Junkyard Journal | a 1999 RS rescue mission

[JDMJNKY]

I was dreading buying new valves for this engine and contemplated what to buy? When I remembered I had complete 05 STI valvetrain, I quickly dug them up for some prep work. Downtime is the worst for a dreamer. While I waited on the valve guides, given the spark plug crack, this would be the prime opportunity to test what I've read here and there about "thermal" coatings. Without spoiling my next update Mr.D, this is what I was up too. The heads will eventually need to be replaced, that's a given, but who tears apart a perfectly working engine for no reason? Not I, at least not these days, where time is of the essence. Leaving the cracked heads in play would give me that reason, on the next tear down I can inspect all the shenanigans I've arranged. So the timer is set; 2yrs or less.

Chip resistant so far. I dropped two of them from 4ft high onto a wood floor. :facepalm:


bronze guides not needed for this street car, these stockers will do.


the valve springs from my 05 STI (couldn't dig up any info. about the green color spring; anyone else know?)


05 STI bumpsticks w/ AVCS plugged, "anti friction" coating. Before I install these does the plug need to run the entire length of the AVCS hole?


cylinder heads receive the same "theorized" treatment


typical fan boy wrinkle prep; 18hr days for vanities....what am I thinking

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[JDMJNKY]

I have yet to mic the new sizes - TB all cleaned up




and finally the rallytech radiator shroud arrives. I'll be trimming it myself to accommodate the GD radiator.

[JDMJNKY]

While waiting for parts to arrive, I'd spend some nights after work cleaning and prepping for the re-assembly. I still have a few things left, thankfully I'm almost there - Heads are out getting a valve job and surfacing, if all goes well we should be running by Sun. night. My biggest worry at the moment, is, if my injectors don't come back from cleaning today, that plan goes right out the window.


Failed my first attempt at gray wrinkle





Murk'd it on my second attempt





Freshened up the timing covers. New is always easy, reconditioning is the fun challenge.


purchased a new inlet. Being a WRX engine in a GC, the old inlet was missing one port.


some gaskets, ss and thermal. IDK why, I've always been a thermal gasket fan.


lately for todays' update, I purchased this kit for its current and future provisions

[D-Rodman]

You must not sleep, you are one productive fella.

[JDMJNKY]

I sleep 6-8 hrs. I'm not one to idle the day away if I have much "to do." When I'm dead, I'll get more than my fair share of it, LOL.

On that note, more productivity. Grease and I are not friends. Cleaned up the block as best I could, but this is where it get's scary. I could not heat cure this ceramic coating as I've done everything else. I was afraid to torch the cylinders.







A friend of mine who does powder coating lent me some proper oven/heat safe tape - prepped TGVs for wrinkle as well. and plan on re-shooting the IM. Just awaiting heads, Injectors, and the 05 sti oil pan.

[jvh22a]

wrinkle grey looks great! never even thought about that color. always looking to paint things black.

[D-Rodman]

God bless you dude.
Looking good, wrinkle gray looks very good.

[JDMJNKY]

I've been wanting to try the gray for a while now. Seems like this car is my first of everything, it's my guinea pig of ideas.

TY both.

[JDMJNKY]

Pinks are back from cleaning, 05 sti oil pan has arrived. I have the 05 pick up and baffle, but I have a deal pending for the moroso pick up. Still awaiting heads to come back from the machine shop.

Things I'd like to finish to get this thing put back together but the winds here are ridiculous RN: wrinkle TGVs, Redo Intake manifold, match port/port headers that were on the engine.







pan arrived w/ a lil damage, but should be ok.

[JDMJNKY]

Laid some wrinkle down on the TGVs. Now, before I ran out of paint I had 2 orders from separate places cancel them, one was set to arrive today or tomorrow; I saw the cancel notice this morning. The other I asked if it was in stock and seller cancelled my order with no reply; GRRRR! Well, I just ordered 4 cans as a precautionary measure. I hope this order doesn't get cancelled, I'd love to shoot the manifold and be done with it all.

[firebane]

I'm surprised with all the work your doing that you didn't do a TGV delete mod.

[Shinji N]

Originally Posted by firebane

I'm surprised with all the work your doing that you didn't do a TGV delete mod.

While there are ways to fake it, leaving them in simplifies the wonderful California BAR referee process. (honestly glad there’s at least some way to do this in California)

[JDMJNKY]

Originally Posted by firebane

I'm surprised with all the work your doing that you didn't do a TGV delete mod.

The brass plates will be deleted, the rest will stay put, perks of living in CA. Since this car is a swap and I don't want to deal w/ paying for abnormal smogs every year, my plans are to take it to state ref and get it certified with the wrx engine.


- Todays Shenanigans
wrapped the oil pan in silver "heat shield."


New mounts


Began taper porting of the exhaust manifold

[JDMJNKY]

Intake manifold finally redone, what a learning experience it has been. This wrinkle gray is definitely most finicky of all the wrinkles I've used. From now on I'll leave it to the pros.






overboard hardware.

[Fndragn]

Very nice, how did you get all the gold parts looking so good?

[JDMJNKY]

They were zinc coated.I should have said silver, his default was gold but oh well lol.

[JDMJNKY]

The long days are beginning to catch up with me. A laundry list of tedious updates await the engine but I either forget parts here or there and kick myself for not remembering. Having a moment to self, I decided to fit some parts to the short block today, and as I was about to clock out, the cylinder heads were dropped off. YEEEEEE!

Cheap security for $45 shipped, moroso pick up + 05 sti windage tray


05 oil pan on



forgot to send the mount & oil pan bolts off to zinc, so I painted them with rustoleum.





visual fruits of labor

[Fndragn]

Very nice!

[JDMJNKY]

Thanks Dragn

Wife mentioned the parts zone, which meant move them; My how quickly a short block becomes a longblock w/ the proper motivation lol.




as for tonight, once the kids are sleep. I'll begin turning two sketchy harnesses into 1 good one and re-taping it..

[JeffrWRX]

So impressive- both your skills and attention to detail

Coming along!

[raysm]

Just went through the whole journal. Great find and great work! Can't wait to see more!

[WhiteZombie]

Talk about a sketchy harness! Yikes!

[JDMJNKY]

Originally Posted by JeffrWRX

So impressive- both your skills and attention to detail

Coming along!

The little details can be a gift and a curse man, the two actually met when I pulled the motor that it would not go back in the way it was removed LOL.

Appreciate ya.

Originally Posted by raysm

Just went through the whole journal. Great find and great work! Can't wait to see more!

Thank you, Thank You. I'm enjoying every minute so far, it's not a stock gem, but a cool find for sure.

Originally Posted by WhiteZombie

Talk about a sketchy harness! Yikes!

Man, It drives me nuts. Given the fact that wiring is not my strong suit, for me to tackle such a project boldly should shed some insight on how worried I am.


Last Nights Fiasco. I found that harness was retapped before, de-looming took some effort. There were also hidden twisted wire repairs and twisted frayed wiring throughout the tear down.

de-loomed, soldered and shrinked repairs.


ended the night with this quick tape job to hold wires together and mark the areas I'm unfamiliar with. Tonight we TESA

[JDMJNKY]

Can't believe I missed this last night......so much for attention to detail giggty giggity


corrected.


final prep


Thanos level unlocked. End Game. Now it's time for a good nights rest. Be sure to treat those Ladies like Queens today fellas, it's Valentines Day. GNYT!

[WhiteZombie]

Wiring is not my strong suit either, but the more I do it, the easier it gets. Patience helps, haha. You're doing a killer job, and seem to have a pretty good photo setup too