyme Joints
FOA 10” Travel Dual Rate 2.5” w/ Remote Rez Coilover
FOA 16” Travel Dual Rate 2.5” w/ Remote Rez Coilover
FOA 4” Travel 2.5” Hydraulic Bumpstops
Custom Re-drilled Forester Rotors (5x114.3)
Hydraulic Handbrake Lever (Dual Pistons)
Black Rock 15x10 -38 Wheels
Goodyear Wrangler Duratrak 33x12.50x15 tires
Custom 45gal Fual Tank w/ Baffles

Exterior:
OE Headlights w/ 100w HIDs
Universal 3" Driving Lights w/ 100w HIDs
X10 4.5” 27w LED Fog Lights
2009 Ford Raptor LED Taillights
Couple Universal LED Taillights
Custom All-Metal Bumper
Custom All-Metal Fenders w/ Custom Plastic Liners
Custom All-Metal Hood
Custom All-Metal Armored Door Skins
Custom All Metal Rear Bed Sections
Custom All Metal Radiator Ducting
Custom Smooth Bottom Aluminum Skid Plating
Custom Side Steps
Custom EXO Cage of Cab (to tie in underchassis bracing and for rear shock mounts)
Custom Lugage Rack
Custom Bike Rack
Custom integrated x4 Snowboard/ Kiyak Rack
Custom Rear Swing Gate w/ Full Size (33") spare tire, Off road Jack Mount, x2 5gal Gas Can Storage

Interior:

GPS Nav System
Good System
Cusom Floor Covering (Removed Carpet)

I'll be giving the full rundown of my to-do list once the rear suspension is finished and the concept it made or it wil confuse you all. I may have lost my mind but if I can pull it off (you know I can) this will be the King of all the Foresters...
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Old 05-20-2013, 04:11 PM   #3
Bad Wagon
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08 Lego 3.0R Flared

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I'll post this first...

2.5" hydraulic Bumpstops with 4" of travel.. Far and away from a block of rubber....



So.. There has been a slight change of plans... What I thought was going to be a nice couple months to use the shop in a house that would never sell turned in to a "the house has an offer and I need to be out by the end of the month".. So, with that said this project is not getting canned but there needs to be a couple changes. I am obviously not going to have time to finish all of this project in the 2 weeks I have before I have to move. So... the plan is to get as many of the parts as I can fabed and swapped in to the Forester I have the runs as I can. I'll be doing the wheels and tires because they are already here, extending the CV axles to the same width as the Baja Foz needs, and I will be making a less burly but comparable set of front upper and lower A-arms. I will be making brackets to convert the stock 05 STi knuckles in the front to work with a double a-arm suspension and I will be extending the rear suspension with some whitline control arms. Custom modded trailing arms and a custom upper control arm using pieces from a damaged set of whiteline control arms. For the suspension I am going to take some stock STi struts and springs (because they are stiffer) and basically turning them into shocks by mounting a Hyme ball joint on the bottom of them and attaching them to the upper arms. I am going to do a 3:2 ratio so I will get a bit more travel but for now its only going to be about 10-11" I'll be making the bumper, fenders, lightbar per the specs of my Baja Foz so I only need to do it once and probably some cool looking flares in the rear. I probably won't have room for the Foz shell to come with me so I will probably have to do the truck conversion to the shell at another location or wait till I have time to do it to the Foz I have. I can build the super arms at the new place and just get another set of the mounting hardware for the Hyme joints and swap over later when I have more time. So this is going to be a balls to the wall quick version of a long travel setup that I can bust out in the fastest amount of time possible.... After that I can go back to working diligently on the actually Baja Foz but the more parts I can swap into my new Foz and get fabed the less parts I have to move and find space for....

So with that said Sunday I got one of the cars I was working on out of the shop and reconfigured the other and got to work.

Got the Front, Tranny, and Rear Crossmembers Extended. 4" Body Lift I guess you'd say. Got the tranny and the shortblock from my dummy engine in there so that I could fab up the front and rear suspension and make sure the driveshaft fit. I'll be taking all the parts out of this as soon as they are finished and swapping them into the other Foz so I am going to make these as much of a bolt on as I can.





So when I ordered all my joints from balistic they send me 12 of these cool water jet cut skulls. No idea what I was going to use them for untill. BAM gussets....



So tonight I will be making the lower A-Arm and working on the rear suspension. I am waiting for a blown set of stock lower knuckle ball joints so I can stick another bolt in them like I did with the race Foz so I won;t be able to finish up the front suspension till I get those.

More to come.

Johann
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Old 05-20-2013, 04:11 PM   #4
Bad Wagon
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Hey all. Well I had a killer weekend in the shop. I got a crap ton of stuff done. Let’s get started.

Started off by finishing the front lower a-arms. Had to make a custom rear arm bracket using the stock rear a-arm point and make it lower. Cut the front Crossmember and used the front stock point and then added a gusseted rear to fit the front Hyme:



Mounted:



Then I worked on the knuckle. For the lower mount I took a stock ball joint and cut the ***** out of it and welded a grade 8 ¾” x 5” bolt to it for a super stud. For the upper mount I took the ears off a set of blown STi struts and welded a bolt point to the top of it. The nice think about this is that I can adjust the camber with the upper camber bolt just like you could from the factory so I won’t have to waste time taking off the arm and running the Hymes in and out. Then I worked on the upper a-arm. This is using mount points off the risers of the Crossmember. Nice and sturdy after some gusseting and it makes the kit a complete bolt on with no invasive surgery on the chassis except for some notching of the frames pinch weld.



On Friday I got the call my wheels/ tires were here. Baller! Got some 15x10 -50mm offset (yes negative 50mm) on some 33x12.5x15 Goodyear Wrangler Duratrak tires. Got 5 to have a full size spare. 5.5” of lip and the beadlock is functional if you replace the ring with one that lips over on the tire. I’ll probably won’t upgrade till I actually blow a bead I don’t plan on airing down much. I just think if I jump it might be nice to have it for impact blow-outs…



Next was to test fit. I did all my measurements. I knew what I needed extend the axle out to get the desired amount off travel but once I saw it with the tire on the wheel the spec of my vision really came into prospective.





This is by far the widest Forester in the world. Front wheel base measures out at 86” across from the outside of the tire treads. The first 2 pics kinda show it but this pick really shows the scope of my insanity…



Front flares will be 17” from the top the fender by the hood. I’ll be running the flare into the middle of the front door with some ducting on the side so the door will still open. It’s going to look pretty sweet given the ideas I have floating my head.
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Old 05-20-2013, 04:12 PM   #5
Bad Wagon
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08 Lego 3.0R Flared

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With that done it was game on for the rear. The make issue I had by not going with the truck idea was that I was worried about all the cutting to the rear quarters I would have to do to get the 33” tires to fit. I was totally right and the biggest issue I saw when I got the tires home and stuck one up there was the rear door. So I needed to get the wheel to drop back a bit… So I took the rear Crossmember and ran the front bolt from the stock hole to the extra mount point in the middle where you would put a sub frame lock bolt. This gave me 3” which was perfect because now I can just use a 5-speed driveshaft with my longer 6-speed tranny and I get an additional 3.375” in length. I’ll pick up the .375” with the angle of the center pivot…







Then I made the lower control arms and trailing arms to get an additional 3” of rear spacing so the rear axle angles back a bit but its pretty minimal angle.. Trailing arms is 33.5” long and control arms are 23” long… Upper control arm is made from remnants of a bent set of whiteline control arms and it mounted to the upper hole of the hub. The Coilover will run from the stock strut tower to the trailing arm in front of the knuckle.

Total tally for travel came to 17.50” of front travel and 13.75” of rear travel. It’s not the 22” I was hoping for but that was with a totally different type of suspension system. I think its plenty for now...

While I was finishing up the opposite sides of the suspension parts my buddy Philip (run forester run) stripped my 01 Foz down for the transplant. Once he was done I started by getting the front x-member/ tranny/ and dummy block into the new Foz for its final resting place... My actual engine is waiting for a couple parts to come in before I can assemble it so I put the dummy block in there to locate the tranny so I could finish extending the axles in the new Foz.



Nice lit up pic of front suspension:



Next was to start prepping the new Foz for Coilover action… The first step was to cut out the stock strut towers to make room.



Tonight, I will be making and installing the front Coilovers. If I have enough time I will try and swap the rear suspension over into the new Foz as well... This week after work I will be focusing on finishing the install on the Coilovers and bump stops to I can verify their movement and get them charged. Spring are on order now that I know where they need to sit so they should be getting here this week so this weekend I can set the Foz on the ground under its own weight and check out the ride a bit. I should be getting my parts to finish my engine today so I will be assembling and installing the engine at some point mid week probably. Also I will begin the fab work for making the fenders for fitting these massive tires. Any resemblance to a stock Forester will be gone….

Johann
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Old 05-20-2013, 04:14 PM   #6
Bad Wagon
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I didn't really like my whiteline butchered upper control arms... They too short and I have hymes everywhere else. Also that long unsupported part at the turnbuckle looks weak... Just ordered parts to make them bullet proof like the upper front arms... Should have the parts Thursday so I can bust them out and install them when the rear suspension goes in but I can still use the old arms to fab my flares... I am also increasing the diameter and thickness of the pipe on my control arms to the same as the arms just for added unsurence. I am ahead of where I thought I was going to be so if I have time I will swap them before I move and if not at least there is something in there to get me to the new house.

Ordered the springs.

Going single rate in the front. 3" wide/20" long/ 500lbs rate
Going dual rate in the rear. 3" wide/14" long/ 600lbs rate tender, 3" wide/ 18" long/ 750lbs main

Should give me 30% droop in the front and 40% droop in the rear. So the front will be higher in the rear (about 3”) so I can hit the crap faster and be more stable like the Baja trucks. Went a little higher rate then needed for its weight because I wanted it to sit a little high for wheelin, and have a slightly stuffer rate so it would be more street able. I would prefer not to put a sway bar in it but I might have to it leans too far. The exploder was alright and it looks cool when you lean way over taking a fast corner cuz it freaks people out... Its not like its going to flip over….

Ordered a mushimoto rad for it as well and some 10mm spark plug wires. The universal one I ordered for the truck conversion to go in the rear won't really work in the front for ground clearance cuz it was huge but the Mushi should be adequate for this motor even after I supercharge it..

Next up (not sure if I'll be able to get to it till after its running) is a 150amp high output alternator, new headlights, and new high output LED headlight and driving light bulbs.. Then it’s off into the sunset with this build.

Johann
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Old 05-20-2013, 04:21 PM   #7
EvileyeZ88
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99 outback sport

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Last edited by EvileyeZ88; 05-20-2013 at 05:30 PM.
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Old 05-20-2013, 04:25 PM   #8
dburgoon
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Bugeye

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Holy hell! This looks awesome!
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Old 05-20-2013, 04:26 PM   #9
Bad Wagon
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08 Lego 3.0R Flared

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lemmi fix that for ya

Quote:
Originally Posted by EvileyeZ88 View Post
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Old 05-20-2013, 04:28 PM   #10
mike280
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Sub'd Looks neat.
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Old 05-20-2013, 04:39 PM   #11
hayate_gekko
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Always admired your work. Sub'd
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Old 05-20-2013, 04:45 PM   #12
25rsti
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I forgot about this car, pure badass!!
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Old 05-20-2013, 04:50 PM   #13
silverF4turbo
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That front fender:

I wholeheartedly approve.

Also didn't know that Bad Wagon and Girodisc were the same person. You've built some incredible Subaru's
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Old 05-20-2013, 04:53 PM   #14
Bad Wagon
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Thank you. I know. I posted my personal builds under Girodisc SN to gain respect on the boards. Kinda backfired because after I stopped working there, everyone assume Girodisc built all those cars and not me.... Anyways, thats all in the past but yes "Bad Wagon" and "Girodisc" were both me... All personal builds. Nothing posted under "Girodisc" was done at their facility. Just an eger sales guy trying to get into the Subaru comunity and using all the tools he had to get noticed..

Johann
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Old 05-20-2013, 04:57 PM   #15
OneManArmy
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WTF? That makes me sad. Shoulda just sold it and started over with another donor car. Looking forward to seeing it done... but I loved the last one. Woulda been nice to see it survive on.
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Old 05-20-2013, 05:12 PM   #16
Bad Wagon
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08 Lego 3.0R Flared

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The ForeSTAR is living on. Initial idea for this build was to use the ForeSTAR shell and swap parts in from my new foz but I just used the shell for the suspension pre-fab and then swaped it into my new 01 Foz. ForeSTAR is being sold to another member on here that fully intents to restore her to time attack mode. Same Suspension, Same Wheels/ Tires, different engine though... EG33 twin turbo most likely. I made the new thread because I am leaving the ForeSTAR thread for him to continue or to use as history for his new build thread. And because this isn't the ForeSTAR. This... is... BATLFOZ!!!!

Johann
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Old 05-20-2013, 08:22 PM   #17
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:fap:
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Old 05-20-2013, 09:02 PM   #18
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Quote:
Originally Posted by Bad Wagon View Post
The ForeSTAR is living on. Initial idea for this build was to use the ForeSTAR shell and swap parts in from my new foz but I just used the shell for the suspension pre-fab and then swaped it into my new 01 Foz. ForeSTAR is being sold to another member on here that fully intents to restore her to time attack mode. Same Suspension, Same Wheels/ Tires, different engine though... EG33 twin turbo most likely. I made the new thread because I am leaving the ForeSTAR thread for him to continue or to use as history for his new build thread. And because this isn't the ForeSTAR. This... is... BATLFOZ!!!!

Johann
Oh good stuff. I was like NOZE!
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Old 05-20-2013, 09:21 PM   #19
SDoBB
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Fu(k yea.
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Old 05-20-2013, 09:24 PM   #20
aigburth
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i like where this is goin' low is slow.
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Old 05-20-2013, 09:27 PM   #21
kolten493
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haha this should be on pirate4x4. sweet build, lovin the FOA goodness
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Old 05-20-2013, 09:40 PM   #22
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Holy Hell those rims and tires look great on there. Its hard to imagine a forrester with 33x12.5's I had a set on my 85 ford F150 about a million years ago they are an awesome size tire.
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Old 05-20-2013, 10:12 PM   #23
SubyStud555
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Simply Badass Yohann!!!
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Old 05-21-2013, 09:06 AM   #24
Bad Wagon
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Good morning all. Got a late start last night (had to deal with some moving arrangements) but I got a couple hours in the shop at least. Started cutting all the pieces and figuring out my new front shock towers. In order to get the full range of travel (17.5") out of my baby 10" travel coilover, I needed to mount it high in the tower so the arm wouldn't bottom out till the tire just touched the underside of the upper frame rail. This meant that I needed to mount the upper joint of the coilover about 7" higher then the old stock struts mounting point. So yes for those of you wondering these are going to stick about 4" above the hood line and yes I will be cutting holes in the hood. Should look cool right? Anyways, it took me a bit of time to iron out in my head the best way to build these bad boys so I got one about 70% done and cut all the pieces out for the other side as I went along. Here is what I had by 9:30 when I turned in for the night...





The plan is to actually mount the reservoir cans going the other way but I need to notch part of the new tower so I can slide the hose through but I don't want to cut it till it’s finished. I am going to be welding in a permanent strut bar to share the load of both towers (unibodies are flexy) and mount the reservoirs in the middle above my tranny.

Here is a pic of my holding the shock as close to its final resting place as I could (heavy...)



Should have the towers and coilovers mounted by the end of the night tonight. I am hoping there might even be enough time for me to start pulling the rear suspension parts out of the ForeSTAR shell so I can finish welding a few parts and start designing my new upper control arms. I have decided to mount them inside the void of where the crossmember used to be when it wasn't dropped 4" and go from a 12" arm to an 18" arm. Should make my suspension cycle a little better and it will ease up the angles on the hub at the bottom and top of its stroke and if I do it right I should be able to get the full 17.5" of rear travel in the rear as well. The 13.75" is only because of the limitations of the lame ass upper arm I have in there now but time was against me and I didn't think I would have time to do another till after I moved. I have decided I do so I'm doing it... Not sure when I am going to be able to get started on the exterior parts I am hoping I will be done with suspension and Drivetrain by Friday so I can focus all my weekend efforts on encasing my tires...

More to come tomorrow.

Johann
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Old 05-21-2013, 09:13 AM   #25
dburgoon
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03 vf37'd WRB
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^^ great fab work! Very impressed and can't wait for the outcome! I've always wanted a lifted foz
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