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Old 11-28-2016, 05:30 PM   #251
no694terry
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updates?

sub'd because SF
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Old 12-02-2016, 12:40 AM   #252
PHATsuby
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Wow, I'm so glad I came back across this. You just answered a lot of questions I had in terms of using a BRZ/FRS transmission with the EZ/EJ/EG engines.

Awesome work and great fabrication! Keep up the good work, definitely curious on recent progress as well.

Ben
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Old 01-11-2017, 12:04 PM   #253
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Amazing fabrication work. Definitely need to sub.
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Old 01-21-2017, 09:09 PM   #254
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Default Small Updates

So not many updates, kinda slow progress lately I did break my collarbone a few weeks ago so that has been a bit inconvenient. But a couple new things i Have been working on

Axle related, I cut down the front outer stubs since I only need the to keep bearings and my center lock wheels.




Also completely disassembled the rear axles and packed new greased into everything. Was quite messy




And for some fabrication work, Thinking down the road about aero and wanting to move the mufflers up so the tips come out of the rear bumper. I cut a hole in the back



To patch that hole and create flat rear floor, I welded some 1" square tubes into the chassis. And cut some 18 gage steel to fill it in. This is where I need more space and tools.





I used steel rivets to help pull the panel tight for plug welding. I have a few more welds to go and a little more patching at the rear where it blends into the lower tailgate panel.



I will probably add a couple more 1" tubes to stiffen the panel from below, Also will probably put some sort off tie down system I like the idea of being able to use my wagon for picking up heavy things that don't fit into the trunk of my other car so well. i.e. more car parts lol
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Old 01-21-2017, 09:16 PM   #255
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Since I shouldn't be doing any work that requires heavy lifting, I started to sort out my wiring. Made a collapsable 4x8 foot pegboard table to do some layouts and keep track of everything.







The plan with wiring is to clean up and remove unneeded wires, also I want to clean up the engine bay and move the battery and fuse panels to behind my front seats. Want to also put in some bulkhead connectors instead of having wire bundles pass through the firewall.
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Old 03-11-2017, 03:58 AM   #256
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Amazing. Read the whole thread.
A little disappointed you cut her arms off and went RWD, but it's your car. Twice the power, half the traction, three times the fun.
And yeah, the 6speed swap is a bit on the pricey side.

How did your wiring go?
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Old 03-11-2017, 11:09 PM   #257
lodown1
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Well wiring has not made any progress, its one of those things I need to be in the right mindset to do. The wiring right now is good to run the car I just want it cleaner, moving things around a little bit. Will move the battery, fuse panel and a couple other things behind the front seats.
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Old 03-11-2017, 11:20 PM   #258
lodown1
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Other things I have been working on finishing are the front spindle modifications. Since my steering rack is much lower than the stock geometry I have to move it down a couple inches. I have drilled the spindle to accept a 5/8" bolt and made some new tie rod ends with aurora rod ends. I did not like the long bolt scenario and the bending loads, so I decided to add on to the spindle to make a double shear connection.

Started with these three pieces


Added some holes and bends






Once I weld those pieces into the spindle I will box it in with these pieces


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Old 03-12-2017, 05:13 AM   #259
Master467
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Quote:
Originally Posted by lodown1 View Post
Will move the battery, fuse panel and a couple other things behind the front seats.
Not in the back? I'd throw it in the spare tire compartment. Maybe you want to actually carry a spare though...

If so, find a battery that's short and wide that you can throw under the seat. I tried to find an example, but "low" "flat" and "short" with battery next to them sets google off in a different direction then geometric. 2 narrow lawn mower batteries on their side? Maybe you can make a string of lithium batteries and hide it literally anywhere.

Has the car really been down since may?
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Old 03-12-2017, 12:10 PM   #260
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I have no spare tire compartment, it was removed to make more room underneath the car. As for carrying a spare I would need to source another 996/997 porsche cup center lock wheel. And not all that concerned about getting a super light/small lithium battery. I have been running a Deka ETX18L battery that is 15lb and smaller than than standard.

Ultra lightweight was never the intention with this build, and honestly quite pointless from a performance aspect for everything except hardcore racing where professional drivers and battling for hundredths of seconds.

The car has been down since the transmission broke its shift sector forks in sept. 2015
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Old 03-16-2017, 10:35 PM   #261
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Some more part came in today for upgrades to the rear suspension. Will be replacing the stock aluminum STI lateral links and trailing arms with rod ends, and steel tubes. Everything will allow full adjustment for toe, camber, track width, and wheelbase.







Rod ends are 5/8" for the lateral links and 3/4 for the trailing arms
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Old 03-16-2017, 11:57 PM   #262
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This thread is bad ass! Keep up the good work man!
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Old 03-23-2017, 10:31 PM   #263
lodown1
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Default More suspension upgrades

Continuing with some suspension upgrades...



While I would not mind just buying coil-overs 1500 dollars with all the changes to my weights and balance is hard to justify. Especially when I really want to redesign the suspension completely. So some eibach springs with allstar coil-over sleeves, will be an inexpensive start that will still allow me to corner balance and set my ride heights correctly. from some of the data i have gathered the max spring rates I choose go with are about 300 lb/in front and 280lb/in rear. I am going to go with 300/250 front rear respectively. being RWD and lighter and with a better weight distribution (sub 2500lb and around 55/45 f/r) I think those rates will be a good start.
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Old 05-15-2017, 12:10 AM   #264
lodown1
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Default Suspensions Stuffs

Well I found a deal on some KW V3 coilovers, they will need a rebuild, I will be sending them to either KW or i need to see if Race Comp will rebuild them to their tarmac 2 specs.



Once those get rebuilt, I will should be nearly finished with the suspension changes. Did a little work this weekend to get front and rear uprights back together.

Here are the rear uprights with parking brake hardware permanently removed, and the torque plates flipped around to put the brake caliper in the leading underslung position. I also added some nice new black paint.




The rest of the rear suspension, I added some nuts to the lateral arms , and fabricated some spherical bearing adjustable trailing arms. Put some nice new grey paint on all those. Using 5/8" lateral link bearings and 3/4" trailing arm bearings. These were done a few weeks ago.

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Old 05-15-2017, 12:18 AM   #265
lodown1
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And finally put some welds on the front uprights to box in the new bracing to convert to a double shear steering tie rod connection. With my steering rack being lower the rod ends are going to be down near the bottom of the bolt.

First I welded the rib edges to the upright.


Then I added the box plates, I drilled the holes down he center to be able to weld to the center rib.




Finished welds






Will do a little clean up and put some black paint on them and be ready to put bearing assemblies back on. So by the time I get the KW's rebuilt I should be ready to bolt all the suspension back together and move on to new wide body fenders. Which is good timing as i need to have the car sitting on the wheels to see where I want my ride height to be which will dictate where the fenders will need to go.
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Old 05-15-2017, 03:30 AM   #266
Master467
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Nice to see you working on it again! Are you going to widebody the rear or just roll the fenders? Are you trying to go really low, or do you want to keep it streetable?
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Old 05-15-2017, 10:18 PM   #267
lodown1
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Well its going to be wide body front and rear as the wheels stick out about 3" from the body. As fro really low, I would like it to be however my limiting factor is going to be the exhaust headers, With the sti suspension I think the headers would be a bout 4" from the ground at ride height.
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Old 05-26-2017, 12:39 AM   #268
lodown1
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I have been trying to spend a little more time on the various projects associated with this build, very close on all the suspension changes.

Here is a shot of the new sway bar, this is a 15/16 nascar torsion bar that runs inside one of the lower subframe tubes. I need to get some bronze bushings and fab up the bar ends and links


Then i realized last night that my front axle stubs needed something to keep them from spinning when I go to torque my center lock adapters down.


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Old 05-29-2017, 06:37 PM   #269
lodown1
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Ive been spending the holiday weekend putting the suspension back together. I will need to send the KW v3 dampers off the KW for a rebuild but I wanted to check everything fit wise ad make sure I was going to have any issues with the modifications I have made as well as see where ride heights will put me for ground clearance.


Modified front and rear uprights. Fronts have the new double shear steering connection that allows me to adjust bump steer. Rear have the brake mounting plates flipped around to put the caliper in a leading underslung position.








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Old 05-29-2017, 06:49 PM   #270
lodown1
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A few more shots of the suspension modifications, i have a little more room for moving the steering rod down to help with bump steer and luckily nothing fouls under full droop, bump and lock to lock.







And rear suspension, with the new spherical bearing fully adjustable lateral arms, and trailing arms





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Old 05-29-2017, 06:59 PM   #271
sdunlimited
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We're going to need some handling videos once it's back on the road. Gonna be one tight Foz
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Old 05-29-2017, 07:05 PM   #272
lodown1
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Here is the car sitting on the suspension, my garage is much to small to get any good full car shots.





The coilovers are set at max ride height and I will have to see how much lower i can go. Its about where it was with the factory STI suspension, while the coilovers will allow my to go down prob 3" lower I have a couple other limiting factors. First is exhaust, the headers are about 5" from the ground now, second issue is the rear doors, they will get in the way of going much lower.

And here is a good shot showing how low the engine sits currently. I don't really know how much lower I am than "stock" But the crankshaft is about 18.25" from the ground






So from here I have a few more items to finish fabrication wise, steering column u joint and mounting, Sway bar mounting and ends, various nuts/bolts and new seat mounts. hope to spend some time on those items over the next few weeks.
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Old 05-30-2017, 05:29 AM   #273
Master467
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She's THICC! That's going to be one hell of a wide body. You know that front lower control arm looks a lot like a high angle kit, and your front tires are really out there. RWD, high steering angle, lots of power... Nope, no clue what you're going to do with it!

With the motor so low, do you have a skid plate to protect those beautiful custom headers and oil pan? This Fozzy is beautiful, inside and out. Good work.
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Old 05-30-2017, 09:24 PM   #274
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Not a high angle steering kit, the outer rod end is same location as stock just lowered a few inches. The BRZ steering rack will give me a bit quicker steering with a 13:1 ratio. The front wheel width is a bit deceiving its not quite as wide as it looks, but with the fenders removed it looks very aggressive. No intentions to do drifting either, but will do something for some skid blocks.
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Old 06-11-2017, 11:14 PM   #275
lodown1
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A little more progress I guess. Steering linkage need to be longer so i sourced some 7/8 OD tube









Of course once I had everything connected, I was testing the steering force and realized I made a pretty big mistake with the steering rack. In the BRZ they wanted to get the engine closer to the firewall, with the steering rack being the biggest component in the way they moved from a front steer configuration (tie rod in front of the wheel axis) To a rear steer configuration. Since my car needs a front steer configuration using the BRZ rack results in a car that turns left when you turn the wheel right and vice versa.

So I have so re-engineering to get the correct steering rack, I have been looking into options one of course being a custom rack this would be great but comes with a price tag of 800-1200 dollars. The I though well if I flip the rack over and convert the car to RHD the BRZ steering it would steer the right direction, not really something i would do but it did make me think about RHD steering racks from the BRZ flipped over in LHD configuration would work correctly. After a little more research the toyota yaris used a similar steering rack from 06-current year models, they should be a 12.8:1 ratio (brz is 13.1:1) And they should be about 3" shorter on the rack length. With the BRZ rack the length of the inner/outer arms is about 13" Lower control arm on the STI has about a 14" length. This was giving me a little bump steer. So with the yaris rack I should be able to better tune out the bump steer. There are plenty of these over on eBay UK so I bought one for about 175 shipped, once it gets in i will have to make sure it works.
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