Welcome to the North American Subaru Impreza Owners Club Monday May 20, 2019
Home Forums WikiNASIOC Products Store Modifications Upgrade Garage
NASIOC
Go Back   NASIOC > NASIOC General > Member's Car Gallery

Welcome to NASIOC - The world's largest online community for Subaru enthusiasts!
Welcome to the NASIOC.com Subaru forum.

You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, free of charge, you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, so please join our community today!

If you have any problems with the registration process or your account login, please contact us.
* Registered users of the site do not see these ads. 
Reply
 
Thread Tools Display Modes
Old 04-06-2014, 08:13 PM   #51
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

Sure, that bar measures 50 and 1/8".

This week was a lot of prep work for the front suspension. Progress was slow as it seemed like I took 2 steps forward and 1 step back. Several trips to the hardware store and had to repaint one bracket after modifying it.

First off - more organization! Searching through a 12x12" box for hardware was getting old. Separated out all the hardware for easier searching.



Installed Turn in Concepts FCAR bushings


Prepared the front LCA to accept the Koni suspension. I purchased these aluminum LCA from a 2006 wrx specifically because that's the only year that these are aluminum - lighter and stronger than the stamped steel donor LCA. Drilling your aluminum LCA is something that requires double and triple checking first. The top side bracket was originally painted and ready to go. However, I found I couldn't got a socket down between the uprights in order to tighten the hardware. I clearanced the sides just a touch to allow my socket to fit and then repainted them.



The bracket pictured on the right is bolted on the opposite side of the LCA, effectively acting as a large nut/washer for the top bolt/bracket.



Front Koni Shocks - 500# springs - both are the 818R equipment that I upgraded for my 818S. These are double adjustable.

Assembled:


The rear donor sway bar is used in the front of the 818. My donor came with a whiteline sway bar that had served the previous owner for a number of years (evidently). The only thing that didn't have a coat of rust on it was the Whiteline sticker.

Start:


Surface rust ground off and etched with POR15 prep and ready.


After 2 coats of POR15 - I ended up doing one more coat.


Put the upright brackets on the front knuckles - Still need to find 2 of the donor rear strut bolts.
* Registered users of the site do not see these ads.

Last edited by metros; 04-06-2018 at 09:55 PM.
metros is offline   Reply With Quote
Sponsored Links
* Registered users of the site do not see these ads.
Old 04-07-2014, 09:15 AM   #52
lavid2002
Scooby Specialist
 
Member#: 226864
Join Date: Oct 2009
Location: Southern NJ
Default

I am going to the junk yard this week to get some rear strut bolts myself. If you'd like I can grab a couple extra and mail em to you.
lavid2002 is offline   Reply With Quote
Old 04-07-2014, 10:13 AM   #53
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

Thanks for the offer. Worst case I'll take the 2 I have to the hardware store and find a match.
metros is offline   Reply With Quote
Old 04-13-2014, 08:13 PM   #54
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

Made some decent progress this week. Really felt good to start bolting parts on to the car instead of spending time preparing parts.

The lower control arm bracket that I showed last week was re-painted and bolted to the front LCA (aluminum). The front LCA rear bushings were upgraded with TiC FCAR bushings and ready to go. I sourced 4 new grade 8 bolts for the upright to knuckle adapters. My OCD kicked in again as I didn't want to use 2 old bolts and 2 new bolts. Then I could only source 3 of the properly sized bolts, which I eventually found a 4th after visiting several hardware stores (M14x2.0 60mm BTW). The front struts/shocks were assembled and ready to install. Now the fun part, putting it all together!





I had everything for the front UCA prepared to install, however I received 2 different balljoint mounts that I'll have to sort out with FFR before moving forward. See below - one mount is perfectly flat and the other has the balljoint at a clear angle. Frustrating but I can see how that would be easy to do.



Continued the painting of brackets - it's never ending!


Then I started on the axles for the 818. Due to the engine/trans being in the rear of the 818 you have to mix and match the 4 donor axles to account for that. You take the inner CV joint of the front axles and the outer of the rear axles to make 1 set of axles to use in the rear of the car. Then the front bearings are held in place by the front outers only.



Front inners disassembled, cleaned and ready to install on the FFR axle shaft.



Overall not difficult to dis-assemble this end, but cleaning gobs of bearing grease is never fun. The inner cv cups will be getting sanded and painted.

That's all I had time for this weekend as I had to do some work on the house this weekend and spent some time enjoying the beautiful weather as well.

All this work sure is tiring though!

Last edited by metros; 04-06-2018 at 09:56 PM.
metros is offline   Reply With Quote
Old 04-13-2014, 09:41 PM   #55
insane_one
Scooby Specialist
 
Member#: 301431
Join Date: Nov 2011
Chapter/Region: AKIC
Location: Anchorage, AK
Vehicle:
2005 Evolution VIII

Default

Keep it up! by the time your done, your son will be able to drive. Hahaha. JK.
insane_one is offline   Reply With Quote
Old 04-20-2014, 03:46 PM   #56
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

My focus this week was to finish setting up the axles for the 818. As I said in the previous post, the 818 uses all 4 axles to make a set of rear axles. Factory five provides axle shafts and you use the front inner CV and rear outer CV to create the rear set of axles.

Last weekend I pulled apart the front inner axles and cleaned everything. Over the week I sanded and painted the cv buckets.

Outer axles in process of removal. These get positioned in a vice and you have to pound the inner race to get them off the axle shaft.



The sprocket looking thing is the inner race.


Once I had them apart I cleaned as much grease out of them as I could and repacked them with Redline Synthetic CV grease.

New shafts with new rubber boots ready for the ends to be installed.



818 Axles ready to install: Also shown is the finished product of my sway bar refurbishing.


I started prepping the pedals for install.

Rusty:


Ground and sanded - ready to paint


I also did the same for the gas pedal. But that needs to be modified for the 818 before I can paint.

I also completed the final part of de-powering the steering rack. A lot of builders will just tie the ports together. But that just leaves useless lines that aren't visually appealing wherever they are. Instead I followed another builder's idea and cut the stock fittings off the power steering lines and had a friend weld them closed, then grind smooth and paint.


Last edited by metros; 04-06-2018 at 09:56 PM.
metros is offline   Reply With Quote
Old 04-27-2014, 08:03 PM   #57
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

As the build is going along I'm realizing that I need to work at the step I am currently on as well as several steps ahead in order to prep. This makes progress slow as you're hopping around to several different areas constantly.

This weekend I:

Finished the lateral links by installing the Turn in Concepts bushings. Ready to go now.


Set up the 'Very Cool Parts' trailing arms. These will allow me to run wider wheels/tires in the rear than the stock trailing arms. I'm debating between Mach V's "Awesome" 17x9 rear wheels and their "Wicked Awesome" 18x9.5 rear wheels. I'll be using a 265 series tire, which is more easily available in 18" diameters but that adds weight overall. Decisions.



Installed the front upper control arms. Prior to installation you need to thread the balljoints into the UCA. A note to future builders - grease the threads on both initially and thread it on, then remove and clean the grease before re-installing. The balljoint threads are full of paint/powdercoat, which takes a ton of force to cut through. Afterwards you can threadlock the threads for permanent installation.

Front suspension:


Had the steering column ready to install, then realized I hadn't set the mounting brackets aside. Very frustrating to have everything ready to install then realize you didn't keep the mounting brackets. I've got a set on the way to install next weekend.



Loosely installed the adapters for the rear hubs/suspension. Should be able to hang the rear suspension next weekend. *Crosses fingers*



Overall I'm enjoying the build and seeing parts come together.

Last edited by metros; 04-06-2018 at 09:57 PM.
metros is offline   Reply With Quote
Old 05-02-2014, 08:13 PM   #58
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

Parts!

I received some of the crucial parts of my build today. From 'Very Cool Parts' I received the AWIC set up that I'll be using and the K-Tuned Shifter - which is just as badass as I anticipated it was going to be. My local Subaru experts at Mach V Motorsports set me up with a CSF radiator, valve cover gasket kit, colder spark plugs, new o2 sensor, axle nuts and group N trans mount. All of the above was ready for pick up with just 2 days notice. Thanks Mach V!

Pictures:




K-Tuned Shifter - such an impressive piece. I cannot wait to sit in my 818 and feel the way this thing shifts. I would anticipate it'll shift nicer than my s2000 did, which was glorious.




Sunday updates will show progress I've made over the weekend.

Last edited by metros; 04-06-2018 at 09:57 PM.
metros is offline   Reply With Quote
Old 05-03-2014, 07:50 AM   #59
Shik
NASIOC Supporter
 
Member#: 132
Join Date: Jul 1999
Chapter/Region: Tri-State
Location: PA
Vehicle:
2006 GT Ltd 5spd sdn
'15 WRX 6spd CWP, '02 WRX

Default

Metros, your kiddo needs the proper attire to be working on the car :

Shik is offline   Reply With Quote
Old 05-03-2014, 04:46 PM   #60
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

That's awesome! I'll show the wife.
metros is offline   Reply With Quote
Old 05-04-2014, 05:00 PM   #61
xxguitarist
Scooby Newbie
 
Member#: 389899
Join Date: May 2014
Location: Shelton CT
Default

Nice work so far! We put in our deposit on a 818S, also with R package shocks this weekend, now to find a donor!
xxguitarist is offline   Reply With Quote
Old 05-04-2014, 06:46 PM   #62
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

^^^Welcome to the FFR family. Good luck finding a clean donor and the part out that's sure to follow.

I didn't make a ton of forward progress this weekend. I'm trying to remind myself to enjoy the journey and not focus on completion. At times that's hard to do because progress is slow compared to what I'd like. Personality wise, I need to see/feel progress to be satisfied with any project I'm working on.

I was able to mount the steering rack.



I also had to go back and redo a portion of the firewall. I didn't read far enough ahead in the manual and realized that the steering column bracket needed to be bolted on before the firewall was installed. I was able to drill out the rivets, install, and re-install the firewall in an hour.

The rear suspension was fighting me this weekend as well. I was planning on re-using the stock rear lateral links with new Turn in Concepts bushings. However, with those installed and the hubs mounted I can't get the rear trailing arms to line up with the hub. The toe adjustment isn't getting to where everything lines up nicely. If I get aftermarket lateral links then I can adjust rear toe to where everything lines up nicely and then re-adjust at alignment time.

Going to make time this Friday to get some things accomplished.

Last edited by metros; 04-06-2018 at 09:57 PM.
metros is offline   Reply With Quote
Old 05-09-2014, 07:57 PM   #63
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

Out with the old and in with the new - group N engine mounts.


Trans mount - the old one has clearly seen better days. Glad I decided to replace this as the nice new/clean paint is nice as well.


Made some good progress today. Will have more updates on Sunday.

Last edited by metros; 04-06-2018 at 09:57 PM.
metros is offline   Reply With Quote
Old 05-10-2014, 09:59 PM   #64
xxguitarist
Scooby Newbie
 
Member#: 389899
Join Date: May 2014
Location: Shelton CT
Default

Hey, we found our donor! Clean? Maybe... it does have an EJ257 built motor with 2.0 machined heads and a VF22 turbo, so we've got that going for us. It is an East Coast car though.

How many hours do you estimate that it took you to tear down your donor?
xxguitarist is offline   Reply With Quote
Old 05-11-2014, 01:13 PM   #65
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

Congrats! It took me 3 months with some down time in between. This was working primarily on the weekend and also preparing for my son to be born. Bear in mind that I had also never pulled an engine/transmission prior to my donor tear down. Someone with experience is going to be much faster than I was.

Looking back on it, I could have done it much faster. I recommend spending extra time and attention to labeling all the hardware. I thought I had done so but have been chasing down hardware, which has taken more time than I'd like.
metros is offline   Reply With Quote
Old 05-11-2014, 05:14 PM   #66
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

Progress!

After wrestling with the stock lateral links last weekend and not getting everything to line up due to lack of toe adjustment, I decided to upgrade to the whiteline units that would allow camber adjustment and lots of toe adjustment. With these units it was still a wrestling match to get everything cohesive but I think I'll be much happier with the additional adjustment that these provide.

I'm also using the VCP trailing arms to allow wider wheels/tires. I'm planning on using the Mach V 'Wicked Awesome' in the rear, which is 18x9.5 +42.



Lots of toe right now:


Front outer cv joints - As you can see these won't be attached to anything. They're only there to keep the bearing in place and happy. This weekend I popped all the original ball bearings out of it and cleaned it up.



Michael Everson master cylinder mounting flange. This is an add on that's used solely to level the master cylinder mounting out, instead of the weird twist that the FFR hardware uses. Very happy with the quality of the piece. Maybe next weekend you'll be able to see how the master cylinder looks all mounted in place.



Pedals! If anything makes you feel like you're making progress it's putting the pedals into the car! Gas should be installed next weekend. So no vroom vroom noises until then. Anybody have pictures of the gas pedal bracket installed?

This is after finishing painting them up with POR15.



Next Weekend:
-Paint steering column adapter
-Finish pedal install
-Look at mounting ABS unit

Last edited by metros; 04-06-2018 at 09:58 PM.
metros is offline   Reply With Quote
Old 05-11-2014, 11:01 PM   #67
xxguitarist
Scooby Newbie
 
Member#: 389899
Join Date: May 2014
Location: Shelton CT
Default

Quote:
Originally Posted by metros View Post
Congrats! It took me 3 months with some down time in between. This was working primarily on the weekend and also preparing for my son to be born. Bear in mind that I had also never pulled an engine/transmission prior to my donor tear down. Someone with experience is going to be much faster than I was.

Looking back on it, I could have done it much faster. I recommend spending extra time and attention to labeling all the hardware. I thought I had done so but have been chasing down hardware, which has taken more time than I'd like.
Thanks!

We have done a engine swap on a Miata before, but limited experience with that level of stuff. Pretty comfortable with suspension work etc.

Even if we take 3 months to pull it apart, we'll beat our kit delivery date, and have some time to start working on cleaning parts up before it arrives.

Appreciate the note to label hardware. We have a rack of the little colored buckets, might be worth picking up another two or three!

Today I stripped the wagon's interior, everything behind the front seats. Not exciting compared with yours, but it's progress anyway! Intend to get a temp reg for the WRX and drive it this week as a shakedown.
xxguitarist is offline   Reply With Quote
Old 05-12-2014, 09:05 AM   #68
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

Nice! The more time refurbishing parts before your kit arrives the better off you'll be. Of course that depends on how anal you are but it's very time consuming. You could also depower your steering rack, press in new wheel bearings, upgrade to arp studs, the list goes on.
metros is offline   Reply With Quote
Old 05-13-2014, 12:31 AM   #69
xxguitarist
Scooby Newbie
 
Member#: 389899
Join Date: May 2014
Location: Shelton CT
Default

Well, in response to that, I've got a case of twist tie-on tags (think: morgue toe tags) on order, along with a case of sharpies, a handful of clear plastic organizer cases..etc. Will be stopping by the DMV tomorrow to pay our taxes on it, along with getting a 10 day temp tag to drive the WRX to make sure all seems good to go. We'll probably start digging in a bit more this weekend.
xxguitarist is offline   Reply With Quote
Old 05-18-2014, 07:58 PM   #70
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

^^Looking forward to seeing your build thread.

Not a ton of progress to report this weekend. I did get some necessities taken care of this weekend though.

-New Gates timing belt, water pump, t-belt tensioner, and idler pulleys. All of mine seemed to be in good condition and fairly fresh. However, I didn't know when exactly they were replaced so I replaced them anyways. One less thing to think about once the engine is installed. Especially since the timing belt side of the engine will be inaccessible once installed in the 818.

The timing belt guide I used:
http://forums.nasioc.com/forums/show...94043~original

-I freshened up the timing belt covers as they were all showing their age to some degree. I used Bumper/Trim coating from duplicolor and they came out looking brand new.

-Tore the rest of the top of the engine off. Removed the intake manifold, TGV all coolant piping, etc. Took these parts to get powdercoat in addition to the interior panels. The engine parts will be powdercoated gloss black and the interior panels will be satin black. I also took my brand new air to water intercooler to be powdercoated gloss black as well. I pushed to get these parts to powder because I'll be busy with family next weekend, which will allow the shop plenty of time to get them powdercoated.



-The small coolant lines and oil dipstick tube were starting to show some rust bubbles. I removed those, ground them down, and sprayed them with fresh gloss black engine paint and clear. Should look brand new once they're dry and reinstalled.

Last edited by metros; 04-06-2018 at 09:58 PM.
metros is offline   Reply With Quote
Old 05-18-2014, 09:03 PM   #71
Sir Wagon
Scooby Newbie
 
Member#: 160556
Join Date: Sep 2007
Chapter/Region: South East
Location: Mebane, NC
Vehicle:
2015 WRX STI
Lightning Red

Default

Subbing, you planning on bringing it to VIR any?
Sir Wagon is offline   Reply With Quote
Old 05-19-2014, 05:59 AM   #72
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

I'd love to but that's far in the future right now.
metros is offline   Reply With Quote
Old 05-26-2014, 07:47 PM   #73
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

Not a ton to report this weekend as I was tied up with family obligations and had a very limited amount of time to work.

-Changed spark plugs to one step colder as recommended by my tuner.

-Finished the coolant tube refurbishing. Also refurbished the oil dipstick tube.

Before: Rust bubbling up underneath the paint, especially around the ends.


Prepped: Ground down and sanded all the rust off. Then used metal prep to etch the metal in prep for paint.


Finished with Gloss Black VHT Engine enamel and clear.


Pulled these out in prep for putting the engine back together. They may free up some airflow.


Put on the PTP Lava Turbo Blanket - the hotside of my blouch 18g is ceramic coated to help retain heat and improve spool. Adding the Blanket for further gains in spool and controlling engine bay heat.



Wires - .032 diameter

Last edited by metros; 04-06-2018 at 09:58 PM.
metros is offline   Reply With Quote
Old 05-31-2014, 09:49 PM   #74
metros
Scooby Specialist
 
Member#: 111343
Join Date: Mar 2006
Chapter/Region: MAIC
Location: NoVA
Default

Parts are back from powder coating!

I've never had any powder coating done for previous projects (other than what parts came powdered). I used Frederick County Customs out in Winchester. I'm very pleased with the parts. They taped/plugged parts as requested, sand blasted everything, primed, and powdered. Prices were reasonable and the parts were ready on schedule.

All the engine parts I had coated gloss black. The interior aluminum I had them do a satin black so that it wouldn't show as much dust on the interior.

Pictures!
AWIC I'll be using.


Valve covers


Coolant tube and intake manifold


Interior panels


Made some decent progress toward re-assembling the engine today. More pictures tomorrow!

Last edited by metros; 04-06-2018 at 09:59 PM.
metros is offline   Reply With Quote
Old 05-31-2014, 10:15 PM   #75
Ultimateone
Scooby Guru
 
Member#: 48025
Join Date: Nov 2003
Chapter/Region: NESIC
Location: By the Ocean, MA
Vehicle:
17 RS
SB

Default

Awesome build, love reading threads like this.
Ultimateone is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump

All times are GMT -4. The time now is 12:23 AM.


Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2019, Jelsoft Enterprises Ltd.
Powered by Searchlight © 2019 Axivo Inc.
Copyright ©1999 - 2017, North American Subaru Impreza Owners Club, Inc.