Building a car

Subafury · Post by **Subafury** » Thu Feb 14, 2008 9:50 am

lol yes we stood and helped watch. moral support included haha

AndrewT · Post by **AndrewT** » Mon Feb 18, 2008 12:59 am

A few small updates,

- Engine is now *almost* ready to put in the car. It's got the new pulley, new timing belt, new main crank oil seal, new water pump all fitted now. Just waiting on the cam cover bolt gaskets to arrive at Subaru before I can slap those back on.
- Engine bay is now 90% in primer, just a few fidly bits left to do then I will crank out the spray gun/compressor and spray some white onto it.
- Wiring loom is now removed from the frontcut - bloody hell there is ALOT of wiring in Legacy's!

Discovered today that the AWD gearbox actually has a genuine STI short shifter attached! Bonus!

Also discovered the frontcut had one of those little solar panels sitting ontop of the dashboard which has a button to test the condition of your battery and keeps it constantly topped up from the solar panel - pretty stupid but kinda funny.

SUBYDAZZ · Post by **SUBYDAZZ** » Mon Feb 18, 2008 9:10 am

AndrewT wrote:Yeah I am doing the timing belt, got a Daico one. Not worth getting the full kit in this case as all the idlers are fine except one.

It may be worth it if the entire Dayco kit is cheaper than the one bearing from Subaru

As sometimes happens.

AndrewT · Post by **AndrewT** » Mon Feb 18, 2008 9:29 am

Yeah $300+ for the whole kit, only needed to buy one idler which was $100 from Subaru. I got the Dayco timing belt for free.

AndrewT · Post by **AndrewT** » Tue Feb 19, 2008 9:22 am

Update
- engine bay priming is now completely done
- removed old clutch cable
- removed old accelerator cable
- enlarged accelerator cable hole to accept Lib cable
- rocker cover bolt gasket/grommets now in stock @ Subaru ready for me to collect

BrennyV · Post by **BrennyV** » Tue Feb 19, 2008 10:25 am

good to see ya staying commited. some pix?

SuBaRiNo · Post by **SuBaRiNo** » Tue Feb 19, 2008 8:28 pm

How long you got till it needs to be done??

Dave

AndrewT · Post by **AndrewT** » Tue Feb 19, 2008 8:50 pm

Until the end of next week. Bout a week and a half.
I'm at WackyWorkshop right now. Putting motor back together and going to try to spray the engine bay.
Spraying engine bay might be a problem as my spray gun appears to be clogged, it's soaking in thinners now.

AndrewT · Post by **AndrewT** » Wed Feb 20, 2008 1:12 am

Well I couldn't get the spray gun working, it's still soaking in thinners at the moment.

Here is a couple of photos of the engine bay as it sits now;
http://members.iinet.net.au/~carine3/RXIMAGE_016.jpg
http://members.iinet.net.au/~carine3/RXIMAGE_017.jpg

Here's the motor as it sits now. I just need to put the front plastic timing covers on, fit the new spark plugs, and she's ready to drop in.
http://members.iinet.net.au/~carine3/RXIMAGE_002.jpg
http://members.iinet.net.au/~carine3/RXIMAGE_014.jpg

This amused me on the way home;
http://members.iinet.net.au/~carine3/RXIMAGE_019.jpg

Bumpty · Post by **Bumpty** » Wed Feb 20, 2008 7:54 am

AndrewT wrote: This amused me on the way home;
http://members.iinet.net.au/~carine3/RXIMAGE_019.jpg

Amuses me aswell haha

BrennyV · Post by **BrennyV** » Wed Feb 20, 2008 9:59 am

engine bays lookn good mate. havent got too much overspray :P

YouTube · Post by **El_Freddo** » Wed Feb 20, 2008 10:35 am

Mate love your work with the engine bay detail you go into... only one problem...

It makes me want to do up a car! And i just don't have the funds to do that right now (it would have to be a brumby or a coupe)...

Bennie

AndrewT · Post by **AndrewT** » Wed Feb 20, 2008 11:13 am

Thanks, although it's actually not that detailed. There are plenty of little divots and scratches which will show when the shiny coat is on. I could spend time smoothing them over but I just don't have the time. It's mostly just to present a very clean engine bay because the old paint was in the pretty bad way.
The bits with overspray all over them are going to get sprayed individually anyways

Suby Wan Kenobi · Post by **Suby Wan Kenobi** » Wed Feb 20, 2008 12:11 pm

Nice work

love the number plate gave me a laugh

YouTube · Post by **El_Freddo** » Wed Feb 20, 2008 4:11 pm

AndrewT wrote:Thanks, although it's actually not that detailed. There are plenty of little divots and scratches which will show when the shiny coat is on.

Better than 20 years of grease and grime... Plus a newly sprayed engine bay looks sh!t hot over a non-resprayed bay any day

Bennie

AndrewT · Post by **AndrewT** » Mon Feb 25, 2008 12:45 am

Okay, I've done a bit more stuff.

Fitted new front seat belts. Well not new, just good condition...thanks Lapsed! - (from his wrecking wagon). I'll tackle the rears soon too because they also need replacing. I hope they are the same in a wagon as a sedan, can anyone confirm?
Anyone want a set of nifty Genuine RX black and white checkerplate seatbelts? You just have to risk your life with the tears and frayed fabric

Sprayed the inside of the engine bay today.
I did a really quick job (it took about 10 minutes). I got a couple of smallish runs which I will sand out once it's completely hardened. I'll also hit it with some cutting compound to bring up a nice shine. Here are a few photos of it straight off the gun.
http://members.iinet.net.au/~carine3/newIMAGE_022.jpg
http://members.iinet.net.au/~carine3/newIMAGE_023.jpg
http://members.iinet.net.au/~carine3/newIMAGE_024.jpg

After the paint was reasonably dry I did a few more things which you can probably see in the photos;
- enlarged the firewall mounting hole and fitted the EJ accellerator cable
- fitted the brake booster back on, with Liberty master cylinder and hooked up all the lines.
- custom mounted the Liberty hydraulic clutch master cylinder. A very solid mount was achieved with a 5mm think spacer between the cylinder and firewall just on the passenger side mount hole (the drivers side sits flush already) and by bracing with a metal plate and a large washer on the inside.
I will have to weld a bracket onto the clutch pedal for this next.
- fitted the EJ power steering lines

PeeJay · Post by **PeeJay** » Mon Feb 25, 2008 9:56 am

AndrewT wrote:I will have to weld a bracket onto the clutch pedal for this next.

With mine I ended up drilling a hole through the clutch pedal to which I bolted a custom made bracket. I couldn't get access to weld in there properly, and I didn't want to risk setting anything on fire. I also found it easier to adjust that way as well.

AndrewT · Post by **AndrewT** » Mon Feb 25, 2008 10:09 am

Cool I'll look into that as my welding skills aren't that good yet!

(btw, it's extremely easy to just remove the clutch pedal from the car for welding purposes)

ToyRX · Post by **ToyRX** » Mon Feb 25, 2008 10:39 am

This is looking really good Andrew, expecially given the time bracket involved!!
I have 10-12 weeks left to build mine and I am concerned about running out of time, let alone doing the whole thing!

AndrewT · Post by **AndrewT** » Mon Feb 25, 2008 11:45 am

Thanks...

I'm definitely not going to get it done on time. I have exactly 1 week left. With a fulltime job and Tuesday and Wednesday nights both writeoff's this week due to other commitments....it aint happening.

Still needs;
- put engine in
- put all engine accessories into engine bay
- fit VL turbo fuel pump and plumb it all up
- get the turbo dump adapted to the rest of the exhaust by an exhaust shop
- put clutch back on engine (I'll take a chance due to time constraints and use the clutch that came with the frontcut, it looks to be in good nick).
- put gearbox in (customize crossmember)
- Cut down wiring loom! (not started yet)
- Fit wiring loom
- fill up all oils etc
- Fit radiator and fans and fill up with coolant
- get a good set of 13" tyres onto the mags
- fit the front hubs, struts, brakes etc (still need to buy brake pads for these)
- get a front wheel alignment done
- do a few test drives to make sure it's all good (in the dark backstreets!)
- give the entire body a very aggressive cut/polish (the paint is very marginal)
- get it police inspected and licensed!!