Building a car

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AndrewT
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Post by AndrewT » Mon Mar 10, 2008 2:45 pm

The old EA dump pipe looks like its about 2.25" or so - seems to be a fairly custom one. I will take some photos for you tonight and measure the size.
There's plenty of it left, it continues under the car abit and even has an intact flexi joint still there.

*edit
Oh yes definitely I will happily part with it.
btw it also has the O2 sensor still in it.

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Subafury
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Post by Subafury » Mon Mar 10, 2008 3:04 pm

well done andrew. she's almost ready to rock n roll
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BrennyV
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Post by BrennyV » Mon Mar 10, 2008 3:16 pm

AndrewT wrote:The old EA dump pipe looks like its about 2.25" or so - seems to be a fairly custom one. I will take some photos for you tonight and measure the size.
There's plenty of it left, it continues under the car abit and even has an intact flexi joint still there.

*edit
Oh yes definitely I will happily part with it.
btw it also has the O2 sensor still in it.
im fairly sure it was a custom bell mouthed one
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AndrewT
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Post by AndrewT » Mon Mar 10, 2008 6:52 pm

Just picked up the early WRX metal radiator tank from JWS so all good to chuck that in tonight...

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vincentvega
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Post by vincentvega » Mon Mar 10, 2008 7:01 pm

those plastic tanks are a bastard hey :(
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brumbyrunner wrote:And just to clarify the real 4WD thing, Subarus are an unreal 4WD.

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Willie
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Post by Willie » Mon Mar 10, 2008 8:54 pm

Andrew, I've been watching this thread ever since you started. I am very impressed with your work and commitment. Your tight timeframe was considered impossible by a few of us at the start, however you have stuck at it and proved us wrong. This car is awesome.

(Let me know if you're ever going to sell it!)

Well done, mate.

Cheers,
Willie.
Canberra


MY06 Forester XT Luxury
MY05 Pajero Exceed DiD
1975 VW L Bug (1303)

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AndrewT
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Post by AndrewT » Tue Mar 11, 2008 2:43 am

Thanks Willie. Pity it hasn't ended up as extreme as my idea was at the start of the thread but the rest can always come later. Only so much you can do in 5 and a bit weeks after work some nights.


Thanks to Subafury, Alextacy and Devil Dave for the last minute preps for the test run tonight! And thanks to Matatak for his late night gearbox oil supply service :)

She drives pretty well.

Lots of smoke coming from the engine bay but it's just from copious amounts of oily degreaser burning off the exhaust headers.

She is suffering from the classic Liberty RS problem of one coil cutting out under hard acceleration after warming up - I will have to go for the Bosche coil conversion straight away I think.

Lots of smoke coming out the exhaust under boost (according to the guys following) but this isn't from the motor....when I cut the exhaust in half yesterday I discovered it was full of black soot from the old EA turbo motor which shat itself horribly a few years ago in the hands of the previous owner. The soot is now all getting forced out by a fire breathing EJ now :)
The exhaust note is quite subtle. It has the boxer rumble but is quietened heaps by the very long exhaust tip (as all Leone's and RX's have due to the muffler being mounted quite far forward in the car). Exhaust seems to breath quite well.

She seems to drive nice and smooth, almost no harshness or shudders etc.
No strange bumps or noises at all coming from the driveline. I was half expecting at least something to touch something else and need realignment (such as shifter linkage being about 3mm from the tailshaft, gearbox being very close to the EA front gearbox crossmember....but nothing). Although there is a very slight clunk from the rear end but I suspect I just need to double check the diff mounting bolts.

The gearbox shifts very well into all gears, the STI short shifter is fantastic!

The clutch friction point is very close to the floor but there is heaps of adjustment left on the pedal - had no time to adjust this before setting out - Tomorrow job. The clutch is holding on very nicely...I took a risk not buying a brand new one because my wallet was hurting too much. The frontcut one looked good enough on inspection and turns out it's fine. Hope I get a good life out of it.

Engine temp is staying nice and cool with the thermo fans coming on and off nicely as the ECU tells them to.

Alex and Dave will probably post some mobile phone photos and videos tomorrow some time.




From here;

Clean her up heaps. She needs a very aggressive cut/polish, finish removing the old tint, paint over the rust repairs, weld up a few rust holes in the thin outer layer under the car, pin up the roof lining.
Tidy and hide the wiring loom under the dash properly.
Figure out and resolve weird electrical problems in cabin (indicators intermittently working etc - suspect minor earthing problem).
Figure out why the windscreen wipers stopped working after we pulled the dashboard cluster out and put back in again
Trace which wire activates the reverse lights and hook that up.
Redo fuel pump mount to try and reduce noise (damn VL commodore pumps are not very quiet!)
Buy and mount a wanky new sports steering wheel
Buy and install a wanky new gearstick boot
Get a few more kms under her belt and change the engine and gearbox oil again
Get a set of matching tyres
Get the exhaust welded up properly with a flange joint
Glue the RX rear boot spoiler to the boot lid so it doesn't blow away in the wind!
Take her in to the Police inspection place hopefully in a few days and hopefully pass then get some number plates :)

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D3V1L
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Post by D3V1L » Tue Mar 11, 2008 8:58 am

oooo yeh does she go:P
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going over her for the first time (COPIOUS amounts of smoke around..hence the veruy light smokey photo :))
no more subarus


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Subafury
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Post by Subafury » Tue Mar 11, 2008 9:41 am

oo yeh she goes and sounds awesome - especially just for a first run!
Wanky Workshop sure is putting out some quality conversions.

she dumps a cloud of black smoke from the sooty zorst every time andrew nails it. oh and she is very quick- like twice as fast as my rx wagon.

she needs new tyres too andrew- maybe someone can shout some 13" tread.
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AndrewT
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Post by AndrewT » Tue Mar 11, 2008 9:51 am

Those tyres are all legal I'm pretty sure, but I will certainly organize a good matching set to take to the pit inspections.

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AndrewT
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Post by AndrewT » Tue Mar 11, 2008 1:48 pm


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Subafury
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Post by Subafury » Tue Mar 11, 2008 4:19 pm

we'll have to take some proper video. and when i dont have a boost leak too hahah. also it was 90k's coz of my big tyres :p
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adamb
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Post by adamb » Tue Mar 11, 2008 8:53 pm

woah, nice job andrew, that thing boots! when you find out why ur windscreen wipers aren't working give us a shout, ive got the exact same problem and have no idea why.

cheers,
adam

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SuBaRiNo
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Post by SuBaRiNo » Tue Mar 11, 2008 11:31 pm

Did they work before we did anything Andrew??

Dave
EJ conversion wiring harness cut downs available. Please PM or email (davem2000@hotmail.com) for details.

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Post by Matatak » Wed Mar 12, 2008 12:34 am

she definetely does drive VERY nicely. i love the shortshift.

and the wipers....well that was just dodgy connection on the plug into the motor...which Devil Dave seemed to think there was no feed going to it :p:p
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Wagon is no longer....:(

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AndrewT
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Post by AndrewT » Wed Mar 12, 2008 1:12 am

Yep Dave they were working before we dismantled the dash (and didn't touch the plug in the engine bay). However it turned out to be fixed by jiggling the plug in the engine bay, go figure!

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BrennyV
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Post by BrennyV » Wed Mar 12, 2008 12:40 pm

great job you have done there andrew! looks the business in the flesh.
[SIGPIC][/SIGPIC]
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Alex
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Post by Alex » Wed Mar 12, 2008 1:38 pm

was great last night, watching the RX make a my99 wrx piss. Love it!

alex
my07 Outback
my13 Hyundai i45(shhhh)
my02 Gen3 Liberty limited ed.

previously
L-series wagon, LSD, EJ20turbo, 29in tyres, 'wanky wagon'
2000 gen3 outback, lifted, otherwise stock.

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AndrewT
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Post by AndrewT » Wed Mar 12, 2008 4:57 pm

Actually Dave, you did mention that there was no voltage going to it. I guess u must have tested it with the test light? Dunno....point is it was a weird problem with a very weird resolution!

I assumed the plug was alright seeing as it hadn't been touched since the last time it was working, plus the dashboard had been completely pulled apart and reassembled meant it was much more likely something the dash would cause a problem.

Random it ended up being the plug on the actual wiper motor, although maybe not so random given how full of gunk it was! :)

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Subafury
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Post by Subafury » Wed Mar 12, 2008 8:45 pm

Alex wrote:was great last night, watching the RX make a my99 wrx piss. Love it!

alex
yeh guys concentrate on the important things! that wrxy was FMIC'd as well. gotta love subaru sleepers!!! he also gave the ba xr8 ute a run for his money. i have a shitty vid- mostly wind. maybe ill post.

btw fyi there were 2 identical test lights that i made. might of been some cunfusion in regards to that.
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