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Old 05-21-2013, 09:42 AM   #26
docNUCCA
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Join Date: Mar 2010
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Location: SLC, Utah
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2006 Legacy GT Wagon
For Sale

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Wow! In for more Foz lovin!
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Old 05-21-2013, 03:37 PM   #27
vipers
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this....is.....amazing!
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Old 05-21-2013, 03:50 PM   #28
wtyree
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subscribed
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Old 05-22-2013, 09:00 AM   #29
Bad Wagon
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08 Lego 3.0R Flared

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Hey all it’s another day and that means another update... Finished up the fab on the one strut tower extension and then made the other side. It goes pretty fast if you just fab one and cut the pieces for the other side at the same time. I think I am going to do that with the body parts as well. Then I installed the front coilovers and located them on the arms. I still need to make the strut bar and then brace the towers to them and mount my reservoirs but that should go pretty quick.





Here are some pics of the finished front suspension (minus the steering links)

Extended:



Compressed:



I am getting 17.5” of travel. The Coilover maxes out with the tire about ľ” from touching the upper frame rail. I am using about 9.25” of the coilovers 10” of travel so pretty good use I’d say.

And lastly to put the cherry on top I had to cut the hood out to see how this was actually going to look…



Pic from the office. It’s no hood scoop but its something…



I am going to yard out the rear suspension out of the ForeSTAR tonight and finish welding as much as I can to get it ready to fab the new upper control arms and get it into the BATLFOZ. I am also going to start cutting pieces for mounting the steering links. Maybe if I have enough time (prolly not) I can start cutting out the pieces to make the rear Coilover upper mounts.

More tomorrow.

Johann
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Old 05-22-2013, 11:23 AM   #30
dburgoon
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So are you leaving the hood the way it is or are you going to do like pre-runner style bulges and cover up the towers? Maybe make it out of fiberglass or something like that? Cant wait to see it finished!
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Old 05-22-2013, 11:43 AM   #31
Bad Wagon
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I need to make a hood scoop for it for the tmic on my sc kit so I will wait till its done and I have the look of the rig sorted out. I'm thinking of leaving them exposed because thats kinda how the vibe is going for me.. The new fenders and flares are getting made out of 16g steal so it will look very stealthy like all the new lambos. Sharp angles... I'm thinking exposed will suite the nature of this beast. She is telling me to make her super mad max/ death race style...
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Old 05-22-2013, 11:48 AM   #32
jvsoundwave
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Crystal Gray

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FOZTASTIC!!!

Man this thing is BEAST!!!
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Old 05-22-2013, 11:56 AM   #33
dburgoon
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Quote:
Originally Posted by Bad Wagon View Post
I need to make a hood scoop for it for the tmic on my sc kit so I will wait till its done and I have the look of the rig sorted out. I'm thinking of leaving them exposed because thats kinda how the vibe is going for me.. The new fenders and flares are getting made out of 16g steal so it will look very stealthy like all the new lambos. Sharp angles... I'm thinking exposed will suite the nature of this beast. She is telling me to make her super mad max/ death race style...
Hell yeah, sounds like this is going to be awesome! I've been trying to talk my girlfriend into buying a fozz so I can lift it, but it will be nothing compared to yours! Hurry up and finish it!
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Old 05-22-2013, 12:38 PM   #34
Bad Wagon
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I am trying!! I have till Monday to be at least running and exterior finished.. Maybe not painted but the rest needs to be done so I can drive it to the new rental.

Johann
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Old 05-22-2013, 01:00 PM   #35
dburgoon
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Quote:
Originally Posted by Bad Wagon View Post
I am trying!! I have till Monday to be at least running and exterior finished.. Maybe not painted but the rest needs to be done so I can drive it to the new rental.

Johann
Sweet! I can't wait and I know you can't. One more questions as of now, what welder are you using? I have been doing some fab work but my welder isn't powerful enough to weld some heavy aluminum.
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Old 05-22-2013, 01:16 PM   #36
Bad Wagon
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I have a Lincon 180 MIG with a spool gun for aluminum. Mine sucks at welding aluminum too. I only use it to tack. It welds steel great. I have it cranked almost all the way up to do almost all my welding cuz I like ti hot and flat so its going to die on me someday but that day better not be this day or any other day while I am working on the foz...

Johann

Last edited by Bad Wagon; 05-22-2013 at 01:33 PM.
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Old 05-22-2013, 01:32 PM   #37
Bad Wagon
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Got a date with the paintbooth on Tuesday so I can get her painted. and road worthy before the move. This weekend is going to be brutal....

The body is going 2010 Shelby GT500 Mustang Blue



The hood and roof are going 2011 STi plasma blue w/o clear for a blackish purple/blue semi gloss.

Prolly going to do the GT500 side stripe with "forester" instead of "gt500" in black

I am designing a graphic for the side thats a merge of the Star Wars Rebel Alliance logo and the Subaru Logo. Going to go on the back doors/ quarder in black to help break up the GT 500 blue and a cyan one on the corner of my hood. REBELRU!

Think I am going to paint my engine bay white but not untill after I move and get the supercharger in it.

Johann
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Old 05-22-2013, 03:44 PM   #38
jhaddock07
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Aspen White

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Absolutely stupid.................








I love it!
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Old 05-22-2013, 03:46 PM   #39
BeBop86
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'85 Toyota Corolla

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Are you just going to get it to be a roller, or driven under it's own power? What are you doing for axles in the mean time?

(Do you still want those WRX brakes btw?)
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Old 05-22-2013, 03:50 PM   #40
Bad Wagon
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Extending them by sleaving them.

No I got rebult forester ones.
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Old 05-22-2013, 04:49 PM   #41
BeBop86
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I don't know much about axles. Is that common practice in off-roading?

That color is pretty awesome, who is painting it?
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Old 05-22-2013, 06:49 PM   #42
Bad Wagon
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Luke. Itís not because most off roaders have solid axles. There are not a lot of trucks with IRS and not many widen them because they wonít fit down narrow trails. I am using thick walled pipe to sleeve them, then drilling dimples 1/4" into the axle through the pipe and plug welding them. I think it will be stronger then drilling all the way through and welding in a pin because it will keep the axles shafts thickness intact. They won't be strait and true, but at the center of the wheel they won't spin fast enough to cause a problem or even notice. Its not like I am going to be doing a 100+ mph in this thing very often and 60-70mph off road the vibration of an out of balance CV axle will be the lease of my worries. I am going to try to find a machine shop to make me some new center shafts at some point but for now while its N/A it will be more then adequate to get me down the road.

Johann
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Old 05-23-2013, 05:32 AM   #43
vipers
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you may be able to talk to a driveshaft shop and see if they can somehow balance them for you. i wouldnt imagine it to be too much different then balancing a driveshaft.
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Old 05-23-2013, 09:40 AM   #44
Bad Wagon
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Yes I have herd of shops doing that but in all honestly this idea to sleeve them was really for temporary use while I searched for a place that can make me completely new shafts in the correct length. They are probably strong enough but I am always going to worry about them breaking at the welds and if one of my local machine shops can do it they will have the tool paths to make more if the off chance I do f one up.. My plan it to have 2 sets made so I can have a couple spare axle shafts in the Foz in case one goes out on the trail.. Anyways…

Good morning everyone. Well... Last night was a bit of a long one for me. What started out as another day in the shop turned in to an “OMG I am f’ed”, to a “thank god it wasn’t as bad as I thought”. I started the night out getting a used blown STi front bearing ready to use as a template to re-drill a new set of stock Forester rotors to 5x114.3. They have been sitting at Girodisc waiting to be re-drilled for a week and they hadn’t even gotten it into their scheduling so I took them back and gave them the finger in my head. That place has changed a lot since I left I am glad it worked out that way and I am never going back there for anything again… I punched the studs out, and then tried to put the rotor on the bearing and it didn’t fit… AT ALL. Because the rotor was 5x100 and so small the flange of the 5x114.3 bearing was way too big to fit the rotor. I was like OMG OMG I am so screwed. After a bit of freaking out and thinking, I am going to re-use my stock Forester hubs. I will be transferring (with minor modifications) the upper and lower ball joint studs to the front hubs and the rear hubs can be installed normally. Front CV axles will swap just fine but for the time being I am going to have to make an extended hybrid rear CV axle with the r180 diff side and r160 hub side. I am going to make some quick and dirty jigs of the hubs so once I have more time I will make a new set of knuckles front and rear to hold a set of newer Forester bolt on bearings in the front and the rear. For the wheels I ordered a set of 5x100 to 5x114.3 conversion spacers. They are hub-centric to the Subaru and 1” thick. I will take them and press the 5x114.3 m12x1.5 studs out and swap up to m14x1.5 so my wheels fit them perfectly and I will then have some custom hub centric rings/ center caps made for them. It’s not ideal but after taking some measurements the 1” spacers might actually work to my benefit. The spacing out of the wheel gets me a little better turning radius before I touch the a-pillar so I only need to bash it in and not cut and re-weld, and with the wheel that far out I think I might even have enough room to eventually swap to 06-07 WRX 4pot/ 2pot calipers and get some better braking. I was intending on doing a custom Wilwood setup but the Subaru stuff would be much less cost and hassle.

So with that figured out and the parts ordered, I moved my attention to actually getting work done… Started by pulling the rest of the suspension out of the ForeSTAR shell and got parts ready to finish weld. Got the T-Bar finished and then ran out of welding wire….. I went through a 15lbs spool in 2 weeks…. Guess the BATLFOZ likes welding wire… So with that I tried to busy myself by prepping the rear crossmember for the new upper control arms. Cut some pieces out for getting my steering links setup and then moved my attention to my engine.



Got my oil pan baffle/ pan on, my ARP studs in, and my heads prepped for install and realized I was missing the guides that are pressed in the block to located the gaskets and heads… Sigh… To the dealer after work I go I hope they are in stock…

After that I felt kind of defeated so I decided I would check the cycle of the front suspension to make sure I didn’t need to make any additional changes (aside from swapping out the front hubs)

Here it is fully extended:





Here it is as my estimated ride height:





Here is it full compressed:





It’s pretty much perfect. It pulls in 3.5” by the time it would reaching the fender so that means instead of me making a 17” wide flare per side I really only need a 13.5” wide flare I think that will look a little less obnochious.

Anyways that’s all I got for now. I’ll e getting another 15lbs spool of welding wire tonight (already checked the gas I have plenty) so I can finish welding the rest of my suspension bits. Parts for the new Upper Arms and beefier Control Arms arrive today so I am hoping by the end of the night the rear suspension is finished and installed. Springs for the coilovers also show up tomorrow and I will be dropping that off at the local diesel truck shop to have the coilovers filled with nitrogen while I am out doing the rest of my errands. That should mean that by the end of Friday my suspension/ Drivetrain will be crossed off the list and once the spacers get here I will be able to st her down on her new legs. New calipers are at my buddies shop ready to pick up but the new studs and spacers probably won’t be here till Tuesday so that throws my paint booth appointment out the window... I will have to wait for paint till after the move is complete, unless I could get in like Thursday but that’s still up in the air. Still looks like I can have this thing pretty much finished and the ForeSTAR shell off to its new owner by Monday so I can start packing up the shop for the move. Next update won’t be till Tuesday but it will be a big one to stay tuned.

Johann
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Old 05-23-2013, 09:45 AM   #45
dburgoon
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Bugeye

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That is some serious range of travel! Maybe I missed it somewhere but whats the purpose of this build besides being completely awesome!? Are you trying to do rock crawling, desert racing or just trying to make another unique and awesome Fozz?
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Old 05-23-2013, 09:52 AM   #46
SubarooNH
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This is a win-win! Here you go diving into another amazing forester project.... and your old one is going to get finished by the new owner. Wooo!
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Old 05-23-2013, 10:34 AM   #47
Bad Wagon
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08 Lego 3.0R Flared

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I'll be taking it to the dunes, desert type stuff. New new land lord has a dune climbing drag quad so I prolly rool up with him to play. Rock crawling wouldn't be this rigs strong suit with the 6-speed manual and small engine.. I'll take it wheeling but nothing super crazy. Foresters can actually handle pretty well off road so this should be able to go much farther then any stock Forester I just need to keep going till I find a limit lol.. Also biking, camping, boarding bus. Winter dd. Everything and anything I need that my 2 seater corner missle MR2 can't do.

It definetly is. Once the ForeSTAR is reborn and finished we are going to do a cool photo shoot. I envision an action shot of a corner and the ForeSTAR will be taking it at race speed on the pavment and I will be in a full drift cutting the corner short in the dirt.

I'll call it "different paths to a single goal"

Johann
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Old 05-23-2013, 10:39 AM   #48
dburgoon
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Bugeye

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I envy those near dunes. All I get around here is jacked up 4x4's with large v8's and a deep mud hole no talent there, just a bunch of dumb rednecks.

I will be moving to Arizona as soon as I finish grad school
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Old 05-23-2013, 12:02 PM   #49
BeBop86
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'85 Toyota Corolla

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Man, look at that camber curve!! That's bad ass
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Old 05-26-2013, 09:08 PM   #50
gutie04
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05 FXT Dom2.5R
4EAT FTW!!!!

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So awesome... Subscribed.
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