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Old 12-20-2018, 12:25 PM   #1
fartbox420
Scooby Newbie
 
Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default The cheapest WRX in Canada.

I purchased this 2004 wrx in the spring, I always wanted a WRX, but affording a new one was out of the question. I got it for cheap, but that came with some issues, mostly rust. I Started working on it a month after i bought it, and have been working on it since.

Here is how it looked with i got it.
[IMG][/IMG]



The sideskirts were hiding rusted rocker panels.[IMG][/IMG]


I also knew i needed a rad support, but i didn't anticipate the state of the bumper beam.[IMG][/IMG]

[IMG][/IMG]


What i thought was a rust bubble on the wheel well was a sign of a previous fix. This is after i removed the body filler.[IMG][/IMG]


I started with the rockers, cutting out rust and forming new panels, welded them in and making them look decent. [IMG][/IMG]

Its been a lot of work but im getting closer to driving, ill keep adding pics as i i have a few more on my phone. Unfortunately, i didn't take pics during every step along the way. and yeah, i did most of the work outside.
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Last edited by fartbox420; 12-20-2018 at 02:34 PM. Reason: formatting
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Old 12-20-2018, 02:28 PM   #2
silverscooby
Scooby Specialist
 
Member#: 15060
Join Date: Feb 2002
Chapter/Region: MWSOC
Location: OH
Vehicle:
2015 WRX
MAPerformance Stage2+ E30

Default

I don't see any pictures but with the description in the post and the username of fartbox420, I can't wait!
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Old 12-20-2018, 02:36 PM   #3
fartbox420
Scooby Newbie
 
Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default

i figured out the formatting a bit better, also thinking of usernames is hard.
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Old 12-21-2018, 09:51 AM   #4
fartbox420
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Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default

I removed the fenders and bumpers to find all the rust. it was in both rear wheel wells. there was a spot on the roof, and lots of rock chips all over. There was also a nice dent in the hood above the passenger headlight.


When the weather was crappy, i worked on smaller parts inside. Here i painted my grill with Honda Nighthawk pearl black, which has a blue flake in it. The more coats i did, the more the blue would show in direct light.


I borrowed a welder to start making my front bumper beam. Not shown is the bracing i added after. You can see also that i had to weld on the rad support if a few spots.



it turns out a Spec C JDM bumper is basically the same with a piece of tubing. It actually ended up being quite a bit lighter than a stock bumper beam.

Last edited by fartbox420; 12-21-2018 at 10:16 AM.
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Old 12-21-2018, 11:13 AM   #5
fartbox420
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Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default

I bought a 2015 + wrx badge for my car, thought it would look cool, decided to make a blue one too. I made a silicone mold of the original and used epoxy resin to make the emblem.
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Old 12-21-2018, 03:57 PM   #6
fartbox420
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Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default

[IMG][/IMG]
Here you can see the drivers wheel well, i have a closer image somewhere.also note all the touch up spots.
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Old 12-22-2018, 09:43 AM   #7
fartbox420
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Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default

So i thought id add a little more info about the car and myself. The car has 260k km and has been running Cobb stage 2 since AP 1 was new. It is running a V2 but the someone decided to steal the married Accessport. There were some positives though. It had a Kartboy short throw and delrin knob, Stainless brake lines, whiteline rear endlinks, the timing belt was replaced already, and it came with three sets of wheels and tires. Stock with old winters, new winter steelies and winter tires (pictured), and some ugly ass 18" wheels that i sold.

AS for myself, and why a new car was out of the question. I started developing health problems and at 22 and after seeing specialists, i was found to have Crohn's Disease. It slowed me down and made me exhausted all the time, making it hard to work and making me depressed. After finding a job i could manage. I started to feel a bit better mentally. After a while though, i found myself without a hobby and just working. I wanted a project car to play with, although i didn't realize how much work the WRX actually needed. Working on it though became like therapy. Seeing the progress and work i did was rewarding.

Here is a shot of the drivers rear wheel well. the rust was turing the metal paper thin.

I didnt take a lot of pics during the rust repair. but there was several big holes in both rockers, and the wheel well rust went into the trunk area.

Last edited by fartbox420; 12-22-2018 at 12:26 PM. Reason: more car info
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Old 12-22-2018, 01:08 PM   #8
fartbox420
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Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default

I worked on it all summer, in the evenings after work and weekends to get the body ready for paint. It took longer than expected and the weather changed fast. It went from 20 degree Celsius to 5C from one day to the next and it started raining almost every day. During the rainy days i polished my cloudy headlights clear. and made a few more WRX badges for fun.



I tried different pigment powders with the resin. Chalk line chalk, red and blue, i also got some pearl pigment samples to mix in. they turned out a bit different than if they were sprayed on a surface like paint.Some turned out pretty good,few air bubbles in the resin. You can see the black one i bought and the mold i made.



They came out matte so i used my headlight restoration kit to bring out a shine. There is red-blue flip, blue with purple flake, and dark green with metal flake The dark red is the chalk, it's way too dark for my liking. The original i posted was blue chalk line chalk, which i really liked. i have added 3m tape to the backs of the ones i might use. They didnt photograph well, most of the specks on the blue is pink flake.



I soon realized painting was out of the question and figured i would plasti-dip it. I lucked out and was introduced to a guy with a heated garage with a ventilation system for painting cars. I rented his garage for a weekend, and started to get it ready to dip. I originally figured i would go for a wild colour for the winter, green or purple, but i found a few gallons of flat black cheap on ebay. shots before i sprayed it. you can see i had to remove all the peeling paint from the hood scoop.





I finished late sunday night and didn't take a after pic as i was rushing to clean up. I could use more practice spraying cars. i had a few runs but it looks good from 10 feet away.

I also replaced the side skirts as the originals were messed up. I thought i ordered wrx replacements but when they arrived i noticed they were STi replacements. They were going on regardless.

The weather was warmer but the rain persisted. A friend let me use his garage to install my sides and to replace my worn struts.


You can see my replacement caliper and rotor as well as a "new" subframe i needed for to get safety certificate. I was able to score one for about $100 from one of the many JDM parts stores in Ontario.

I will post some exterior pictures in my next update.

Last edited by fartbox420; 01-01-2019 at 11:38 AM.
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Old 12-25-2018, 10:23 AM   #9
fartbox420
Scooby Newbie
 
Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default

Here it sits now, as i change my trailing arms. Notice the Ebay lip made for the WRX, only like 50 dollars, i think its a nice visual upgrade.


The headlights cleaned up pretty good.


Dspecs with STi springs are in. They have Group N top hats front and rear. They now have attachments for brake and abs lines, not sure when they started that. The trailing arms are out, and the new ones came in. Im gonna box them in with some steel for a bit of extra strength. When the snow goes i will probably upgrade all the worn bushings to Group N or similar. It also has group N engine mounts.


Almost ready, I picked up some Rally armor flaps to help keep it clean.


The lighting wasn't great, but here are my sideskirts installed. definitely not the wrx ones. She needs a wash after working on it. While I had the car up on jack stands i coated the underside with POR-15 to stop the surface rust, and prevent more from forming, it cures hard like rock.


Not pictured is the aluminum skid plate i installed. I noticed a dent in the oil pan, and wanted to prevent a killshot by a rock. i do plan on doing some adventuring with this thing. Feel free to leave comments or questions, im sure i have forgotten a few things.

I hope everyone has a safe holiday season!

Last edited by fartbox420; 12-25-2018 at 03:42 PM. Reason: more details
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Old 12-26-2018, 10:31 AM   #10
jimmypop
Scooby Newbie
 
Member#: 420367
Join Date: May 2015
Location: canada
Vehicle:
2015 wrx
swp

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nice job ! i like when guys like you pick a used car that need some tlc ! its fun to read the developpements of the project, keep them coming !
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Old 12-26-2018, 01:16 PM   #11
MAD WRX
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Member#: 472279
Join Date: Aug 2017
Chapter/Region: NESIC
Location: Lyman,Maine
Vehicle:
2015 WRX
Ice Silver Metallic

Default

Nice work man, looking good.
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Old 12-31-2018, 01:26 PM   #12
fartbox420
Scooby Newbie
 
Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default

I added some 1/8th inch steel to semi box in the trailing arms. I left openings for water and dirt to run out. I also did not want to heat up the bushing.


My welds are not pretty but it should hold just fine. I also need to clean my bench again.


Because it is winter here, I made a mini "paint booth" out of a cardboard box and a small heater. I used it to warm up the parts and the paint, then sprayed it with primer and rust paint, putting them back in the box to dry after each coat.


I had to cut one of the bolts that connect the arms to the knuckle so i have new ones ordered. I didn't want to cheap out and use a lower grade bolt on something as important as suspension. That will give me time to clean up the trailing arm perches.

The trailing arm bolt is called a flange bolt if you are looking for them. Bolt Part Number: 901000109 and Nut Part Number: 902350006.
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Old 01-25-2019, 04:18 PM   #13
fartbox420
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Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default

So i finally got an alignment, and picked up my car. I had a setback when the shop that swapped my springs. I guess my Group N top hats came without the washer for the rears. That caused the dreaded rear clunk. Luckily the shop took care of it free of charge. Here is how it sits now, after playing in some snow.






Last edited by fartbox420; 01-25-2019 at 04:20 PM. Reason: more pics
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Old 01-25-2019, 09:43 PM   #14
tbursaw
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Member#: 496962
Join Date: Jan 2019
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looks like a solid start! keep up with the great work
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Old 01-26-2019, 02:24 PM   #15
fartbox420
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Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default

Quote:
Originally Posted by tbursaw View Post
looks like a solid start! keep up with the great work

Thanks, its been quite a journey. I still need to change a lot of bushings. Then theres a lot of stuff id like to do but $$ like LSDs front and rear, new center diff, or 6 speed swap but thats way out of my price range.
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Old 06-12-2019, 12:00 PM   #16
fartbox420
Scooby Newbie
 
Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default

So it seemed like i was getting on top of everything, thats when i started to notice the smell of fuel coming from under the hood. Seems the rubber lines were leaking. The lines under the intake manifold... You just have to unbolt a few things.



Well now is a good time to do my 2015+ Sti steering swap, as well as replace all the rubber vacuum hoses with Silicone. While i wait on parts, i decided to clean up and paint my intake manifold and TGVs.




I didn't want to do a TGV delete as they help with cold starts, which is needed in the Canadian North. What i did do was grind down the screws that stick out on the butterfly valves on them as well as the Throttle body. (pics to come). I also ground down the transition and smoothed out the Throttle body plate.

Now that the weather is getting nicer, i will have more updates to come.

Last edited by fartbox420; 06-12-2019 at 12:44 PM.
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Old 06-13-2019, 10:45 AM   #17
snobordboi
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Member#: 149130
Join Date: May 2007
Location: Denver
Vehicle:
2002 WRX,
2010 X5M

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Just an FYI, the TGV's are for cold start emissions, not the actual starting. My cold starts actually improved after I did the full delete on my car, while I was living in Calgary.
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Old 06-14-2019, 02:00 PM   #18
fartbox420
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Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default

Quote:
Originally Posted by snobordboi View Post
Just an FYI, the TGV's are for cold start emissions, not the actual starting. My cold starts actually improved after I did the full delete on my car, while I was living in Calgary.
oh ok good to know, My car is OTS Stage 2 and pretty rich anyway so they are staying for now, plus i've already bolted everything back together and put my injectors in.
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Old 06-17-2019, 03:49 PM   #19
fartbox420
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Member#: 483915
Join Date: Mar 2018
Location: Canada
Vehicle:
2004 wrx
WRB

Default

Here you can see i removed the transition in the throttle body and ground down the protruding screws, as well as the tgv screws.





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