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Old 09-05-2018, 11:10 AM   #1
Dadsquatch
Scooby Specialist
 
Member#: 458140
Join Date: Nov 2016
Chapter/Region: BAIC
Location: Shingletown Ca
Vehicle:
1995 Impreza
White, green,

Default Open class gf4 rally car build.

Hi everybody, I'm new to these forums. I just thought I'd start a journal.
I've been a Subaru lover since the late 90's. Back in 2000- 2005 I raced scca, Rally America and NASA autovsport. Stage rally and some rallycross.
I started off with a galant.(non vr4) Rolled that thing at Gorman ridge back in 2003. Then I decided to get serious. I bought a gc8. 2 door coup. Raced her hard in 04-05 and got 3rd place in western regional championship series in Rally america. 2005

The car had v3 ej20, DMS suspension.
The car is now just an empty shell sitting I'm my back yard. I will be rebuilding her. Soon..

But for now, back to the gf4..

I'm going to document the complete build. From teardown, weight reduction, seam welding, building a spec. Cage, swapping a 2003 wrx complete powertrain, harness merging, underbody protection and a whole lot more into a 2000 impreza wagon. This is a low budget high skill build. Many of the parts will be custom built by my boys and me. I will purchase as few parts as possible.
We do it all. Metal fabrication, carbon fiber work, wiring, paint,
This car will be for sale after the build. My goal is to build affordable rally cars.
I have 15+ years experience in performance automotive repair and fabrication. I'm trying to teach as much of it to my boys as possible. I'll be posting as regularly as possible.

I have tons of parts for sale. Most are oem. Nothing too fancy.
But I'll give great deals. Here's what I have right now for cars. (Parting)

2003 wrx wagon
2000 gf4 wagon. (Impreza outback)
2000 forester.
1998 legacy wagon

I'll post them in a separate section. Just getting the word out.

If you have any suggestions (not calling out the armchair pros here) post it.

If you have something that you think I need, post it.

If you have something that you want to donate to the rally cause, I'll take it! I'll even drive to pick it up if need be.

This will be an adventure
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Last edited by Dadsquatch; 11-21-2018 at 01:35 PM.
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Old 11-21-2018, 01:30 PM   #2
Dadsquatch
Scooby Specialist
 
Member#: 458140
Join Date: Nov 2016
Chapter/Region: BAIC
Location: Shingletown Ca
Vehicle:
1995 Impreza
White, green,

Default

Well, I've been having just enough luck buying fixing and selling cars and selling parts to continue with the build. So far, I have built a cheap rotisserie. I bought 2- $80 summit racing engine stands. I went out back to the barn and found enough steel stock laying around to build this without spending a bunch of extra cash. The boys and I stripped the car and pressure washed. I still have a few more parts to remove. (Fuel tank and lines) but for the most part she is now ready for dry ice, the sand blaster, wire wheel and then seam welding.. then pin stand slots, then cage, then motor and swap.. It's a ways away.. I have about 3 hours per every other evening that I can work on this.









Last edited by Dadsquatch; 11-21-2018 at 01:34 PM. Reason: Wrong thread.. lol
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Old 11-30-2018, 12:53 PM   #3
Rsluv
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Join Date: Jul 2015
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Dammm looks nice I want to make a rotisserie now too but I am in the Monterey bay area and it nice to see a new build like this I will be watching how good it turns out
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Old 11-30-2018, 03:07 PM   #4
Dadsquatch
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Member#: 458140
Join Date: Nov 2016
Chapter/Region: BAIC
Location: Shingletown Ca
Vehicle:
1995 Impreza
White, green,

Default

Thanks rsluv! I hope you decide to build one.

Here's where I'm at with the car. After pressure washing the ej205 I found a few problems. A few of the sensor connectors have zip ties holding them together. Not a big deal. Also, found the turbo has about .020 of shaft play. The turbo inlet hose is broken. Probably from the crash and it seems to be brittle. I hear that this is a common problem.
Some of the good. It has a moroso deep sump oil pan. I do not know if this is good for rally... I figure either it has some mods or at one time it had a bad bearing due to low level. I also see mishimoto turbo hoses. There is also a Cobb tuning license plate frame. I would be quite fortunate if it had a married accessport.
So we have 3 good doors. So we decided to do some serious weight reduction. We removed over 10lbs from each door. The front windows need to roll up and down, but the rear do not. So, we bolted them in place and removed the motors and regulators.

Also have started repairs and weight reduction on the rear hatch.

The tweaker that I bought this jewl from ripped the rear spoiler off of the hatch as his buddy was trying to use rope to pull the car onto my trailer. Yeah.. I think I said that correctly..
So a little back story about this beauty. I think it was day 5 of the car fire. In Redding. I got a call from a someone saying that he has a subie that he was going to tune. But the calfire bulldozers were plowing dirt over his cars and he needed to get rid of it before they destroyed it. I am about 30 minutes from Redding.
I met him at the DG near Keswick
I followed this guy for almost an hour. Out to bum **** Egypt. We traveled through some of the worst damaged homes and properties. It was pretty bad. Anyways, we finally got to this guys place and sure as **** there was a bulldozer plowing dirt over this guys junk yard of cars. They were telling this guy that his cars were fire hazards that would engulf the whole area. And if he couldn't move them then they were going to bury them with dirt. WTF? So, I got into my truck to line my trailer up to the car. Before I knew it, this guys buddy hooked a rope to it and started pulling the car out. One guy near the back started yelling to stop. He did, but not before he ripped the spoiler off trying to play tug of war with a 350..
I got $100 off of the $450 that he wanted. I used my winch and my youngest at the wheel to pull the car onto the trailer.

So a couple of hours went into the rear hatch. Removing the wiper motor and reattaching the spoiler.






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Old 03-29-2019, 06:55 PM   #5
russellh68
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Member#: 7197
Join Date: Jun 2001
Location: Milpitas, CA, USA
Vehicle:
2002 WRX Wagon
Aspen White

Default EJ205 Things to Check

Hi Dadsquatch,

Looks like a fun project. Where are you at now? Just did a motor out refresh on my 2002 WRX and here is what I found on the EJ205:

Bottom end was immaculate so YMMV
Replaced every rubber gasket and seal on the motor
- Valve cover gaskets
- Crank seal
- Cam seals
- Oil Pan
- Fuel Injector Seals (rock hard and probably leaking)
- Oil cooler seal (under the oil filter)
Replaced all rubber hoses as many would just break as I was trying to remove them. Look up a how to on the hoses in the forum which has great information.
- Coolant
- Vacuum
- PCV
Full timing belt and idler replacement because it was off anyway. Found that the small idler bearings were going. Didn't do the water pump as it only had 40k miles on it and bearings were smooth.
All of the rubber on the turbo side of my engine was hard as a rock and needed replacing. I would, at the very least, check all of this before dropping that lump into your rally car.
Hope the project is going well.
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Old 03-29-2019, 07:25 PM   #6
Salma21
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Quote:
Originally Posted by russellh68 View Post
Hi Dadsquatch,

Looks like a fun project. Where are you at now? Just did a motor out refresh on my 2002 WRX and here is what I found on the EJ205:

Bottom end was immaculate so YMMV
Replaced every rubber gasket and seal on the motor
- Valve cover gaskets
- Crank seal
- Cam seals
- Oil Pan
- Fuel Injector Seals (rock hard and probably leaking)
- Oil cooler seal (under the oil filter)
Replaced all rubber hoses as many would just break as I was trying to remove them. Look up a how to on the hoses in the forum which has great information.
- Coolant
- Vacuum
- PCV
Full timing belt and idler replacement because it was off anyway. Found that the small idler bearings were going. Didn't do the water pump as it only had 40k miles on it and bearings were smooth.
All of the rubber on the turbo side of my engine was hard as a rock and needed replacing. I would, at the very least, check all of this before dropping that lump into your rally car.
Hope the project is going well.
+1
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Old 03-31-2019, 02:31 AM   #7
Dadsquatch
Scooby Specialist
 
Member#: 458140
Join Date: Nov 2016
Chapter/Region: BAIC
Location: Shingletown Ca
Vehicle:
1995 Impreza
White, green,

Default

Well, it seems to be going backwards.. the wife's 2002 wrx popped the throw out bearing. I pulled the motor (because it needed to be resealed) I also wanted to do some performance upgrades to the motor. Broke all of vacuum hoses.. So I took them off the other ej205.. I went to o'riley and got new ones for it for only $20. That includes the 90 for the PCV.
Pulled the tranny and replaced it with the tranny out of the rally donor. That was the plan though. We bought the 02 about 5 years ago with a bad 1st gear syncros. Got her cheap.. the donor 03 has a good tranny and a group n mount! Keeping that for the rally car. the plan is to put 1-2 ppg gears into the bad tranny. It should work itself out.

Other than that, I've dry iced her and started the seam welding. Drilled holes for the pin stand sockets. I'll take pics in the morning..

Also been busy helping my oldest put his car back together. (Its looking good theres a thread on it)

Last edited by Dadsquatch; 03-31-2019 at 02:43 AM.
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