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Stuff done tonight,

- Fixed up accelerator cable, had no slack in it so engine idled about 4000rpm - all good now tho.
- Fitted WAIC intercooler (actual intercooler bit only). Had to buzz off some of the spare wheel platform but way less than you do with a lift kit. Intercooler fits very well with lots of room to move.
- Dummy fitted shifter linkage - looks like it will need about 1" shortening.
- Bleed the brake system. Wow SO much air in them after sitting for over a year with no master cylinder. Seem now too bad now but will need another bleed soon.

so bat laps of northies in no time? :P

yeh whats left on the list. we can bust it out asap

Did a little more last night.
Really just cut, shortened and welded the shifter linkage. Seems to fit pretty well now, I just need to make a bracket to hold the rear section in and that part is done.

Still need to fit the dump pipe and maybe weld it to the rest of the exhaust (but might need the exhaust shop to do it properly - especially because I would like a flange joint there).
Still needs abit of underdash wiring done.
Still need to mount the fuel pump properly and extend the rubber fuel lines down there to prevent kinking because of the VL fuel pump inlet angle is different.
Still gotta mount and wire up the two thermo fans.
Gotta cut, shorten, re-weld the engine stay rod.
Gotta fit the extra bracket to the clutch pedal and bleed the hydraulic clutch pedal.
Probably a few more things then I can throw the new bonnet on and start test driving.

I'll take the set of RX 13" mags in to a tyre place to get new tyres today.
Also gotta get some fuel for her! There is probably only about 1litre left in the tank and it's been there for a very long time.

Few more things tonight;

Test fitted the dump pipe.
http://members.iinet.net.au/~carine3/wIMAGE_042.jpg
http://members.iinet.net.au/~carine3/wIMAGE_043.jpg
Just temporary bolts for now, I will be getting some high temp ones.
Yes I know I haven't put the top bolt in the steering extension yet
As you can see there is very little clearance all around but it does fit, complete with the catalytic converter and full heat shields intact.
The Legacy hydraulic clutch master cylinder actually came with a factory heat shield which I will attempt to re-fit, it's probably going to need it.

http://members.iinet.net.au/~carine3/wIMAGE_044.jpg
The existing 2.5" exhaust lines up to the Legacy dump pipe pretty much perfectly! The existing exhaust is pushed down abit in the above photo and is basically directly beneath the dump. I will choose a good spot to cut them both and do a temporary weld - should be good enough to last for the 15 minute drive to the exhaust shop to get them to put in a proper flange joint.


Engine bay....looking basically complete now;
http://members.iinet.net.au/~carine3/wIMAGE_045.jpg

Intercooler all fitted up - temporary, still need to fit the engine stay rod underneath ;
http://members.iinet.net.au/~carine3/wIMAGE_046.jpg
You can see the white section of metal of the platform I had to cut off sitting up there in the spare wheel well.

Shifter linkage;
Finished the mounting for this, all done now.
http://members.iinet.net.au/~carine3/wIMAGE_047.jpg
**Very dirty interior! Needs a vacuum and some armourall!
Note that the original RX dual range centre console has been ditched and replaced by a 2wheel drive one from a Leone (Thanks BrennyV!). It will obviously have to be painted black to match the rest of the RX interior.
The rubber gearstick boot has been changed to a Liberty one but you will notice it is still too high and looks abit squashed, the gearstick is too short, I will have to get some kind of wanky aftermarket boot from an auto shop I think. Very unassuming anyway...nobody would guess there is an STI short shifter and a 4.111 AWD Turbo gearbox lurking beneath


I think that deserves a nice cold Becks opened by the patented Wacky Workshop bottle opener!
http://members.iinet.net.au/~carine3/wIMAGE_048.jpg

hahah nice. not long to go mate!

sooo close.....cant wait to test drive her for myself


dave

i herd andrews gonna be droping skidz this sunday

D3V1L wrote:sooo close.....cant wait to test drive her for myself


dave

if u get a drive surely i do to

haha. coming together real good. shell be out on the road in no time


(time to move that damnede wagon )

Im going to try find time this weekend to come out and finish that wiring for ya Andrew... Let me know when your going to be working on it and i will let you know.

Dave

this is pretty sweet, good work.

so the engine was a basic bolt in job? nice

Bolt in well kindof, I did have to do a few bolts up here and there

Well did abit of work yesterday, she will drive now but haven't tried yet.
Okay well I admit I have driven her - but about 20mm

Finished the clutch pedal mods. It now has a custom bracket bolted to the side which actuates the hydraulic clutch master cylinder. The friction point is pretty close to the floor but there is plenty of adjustment left on the pedal so shouldn't be an issue. With the car idling and in 1st gear I let the clutch out slightly and it crept forwards slightly - woohoo first baby steps!
There were too many wires around my feet, and no radiator fans etc, and tools all over the car so couldn't proper test drive just yet.

Cut and shortened the engine stay rod, welded it back together, thats all fitted now.

Cut the old EA82 turbo dump pipe off and welded the Lib dump pipe to the rest of the exhaust - VERY temporary job but it works Sounds quite nice...surprisingly quiet considering there are no resonators or intermediate mufflers. Just a big long pipe leading to the rear muffler.

Massive thanks again to Subarino who came over and finished connecting up the dashboard lights and gauges, fuel pump etc. Now I just have the task of cable tieing it all up out of the way, man there are so many wires!

I've re-fitted the front guards, grill and front bumper again. Face-lift to late model grill and colour coded bumper looks great!

Fitted two 12" Davies Craig thermo fans. Wow there is SO much room around them when you don't have a lift kit!

Slight set-back...I noticed a slight coolant leak coming from one of the turbo coolant lines right where it connects to the RS Legacy plastic radiator header tank (you all know the ones....brittle as all hell). I slightly jiggled the rubber pipe but the inlet pipe just snapped off and spurted hot coolant into my face (No burns luckily). It was bound to happen at some point, these plastic tanks are all so old now. I will be picking up a nice durable metal header tank from an early WRX shortly to replace it.

She's very close to driving now. Couple more evenings and I will be test driving properly. Couple days after that and we'll see how she fares at the police roadworthy inspections!

congrats man! you have done well! and fast!!!!!!!

Andrew, sounds like she is really coming together - good stuff. Just a few questions re the zort…
1) How big (in inches) is the dump pipe?
2) How much of the dump is there from the 82t after you hacked it off?
3) Are you willing to part with it (if its not already taken)?

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.

well done andrew. she's almost ready to rock n roll

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

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

those plastic tanks are a bastard hey