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Old 09-05-2007, 12:09 PM   #1
[email protected]
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Location: At the sea side, UK style
Default Wide Arch, 400+ Newage rebuild for the road

OK,I thought it was about time I shared my latest little project with you guys over in the States..

It started off when I bought a 2003 WRX back in August 2006, which had had a bit of a fire..

As can be seen from the pics, it had got a touch hot, especially in the engine bay area, which had sustained most of the damage.

The interior also was a bit of a mess, mainly due to smoke damage.

Here is what I bought...





I am obviously quite lucky, in that I work in the trade, and have all the facilities at my disposal to carry out all the work myself.
Even though, this job is being carried out on a 'As I can afford it basis', so is being done in various stages, due to finances and time constraints...

First job was to strip all the crusty burnt stuff out of the car, mainly due to the toxic nature of the remains, and of course to throw it all in the skip...



All the interior, and the engine bay area were stripped completely, and the engine bay was shot blasted, to clean up all the metal.
This was carried out by a mobile blaster, who normally blasts buildings.
Well worth it, took him about an hour to do something that would have took me days to complete, and still would not have been as good.

Due the fire, all of the outer front body panels were scrap, and the some of the structural panels in the engine bay wre damaged and would need replacing.

The front panels and cross members were also badly damaged, probably because of what would appear to be the attempts made by the Fire Services to open the bonnet at the time of the fire, so these too would need replacing, and have been removed.

Here it is once shotblasted, and with a quick coat of etching primer to avoid any rusting...





The inner wings were a bit distorted as well, so these were removed, ready for new panels to be fitted.

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Old 09-05-2007, 12:10 PM   #2
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I managed to get hold of a front cross member set up, along with inner wings from a breakers nearby. which not only makes the job a bit easier, but cheaper too





Here you can see where the new (used) panels have been welded into place, along with a few coats of primer, again to avoid any surface corrosion.





You can also see where all the seams have been sealed up, due to the original being burnt off.

With all the underseal protection also being burnt off, I thought it wise to replace this, so a few coats of stonechip have been applied to the required areas.





Next stage is to purchase new front panels from the dealers , and get it looking at least like a Scoob again
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Old 09-05-2007, 12:12 PM   #3
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Next up, new panels and goodies....

OK, got new front panels, so time to line everything up and see what it's gonna look like..





Front wings are wide arched, and are fibreglass, and as such I expected some fitting issues.
However, they are an extremely good fit, and line up with the doors/bonnet and lights as factory intended.

Here is the front all welded up and ready for paint..



Now comes the part the takes the longest amount of time...


What colour to go for...
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Old 09-05-2007, 12:14 PM   #4
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As can be seen from the front pics, the wide arches are simply replacement front wings, the rear however is a bit more complex..

Here's are some shots showing one side, roughly in place..









With the new arches in place, the next job would be to cut out the original rear arches, in order to gain clearance for the new rear axle width.

Before I carry this out though, I need to sort out the ride height, suspension travel and the size of wheel neccesary..

I have roughly calculated that I am going to need a 9" wide rim, with an ET of 15-25mm, in order to fill the arches..

But I don't know if that will be too much for the front, so I'm going to get the front suspension all built up, and get the car at normal ride height and try some wheels on.

Problem is, getting wheels at that size/offset, means either getting a set made, or sending my existing OZ wheels back to Italy to be altered.
Both are going to be a bit costly, so I need to make sure I work it out accurately

The wheels shown in the pics for reference are 8.5"x18" with an ET of 35mm, bolted on with 10mm spacers for the time being, and they are just a bit too narrow for the rear arches as they stand by about 10mm (depending on camber angle).

Gets a bit complicated for my brain trying to work all these measurements out
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Old 09-05-2007, 12:15 PM   #5
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Managed to get hold of some rather nice powder coated suspension components this week,along with a box of shiney nuts/bolts and brackets, courtesy of someone else's unfinished project





I've also managed to get some paint thrown at it..
Here's the engine bay during paint..







White is the new black...apparently..
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Old 09-05-2007, 12:15 PM   #6
Dforce
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No holes for the sidemarkers?
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Old 09-05-2007, 12:16 PM   #7
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Quote:
Originally Posted by Dforce View Post
No holes for the sidemarkers?
Nah, they is ugly
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Old 09-05-2007, 12:17 PM   #8
RSTimpreza
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subscribed!
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Old 09-05-2007, 12:18 PM   #9
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Also, I thought it would be rude not to get some of them luverly bits bolted upto the car..




The bottom arms even came with new ball joints






And a little shot of a nice chrome bracket, which won't be seen once built up



Next job is going to get the front hubs built up with new wheel bearings, and back on its wheels, so I can determine ride height for clearance issues..

I have a newage WRX steering rack to go on, but I also have a rack off an STi8 available as well, which will make its way on eventually.
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Old 09-05-2007, 12:20 PM   #10
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Got some new bearings fitted, along with the front suspension temporarily built up, and got it down on its wheels.



Looking a bit on the high side at first, although the camera angle doesn't quite show it...



Just dropped it 25mm all round, and it's getting there..










Just need to try and work out what size wheels I definately need now, as the ones on it are just too skinny...

Then I can attack the rear arches for clearance, and get all the underside and inner rear arches looking like the front (not a job I am looking forward to).
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Old 09-05-2007, 12:20 PM   #11
Cusson
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2003 WRX Sedan
ACLASS

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so far it looks like a nice build.
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Old 09-05-2007, 12:20 PM   #12
IIdiceII
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gonna be sick!
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Old 09-05-2007, 12:20 PM   #13
coolblue05
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very nice project!
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Old 09-05-2007, 12:22 PM   #14
THE-95-STi
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wow looks like you have alot of work ahead of you, good job thus far

any reason you went with 04-05 front end and not the 06-07
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Old 09-05-2007, 12:23 PM   #15
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Not done much else, but I did get my new front bumper support, so I thought I would try the front bumper on, and see how it fits.

Here's the front bumper support, nice lightweight alloy job




And here's a few pics with the bumper on.
Starting to look a bit like a car now







Oh, and here's what's behind the bumper



Think I'll get the intercooler anodised black though..

I really need to get the rear arches sorted out now, but the wheel situation is holding me up


I have taken the UK 6 speed box out of my classic, along with the STi8 quick steering rack, ready to go in this new one.

Also put the bonnet on just to see what it's going to look like


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Old 09-05-2007, 12:23 PM   #16
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CRAZY!

Want to see it finished!
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Old 09-05-2007, 12:25 PM   #17
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Quote:
Originally Posted by PSM-04-STi View Post
wow looks like you have alot of work ahead of you, good job thus far

any reason you went with 04-05 front end and not the 06-07
Simple..

04-05 headlights...Free.

06-07 headlights....1100 ish the pair..

Money no object, I would go the 06-07 route...
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Old 09-05-2007, 12:25 PM   #18
THE-95-STi
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yeah thats what I was thinking much easier/cheaper to get those parts
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Old 09-05-2007, 12:26 PM   #19
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Quote:
Originally Posted by Evil_STI View Post
CRAZY!

Want to see it finished!
Me too
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Old 09-05-2007, 12:27 PM   #20
dubya05
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gas sucker yukon

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suscribed. Wish i had the time and money to do this completely.
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Old 09-05-2007, 12:28 PM   #21
Schumacher
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Looking forward to seeing this done, Neil.

Show these guys & girls pics of your GC8 as well.
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Old 09-05-2007, 12:28 PM   #22
chewbakarox
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PSM

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Looking good, and also looking foward to more pics and updates.
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Old 09-05-2007, 12:38 PM   #23
F EVOZ
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o2 WRX BlankitaRIP
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Subscribe and good luck homie...this is gonna be great once done!!!
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Old 09-05-2007, 12:44 PM   #24
Kiel
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Sonic Yellow - Stage Taxi

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That's sick. Good luck with getting everything finished, and keep us updated (as I'm sure you will).
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Old 09-05-2007, 12:52 PM   #25
Freeman
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dark side

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looking good so far
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