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Old 01-14-2015, 09:56 PM   #1
gmacmt
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Default Trash Wagon build

Cross posting from dirty impreza, so ignore the fact that a lot of this is being posted on the same date...

Well not really rally, more like slam through ditches and stuff.

My plans are to run Forester struts with wrx king lift springs, which should give me a 2" lift over stock, and pretty decent handling. The suspension is in the mail right now, should be installed by the weekend. I am switching to a 15" wheel to run 215/75/15 tires, which should be about 28", so 3" bigger than stock. Going to run a light truck tire like the general grabber.

Then its gonna get a messed up nose, with full tube bumper, and a whole bunch of stuff will happen to the rear end too. But that stuff wont happen as much until its warm.

So here is how it is sitting as of this afternoon. Got excited and decided to do some chopping today.

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Old 01-14-2015, 09:57 PM   #2
gmacmt
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Got some more work done today. Installed the forester struts and king springs.


Great start to the day




It was kinda cold. Insulated carhart pants FTW




The lift is definitely not that big. I forgot to do before and after lift pics, but I am thinking I maybe got 1.5 inches or so. Can definitely see old t-bone marks in this shot. The other side of the car is much better looking. Planning on fabricating a couple of spacers for the trailing arm brackets instead of paying 50 bucks for the subaru ones.



Front bumper work begins tomorrow. People in montana can't drive. This car totally backed into me last night while I was parked. With the new bumper planned, I dont think this will be a big problem...



Didnt have any issues with sway bars, front or rear. Not totally sure why? Maybe because the lift was so insignificant? Might need some really small spacers on the front to get the car to sit right, but I will wait until new bumper, tires and wheels are on.

Ended up going with the 205/75/15. I think the 215's would look bitchen, but the 205s are much more practical for a car this slow.

Car drives awesome now. No body roll at all compared to previous. Tracks really nicely. Probably needs a little alignment.
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Old 01-14-2015, 09:58 PM   #3
gmacmt
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So news I guess. Detailed the car, which took forever because it was trashed. Decided to try to get the bumper done before wheels and tires get mounted wednesday. Never used a tube bender before, but its pretty cool. Fabrication skillset is rapidly growing. Pretty much spent all my time on a mill and doing square tube fabrication previous to this, so the mitering is a new challenge. Luckily working with adam from Sklar Bikes to knock this out. Doing a sort of complicated bend for a first build, modeled after this bumper***8230;



Gonna have a more generous top bar than the one pictured to accomodate some hella lights.

First off cut the bumper another 4 inches***8230;



Did seven bends on the upper horizontal bar that hug the body line of the hood pretty well. Four on the lower, which is mounted in this photo. I think my biggest challenge is how to mount the bumper to the chasis. Trying to avoid mounting to the OEM bumper, but its tricky because everything up front is just really flimsy. Planning on welding a few plate brackets to the tubing that will sneak underneath the radiator and mount to stock frame rails. Other than that, Just trying to create a lot of contact points (~8 bolted points) to diversify force on impact***8230; This is all new to me though. Here is where I ended up today, a lot of work isnt pictured.



Gonna paint all the OEM bumper bits and radiator housing crap black so its less obvious tomorrow. Hopefully it is sunny enough to do that. Should be big updates tomorrow!
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Old 01-14-2015, 09:59 PM   #4
gmacmt
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Todays progress is more bumper stuff.

Was fortunate enough to work inside, which was amazing for productivity.

Had the downside of working by myself for most of the day, which sucked for tacking the bar on (See picture below of using the groundflat grinder bench to fixture main tube on uneven concrete floor)

Decided to scratch out the mount points I made yesterday, and get rid of the OEM bumper bar. I didnt realize this was an option until this morning, so I was happy to find out how to do this. I basically made a plate that utilizes three of the OEM bumper mounts, and mitered a tube that was welded onto the face of the plate, and connected to the bar. It feels so solid now.

Here are some pictures...



you can see the new mount in this picture



pretty happy with my first tube bend. Not perfect, but it looks pretty good. Some of the asymmetrical part of the picture can be explained away by the body panels not actually being correctly installed after front end damage. The other part is just that it isn't perfect.



As it sits. New wheels and tires tomorrow. Also first day of a 20 credit semester of EE. Need I remind you that truck is still for sale?

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Old 01-14-2015, 10:00 PM   #5
gmacmt
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Good news!

Tires and wheels are in.

Bad news!

Had to order special "tuner" lug nuts because of the chinese wheels.

Turns out that 27" is about as big a tire as I would ever be comfortable going. Honestly, it was probably for the best that I didnt have the lug nuts in time because I think tomorrow I will have to spend some time machining spacers for the rear trailing arm brackets to center the wheel in the arch.

And a little worried about the tall gearing from these tires...

Photos:



And a teaser. These wheels should all tuck well in the wells.

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Old 01-15-2015, 10:34 PM   #6
Ryan25i
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Subscribed, because this is what I want to do to my Rex to make it a winter monster after I get a summer car.
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Old 01-16-2015, 11:07 AM   #7
gmacmt
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Almost stopped posting on nasioc because I didn't think anyone was interested. Thanks for the comment Ryan, I will keep it updated.

Lug nuts should come in today so I can get the wheels on the car. Was planning on machining some spacers to drop the trailing arm brackets 1" yesterday, but decided that I could go spend an hour at the junkyard and pull a couple trailing arm brackets off some old outbacks.

So 3 hours later, I was covered in snow and soaking wet with bloody hands and only one bracket. Every other bracket I tried to pull ended up having a seized bolt inside that bushing assembly. Didn't help that all the cars were on stands that almost perfectly blocked the assembly I was trying to work on. Kinda couldn't believe that I was allowed to just walk into the junkyard and start turning wrenches without signing a release waiver or anything. But, this is Belgrade Montana, so it isn't too surprising.

After admitting defeat, I called the dealership and ordered the parts in for 70 bucks, which is about the same money as I lost wasting time at the pick and pull. So yesterdays net loss was about 140.

The good news is that I think I might be able to score bodywork from a subaru front end pretty cheap. Maybe even sell my headlights for the majority of the money I would have in the bodywork/subaru lights. Not sure if that is a route I want to take, but it would be cool to find some bodywork that isnt smashed to hell.

Trailing arm brackets may keep me from getting the wheels on tonite. Will keep you posted.
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Old 01-16-2015, 02:22 PM   #8
lub
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Can't wait to see this thing with the wheels on.
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Old 01-16-2015, 06:39 PM   #9
98jdmlegacy
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where are you located in montana? im in bozeman and have not seen you i dont believe
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Old 01-16-2015, 06:47 PM   #10
Drummerboy0518
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Looks awesome so far cant wait to see the finished product!
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Old 01-16-2015, 06:54 PM   #11
wallster13
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I can't believe you cut up a 92x bumper... People would kill to have one in good shape, myself included haha but car looks sick so far
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Old 01-16-2015, 07:53 PM   #12
gmacmt
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Quote:
Originally Posted by 98jdmlegacy View Post
where are you located in montana? im in bozeman and have not seen you i dont believe
In bozeman too. Just started this build like last week. Bought the car right after the new year.


Quote:
Originally Posted by wallster13 View Post
I can't believe you cut up a 92x bumper... People would kill to have one in good shape, myself included haha but car looks sick so far
I think it was kinda messed up before I cut it, definitely wasnt perfect.

I want a hood and a fender tho, or a subaru swap.
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Old 01-16-2015, 07:54 PM   #13
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Got the wheels to fit, had to do some surgery on the valence until I get the trailing arm brackets on. Might leave it like that tho, plastic stuff just falls off anyway.
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Old 01-16-2015, 08:25 PM   #14
Hondaslayer
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What tires did you go with?

GG AT2 like the rest of us weirdos that lift Subarus?
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Old 01-16-2015, 10:12 PM   #15
Ryan25i
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Yes sir, that's what I like to see!
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Old 01-17-2015, 08:27 AM   #16
goswald79
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Subscribed. I would love to see you add more to that tube bumper. There is so much potential here.
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Old 01-17-2015, 12:42 PM   #17
gmacmt
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Quote:
Originally Posted by Hondaslayer View Post
What tires did you go with?

GG AT2 like the rest of us weirdos that lift Subarus?
Yup, thats what they are. Was debating between that and the BFG's, but I kinda hated them on my truck when I used to run them. Yokohama geolanders are probably a better tire for what I do (DD, commute) but these are bitchin.

Quote:
Originally Posted by Ryan25i View Post
Yes sir, that's what I like to see!
Thanks dude!

Quote:
Originally Posted by goswald79 View Post
Subscribed. I would love to see you add more to that tube bumper. There is so much potential here.
Yeah! The plan is in action. I am gonna get some work on the tube this weekend. This thing is my DD, so I was going to school last week and am just running what I have. Also, always open to suggestions!



The car has a serious overbite now, so I am thinking about doing a back quarter job like the jackson rally wrx. Well, that has been a plan all along, but now I want to do it this winter, although thats kind of a summer weather job...

Maybe I can knock it out in a weekend.
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Old 01-18-2015, 07:38 AM   #18
goswald79
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Quote:
Originally Posted by gmacmt View Post



Also, always open to suggestions!


Pre-runner style front bumper.



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Old 01-20-2015, 03:23 PM   #19
gmacmt
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^ If you look at post 3, you will see what that bumper is gonna look like. I think it is as close as I can get to a prerunner bumper without looking a little out of place.

Got rid of that stupid washer fluid tank that made my car look like I had been in an accident. Replaced with a 48oz tallboy nalgene that fits perfectly between the battery and radiator. No mounting required!

The only downside is the nalgene I used is HDPE, which is a terrible thing in regards to adhesion. Almost no epoxies will stick to it, and the stuff I used (plumbing putty, what I had lying around) failed pretty quickly resulting in a slow leak. I am going to try to use E-6000 when I get to the hardware store next, but might have to switch to a lexan nalgene.

Just pulled the pump off the old tank, and drilled a hole in the nalgene to feed the pump into. Extended the wires from the harness to power the pump. Deleted the rear wiper fluid thing for now, might put a tank in the back of the car later on, but I also dont care about rear wiper stuff either.



I will get a photo of the tank in the engine bay once I get the leak to stop.

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Old 01-20-2015, 04:20 PM   #20
S65E93
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Haha wow this is pretty awesome. Keep up the good work, OP.
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Old 01-22-2015, 11:58 PM   #21
gmacmt
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SIDETRACKED


So I bought that another car. Dude put an ad up on craigslist and took it down in 3 hours because he got too many calls. I offered him $100 over asking, and was moved to first in line, so paid $1300 for a 1998 OBS w/ auto trans, 140K on the clock, and working everything.


I think I could flip this for 3000 with the new wheels and tires. Bozeman people love subaru's and this one just needs some cleaning. EVERYTHING works, looks like it was garage kept. But it has super light hail damage (like, not even noticeable) which made the car have a salvage title. But its a 17 year old car and the salvage title is due to hail damage, so it really doesnt affect resale value.

Here it was before...



Here it is after



Recognize those wheels?


I think I am going to hold onto the car. My fiance can drive it once we clean it up, and we can sell her 2002 GMC yukon with 185k on the clock (with original trans, and not-rebuilt engine) that is just a money pit.


Plans for this car are going to be return to better than stock.


-16" alloy wheels (done).
-Leather seats -$400
-Dye interior carpet black. $30
-Clean and paint all interior plastic $30
-Buy new door cards and paint plastic/dye fabric (already sourced) $40
-Install new stereo deck with aux input $75
-Remove all black exterior plastic trim and paint $20
-Find a rocket box or ski rack for the roof $300
-Front and rear discs (for safety) $~400?




Headed to courd'alene tomorrow to pick up door cards and leather fronts and rear out of a 2.5rs that should be a simply swap. Except for the rear. Anticipating losing functionality of folding rear seats in exchange for the leather swap. I think it's worth it, can put a roof rack on top to compensate. Should make the car a lot more comfortable.


Painting and dyeing probably wont happen until it warms up (consistently) over here, although I might get ambitious one of these weekends.


I think these mods will not only make the car more comfortable . With all my planned modifications, I expect this to cost $2500 (including purchase price) over the next year, but it should be a good investment over the life of the car. Need to do further inspection of maintenance records and see if I need to do timing belt/pumps/pulleys/intake/plugs etc.


Plus I am taking a 19 credit course load of all electrical engineering credits, working (super flexible freelance machining/metal work), planning a wedding (in may) and trying to finish my car.


We'll see how this goes.
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Old 01-23-2015, 06:13 PM   #22
poodlchu
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love the car. Keep us updated!
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Old 01-23-2015, 11:17 PM   #23
casper_actual
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Love the outback sport, it's my favorite late 90's subaru. Are those Saab wheels you threw on it?
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Old 05-11-2015, 01:47 PM   #24
lambchop
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Any headway on your project? i'm trying to do something similar
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Old 05-25-2015, 11:16 PM   #25
jsfauxtaug
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Subbed. Really want to see how this turns out. Really loving how it's looking so far.
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