So if you don't know yet my 97' BD GT got totaled

I replaced it with this sweet scooby.

1996 Subaru Outback BG7 EJ22 @ 350,000km running like a champ w/ cracked windshield and seized brakes. First owner happened to be a police department up north. They maintained everything on this car its so mint. Second owner a very friendly dyke who used the car for 3 years. All in all a very well kept high mileage subaru!





Price = $460 CAN

Needed:
-Windshield = $150
-Both left calipers (all brake stuff $420 :-D)
-Rotors and pads
-Ebrake shoes w/ springs and adjusters.
-Rust repair = Free
---------------------------------------------------
Total cost = $1030 CAN


The old ---> http://sl-i.net/FORUM/viewtopic.php?f=6&t=10911
The new :-D


getting ready


Windshield removed and rust repair begun


The uglyness, most rust removed just need to patch the holes and prep for paint.


Most common spot for a scooby to rust out. Not so bad though just surface rust thankfully.


UPDATE: finished..


bondo sanded


bondo sanded cont'd


Notice anything missing :-D


turns out the rust on the quarter panel was much worse then I expected. After some old school brazing the quarter was mint.


diff angle


fiberglassed over the welds and bondo over the fiberglass


primed the roof


primed the roof cont'd


primed the quarter / duragaurd the inside of the wheel well / under the bumper / inside the quarter from the trunk


roof rack removed. time to sand


headliner removed (oem roof rails consist of 10x 12mm or 10mm bolts that on the inside of the roof skin.


shoots some green

quarter end result without clear coat (not sure if i am going to clear it or paint the car flat black)


roof sanded (yeah yeah... i didn't take off the rubber strips.. who gives a shit its a beater.)


sanded..


3-tone :-D Flat Black/Green/Outback Grey vinyl


2nd coat done.


Repairs finished waiting for windshield and an emissions test.














Completed List:
-JDM GT center console w/ raised arm rest
-B&M short shifter w/ stay bushings
-Sti titanium shift knob
-Optima red top battery
-JDM Nardi wheel w/o airbag
--No click spring
--modified steering column cover
-Cruise control delete
-Antenna delete
-A/C delete
-04' WRX 6-disc (double-din)
-Tint [fronts = 30 / rears = 10)
-03' WRX 16" twin 5-spokes w/ Winters (Continental Tires)
-JDM taillights (corners)
-DIY center tail light lense blacked out

Waiting list:
---------------------------------------------
-Hella supertones
-Debadged
---
Maintenance items:
-Water pump
-Timing belt
-Seals
-Plugs
-Wires
-oil pump (to be determined)
-and anything that snaps, pops, cracks, lets go along the way.

-Chuck

Nice!

looks like you have some work ahead of you. keep that motor goin ej22 ftw!!

I was under the impression Outbacks had the EJ25 not the EJ22, I know mine does. Good luck with the car either way, Outbacks are fun.

^^not in 96

Nice job on the rust repair man! The rust around the window.. how hard was that to fix up? Definitely wanna see more pics as this progresses!

Btw.. how the other one get totaled? Why you decide on a wagon this time around?

The Rust:
Basic windshield removal ->> Remove silicon sealer -> Grinding bit with die-grinder and remove all rust -> 180 grit sand paper to prep the areas. -> A few mig welds to fill in the rusted gaps -> some mixed fiberglass to fill in the pits and grooves from sanding -> 240 grit sand -> thin layer of body filler -> sand 240 -> primer -> sand with 320 grit -> then 400 grit -> then base/clear

Its around 5 hours of work once the windshield is removed and the sealer is gone. Not for the faint of heart.

The story: Read first post --> http://sl-i.net/FORUM/viewtopic.php?f=6&t=10911

The Wagon: I'm an IT Professional blah blah blah I work with workstations, desktops, racking equipment, ups's and printers. My BD slowly became... whats the word.. "not street legal" and it made it very hard to transport gear around. Since I joined this forum 2 years ago I have said from the beginning that my BD was going to be a track car and I would purchase a BG/BK for work. When the accident happened I put up a poll on SLi and everyone voted for the BG outback. So thats how it happened.

Will post more pictures tonight. I am going back to the shop after work to finish the sanding and prepping for paint. Unfortunately the rear quarter panel was worse then I expected. Total of 4 nickle sized holes. Anyways till then,.
-Chuck

They did come EJ25D in 96' it just depends on the production date of the chassis.

Example mine was 06/95. If my car were 11/95 it would of had the EJ25D if i am not mistaken.

-Chuck

Repairs finished (first post)

Now I have to deal with a wonky steering wheel. It doesn't feel smooth, almost clunky when you turn the wheel. Steering rack? Power steering pump? Bad bushings?

Any ideas before I call my mechanics and bother them once again..
-Chuck

Nice work man! Where abouts in ontario are you? Maybe you can do the work on my BG! :D:D

chuckthefuk
SLi Resident

Posts: 640
Joined: Sun Jun 08, 2008 9:31 pm
Location: Toronto, ON, Canada

I am part time auto body. I am full time IT Professional.. Spare time is rare for me so don't count on anything. My father however is full time auto body but he will not work on RUST. He helped me out since I am blood.

But hey if you get nailed (which I hope this does not happen) feel free to come down to Concord/Woodbridge.

If your around the 401/400 area pm and lets talk scooby.
-Chuck

Chuck, in the US at least, ALL MY96 Outbacks with a 5spd were 2.2s. ALL MY96 with the auto were 2.5s. Similar to when our Imprezas first got the 2.2 in 1995. Autos=2.2, 5spds=1.8 . Also why all of our 1996 Legacy GT's were autos. No 5spd 2.5s in 1996, again, in the US at least.

-Matt