Giro Disc Posted October 24, 2011 Share Posted October 24, 2011 Hey all. I know have a couple build threads going on right now but I figure I would share this one as well since there is so much love for the GCs. This project is a compliation of me and a few of my friends coming together to rebuild a car that was lost by my buddy. A freind of his rolled it. Originally this car was owned by a member on this forum that was attempting to do an EZ30r swap to it. After taking it to a few shops and getting hosed he decided to give up on the project and sold it to my buddy over at PIA. I bought a car from a freind of mine that need to get rid of it because he needed cash to buy a new car. It was a 2002 RS that I converted into a stock WRX. I traded this car to get the GC because I wanted the EZ30r for the Legacy. Held onto the car for a long time while I was waiting for time to start the EZ swap and my freind (the one that got his car wrecked) bought his old car back from insurence and was looking for a good 4dr shell to rebuild the car. I sold him this car w/o the EZ and this is where this build starts. All these first pics are from him while he was stripping the car down at my shop. He stipped all the drivetrain out of this car and out of the Forester I just bought (the ForeSTAR build thread car) because I sold some parts off it for the GC. His original car had a Ver 7 STi swap but he was worried that because of the rollover there could have been some internal dammage to the motor so he gave the engine to another good freind of mine for a rebuild. The tranny is also getting a once over by my buddy Mike at PIA so this car is getting worked on from all fronts all at the same time by a small team of misfits. Okay lets start off with the mods list. Engine: JDM EJ20 STi Engine Mods: Balanced internals (crank pulley to flywheel) ACL racing bearings Port and polished cylinder heads ARP head studs Rotated Intake Manifold 850cc Injectors Engine Management: Hydra EMS ECU Innovative wideband Turbo timer (integrated with alarm system) Tune from Maxwell Power Services Turbo: 16G EVO Turbo Mods: Port and polished Tial 38mm wastegate Custom Rotated uppipe, downpipe, and screamer pipe Greddy Ti-C catback OBX FMIC with custom piping Transmission/Drivetrain: Custom build 5 speed PPG semi-straight cut gear set Spec Stage 3 clutch (6 puck) ACT lightweight flywheel 2004 STi R180 Raer Diff/ Hubs/ Brake Swap Brakes: 2004 STi Brembo's custom painted Girodisc slotted rotors Girodisc stainless brake lines Girodisc Magic Pads Wheels/Tires Rota SVN-R 18x10, +30 offset 255/35/18 G-force KDW's 15mm hub-centric wheel spacers Suspension: Tein SS coil-overs -TEMPORARY LOL Perrin sway bars (front/rear) Whiteline anti-lift kit Cusco strut tower bars (front/rear) Interior: 2004 WRX dash assembly 2004 WRX Pedal set 2007 STi gauge cluster 2005 STi Seats, Carpet, Steering wheel Defi boost, Oil Press, Fuel Pressure gauges in ATI dash pod Custom painted door panels, headliner Custom door cards wrapped in blue fabric Custom Modded 6 point roll cage Corbeau harnesses Exterior: Por-15 undercarriage/ engine bay Vis racing side skirts Seibon CW carbon fiber front lip JUN S-13 replica fender flares 3M carbon fiber wrap (hood, roof, trunk 2.5RS front bumper Depo smoked headlamps, corner lights, turn signals (bumper and fender) JDM v6 front grill JDM v6 fog light covers JDM v6 tail lamps Hood latch/vertical beam mount delete Sparco hood pins Heres the car the day he bouight the car from me: http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton01.jpg http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton02.jpg Shortly after he started cleaning out the inside and getting all the interior gutted. It was tan. Its getting dropped off at my buddy's shop so it can get painted black. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton03.jpg A week latre he had the drivetrain all dropped out: http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton04.jpg Then I spent a night and stripped all the parts out of the engine bay and removed all the dash wiring to get access to the firewall. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton05.jpg Link to comment Share on other sites More sharing options...
Giro Disc Posted October 24, 2011 Author Share Posted October 24, 2011 Once that was done he wanted to touch up a couple little rust spots on the chassis so I cleaned the underside and then coated it in POR15 and some undercoating. Before: http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton06.jpg After: http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton07.jpg The next day after it was all dry he swapped in the rearend and front assy from the Forester. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton08.jpg http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton09.jpg Suspension and wheels in and back on the ground: http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton10.jpg In another location that same night my buddy with the engine was getting started on his rebuild. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton11.jpg http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton12.jpg Should be finished in a week or so. While the engine and tranny are getting loved I got busy with my portion of the project: WRX Wiring Conversion WRX Dash Swap Custom Modded 6pt Roll Cage Smoothed Engine Bay Relocated Battery, Fuse Box Relocated ABS w/ Custom Brake Lines Bolt On Fender Flares w/ Herra Frush but functional stance (Like the Lego) Got Started on the Dash Swap. I was happy I got to do this one right way because the windshield needs to be swapped so I got to pull it. Tonight I will make the holes for the Blower and Heater in the Firewall and plug all the un-used holes along with removal and addign metal to start the smoothed out engine bay. Once the Dash and wiring are in for good I am going to make some nice custom trim pieces that cover the gap on the sides from the dash swap so it will be cleaner. I'll be doing it from laser cut acrylic and then having it panted to match. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton13.jpg This project is on the fast track so stay tuned for updates. Once I run out of work and I am waiting for parts back from other places I will be back onthe ForeSTAR project to check that one out too its also going to be a good one. Johann @ Girodisc Link to comment Share on other sites More sharing options...
nemo Posted October 24, 2011 Share Posted October 24, 2011 If you don't vote Trump, out, you're a bigot who hates america. Link to comment Share on other sites More sharing options...
BAC5.2 Posted October 24, 2011 Share Posted October 24, 2011 I wish your builds had their own subforum... Why run an R160? [URL="http://legacygt.com/forums/showthread.php/proper-flip-key-interesti-159894.html"]Flip Key Development Thread[/URL] "Genius may have its limitations, but stupidity is not thus handicapped." - E. Hubbard Link to comment Share on other sites More sharing options...
BDII Posted October 24, 2011 Share Posted October 24, 2011 How you working AVCS in? what harness are you using? Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
Giro Disc Posted October 24, 2011 Author Share Posted October 24, 2011 I have a spare harness that I can isolate the AVCS to be controlled by ether the Hydra or a stand alone system I need to talk to Dom at Maxwell and ask him what he would like to see since hes tuning it. I am going to use a WRX Engine Harness on the JDM motor to ensure compatibility and then add a second stand alone harness for the cam sensors, AVCS etc... Johann @ Girodisc Link to comment Share on other sites More sharing options...
BDII Posted October 24, 2011 Share Posted October 24, 2011 why the WRX engine harness and stand alone for the AVCS?? The JDM one already has AVCS wired in and you can get the IAPerformance AVCS kit that plugs into the harness and the ECU. The JDM harness is virtually identical to the WRX. It just has a few more wires for AVCS and throttle body temp sensor. Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
Giro Disc Posted October 25, 2011 Author Share Posted October 25, 2011 Gotcha. It was just what I had envisioned without actually seeing the harness. I have not yet seen the engine so once I get it and have both harnesses in hand I could make a better assessing of what I was going to do with that. Link to comment Share on other sites More sharing options...
N.sane Posted October 25, 2011 Share Posted October 25, 2011 Subscribed for another epic build by Johann Link to comment Share on other sites More sharing options...
BDII Posted October 25, 2011 Share Posted October 25, 2011 Gotcha. It was just what I had envisioned without actually seeing the harness. I have not yet seen the engine so once I get it and have both harnesses in hand I could make a better assessing of what I was going to do with that. normally on the ver7/8 swaps you use the provided JDM ECU with the IAPerformance harness (or in your case, one can wire it themselves and save $150.00 ) I don't know enough about Hydra to give any advice on how well it will work with the ver7 motor. I do know that the 16bit ecu from the JDM motor is better than the USDM but still has it's limitations. I would assume the Hydra would be much better. I'm positive that once you see the JDM engine harness you will want to use it If you can sort a way to make the intake temp sensor work externally from the ECU I would buy it from you in a heart beat I wrote this when I did my swap, hope it helps http://www.newenglandsubarus.com/forums/showthread.php?t=19548 this thread also has a lot of good info but it's scattered throughout the the pages http://forums.nasioc.com/forums/showthread.php?t=1088585&highlight=ej207 Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
DocHolladay23 Posted October 25, 2011 Share Posted October 25, 2011 As usual, subscribed! [sIGPIC][/sIGPIC] You want stickers? Hit me up here!!! You want a shirt? Hit me up here!!! Link to comment Share on other sites More sharing options...
Giro Disc Posted October 26, 2011 Author Share Posted October 26, 2011 Got some more work done last night. Started by finishing my modifications to the cage. I'm not going to finish it for good until the interior panels are back in to make sure there is enough clearance. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton14.jpg Removed some parts off the engine bay to get ready to smooth it out. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton15.jpg mocked up the cover pieces to be redone in metal and welded on. However by the time I was ready to cut metal it was to late to make that much noise. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton16.jpg Also got the ABS Pump Relocated. Had to order some tools last night for mounting the fender flares, I needed to get a new flaring tool. Also ordered up some parts, Wire, Nutzerts, so while I am waiting for those things I am going to install the heater and blower so I can get the holes cut in the wall and start smoothing everything out. Also I have to de-loom all the wiring so I can relocate the fuse box and crap. More pics soon. Johann @ Girodisc Link to comment Share on other sites More sharing options...
Mega Users paintpollz Posted October 26, 2011 Mega Users Share Posted October 26, 2011 subsribed "Remember Danny - Two wrongs don't make a right but three rights make a left." Link to comment Share on other sites More sharing options...
GEE-OTTO Posted October 26, 2011 Share Posted October 26, 2011 I love how easy different models simply bolt up to one another within the Subaru lineup that is WAYYYYYY easier that other swaps Link to comment Share on other sites More sharing options...
compsurge Posted October 26, 2011 Share Posted October 26, 2011 I envision a product of awesome. Subscribed Link to comment Share on other sites More sharing options...
DeltaSniper Posted October 27, 2011 Share Posted October 27, 2011 Subscribed. Link to comment Share on other sites More sharing options...
rodan Posted October 27, 2011 Share Posted October 27, 2011 http://i5.photobucket.com/albums/y185/RodanAZ/Subscribe.jpg 5 of 17 total posts so far... Is it really that difficult? Link to comment Share on other sites More sharing options...
BAC5.2 Posted October 27, 2011 Share Posted October 27, 2011 But posting spams the inboxes of those who have already subscribed. Which makes it funny. [URL="http://legacygt.com/forums/showthread.php/proper-flip-key-interesti-159894.html"]Flip Key Development Thread[/URL] "Genius may have its limitations, but stupidity is not thus handicapped." - E. Hubbard Link to comment Share on other sites More sharing options...
BDII Posted October 27, 2011 Share Posted October 27, 2011 subscribe with no email notification. It's not hard Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
Giro Disc Posted October 31, 2011 Author Share Posted October 31, 2011 Got another update. Got a good amount of work done this weekend. I started the day but getting the FMIC Mounted. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton17.jpg Then I got the Header Core and Blower Motor from the WRX Fitted. Got the Fire Wall All ready to go. Plugged a couple unused holes to make it look a little cleaner. I have one more to plug but I need to finish the wiring to figure out with one I am going to keep. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton18.jpg Next I pushed her outside and cleaned the engine bay all out so I could start prepping the bay for the metal pieces I need to make and for the All-metal filler. Used a product calls Scuff It. Its a mild abrasive past that has a cleaning detergent it. One red scuff pad and this stuff will clean your bay down super easy its really great stuff. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton19.jpg Next it was the rear fender flares. Got my nifty nutzert tool and hardware in so I got the rear flares mounted. I need to Jonny to drop the bumper off so I can fit it and trim it for the intercooler and get the front flares on. 15mm spacers and extended studs already on the way. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton20.jpg http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton21.jpg To finish out my weekend I got the harnesses ready for some custom work. The wire isn't here yet so I have to wait before I can cut any wire. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton23.jpg http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton22.jpg For the wiring there are a couple things that need to be done just to get it to fit nicely in the GC with the converted dash. Next will all have to do with the wire tuck. Fuse box wiring will be reversed and extended to mount next to the battery in the trunk. All the wiring for the engine bay is going to come out of the wire wall in one spot just above the tranny so its all clean and consolidated. Wiper motor, and passenger side ABS wires are going to go out through the inside of the fender and poke into the engine bay in a unnoticeable spot. My new brake line flaring tool came in so I will be able to start fab work on the new lines for the relocated ABS pump in a couple days. More updates with the motor and tranny should be soon to follow. Johann @ Girodisc Link to comment Share on other sites More sharing options...
Pinsk18 Posted November 1, 2011 Share Posted November 1, 2011 Where did you get the flares from? And, Subscribed. Link to comment Share on other sites More sharing options...
Giro Disc Posted November 1, 2011 Author Share Posted November 1, 2011 The owner got them. They are Replica s13 Jun Fender Flares. He said they were like 240 for the set. I'll ask him and put up a link. Got the bumper and lip dropped off so tonight and tomorrow I will get the bumper trimmed and mounted and the front flares and side skirts on. Car is going to paint on the 14th so I need to finish up the exterior crap this week and once the wire and stuff get here I can work on the harness while its gone. That's also going to get me about a week and a half to get some work done on the Forester while its gone. I hope to have the chassis pretty much finished and ready for installation of a roll cage and get ready to start throwing parts back in. When the GC comes back to me I should have everything done and ready to install. So a few more fabrication projects (Reversed Manifold and Rotated Turbo) but looks like I should have it done by the end of this month as planned. Johann @ Girodisc Link to comment Share on other sites More sharing options...
BDII Posted November 1, 2011 Share Posted November 1, 2011 I can't wait to see the reverse mani Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
Giro Disc Posted November 3, 2011 Author Share Posted November 3, 2011 Update Time: Had to take a day off work so I could get my fireplace fixed. So... I got a whole day in the shop. Started by trimming the front bumper to fit the FMIC and getting the front fender flares bolted on. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton24.jpg Bumper is sagging in the middle so I fitted the headlights and grill so I can make a new custom bumper support. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton25.jpg Then, I moved on to some wiring. Fitted the WRX Dash harness, heater and blower motor so I could setup the wires to do the custom tuck. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton27.jpg I consolidated all the engine bay wiring to one point on the firewall. Wiper and Passenger ABS will poke through where the rear brake lines used to go. The brown and grey engine harness wires that connect by the fuse box will also be joining these wires so not only will it look super clean but all the wiring will be in one spot so disconnecting the engine for removal will be easier and take less time. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton26.jpg Last a pic of the car at a distance. Its getting there. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton28.jpg Next up will be finishing the engine bay sheet metal and body work, then a coat of gloss black paint. Next will be fab work on the custom bumper support, fitting the lip, side skirts, and rear spats. Then cutting out the fenders and quarters, and finally modification to the harness for the wire tuck and relocated fuse box. Then the car is off the paint for a couple weeks and I'll get some time to work on the ForeSTAR project and get the tranny and engine here. Once it comes back it will be a nice sprint to the finish installing everything, fitting the custom rotated turbo kit, and reversed manifold and sending it on its marry way. Next update will be Monday to show the fruits of my weekend labor. Johann @ Girodisc Link to comment Share on other sites More sharing options...
Giro Disc Posted November 7, 2011 Author Share Posted November 7, 2011 Got some work done over the weekend. Mainly little tedious stuff to get the car ready for paint. I did however get some pics of the bumper beam I made so the bumper would fit correctly. http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton29.jpg http://i186.photobucket.com/albums/x223/badwagon/Brighton/Brighton30.jpg Tonight and tomorrow I will be getting the rear spats and side skirts fitted as well as finish cutting out and modifying the rear quarter panels Johann @ Girodisc Link to comment Share on other sites More sharing options...
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