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Old 05-26-2013, 09:10 PM   #51
dburgoon
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Member#: 310366
Join Date: Feb 2012
Chapter/Region: South East
Location: Ft Myers, FL
Vehicle:
03 vf37'd WRB
Bugeye

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Where's the updates?! We haven't had any ALL weekend! I need my fix
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Old 05-27-2013, 09:35 AM   #52
prochucker
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Member#: 21038
Join Date: Jul 2002
Chapter/Region: South East
Location: Jacksonville, FL JMS #12
Vehicle:
05 STi CGM
08 WRX 5D SSM

Subaru Stars

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Originally Posted by gutie04 View Post
So awesome... Subscribed.
Jesse, wondered how long it would take for you to get here.

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Originally Posted by dburgoon View Post
Where's the updates?! We haven't had any ALL weekend! I need my fix
Yeah...what he said.
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Old 05-27-2013, 10:41 AM   #53
92 SVX
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Chapter/Region: South East
Location: Jax
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92 SVX
Pearl White/Black

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I think he said he would wait until tuesday to update, giving him time to work on it all 3 days and have massive update on tuesday.
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Old 05-27-2013, 11:37 AM   #54
Boorito
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Stuff like this makes this forum so much better than sooo many others I peak through. Great build, excited to see more!
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Old 05-28-2013, 10:33 AM   #55
Bad Wagon
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Member#: 53022
Join Date: Jan 2004
Chapter/Region: NWIC
Location: B-ham WA
Vehicle:
1999 Top Scoob Lego
08 Lego 3.0R Flared

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Well hello all. It’s Tuesday so its time to share the progress I made over the weekend. Out of the available 120hrs from Thursday to Monday I was in the shop for 73 of them... It was was brutal I am surprised I can still do **** like that. In ether case I did make a lot of progress. Not as much as I would have liked due to set back after set back but it’s coming along nicely. I am working to make arrangements to get it out to a shop that close to my new place so I can finish it there and it has a paint booth so I can paint it as well.

Day 1: Thursday.

Got off work at about 1:00 and I was in the shop at around 2:00 after a nice “let’s get this weekend going” lunch… Started off by removing the rear suspension off the ForeSTAR and started to finish weld some of the rear suspension parts. Also my parts from Ballistic came in for the new rear upper arms and the beefier control arms. I started off by finish welding the rear crossmember and then added the new upper control arm mount points.



Then I took of my lower control arms and re-did them with the new parts from Ballistic. Beefier mmmmm…



From there I installed the Crossmember-T-Bar and lower control arms and then installed the Rear STi Hubs. Mocked up 1 of the upper control arms and cut out all the required pieces to do the other side. Went to bed around 2:00 am

Day 2: Friday.

I started the day off (9:00 am) finishing the rear hub mounts for the Upper Control arm and then the Arm itself. In between that I dropped off the Coilovers to get filled with Nitrogen, got some more welding wire, more grade 8 fasteners, and picked up my calipers. These are much better then my old design. They are 18” long as opposed to 12” so not only are they stronger but the angles on the suspension were restored so I went from 13” of travel to the full 17.5” like in the front.



Next was pulling the Filler neck for the gas tank to prep the rear quarter panel to fit these giant 33” tires. Took my time and ended up with this…



As you can see it goes up pretty far but… it doesn’t touch the rear door at all. Moving the Crossmember back and the rear suspension helped big time no cutting of the door or compromising the weather stripping required. With the wheel at full compression I set some round bar templates to figure out where I would need to set the rear flares since after this I would be swapping my 5x114.3 STi hubs out for the stock 5x100 hubs. Here is the front as well



Here is a pic of the Foz with both wheels on at full compression…



Spent the rest of the night removing the front hubs and modifying the upper knuckle mounts so they would work on the 5x100 hubs. This involved cutting and then re-drilling the hub with very slow precise drilling to make it work. By the time I was done it was about 2:00 am but I kept pushing on till 4:00 am and had pieces cut out for the inner and outer steering link mounts.
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Old 05-28-2013, 10:34 AM   #56
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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going to be sick!!!!
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Old 05-28-2013, 10:38 AM   #57
Bad Wagon
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Join Date: Jan 2004
Chapter/Region: NWIC
Location: B-ham WA
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1999 Top Scoob Lego
08 Lego 3.0R Flared

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Day 3: Saturday.

Got up and in the shop again around 9:00 by this time the toll of only getting 4-5 hrs of sleep was starting to affect me… Drove into town and picked up my buddies exploder to head to the shop I get my metal from to pick up more sheet metal to do the exterior parts before they closed for the long weekend (still thinking optimistically at this point) Started up where I finished the night before and finished up the steering rods.

Inner mounts for the rack...



5x100 hubs installed and knuckle outer mounts



And finally the tie rods themselves



I then went about installing the front rotors, calipers, lines, and coilovers with the new springs installed. Front suspension officially done!



Next I got in my package for the rest of my engine parts to assemble my motor… Well I got some spark plugs…. My guy pretty much forgot to put in most of my engine parts and also forgot to send the motor mounts for the other car my buddy was trying to finish up in the back. Enraged, I realized that instead of just assembling my new engine with nice clean parts and being done with it; I would have to transfer most of the parts off my stock engine. Basically adding 4-5 hours to my engine build for no real reason other then the fact that my parts supplier sucks ****… Also I order this parts last week and should have ad them last Sat so I spent the week not prepping for this because I assumed I would get the parts I needed… In ether case I was irritated to say the least. It was then when the guy who is taking my ForeSTAR shell called and said instead of Monday he’d like to get it tomorrow so I needed to both the BATLFOZ and the ForeSTAR in a rollable fashion so I could move them around and get the ForeSTAR out of the shop. This was about 7:00 pm. I started by pulling the rear interior out of the BATLFOZ to gain access to the rear strut towers. Cut them and made some temp Coilover tower for the rear. Assembled the rear Coilover with its new springs... OMG this thing is heavy….



Install it and put the stock wheels on the BATLFOZ so I could move it... Then spent then rest of the time making the ForeSTAR a roller and throwing in all the parts that he was also buying or coming with the shell... Also needed to clean the shop because there was so much **** everywhere from all the work I had been doing that you could barely step anywhere w/o stepping on metal or car parts. Had both Foresters rolling and the shop cleaned at about 5:30am…… Went to bed and was then woken up at 8:00 am by my phone because the guy was there to pick up the ForeSTAR. Took car of that and went back to bed at 9:00am

Day 4: Sunday.

Woke up around 11:00am and back in the shop I went. At this point I was losing it. Had a couple episodes in the shop the morning before from lack of sleep and frustration so I decided to spend most of the day assembling my engine and installing parts into the Forester. I didn’t want to cut, grind, or weld anything….. Finished up installing the Rotors, Calipers, and Lines in the rear, took all the parts of my stock motor that I needed and cleaned as much of them as I could, and got my new engine about 90% assembled. Don’t really have any pics because I was barely functioning at all let alone remember to take pics…. Turned in around 11:00

Day 5: Monday.

Got up at 9:00 and headed into the shop... Felt a little better because I actually got an okay nights rest. Finished up the engine and install it...



Installed the Rear Diff (w/ Perrin high capacity Diff Cover)



And installed my rear coilovers so I could start fabrication on the permanent strut towers...






Cut out a few of the pieces to build them but got tired of getting sparks in my eye and burning my arm from cutting

Don’t have pics of this yet because it was too dark by the time I got around to them but I also modified the shifter linkage so the 6-mt would shift with the lowered tranny. Also set the Driveshaft in place to take measurements of the new mid bracket I need to make to locate the carrier bearing for the Driveshaft. The 5mt shaft was a perfect fit for the rear crossmembers new location.

So that’s about it for this weekend. I was hoping to be a LOT ahead then I am but it would have been even farther behind if I hadn’t worked as hard as I have. I am going to try and finish the rear strut towers and mount the driveshaft tonight which should be the last 2 parts I need to custom fabricate to get write off on the suspension and Drivetrain. From here it should be just installation of parts, and fabricating the parts for the exterior but that should go fast because I get to cut 18g steal instead of 1/8” plate…. I am going to get it into a roller w/ the 33s on it, finish up trimming up the drivers side quarter panel and welding in the rear fender wells. From there I can re-install the back interior and then I will start packing it with all the parts I have left to install in it. I need to start packing up the shop to get ready for the move so the BATLFOZ will be getting put on hold until next week after the move is finished. I have some updates for todays and probably tomorrow’s progress in the shop but then nothing till probably Monday or Tuesday of next week.

Johann
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Old 05-28-2013, 12:12 PM   #58
dburgoon
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Member#: 310366
Join Date: Feb 2012
Chapter/Region: South East
Location: Ft Myers, FL
Vehicle:
03 vf37'd WRB
Bugeye

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^^ those were the updates I have been waiting on! Great progress made this weekend. The bulges on the fenders are going to look sweet, I seen the rods for the mock up. Also that suspension work :jawdrop: just amazing work!
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Old 05-28-2013, 12:22 PM   #59
Bad Wagon
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Member#: 53022
Join Date: Jan 2004
Chapter/Region: NWIC
Location: B-ham WA
Vehicle:
1999 Top Scoob Lego
08 Lego 3.0R Flared

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Yeah I have built way faster cars and some of the cars have had a good amount of fab but for me, for some reason has more meaning. I think its because I am building parts from scratch which masivley improve the potencial of this car not in just terms of hp and speed. Its weird to walk into my shop and see it sitting there with those giant coilovers and say "I built that". Its going to be one of my top 5 fav projects I've done for sure and the best part is its not for somebody else I get to enjoy the work I put in driving it.. I can't wait to finally finish it and see the vision in my head come to life. My concepts are usially spot on so this its going to look really aggresive when the exterior parts start going on.

Johann

Johann
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Old 05-28-2013, 01:01 PM   #60
WinterSubie
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Join Date: Apr 2010
Chapter/Region: NESIC
Location: Charlestown RI/Storrs Ct
Vehicle:
2009 Hatch
OBP

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Amazing fab work, looking forward to seing this finished
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Old 05-28-2013, 01:51 PM   #61
PlasticFoamMan
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Member#: 197764
Join Date: Dec 2008
Chapter/Region: NESIC
Location: Broston
Vehicle:
02 WRX Stage DD
PRND 01G

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Beautiful, sub'd! Makes me want to set up my lift again
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Old 05-29-2013, 12:59 PM   #62
Bad Wagon
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Join Date: Jan 2004
Chapter/Region: NWIC
Location: B-ham WA
Vehicle:
1999 Top Scoob Lego
08 Lego 3.0R Flared

Default

Hey all.. Got my conversion spacers in but the lugs they come with are the wrong thread pitch so I need to get new ones today when I go to get oil and coolant. I should have her on her own weight and i hope to try and fire the engine tonight to make sure it works.

Updates tomorrow.
Johann
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Old 05-29-2013, 04:01 PM   #63
Pencils
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Join Date: Jun 2007
Chapter/Region: SCIC
Location: 626/Houston
Vehicle:
The 2003 pwrFAP
thing

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rad!!!!!
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Old 05-29-2013, 04:22 PM   #64
prashanth
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Member#: 123534
Join Date: Aug 2006
Chapter/Region: MAIC
Location: Baltimore County
Vehicle:
2006 STI
White

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Amazing build and cant wait to see it finished!!
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Old 06-01-2013, 06:39 PM   #65
silverwerx
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Member#: 81246
Join Date: Feb 2005
Chapter/Region: MAIC
Location: 512 whp
Vehicle:
. .13 EVO X MR
.03 Cosworth Wrx, 14 Jeep

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moar!
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Old 06-01-2013, 06:43 PM   #66
domoMKIV
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Member#: 113773
Join Date: Apr 2006
Location: Central FL
Vehicle:
2004 Forester XT

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So much fap material in here
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Old 06-01-2013, 07:08 PM   #67
iZach206
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Member#: 157522
Join Date: Aug 2007
Chapter/Region: NWIC
Location: seattle
Vehicle:
93 gf8 sti
Blaaack

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Always look forward to seeing any of your builds. Love the custom fab and the can do. This thing is going to be nuts!
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Old 06-02-2013, 01:00 PM   #68
LUMBERZACK
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Member#: 340009
Join Date: Dec 2012
Chapter/Region: SWIC
Location: Arizona
Vehicle:
2007 STi
48W

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Hands down dopest dope I've ever seen.
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Old 06-03-2013, 10:31 AM   #69
Bad Wagon
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Member#: 53022
Join Date: Jan 2004
Chapter/Region: NWIC
Location: B-ham WA
Vehicle:
1999 Top Scoob Lego
08 Lego 3.0R Flared

Default

Hello all. So this weekend was a blur. Thursday night I make the temp rear strut towers so I could pack it and get it to the new shop. Got moved and transported the Foz to its new temp home on Sunday. I'll be back on her probably Wed to starting pushing towards the finish line. Sorry I meant to take pics of it when it was outside but it kinda slipped my mind.

As for updates. I realized the metal on the rear strut towers is thin and crappy so first thing once the inside is unpacked is cutting them out and starting from scratch. Then I’ll finish the underside and get the engine all squared away and then its time to make all the exterior bits.. I also need to sort out the cvs and hubs so I might try to do that now or finish the exterior and paint it then get it home and do it there.

Updates soon.

Johann
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Old 06-03-2013, 10:46 AM   #70
calebtharrell
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Member#: 242113
Join Date: Mar 2010
Chapter/Region: South East
Location: Brevard (Asheville), NC
Vehicle:
2004 STi, 2008 STi
2002 WRX

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They need to start a tv series staring you Johann. I'm sure there would be a ton of viewers.
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Old 06-03-2013, 10:59 AM   #71
Bad Wagon
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Join Date: Jan 2004
Chapter/Region: NWIC
Location: B-ham WA
Vehicle:
1999 Top Scoob Lego
08 Lego 3.0R Flared

Default

LOL Nobody wants to see a slightly overweight guy make sparks and sware at everything he builds cuz it ether stabs, burns, or falls on him... Also half the show would just be me walking around the shop looking for tools.... Well on second thought thats "drama" maybe they would...

I met a guy yesterday thats a buddy of the guy letting me rent the shop space for the Foz that actually races baja and he looked over my suspension and said it looked pretty good so that was a nice releif. He had one comment about the location of my coilover mount on my trailling arm which I agreed with so I am going to modify that a bit as well

Johann
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Old 06-03-2013, 11:13 AM   #72
92 SVX
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Join Date: Oct 2011
Chapter/Region: South East
Location: Jax
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92 SVX
Pearl White/Black

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Quote:
Originally Posted by Bad Wagon View Post
LOL Nobody wants to see a slightly overweight guy make sparks and sware at everything he builds cuz it ether stabs, burns, or falls on him... Also half the show would just be me walking around the shop looking for tools.... Well on second thought thats "drama" maybe they would...

I met a guy yesterday thats a buddy of the guy letting me rent the shop space for the Foz that actually races baja and he looked over my suspension and said it looked pretty good so that was a nice releif. He had one comment about the location of my coilover mount on my trailling arm which I agreed with so I am going to modify that a bit as well

Johann
What havent you ever watched the speed channel
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Old 06-03-2013, 11:22 AM   #73
3mlwhly
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Member#: 217648
Join Date: Jul 2009
Location: NOR CAL
Vehicle:
01 2.5rs

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Quote:
Originally Posted by Bad Wagon View Post
LOL Nobody wants to see a slightly overweight guy make sparks and sware at everything he builds cuz it ether stabs, burns, or falls on him... Also half the show would just be me walking around the shop looking for tools.... Well on second thought thats "drama" maybe they would...

I met a guy yesterday thats a buddy of the guy letting me rent the shop space for the Foz that actually races baja and he looked over my suspension and said it looked pretty good so that was a nice releif. He had one comment about the location of my coilover mount on my trailling arm which I agreed with so I am going to modify that a bit as well

Johann
Hahaha... That sounds exactly like my house only I'm more than slightly over wieght.... I can totally relate to dropping stuff on yourself... I even dropped a wrx trans on my forearm while installing it by myself without a trans jack... Hahaha stupid I know.. . Great build really looking forward to the end
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Old 06-03-2013, 11:28 AM   #74
Bad Wagon
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Member#: 53022
Join Date: Jan 2004
Chapter/Region: NWIC
Location: B-ham WA
Vehicle:
1999 Top Scoob Lego
08 Lego 3.0R Flared

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I prefure setting the tranny on my tummy and then pooching out to aline it... Like an otter....
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Old 06-03-2013, 12:17 PM   #75
3mlwhly
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Member#: 217648
Join Date: Jul 2009
Location: NOR CAL
Vehicle:
01 2.5rs

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Quote:
Originally Posted by Bad Wagon View Post
I prefure setting the tranny on my tummy and then pooching out to aline it... Like an otter....
Ya it started like that and it started to get lose, it was either my arm or my face, I chose arm... It was a lot harder with the 6 speed so I got help on that one... Haha
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