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Old 06-10-2014, 12:05 AM   #626
xluben
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Quote:
Originally Posted by yertle View Post
Haven't seen that but I've used the MultiMax (there are plenty of non-Dremel brand competitors too) to flush cut casings and baseboard. It's a handy tool for all sorts of stuff and I'm sure it would cut the bumper too. You'd have the same melting and/or non-smooth cut though. I would still use it and file/sand after, but that's a guess and not from personal experience.

Dremel MM30-01 2.5-Amp Multi-Max Oscillating Tool Kit with 15 Accessories:Amazon:Home Improvement
I thought of something similar to that but the tight space makes me think it wouldn't work. For some of the cuts it would probably be great but there are a few I don't think it would do.

The Dremel 3000 with cut off wheel worked great. Cut off the unpainted part in just a few minutes. Then laid down some masking tape to cut a straight line along the bottom edge. It does melt but the flashing comes off easily and leaves an edge that is probably 80-90% good. A quick once over with a grinding drum and it should look great.

Quote:
Originally Posted by enjoilife1991 View Post
Nice man! Idk if you remember me pm'ing you about the fog light cover install but... I bought some. I also have a brand new bumper sitting in my room without any fog lights and I just can't figure out how they mount up. The brackets that came with my fog covers just don't make since. Lol. So any info on how that install goes will be helpful.
Well I didn't get any brackets or hardware so I'm pretty lost as well. There are three tabs. Those are pretty easy to figure out. Then mine have one hole. I was planning on using a really long bolt to go all the way back to the flog light mounting area. I think the three tabs and one bolt would be good.

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Originally Posted by brett192 View Post
[/list]What purpose does this serve? I'm all for free mods but haven't seen this one yet.
It is part of the evap system. Wouldn't change performance but in some older cars the charcoal has found its way into the fuel system and clogged things up. I'd rather just about that. May get some fuel smell though.
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Old 06-10-2014, 12:06 AM   #627
xluben
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My brother and I cut up the bumper a lot but couldn't get it to fit. The piping is hitting in the fog light area. Going to think about it more and try another day.
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Old 06-10-2014, 12:28 AM   #628
|Rev|
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Quote:
Originally Posted by xluben View Post
My brother and I cut up the bumper a lot but couldn't get it to fit. The piping is hitting in the fog light area. Going to think about it more and try another day.
I had the exact same FMIC on my 02 years ago. Ran into the same issue and ended up needing to cut the corners of the fog light areas that are low and towards the center of the car. Fog lights still mounted fine, I believe the mounting points are in the other corners? At the end I felt like I cut waaay too much but really you do have to cut a lot to get it to fit. Just cut a little at a time and test the fit. Good luck!
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Old 06-10-2014, 12:31 AM   #629
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Originally Posted by |Rev| View Post
I had the exact same FMIC on my 02 years ago. Ran into the same issue and ended up needing to cut the corners of the fog light areas that are low and towards the center of the car. Fog lights still mounted fine, I believe the mounting points are in the other corners? At the end I felt like I cut waaay too much but really you do have to cut a lot to get it to fit. Just cut a little at a time and test the fit. Good luck!
That's exactly the spot. We cut a LOT out of those corners already. It is close but still won't quite fit. We cut all the way up to the painted area of the bumper around the fog light. It would be a big hole it I was going to run fog lights, but I'm just doing covers so right now it would still all be covered. If only it fit. I think the core or the pipes might need to be a little lower. Something is off because I've seen pics where people didn't cut any of that corner out and it still seems to fit.
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Old 06-10-2014, 04:04 AM   #630
enjoilife1991
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Quote:
Originally Posted by xluben View Post
Well I didn't get any brackets or hardware so I'm pretty lost as well. There are three tabs. Those are pretty easy to figure out. Then mine have one hole. I was planning on using a really long bolt to go all the way back to the flog light mounting area. I think the three tabs and one bolt would be good.
that sounds like a good idea to me. on mine when i hold it up to the bumper it seems as tho the tabs don't quite fit well. there almost a bit too big. ill have to sand them down a bit or something for them to fit better.
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Old 06-10-2014, 08:43 AM   #631
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Originally Posted by enjoilife1991 View Post
that sounds like a good idea to me. on mine when i hold it up to the bumper it seems as tho the tabs don't quite fit well. there almost a bit too big. ill have to sand them down a bit or something for them to fit better.
If you jam them in, the tabs should fit. I assume it's supposed to be a tight fit so they don't fall out.
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Old 06-10-2014, 08:49 AM   #632
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Here are some photos of the FMIC/bumper fitment issues. I've basically cut as much as possible that will still be hidden by the fog light covers. From what I can tell the core probably needs to be lower? I'll try shimming the mounts with washers and see if that helps any.

Driver Side:


Passenger Side:


Front (No Issues):


It is somewhat close to fitting, but the piping makes the front of the bumper sit a little to high, and that pull the alignment of the sides of the bumper so it won't fit.



Mock Up:
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Old 06-11-2014, 12:10 PM   #633
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My brother and I did a couple more hours of work last night. First we swapped the hood. Getting the GS dampers onto the new hood was a bit of a challenge since they were already bolted to the car. One I ended up popping the clip off to get it on, the other I just muscled the damper into the right spot and got the bolt in.

Next I went to install the downpipe only to find that it wouldn't fit on with the EWG dump tube in place. I am pretty sure I could do it on my 2011 WRX, but it just wasn't happening, so I took the EWG dump tube off. Then put the DP on, and then up the EWG dump tube back on. Getting that EWG dump was quite a pain to do with the DP on. Very little room to work.

That's all the further we got over a couple hours. Still need to bolt on the





6/10/14 Update
  • Install Downpipe
  • Swap Hood

Things that still need to be done:
  • Install Catback Exhaust
  • Remove Charcoal Canister
  • Plug BPV Recirc Hose
  • Cut Bumper for FMIC
  • Install Bumper/Fog Covers/Lip/Grill/Headlights
  • Install Wheels/Tires
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Old 06-12-2014, 11:33 PM   #634
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I know we spoke about it, but your EWG fitment issues may be a result of a current revision pipe with a previous revision dump tube. It still fits, obviously, but I can't say it's surprising that it's not perfect. That is all!

Matt Beenen
Engineering
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Old 06-13-2014, 08:35 AM   #635
xluben
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Last night I installed the catback and removed the charcoal canister. The gasket between the midpipe and axleback was fused to the flanges. I chipped off as much as possible and then put the sanding barrel on the Dremel and ground off the rest. Flanges ended up fairly smooth and clean and should make a good seal. Used GrimmSpeed 3" exhaust gaskets on the midpipe to axleback and midpipe to downpipe. Everything bolted up great. Looking forward to hearing how it sounds.

I also removed the charcoal canister. The mounting bolts were really rusty. I sprayed them with PBlaster, but they weren't moving with the impact gun or with a ratchet. I eventually just muscled them and broke two of the bolts clean off, but the third on stripped the nut so I had to cut the bracket off with a cutoff wheel. The clamps on the hoses also were rusted frozen so I just cut the hoses off. Now basically all of the evap system has been deleted.

I almost forgot, but I also plugged the BPV recirc hose. The hose is 1.25" ID and a PVC pipe cap for a 3/4" pipe fits perfectly. The walls on the cap are 1/4" so the OD ends up being 1.25". It slips right in and I clamped it down just to be save. I zip tied the hose to the intake manifold so it wouldn't just be flopping around.

Now all that's left is getting that bumper to fit on, and then getting the tires mounted and put on the wheels.
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Old 06-13-2014, 08:54 AM   #636
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H9w did you deal with the evap CELs that came up?
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Old 06-13-2014, 08:56 AM   #637
xluben
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Quote:
Originally Posted by GrimmSpeed View Post
I know we spoke about it, but your EWG fitment issues may be a result of a current revision pipe with a previous revision dump tube. It still fits, obviously, but I can't say it's surprising that it's not perfect. That is all!

Matt Beenen
Engineering
Thanks for pointing that out! They really aren't fitment "issues" that any one should worry about. Just a tight fit, and it's likely because of the Frankenstein setup.

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Originally Posted by Smurftastic View Post
H9w did you deal with the evap CELs that came up?
Nuke just deletes them in the tune.
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Old 06-13-2014, 08:58 AM   #638
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cool to see progress on this car
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Old 06-13-2014, 11:14 AM   #639
blk05wrx
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Just curious what deleting the charcoal canister gets you. I had an old turbo fox body Mustang with it deleted and an open vent fuel cell. All it got me was a garage that smelled like gas.
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Old 06-13-2014, 11:19 AM   #640
xluben
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Originally Posted by SenorDucK View Post
cool to see progress on this car
It's been pretty slow, but now it's crunch time.

Quote:
Originally Posted by blk05wrx View Post
Just curious what deleting the charcoal canister gets you. I had an old turbo fox body Mustang with it deleted and an open vent fuel cell. All it got me was a garage that smelled like gas.
It has been seen on some of the older cars that contaminants from the charcoal canister can get into the fuel system. It is being done as a preventative measure to avoid a possible failure later on. I vented the evap on my 2011 and it didn't bother me. Hopefully that's the case here too.
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Old 06-13-2014, 06:49 PM   #641
xluben
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Old 06-16-2014, 10:24 AM   #642
xluben
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6/13/14 (Friday):
  • Federal 595 RS-R Arrived
  • Dropped Off Tires To Be Mounted
  • Bought A Set of Stock Rear Axles (Just In Case)
  • Adjusted FMIC Piping

To get the bumper to fit on, all I had to do was loosen the clamps on the couplers going to the core. Then angle the couplers down and back as much as possible and then tighten the clamps back down. The pipes angle off the core at a little bit of a downward angle, and the bumper fits pretty well.

The cuts turned out pretty good. Did the Dremel with high speed cutoff wheel for the cutting and then the Dremel with a sanding drum to clean things up. I didn't need to cut nearly that much off for the foglights, but it's all hidden behind the covers so it doesn't matter.


6/14/14 (Saturday):
  • Installed Hood
  • Installed Bumper/Grill/Lights
  • Removed Fender Liners
  • Installed Fog Light Covers
  • Started Car - Oil Leak

Saturday evening the wheels/tires got dropped off. Saturday night my brother and I installed the flat hood, finished installing the bumper/grill/headlights, and put on the fog light covers. I didn't have brackets for the fog light covers, but some 4" long 1/4" bolts worked fine. They aren't quite the right angle, but they'll hold things on. Realized I didn't have headlights bulbs. Still need to buy those.

After he went home I got everything ready to start up the car for the first time. Dead battery. Jumped it (after priming the turbo). Started it up and heard a leak. Look under the car and oil is dripping out at an alarming rate. Turn off the car. Made a big mess in just a few seconds.

After somewhat cleaning up the mess I checked around and figured out the leak was coming from the oil feed line (FP oil feed) on the back of the head. I tried tightening it down and got the banjo bolt to turn a bit more. I thought I had it solved so I redid the whole process and it still leaked. It was getting really late so I cleaned up a little more and then called it quits for the night.

6/15/14 (Sunday):
  • Fixed Turbo Oil Feed Leak
  • Started Car
  • Put On Wheels
  • Drove 20 ft In/Out of Garage

Sunday night I pulled the oil feed line off the head and checked it out. Everything looked fine. I was a little suspect of the washers. The ones FP includes don't appear to be copper. They just look like a regular washer. I decided to try reusing the OEM washers and banjo bolt. I dug that out and started putting things back together.

At some point I realized that when the oil line points straight up (like I had it before), the wrench flats on the FP line hit the head casting and prevent the banjo fitting from sitting flat against the head! Over-tightening it would have just bent/broken something. I found that if point the hose straight down there is plenty of clearance.

The OEM line doesn't have this issue since it is a solid hardline with nut with wrench flats. Just a hardline soldered onto a banjo fitting. It can sit flush without any issue. Once I had the FP oil line oriented properly and tightened down I started up the car and no leak! I did use the OEM bolt and washers, but I don't think that was the issue. Just the alignment and interference.

I threw the wheels on and took the car off the stands. Still no headlight bulbs and it was late so all I did was back it in and out of the garage. Hopefully will get it tuned soon, and then take it to BIR this weekend for Proving Grounds 2014.





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Old 06-16-2014, 11:24 AM   #643
Dillebar
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The car looks great. It is very much a sleeper.....until that wastegate opens
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Old 06-16-2014, 11:49 AM   #644
xluben
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Originally Posted by Dillebar View Post
The car looks great. It is very much a sleeper.....until that wastegate opens
Thanks! Can't wait to get it tuned!

Here's a little more info on the turbo oil feed line issue.

The 02 WRX is non-AVCS and therefore the OEM oil feed line goes of the back of the head and straight to the turbo. It does not go both directions as some of the AVCS setups do. It just uses a normal banjo bolt instead of the dual exit one. Here's an example of what it looks like stock:



My motor does have AVCS (I am not using it, but it's hooked up), but the newer motors pull the AVCS feed from a different banjo on the top of the motor. So it can still use the simple turbo oil feed line on the back of the head. Here's a photo showing how the oil feed for the AVCS is setup.



I bought the Forced Perfomance "NON-AVCS" oil line kit. It's meant to connect to the back of the head and go directly to the turbo. Very simple design. Just a banjo on each end and a hose between. The end of the hose has a nut for using a wrench to tighten down the banjo bolt.

http://store.forcedperformance.net/P...LSSSubaru.html


The issue is with the nut on the end of the hose, before the banjo. Unless the nut just happens to align so that there is a flat side on the same flat as the banjo, it will interfere when mounted to a flat surface. This is what happened to me.

I pointed the hose up, and the nut hit part of the casting on the head, so the banjo wouldn't sit flat. I had to point the hose down and there is a carved out portion that it sits into perfectly. The bolt tightens down fully and no leaks! Simple solution, but quite a headache.
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Old 06-16-2014, 11:57 AM   #645
SenorDucK
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Originally Posted by xluben View Post
Hopefully will get it tuned soon, and then take it to BIR this weekend for Proving Grounds 2014.
I like the sound of this drag or road course?
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Old 06-16-2014, 11:58 AM   #646
xluben
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Originally Posted by SenorDucK View Post
I like the sound of this drag or road course?
Drag or sure. Not set up for road course. No suspension or brake upgrades.

Now the rush to finish as many other NF cars as possible this week!
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Old 06-16-2014, 12:13 PM   #647
JuanWins
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Ben, great progress on the car man! Can't wait to see some numbers once it's tuned.

One question, how do you like the Federals? I know you used to run them on your 2011, I'm really debating getting these. I live in Florida so I want some feedback as to how they grip in the rain. Currently running 17x8 wheels and was also debating on tire size.

I was leaning towards a 245/45 size with these but I see the federals run a bit wider than most tires.

Any feedback is appreciated, thanks!
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Old 06-16-2014, 12:31 PM   #648
xluben
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Originally Posted by JuanWins View Post
Ben, great progress on the car man! Can't wait to see some numbers once it's tuned.

One question, how do you like the Federals? I know you used to run them on your 2011, I'm really debating getting these. I live in Florida so I want some feedback as to how they grip in the rain. Currently running 17x8 wheels and was also debating on tire size.

I was leaning towards a 245/45 size with these but I see the federals run a bit wider than most tires.

Any feedback is appreciated, thanks!
They're alright in the rain. Similar to other high performance tires, I suppose. They do run wide in the 235 size. There is quite a bulge on the 8" wide wheels I have now. I can take a photo soon.
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Old 06-16-2014, 02:19 PM   #649
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Originally Posted by xluben View Post
They're alright in the rain. Similar to other high performance tires, I suppose. They do run wide in the 235 size. There is quite a bulge on the 8" wide wheels I have now. I can take a photo soon.
Pictures would be great. I guess 235s are probably the widest to run on 8" wheels.
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Old 06-16-2014, 02:46 PM   #650
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Nice good to see you almost back in action again
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