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Old 11-15-2017, 03:22 PM   #51
NJReppin
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PSM 04 STi

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continued...




all cleaned up ready to weld..



and heres a pic of us shortening the stub on the brat brake booster... (wrx one is nearly impossible to fit)

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Old 11-30-2017, 01:15 PM   #52
NJReppin
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PSM 04 STi

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got some more progress for those interested...

first up ill show you how to make a wrx steering column fit a brat steering rack ***55357;***56834;



tranny tunnel getting burnt in place



time to cut up rear end of wrx for strut towers crossmember and trailing arm mounting points



towers braced and cut..



crossmember mounts cut out



not much left ..



temporary crossmember made up so we had somewhere to lift from while we figure out trailing arm mounts.



initial crossmember mock up.. before we realized we would have to lower it 3" down to get correct suspension angles



tranny crossmember mocked up



rear crossmember in place after 3" dropdown


Last edited by NJReppin; 11-30-2017 at 01:58 PM.
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Old 11-30-2017, 01:29 PM   #53
NJReppin
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PSM 04 STi

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dat fitment tho...











lol thats just a fixed piece of metal holding wheel in place.. wont stay like that forever but i do like the way it looks lol

will probably be around the final full droop height



so nice to see matching wheels



time to start cleaning and undercoating the areas that will be boxed in and never to be seen again





pitch stop mount tacked in place..


Last edited by NJReppin; 11-30-2017 at 02:02 PM.
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Old 10-25-2018, 02:01 PM   #54
fun2drive95
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2006 Subaru
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I know I'm grave digging an older thread, but I came across this thread in a Google search and am blown away by the amount of work that you've put into it. Please tell me that you have more updates and pictures?!
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Old 10-26-2018, 03:30 PM   #55
NJReppin
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PSM 04 STi

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Quote:
Originally Posted by fun2drive95 View Post
I know I'm grave digging an older thread, but I came across this thread in a Google search and am blown away by the amount of work that you've put into it. Please tell me that you have more updates and pictures?!
Thank you!! Words like those make me feel so good because this really is so much work and I'm so far from any sort of satisfaction.... but yes the project is still going on.. progress has deff slowed down a bit but was never that fast to begin with...

I do have some pictures that haven't been uploaded so I will try and get on that this weekend for you and anyone else who is interested!

Thank you once again!
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Old 10-26-2018, 03:31 PM   #56
OAKOS Automotive
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Would also love to see some updates on this!

-Nick
Oakos Automotive
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Old 10-26-2018, 03:44 PM   #57
Ponzerelli
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Really cool build! Subbed for future updates, excited to see the progress.
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Old 10-26-2018, 06:45 PM   #58
NJReppin
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PSM 04 STi

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Quote:
Originally Posted by OAKOS Automotive View Post
Would also love to see some updates on this!

-Nick
Oakos Automotive
You got it! You guys wanna sponsor me? ***128514;

Quote:
Originally Posted by Ponzerelli View Post
Really cool build! Subbed for future updates, excited to see the progress.

You ask and you shall receive
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Old 10-26-2018, 06:54 PM   #59
NJReppin
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PSM 04 STi

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Notching frame rails out to fit engine more comfortably











Front strut tower work










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Old 10-26-2018, 07:13 PM   #60
NJReppin
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PSM 04 STi

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Not sure if this was coming in or out but for sake of the story I will say were putting it in to test fit after notching frame rails lol

And I apologize some of these pictures will be out of order from how it actually happened.. I have been slacking on posting updates..









Timing covers have good space but I dont think well be doing the spark plugs in the car.. maybe...



This ugly thing had to go...







Notched brat crossmember for turbo uppipe

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Old 10-26-2018, 07:24 PM   #61
NJReppin
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PSM 04 STi

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Time to figure out this firewall situation.. a little foreshadowing.. I'm not thrilled with how this area came out in the end and I might go back and redo it much later but I'm going to keep pushing to the end goal because realistically I'm just not happy with how it is aesthetically.. I dont think I'll have any issues otherwise..













Decided to flatten out where the spare tire area was..









The idea here was to reinforce this area to prevent issues like the GRs have but I got a little sloppier then I wanted to..


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Old 10-26-2018, 07:38 PM   #62
NJReppin
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PSM 04 STi

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So apparently I didnt take much more pictures of the firewall but we will come back to that I guess LOL here are some pics of the frame rails getting fully welded up.. I know I'm no instagram welder













Ughh more rust




I can lay some decent welds with good material lol




You can kinda see the clutch master area here and pitch mount getting boxed in.. its actually slightly crooked.. It wont be an issue i don't think but it might bother me.. the top mount should cover it tho.



Hmmm whats going on back here??

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Old 10-26-2018, 08:21 PM   #63
RJSMITH
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0219 Bug,bug,coup,va
mbp,sr,wrb

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This things awesome keep it up cant wait to see it all together
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Old 10-26-2018, 08:58 PM   #64
Dadsquatch
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Sweet! I have a 1980 gl (WRBish)
Planning the same thing. I'll certainly be back. Looking good!
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Old 10-27-2018, 06:08 AM   #65
NJReppin
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PSM 04 STi

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Quote:
Originally Posted by RJSMITH View Post
This things awesome keep it up cant wait to see it all together

Thank you! You and me both lol

Quote:
Originally Posted by Dadsquatch View Post
Sweet! I have a 1980 gl (WRBish)
Planning the same thing. I'll certainly be back. Looking good!
Thanks man! It's a lot of work so get ready lol the less rust the better.. I have a lot of rust work not even related to the swap

Ok here's a few more pics I got sick of copy and pasting image links last night


Time to make these rear strut towers fit in the bed





Point of no return lol








Time to adress a spot I've been dreading since I bought the car... under the old battery tray.. super rusty here due to battery acid I suppose?



No way for me to make this out of all one piece due to the many curves and bends..

Started off with the two curves made from some pipe cut in section and opened up to match the curves



Pretty happy with how it turned out for the most part.. I think after a little body filler it will look great.. one of my better looking patch panels I think but I also took 4.5 hrs to make....




Okay you guys are pretty much all caught up now.. still finishing up the engine bay area so I can get it prepped and primed.. then back to the rear end to finalize that and then time to start shortening axles and doing wiring, figuring out fuel system... we are so close.... but yet still soooooo far away lol
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Old 10-27-2018, 11:37 PM   #66
monkeyposeur
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93 SS - 06 OB XT
03 WRB GD 205/22T 20G-XT

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Dude, so sick! Haven't checked your progress for a while and I'm glad I did. Complete labor of love! Thanks for sharing your progress. This is my dream project for sure. But between my bugeye and my 93 turbo leggy I'm plenty busy and don't have any room, lol.
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Old 10-28-2018, 01:20 AM   #67
Puniphorous
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Metallic concrete

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Impressive!
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Old 10-28-2018, 06:57 AM   #68
NJReppin
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2004 PBP 2.5RS
PSM 04 STi

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Quote:
Originally Posted by monkeyposeur View Post
Dude, so sick! Haven't checked your progress for a while and I'm glad I did. Complete labor of love! Thanks for sharing your progress. This is my dream project for sure. But between my bugeye and my 93 turbo leggy I'm plenty busy and don't have any room, lol.

I hear you man I have an 04 sti with 165k and an 04 impreza lifted with 235k so I'm always trying to keep those on the road and then still have motivation to work on brat after working on cars all day.. it's tough lol

I'm hoping to be done by my 25th birthday which is about a year and a month away.. I know it wont be 100% and probably no paint but atleast take it for a ride by then..

We will see..

Quote:
Originally Posted by Puniphorous View Post
Impressive!
Thank you man!
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Old 10-29-2018, 07:34 AM   #69
Patbuckley
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Thanks for continuing!

Buildis interruptus sucks!
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Old 12-23-2018, 07:07 AM   #70
NJReppin
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Join Date: Oct 2013
Chapter/Region: Tri-State
Location: (856),New Jersey
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2004 PBP 2.5RS
PSM 04 STi

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Ok guys figure I bomb you guys with a little merry Christmas update.. hope yall enjoy.. which I had more progress to show but the last 2 weeks havent been able to get much done due to work/personal life/ and the weather.



Filling all the little pins holes and building up the real low spots with welds



Battery tray area all fixed up



Fixing some rust and doing some reconstruction where the lower cross bar bolts up



Other side



Couple spots gotta get fixed in the wheel well




Such a beaut





After a little paint stripper.. theres actual some solid metal still on this car LOL



Battery tray area all cleaned up almost ready for some fiberglass filler



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Old 12-23-2018, 07:16 AM   #71
NJReppin
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Join Date: Oct 2013
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Location: (856),New Jersey
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2004 PBP 2.5RS
PSM 04 STi

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Time to put down the fiberglass fill.. for anyone questioning.. I used everglass evercoat anywhere there was mild rust I couldn't adress anywhere there were weld seams.. this is just used as a rough build over the welds and rust them I will use regular filler to smooth it all out... you will see...



Smoothing it out.. if anyone ever uses this stuff.. make sure you let it dry fully or it will he a pain to sand.. and even then.. it's still a pain ***128514;




Little engine bay overlook



Other side frame rail getting fiberglass filled




Little bit of rattle can primer for some extra protection til I come back to it and get an idea how everything is looking



Top half of the firewall getting tacked in place




Firewall getting all the welds blended in



Definitely looks better from a few feet back ***128514;




Time for the fiberglass fill.. are you guys getting sick of this yet? Because at this point I never wanted to mix or sand filler ever again ***128514;***128514;



Getting it smoothed out.. as best as I could..

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Old 12-23-2018, 07:23 AM   #72
NJReppin
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2004 PBP 2.5RS
PSM 04 STi

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Okay now that I was nearly finished up here but not planning on painting just yet... I went ahead and bought a can of USC 2k epoxy primer of Amazon.. this is a true 2 part epoxy.. in a rattle can... there is a button on the bottom you pop to activate the catalyst.. I was skeptical of it at first as it had some mixed reviews but I think it actually worked great.. my biggers complaint is how quickly is goes.. I could barely get a good coats on the important spots with 1 can. I bought another can thinking I could go over the main parts and get a light coat on the whole bay.. wrong.

I wish I would of just bought a gallon of epoxy primer and a hvlp spray gun to start.. you live and learn.. but if you are just doing a smaller patch area.. those cans are Great.



Little mock up with clutch slave and chase bay brake booster delete





And you guys are pretty much all caught up again.. just waiting for a decent day for weather to break so I can get a real good coat of epoxy down. Then crossmemener and all suspension will get reinstalled.. engine and tranny will be put in and nearly all heavy components so I can finalize the rear strut tower height.

After that I will take it to my work to put it on alignment rack and make sure everything is square or within reason.

Then time for a LOTTTTTTT more welding.
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Old 12-30-2018, 05:55 AM   #73
NJReppin
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2004 PBP 2.5RS
PSM 04 STi

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So I messed around with the spray gun the other day and layed down 2 coats of epoxy primer.. looks decent for never using a spray gun before I think.







I still have to go back and do some final body work but right now I just wanna get this thing running and driving before I worry about making it perfect.

Next I bolted up the front crossmember and all the suspension and pushed it over back onto the lift.. then I dropped the motor and the trans shell back in.




Starting to figure out how I want to route this wiring







Originally I was thinking of hiding the fuse box but I think it would be kinda cool to have it in the same location as the wrx



Have to drill/cut out a few holes for wire grommets..

Next I will be taking it to my work to put on the new alignment rack. The rack actually auto calculates your cross diagonal lengths and will tell you if your frame is tweaked or your subframe are out of whack..

Hoping I will be pretty close on measurements then I can start fully boxing in the rear end.

After that is gonna be fuel system then driveshaft, front axles and then finalizing wiring.

Trying to keep the progress going
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Old 12-31-2018, 02:15 AM   #74
AZ-GT
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Location: Las Vegas, NV.
Vehicle:
2011 WRX, 05 FOZ XT,
00 Impreza 2.5RS

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Amazing and inspiring. Please continue to share and thanks!
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Old 12-31-2018, 06:22 AM   #75
NJReppin
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2004 PBP 2.5RS
PSM 04 STi

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Quote:
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Amazing and inspiring. Please continue to share and thanks!
Thank you! Everyone's comments are equally inspiring for me. I will keep this updated with any progress for sure!
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