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Old 12-15-2023, 12:52 PM   #251
06gtleg
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Member#: 197928
Join Date: Dec 2008
Chapter/Region: AKIC
Location: anchorage
Vehicle:
2019 F-350
White

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Awesome to see someone bringing a bugeye back to life!
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Old 01-07-2024, 11:25 PM   #252
500_19B
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Member#: 524021
Join Date: Apr 2021
Chapter/Region: E. Canada
Location: Toronto, Canada
Vehicle:
2021 STI
2002 WRX, 2023 Crosstrek

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Have not done much in the past month, due to a combination of things (waiting on some parts backorders and the cold weather makes certain jobs hard).

Because of that, I actually spent quite a bit of time on the 944 project, which was completely on hold for the Bugeye, but now with the Subie getting close to done, I am gearing up to get back on the 944, so the two projects are sort of overlapping.

Did finally manage to get some small bits done though.

The last remaining backordered door seal showed up, so I was able to complete the interior trim. The three other doors had been very easy, so I expected the same for this one, but it turns out there was a small amount of interference between the actuating rod for the door latch, and the window at one point when going up. It did not make a lot of noise, but there was a discernable soft click. Took me a while to figure out where it was, and then took me longer to get the rod tweaked slightly so that it (1) actuated the latch smoothly when the door handle was pulled, (2) did not interfere with the window and (3) did not foul the lock actuating rod. Turned out getting the rod just right took a lot of trial and error. At one point, I thought maybe I should just order a replacement, but when I looked, it seemed that the rod came with the complete door handle and was not separately available.



Also hardwired the dash cam to the fuse box behind the dash. Everything seemed so simple, but when all was done, I realized that the coin box that covers the fuse panel does not leave enough space when closed to clear the fuse taps.



I briefly considered using the engine room fuse panel and finding a path through the firewall, but I could find no good options, so I am instead thinking of how I will modify the coin box to make it work, but also not look terrible. More to come on that once I figure something out.

I added in new airbag and tire pressure labels into the door jamb:



Also riveted back on the VIN plate at the base of the B-pillar:



Finally, I replaced the AWD decal at the base of the rear window.

The old one was very tired:



The backing paper comes with marking arrows for alignment:



Replaced decal looks much better:





It is a bit nostalgic for me, because that little decal is something I clearly remember noticing when we took delivery of the car. One of those small things that somehow end up in the permanent memory.
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Old 01-16-2024, 10:31 AM   #253
500_19B
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Member#: 524021
Join Date: Apr 2021
Chapter/Region: E. Canada
Location: Toronto, Canada
Vehicle:
2021 STI
2002 WRX, 2023 Crosstrek

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Very slow progress right now.

We are in the middle of a cold snap which generally slows things down, but I am also in a holding pattern on finishing the alignment, which would then allow me to move the car forward enough to finish off the body assembly (rear bumper and side skirts). The reason for the pause on the alignment is that FactionFab has been amazing and sent me a set of the V2 FL-spec coil-overs. At the same time, they are sending a set of updated front strut bottoms that have improved brake cable mounting. They have sent the struts, and the new bottoms are in-process and as soon as they are finished and checked, they will be sent separately.

The communication and level of customer service from FactionFab has been mind-blowing. In terms of the project schedule, that is the main reason I have not done the alignment yet, as I want to put in the new struts with updated front lower housings all in one go and then align.

So as mentioned previously, I have been using some of the time to get things ramping up on the 944 project.

Still did manage to creep forward on a couple of things.

First was solving the coin box fitment issue after hardwiring the dash cam. No matter where I put the fuse taps (constrained by needing one ACC and one constant, both non-critical circuits), the box would not come close to shutting. On the one hand, I have never used that coin box for anything, and I could have just hacked off the back and be done with it, but on the other hand, I did want to preserve some of the functionality and, more importantly, keep the fuse diagram on the back of the box in play.

I started by just cutting near the edges of the back to make the backside more of a flexible flap. Turned out it was way too stiff to allow the box to stay latched. So, I had to break out the heat gun and warm the back enough so that it could be permanently bent. The challenge was to heat it enough to get the bend, but not so much as to destroy the decal. As it was, the bottom edge of the decal did start to lift, but mostly it is OK. I will laminate some clear film over it at the end.



Next two aluminum triangular plates were fashioned up to fit into the sides where the backside had been formed in.





These have since been bonded in two-part urethane adhesive to make it solid. Will let the urethane cure for a week, and then finish it off cosmetically.

The other little thing was refreshing the taillight cosmetics. The passenger side unit was destroyed in the accident, and a replacement was picked up on eBay. It was generally OK but had these deeper scratches on the exposed black area that hand polishing did not fix:



Wet sanded progressively to P5000 and then polished that, and hand polished the rest of both lights, and they now look good.





For anyone curious, here are some pics of the current state of the 944. The engine is getting close to done on the stand, and the engine bay is filling in with the ancillaries. Expect to put the motor in sometime in the spring.








Last edited by 500_19B; 01-16-2024 at 10:42 AM.
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Old 02-12-2024, 01:03 PM   #254
500_19B
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Member#: 524021
Join Date: Apr 2021
Chapter/Region: E. Canada
Location: Toronto, Canada
Vehicle:
2021 STI
2002 WRX, 2023 Crosstrek

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I hope to receive the new front strut bottoms from FactionFab soon. Once those are in place, the wheel alignment will be done. Concurrently, the car will come down off the stands and I can then put the last bit of bodywork on (I need to drive the car six inches forward to make enough clearance for installing the rear bumper). The side skirts cannot go on until the car is off the stands, but I do not want to take the car off until the coil overs are done.

So, major progress on the old bug has been very slow this past month. Instead, I have been putting most of the available time into the 944 project.

However, there have been a few odds and ends done for the bugeye.

When I had removed the lower dash trim for hardwiring the dash cam, the upper tabs were a little damaged. Although it seemed to clip back into place reasonably well, I decided to get a new lower trim, which has now been swapped in. The only tough part of the job was getting the OBD port and bracket out. Very tight.





However, the new one is in, along with the modified fuse door/coin box and the front interior area is all neat and tidy.



Although I cannot put the rear bumper on yet, I did go ahead and get the various brackets etc. assembled, so it should be a quick job to finally put it on when I get there.



The side trim pieces for the trunk were cleaned up, but they both had some tears. I had some very tough material on hand that I thought could make a strong repair (it is material used for the inflatable life jackets used on airliners). My original thought was to use contact cement to adhere strips of material over the tears, but the contact cement did not adhere well. I then tried urethane seam sealer, which stuck very well. So, I put on a layer of the seam sealer over the damaged area and then added patch strips of the lifejacket material, and then overlaid a second coat of seam sealer.





It certainly looks ghetto on the backside, but the repair appears to be very strong, and it is not visible from the inside. I completed the repair by overlaying the cured seam sealer with woven tarp tape, just to clean it up a little.

The finished project actually looks good, and I think I will use these, and replacement left and right items would be approximately $300.



The last bit of noteworthy progress was the paint finessing on the front bumper. Aside from the bumpers, the rest of the body is done, but with some unusually mild weather, I decided to finally get to work on the front bumper.

The front bumper seemed to have the most dust nibs of any of the parts. Makes me think maybe they had it near the front of the booth and opened up the booth too soon? Anyway, you can see a little bit of it here, under the headlights.



I went through the usual process of nib file, wet sanding (P1500 to P5000) and then cut an polish. I did only the LH half of the bumper so far, but it looks a million times better now.





The rear bumper does not have as much trash in the paint, but as with the front, I will leave the paint correction until the bumper is firmly mounted up.
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Old 02-13-2024, 09:58 PM   #255
Skylar827_7
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Member#: 467290
Join Date: May 2017
Location: Northwest florida
Vehicle:
2006 Baja Turbo
Silver

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awesome work
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Old 02-17-2024, 03:48 PM   #256
tomacGTi
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Old 02-22-2024, 07:28 PM   #257
shaundizzle
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Member#: 32174
Join Date: Jan 2003
Chapter/Region: AKIC
Location: Juneau, Alaska
Vehicle:
2003 WRX Wagon
Sonic Yellow

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Looks amazing so far man, I love all the intricate details being fixed/updated!
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Old 02-23-2024, 01:12 AM   #258
cproo12
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Member#: 520219
Join Date: Nov 2020
Chapter/Region: MWSOC
Location: Michigan, USA
Vehicle:
2006 Forester STi
2002 Impreza WRX Wagon

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I have to know what you do for work. I aspire to do this level of work some day to my cars but not sure if my career will ever be able to support it to this extent. I've rebuilt my engine and done many cosmetic repairs but the cost of doing this has to be enormous!

How are you managing/organizing this stuff?

Sorry for the off topic question, just can't help but wonder.
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Old Today, 04:45 PM   #259
500_19B
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Member#: 524021
Join Date: Apr 2021
Chapter/Region: E. Canada
Location: Toronto, Canada
Vehicle:
2021 STI
2002 WRX, 2023 Crosstrek

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Quote:
Originally Posted by tomacGTi View Post
Subaru Rust Repair - 200hr Hyper lapse - Start To Finish - YouTube

Along the same lines. The both of you are in the same province.

-Randy
Hey Randy, sorry to be replying to this so late... I "took a break" and was concentrated on the other project and have not been here for a while...

That video is really good. That guy is really talented. That level of rust repair is well above my work.

Thank you for sharing!
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Old Today, 04:50 PM   #260
500_19B
Scooby Newbie
 
Member#: 524021
Join Date: Apr 2021
Chapter/Region: E. Canada
Location: Toronto, Canada
Vehicle:
2021 STI
2002 WRX, 2023 Crosstrek

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Quote:
Originally Posted by shaundizzle View Post
Looks amazing so far man, I love all the intricate details being fixed/updated!
Thank you very much!



Quote:
Originally Posted by cproo12 View Post
I have to know what you do for work. I aspire to do this level of work some day to my cars but not sure if my career will ever be able to support it to this extent. I've rebuilt my engine and done many cosmetic repairs but the cost of doing this has to be enormous!

How are you managing/organizing this stuff?

Sorry for the off topic question, just can't help but wonder.
I am an engineer by original training and have always liked hands-on work.

I guess over the years and other projects I just came up with all sorts of ways to organize, plan and track things. It is a lot of effort and time, but no skill...

The cost does add up. This is not a smart way to go generally speaking!
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Old Today, 04:59 PM   #261
cproo12
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Member#: 520219
Join Date: Nov 2020
Chapter/Region: MWSOC
Location: Michigan, USA
Vehicle:
2006 Forester STi
2002 Impreza WRX Wagon

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Ha. Nice, I am an electrical engineer as well. Only a year out of college so I guess as I climb that ladder I'll be able to afford more things.

Reassuring to hear someone else agree that it's not the most efficient way to spend money, but I think its worth it for something one is truly passionate about like this!

Thanks for the motivation. 04 STi drivetrain swapping my forester this summer.
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