Grafton's 97' Sold

[Grafton]

Just like I heard that the copper spray is not needed on these gaskets.
that's what cometic says too, but the coating they put on there is thin and doesn't like surfaces that arn't perfect (ie used and re-machined) I dunno about the indian spray but I'll stand by the permatex spray (at least when using cometic gaskets).

[Reason]

Once it goes on the gaskets, will it come off on the heads if I take the heads off again?

[Grafton]

Once it goes on the gaskets, will it come off on the heads if I take the heads off again?

From what I could tell it doesn't create any more of a mess than the normal sealant does, where you normally have to re-clean the head and block

[Baddog]

So you're getting mid 6's to 60? That sure is a nice bump up from the 2.2's 0-60.

[nikolaus.conrad]

Superb Legacy L! I miss mine =( Lousy New York salt...

[Grafton]

Superb Legacy L! I miss mine =( Lousy New York salt...

the WV salt is talking it's toll on my car too...
both upper corners on the windshield, the rear fenders and the front fenders...

[nikolaus.conrad]

Superb Legacy L! I miss mine =( Lousy New York salt...

the WV salt is talking it's toll on my car too...
both upper corners on the windshield, the rear fenders and the front fenders...

EEK :shock: All Legacy's in Upstate have holes in the rear fenders where the bumper meets the metal, it's very frustrating. Don't forget to check the trunk lid periodically, the bottom lip of mine is missing.

[Huffer]

Grafton - I have a set of white 98 GT mirrors if you're interested? I will clean them up and take pics.

[Grafton]

Going to get Dyno'd on Friday yay!

[Reason]

Going to get Dyno'd on Friday yay!


YES!!! LOL Finally I'm starting my build next month when I have free time again.

[Grafton]

Finally got the new engine tested out, thanks to the folks @ J&S Dyno outside of Pittsburgh.

one note, the Dyno reads really low, they built up an EVO for a show running some crazy boost ~32+psi their mustang dyno showed it was pushing about 475hp to the wheels, but when they took it to Wyotech and put it on their dyno jet it pushed ~600hp at least this is what I was told.

Here's my dyno graph:
http://img202.imageshack.us/img202/1113/hicompressionhybrid.jpg (http://img202.imageshack.us/i/hicompressionhybrid.jpg/)

so I'm making 98 hp and 107ft-lbs at the wheels (5.2k rpm & 2.5k rpm) also my AFR is nice and stable so the 2.2L ecu is running things just fine

Moore performance did some baseline runs on a 2007 2.5i Impreza, which stock pushes 175hp and 169ft-lbs at the crank (6k rpm & 4.4k rpm respectively) here is the baseline run they did:

http://img13.imageshack.us/img13/1892/07stock25i.jpg (http://img13.imageshack.us/i/07stock25i.jpg/)

on the J&S dyno it reads 93hp and 98 ft-lbs at the wheels

so by doing the math very roughly it means I'm pushing ~183 hp and 183 ft-lbs at the crank

[Soul Shinobi]

Amazing torque curve, what the hell Subaru.

[Reason]

What kind of dyno is this?? I had 95whp with a cai, axle back and a few little things.

[Grafton]

What kind of dyno is this?? I had 95whp with a cai, axle back and a few little things.
imho a poorly calibrated mustang dyno, I didn't see him hook into the obd2 port for rpm monitoring so...

they told me it read low, but if i owned a dyno and my project car produced a ~125 hp difference* from my dyno to another I'd get that fixed :/


*( evo story they told me , I don't doubt it )

[Reason]

You should bring it to another dyno, and when I get mine done we can compare notes.

[Grafton]

in other news i'm getting a new 18-22mm whiteline rear sway bar for $185 shipped to my door, and I'm selling my old 18mm SUS bar to a local legacy guy for $100 installed so I'm only going to be out $85 for a awesome new rear sway that will re-balance the handing of my car

[Soul Shinobi]

Awesome--what are you running for endlinks?

[Grafton]

stock end-links, till one snaps anyways, but my front links haven't broke with the 23mm bar and I put them through an autocross stress test.

[Huffer]

They won't break because they can flex. People break endlinks and mounts because they don't allow for any flexion. They're cars, not trains. :)

[Wiscon_Mark]

stock end-links, till one snaps anyways, but my front links haven't broke with the 23mm bar and I put them through an autocross stress test.

You're getting almost no benefit from the bar then - if all it does is flex. And as Huffer said, it probably won't break since it's flexible.

[nikolaus.conrad]

I've been rattling this in my brain now for a few days, so I wanted to ask, with a 12:1 Compression ratio, shouldn't you be running a higher Octane? Like 91 or 93? Cost aside, I'm sure your engine wouldn't be making so much carbon build up, plus it would keep you engine from detonation/engine knocking. I'm just curious why you are running regular 87 gas?

[Grafton]

I'm not running 87, I'm running 89. I was running 93 but after my head gaskets popped the was a large amount of carbon build up I figured that this was a result of running too much octane and slowly experimented with lower octane gas.

[nikolaus.conrad]

I see, you are still using the 2.2 ECU? do you think a 2.5 computer would help any?

[Grafton]

Still on the 2.2 ecu, I don't think there is much to gain from a 2.5 ecu, the timing and fuel seem to be spot on as it is now

[Baddog]

Few questions. Are all NGK Plug wires 8mm? The ones I am looking at for my car on Napa's site say they are 7mm.

How much was it to get the heads ported and polished?

Is there a point to have the intake manifold ported and polished?

[Grafton]

That was an error on my part on my mod list, they are 7mm wires.

for me it was ~$60 and my spare time, I bought a die grinder, a port and polish kit, and built a speed control for the die grinder and then just went to town.

I didn't mess with my intake manifold, didn't seem like there was enough to gain from what little could be done and I didn't have to time to mess with it.

[LGT Kirby]

Bump this and give me updates.

[Grafton]

done,
Running fine, albeit due for an oil change, and slowly rusting. and I've had a slight tint mishap that needs to be fixed ( yay lifetime warranty )

If I ever get the rusty front fenders fixed to my satisfaction I'll install my front "rally" flaps. Waiting on Moore performance to get there exhaust sorted out so I can buy it, and sourcing funds for a 140 amp alternator from Ohio Generators.

[Soul Shinobi]

What would the part number and cost be on that alternator?

[Grafton]

~$300, not sure on a part number, it's a custom order based off a forester alternator, because apparently the Hitachi based alternators (OEM on our legacy's) have a crappy design from the get go, at least according to the guy I spoke with on the phone

[Grafton]

Finally getting around to fixing some body rust the correct way, along with my other mechanical issues.

The both front fenders are being replaced, they are rotted out around where the mudflaps are, the rest non-rust parts are going to be used as source material for rust repair on the rest of the car body. Both front calipers and brackets are getting replaced and new pads. I'm also replacing an axle, inner control arm bushings, front endlinks (bushing is gone on the stock ones), and a steering rack boot, the new one (not oem) ripped at some point recently.

And the whole exterior is getting a new coat of paint YAY!

Broken Front Sway-bar mount:
https://sl-i.net/FORUM/

Cross-member from junk yard off of '99 legacy
http://img526.imageshack.us/img526/1277/imag0166d.th.jpg (http://imageshack.us/photo/my-images/526/imag0166d.jpg/)
http://img819.imageshack.us/img819/8323/imag0165r.th.jpg (http://imageshack.us/photo/my-images/819/imag0165r.jpg/)

As my car sits now:
http://img31.imageshack.us/img31/6909/imag0167oo.th.jpg (http://imageshack.us/photo/my-images/31/imag0167oo.jpg/)
http://img221.imageshack.us/img221/3816/imag0168awmt.th.jpg (http://imageshack.us/photo/my-images/221/imag0168awmt.jpg/)

rust spot on actual car body
http://img263.imageshack.us/img263/2940/imag0173e.th.jpg (http://imageshack.us/photo/my-images/263/imag0173e.jpg/)

No control arms here:
http://img818.imageshack.us/img818/9194/imag0172nw.th.jpg (http://imageshack.us/photo/my-images/818/imag0172nw.jpg/)
http://img194.imageshack.us/img194/1426/imag0171np.th.jpg (http://imageshack.us/photo/my-images/194/imag0171np.jpg/)

Control Arms:
http://img703.imageshack.us/img703/2746/imag0174n.th.jpg (http://imageshack.us/photo/my-images/703/imag0174n.jpg/)

[Perdue]

Awesome! What color are you going for? I think I'm going to do the same think while my car is down.

[Grafton]

Sticking with white, the nice part is that everything will be the same color and all have clear coat

[Soul Shinobi]

I'm surprised those long front swaybar mounts don't break more. Wait, weren't you running a Tribeca FSB? Because that'd totally do it. If you or someone you know can weld, reinforce those, and seam weld the front crossmember while you're at it, that's a low weight chassis rigidity mod that's often done on race cars, MSI did it to their latest Impreza race car (link! (http://forums.nasioc.com/forums/showthread.php?t=1990556&page=9)). For godsake don't think twice about putting in some Whiteline steering rack bushings while the crossmember is out, so much easier and well worth the $30.

[Grafton]

The 99 cross-member is a lot beefier than the one on my car, but I'll look into it. I already have the steering rack bushings, and I'll have the inner control arm bushings from whiteline when I'm done :)

I am looking at building a fender brace while the car is apart from this guide: viewtopic.php?f=39&t=23242 (http://www.sl-i.net/FORUM/viewtopic.php?f=39&t=23242)

[Grafton]

Decided not to weld the cross member, I didn't want to deal with heat treating it to relieve the weakened areas from the new welds.

I've figured out how to do the fender brace without welding on the car, instead of welding a stud to the inner fender, I'm going to use these :
https://sl-i.net/FORUM/images/imported/2012/04/71961958large-1.jpg (http://imageshack.us/photo/my-images/215/71961958large.jpg/)
and drill a hole to insert it into the inner fender

I most of my parts in the mail and began some real work on the car.

The new cross member got a coat of rust inhibitor.
http://img715.imageshack.us/img715/7926/imag0178t.jpg

and I started the paint job on my new calipers
http://img687.imageshack.us/img687/6135/imag0179oz.jpg

Tomorrow I'm pulling the windshield, painting the cross member with engine enamel, finishing the calipers, and installing the new axle

the official new parts list:
Fenders
Cross member
front end links (kartboy)
brake calipers/pads/brackets
passenger side half shaft
04 impreza swaybar mounts
Whiteline bushings
OEM steering rack boot
new valve cover gaskets
and a new paint job

[r3v_v3ng3]

I've figured out how to do the fender brace without welding on the car, instead of welding a stud to the inner fender, I'm going to use these :
https://sl-i.net/FORUM/images/imported/2012/04/71961958large-1.jpg (http://imageshack.us/photo/my-images/215/71961958large.jpg/)
and drill a hole to insert it into the inner fender



Make a fender brace and you will notice the difference :smt023

Where would you mount that bolt? Its sorta flimsy on those other holes from the pics. If you have a welder I suggest to do the way I did it because that part is where the two metal connects (spot welded 90 degree) and much more stronger than using the existing holes on the fender frame.

[Grafton]

it'll use the same hole as the one you welded a stud into, I'll post pics/DIY after I get it finished

Edit: Progress made today
cross member painted
control arms cleared of rust and painted
power steering pump and lines painted

rust on the corners of the windshield
http://img690.imageshack.us/img690/3107/imag0181c.jpg

http://img214.imageshack.us/img214/2643/imag0182i.jpg

Rust under the antenna
http://img823.imageshack.us/img823/3213/imag0183mj.jpg

after wire-brushing and sand blasting my control arms
http://img7.imageshack.us/img7/2656/imag0186x.jpg

and a coat of paint
http://img444.imageshack.us/img444/2183/imag0184lf.jpg

[r3v_v3ng3]

I see. When you make the brace, make sure you compensate for the sidemarker (if you have one)

[Grafton]

Painted Power Steering pump
http://img818.imageshack.us/img818/9273/imag0195m.jpg

Drivers side reassembled
http://img513.imageshack.us/img513/4676/imag0192m.jpg

almost back together
http://img821.imageshack.us/img821/7449/imag0193o.jpg

04 Impreza Rear sway-bar mounts
http://img805.imageshack.us/img805/4986/imag0191av.jpg

After I get everything torqued on the front end the only thing left to do will be bodywork. The windshield is out and I hope I never have to do that again ever. Plus I pulled the rear bumper off, these cars look goofy without the rear bumper.

[Reason]

It's coming along nicely, are you coming up for the meet this year? July 28th saturday

[Grafton]

I don't think I'll be able to swing that and WBM with the wife :D

[Grafton]

pics from some recent work:

power steering reinstalled
http://img96.imageshack.us/img96/1469/imag0202l.jpg

this is what you have to tear out to get to the antenna cable...
http://img853.imageshack.us/img853/1069/imag0200s.jpg

the surgery begins
http://img811.imageshack.us/img811/5665/imag0197bb.jpg

[Soul Shinobi]

God damn rear quarter panel rust... Give us some good pics of how that repair goes, it might be motivating. :smile:

[Grafton]

interestingly enough my old man and I have a hypothesis as the the cause of the rust...

flawed design, the two sheets of metal that meet right there aren't as bonded as you would think most of the work of sealing that corner isn't being done by a spot weld, but by seam sealent. so factor in the wheel guard that traps water and a spot where there isn't a weld and it leads to rust

[chrish8r]

Damn them, damn them and the quarter panel rust!!!!!! I had torn off those rubber fender guards and there was a disturbing amount of gravel/dirt/debris contained in there

[Grafton]

Never seen a rotor have its surface flake off. One of my rear rotors had a huge section of the surface flake off and it had a large ring of rust. and the pads look like they havn't worn at all, and they've been on the car for ages.
http://img135.imageshack.us/img135/2642/imag0217o.jpg

After a ton of fighting the rear suspension is disconnected and I'll drop the diff and cross member and finally the fuel tank, draining it via jumping the fuel pump relay. The stock fuel pump has a surprising flow when filling a 5 gallon jug.

http://img857.imageshack.us/img857/6896/imag0219bw.jpg

[Soul Shinobi]

My rear rotors looked like that, and the pads disintegrated to match. I wasn't too surprised having paid $300 for the car on Craig's List though :razz:

[Grafton]

At this point I'm going to call this a restoration way too much work to be a repair job anymore. More parts ordered and more parts are off the car. The gas tank is out along with the diff outrigger and the rear cross member. I believe I've ordered everything under the sun for this car now. as she sits now:
un-holy gas tank:
http://img210.imageshack.us/img210/5685/imag0226l.jpg

the front bumper on the trunk opening:
http://img339.imageshack.us/img339/6107/imag0227d.jpg

random parts stacked along the side of the car:
http://img163.imageshack.us/img163/9893/imag0225q.jpg

pile of sub frame/cross member parts that need sandblasted
http://img820.imageshack.us/img820/3324/imag0221i.jpg

bushings that are getting the window weld treatment:
http://img821.imageshack.us/img821/2618/imag0223ys.jpg
http://img6.imageshack.us/img6/6446/imag0222mj.jpg

lateral links blasted and painted 3/4
http://img254.imageshack.us/img254/6828/imag0224yp.jpg

rear sway-bar mounts ready to install
http://img33.imageshack.us/img33/7826/imag0228y.jpg

[Reason]

Nice! If I did this it would be cheaper to buy a new car lol

[nikolaus.conrad]

Wow! Did you get a new gas tank? How difficult of a job was it to remove it?

[Grafton]

Wow! Did you get a new gas tank? How difficult of a job was it to remove it?
No new tank, it just has surface rust, and the only reason it's out is because I need to weld on the car close to the filler neck.

IT SUCKED, the short list for dropping the gas tank:
rear suspension
rear drive-train
rear sub-frame
diff outrigger
THEN the gas tank


Nice! If I did this it would be cheaper to buy a new car lol

now that I have torn into the rear I'm going to be just shy of the value of the car :/


and I forgot to add the pic of the new rear calipers.
http://img339.imageshack.us/img339/6761/imag0220x.jpg (http://imageshack.us/photo/my-images/339/imag0220x.jpg/)

[chrish8r]

I really like red calipers. My SVX came with them and they give a nice boost to the overall look. I also had my gas tank replaced not too long ago(but i took it to a shop) because i am nowhere near that mechanically inclined.

[Grafton]

looks like I'll be replacing mine anyways, the rust isn't just on the surface, it's made it all the way through where the fill tube is so I'll be grabbing one from a junk yard

[4n70n1n0]

glad to see urs sticking to your BD and haven't given up on it

i got a new one myself but she just sits in the storage unit. hanging out with the tools and spiders

[Grafton]

glad to see urs sticking to your BD and haven't given up on it

i got a new one myself but she just sits in the storage unit. hanging out with the tools and spiders

Even dropping all this money into the car is cheaper in the long run than getting rid of the car and finding another subaru that I know knowing about in terms of maintence...


the non-rusty parts of my front fenders will live on in my rear quater panel, this is almost finished welding in the inner fender before grinding the welds smooth
http://img829.imageshack.us/img829/1417/imag0229on.jpg

Masked off the friction sureface
http://img40.imageshack.us/img40/1797/imag0230o.jpg

painted with 1200° resistant flat black paint
http://img72.imageshack.us/img72/957/imag0231ib.jpg

tape removed
http://img715.imageshack.us/img715/267/imag0234kp.jpg

Subaru windchimes :D
http://img18.imageshack.us/img18/57/imag0232p.jpg

tribecca FSB with new whiteline bushings for the new crossmember
http://img51.imageshack.us/img51/4586/imag0233r.jpg

[96LegacyWagon]

What guage wiring did you use for all of these grounds?

[Grafton]

8 gauge I believe, it was leftovers from an amp wiring kit I had.

[Grafton]

Got some things done during the week. Decided to fix the existing tank, it's been fine for ages. Plus the "restoration" funds are running too low for a new gas tank :/

got the rear cross member sandblasted and primered

http://img193.imageshack.us/img193/5673/imag0236l.jpg

test fitting the outer fender piece, it'll need some body filler to match the fender well curve but otherwise it's a perfect fit.

http://img833.imageshack.us/img833/184/imag0237yn.jpg

[nikolaus.conrad]

Awesome progress!

[Baddog]

which whiteline bushings are those? part number? and do they fit in the stock brackets?

[Grafton]

which whiteline bushings are those? part number? and do they fit in the stock brackets?

W0405-24 and as for the stock brackets Yes and No. I swapped out my front cross member from a 99 with a 2.5L so the sway bar mount was different that the one on my stock cross member. The part number for my older cross member was w0404-24 and this is if your using the tribecca FSB, if you still have the stock FSB the last two digits would be changed to -18


Awesome progress!

Thanks, its going very slowly. I won't have a chance to work on it again till this Thursday.

[Perdue]

Great job, man! I'm probably going to use the unrusted parts of my front fenders to repair my quarterpanel, too. I can't wait to see the car done.

[Huffer]

:thumbsup: for perseverance!

[Grafton]

Finally got more work done on the car. It's moving slowly but surely.

rear drive shaft guard
http://img694.imageshack.us/img694/5852/imag0242i.jpg

Rear axle guards
http://img38.imageshack.us/img38/5434/imag0245f.jpg

fuel filler neck after sand blasting and a coat of rust inhibitor
http://img38.imageshack.us/img38/2062/imag0244mn.jpg

Rear cross member with enamel paint
http://img856.imageshack.us/img856/2396/imag0248w.jpg

outer quarter panel welded in and coated with rust inhibitor, the panel warped slightly but nothing that some body filler wont fix.
http://img11.imageshack.us/img11/1237/imag0246v.jpg

the remains of the front fender after we fixed the rear
http://img837.imageshack.us/img837/6155/imag0249dj.jpg

still left to do:
finish sand blasting and painting rear suspension
window weld bushings
reseal rear diff and paint
minor rust repair to gas tank
surface rust removal from rear of car
finish removing rear dust shields for H6 brakes
reinstall rear end (gas tank, sub frames, drive train, brakes)
bleed brakes
pull front seats and carpet (to protect them from the next step)
fix rust holes around windshield
weld holes in trunk to have a de-badged rear end
valve cover gaskets
painting whole car
get new windshield installed

[Grafton]

The repaired rear fender:
http://img819.imageshack.us/img819/1096/imag0253t.jpg
http://img805.imageshack.us/img805/3337/imag0250l.jpg

[Reason]

Looks better! Keep at it, this is something I need to do soon.

[Grafton]

Looks better! Keep at it, this is something I need to do soon.

good news, as my father and I discovered the front corner from the front fender works to replace the rear corner on the rear quarter:
http://img163.imageshack.us/img163/8008/imag0259i.jpg

http://img37.imageshack.us/img37/633/imag0260p.jpg

painted the bearing retainers
http://img109.imageshack.us/img109/9559/imag0262h.jpg

primed the rear diff
http://img585.imageshack.us/img585/1856/imag0263s.jpg

http://img3.imageshack.us/img3/2504/imag0264ph.jpg

Almost had a LSD for my car today. I'm replacing the rear cover because the PO cross-threaded the drain plug, and I was calling my local junk yards and the second one I called had a rear diff from a turbo legacy. The big problem was when I went to pick it up it was the one year that they had the axle stubs instead of the clip in axles. So no LSD for me unless somewhere local has one I can swap in.

[Grafton]

LSD FOUND!!! looks like I'm getting some goodies here soon, If the deal I have going goes through I'll have a ~32k rear lsd from a WRX and the front seats.

Even if I don't get the seats I need to pull the seats and carpet out so I don't have to worry about stray welding sparks ruining it.

Pulled the driver side seat and only broke lost a nut from the car, no broken bolts yay!
http://img10.imageshack.us/img10/9369/imag0274ua.jpg

Painted the rear diff
http://img20.imageshack.us/img20/6172/imag0276d.jpg
http://img198.imageshack.us/img198/3649/imag0278o.jpg

found this above my headliner:
http://img29.imageshack.us/img29/1792/imag02752.jpg

"Window welded" the out rigger bushings and the diff bushings here's the result:

cleaning the bushings
http://img690.imageshack.us/img690/6197/imag0265o.jpg

http://img208.imageshack.us/img208/8284/imag0273y.th.jpg (http://img208.imageshack.us/i/imag0273y.jpg/)
http://img801.imageshack.us/img801/690/imag0272oi.th.jpg (http://img801.imageshack.us/i/imag0272oi.jpg/)
http://img38.imageshack.us/img38/5003/imag0271p.th.jpg (http://img38.imageshack.us/i/imag0271p.jpg/)
http://img100.imageshack.us/img100/4327/imag0270a.th.jpg (http://img100.imageshack.us/i/imag0270a.jpg/)
http://img855.imageshack.us/img855/7331/imag0269qy.th.jpg (http://img855.imageshack.us/i/imag0269qy.jpg/)
http://img851.imageshack.us/img851/1592/imag0268xf.th.jpg (http://img851.imageshack.us/i/imag0268xf.jpg/)
http://img607.imageshack.us/img607/8284/imag0267fa.th.jpg (http://img607.imageshack.us/i/imag0267fa.jpg/)
http://img717.imageshack.us/img717/5296/imag0266qs.th.jpg (http://img717.imageshack.us/i/imag0266qs.jpg/)

casualty of the war on rust
http://img690.imageshack.us/img690/7034/imag0277u.jpg

I have a fun group of people with access to my dusty car:
http://img534.imageshack.us/img534/7260/imag0279u.jpg

[evolegacy]

man this is coming out nice, I never thought about using the front fenders to fix the rears, my fenders in the back are pretty bad and need to get done asap but the holes would be too big for just bondo and im no good with a welder, any suggestions?

[r3v_v3ng3]

Fiberglass and fill it with bondo/fiberglass resin filler. Use body filler to fill in imperfertion. You will warp the metal if you dont know what you are doing with a welder. Its easier to form with fiberglass.

[Grafton]

Worked on the car all day and got a lot done:

pulled the carpet and headliner
tested the sending units and washed the tank inside and out after I wire brushed the surface rust
sand blasted the tank straps and primed them
de-badged the trunk and finished stripping it, and sand blasted the only rust spot on it
sand blasted the panels that go under the tail lights and primed the blasted areas
wire brushed under the car to hit the surface rust then primed the brushed area's
went to remove the drivers side RSB mount and broke the bolt that also holds the carbon canister then I missed drilled it trying to get it out. So now I'm going to have to cut that part of the frame out and weld in a new section with a new nut


also the window weld is awesome, the rear diff outrigger bushings are quite solid compared to how squishy they were.



Fiberglass and fill it with bondo/fiberglass resin filler. Use body filler to fill in imperfertion. You will warp the metal if you dont know what you are doing with a welder. Its easier to form with fiberglass.

make sure you get rid of any rust or it will bleed through in no time flat, That's how I had done the first rust repair. and even if you know what your doing the rear quarter panel is pretty thin and it warps really easy.

[Grafton]

Finally got a rear LSD and got it installed with my 3.9FD ring gear

here is the difference between the stock open diff and the WRX VLSD diff:

http://img191.imageshack.us/img191/6348/imag0296w.jpg

yay! assembled rear diff:
http://img802.imageshack.us/img802/6006/imag0297m.jpg
http://img822.imageshack.us/img822/1938/imag0298ah.jpg

here is a welded nut I had to drill out for the passenger side RSB mount
http://img831.imageshack.us/img831/327/imag0299t.jpg

this is where there was some slight rust on the inside and outside of the tank and it has been reinforced with a gas tank repair tank
http://img338.imageshack.us/img338/3185/imag0301j.jpg

[Dead91silvia]

HA! You and I are alike, we paint parts are we rebuild... LOL... Looks like shes coming along!

[Grafton]

Finally got back to work on the car after waiting on some parts to roll in (brake lines)

replaced from the compression fittings to the rubber lines in the rear, with a new connector block
http://img811.imageshack.us/img811/2493/imag0306v.jpg

Rear trailing arm and rear brakes installed
http://img267.imageshack.us/img267/2316/imag0308z.jpg

Beefier Rear sway bar mount
http://img823.imageshack.us/img823/8862/imag0309ef.jpg

much bigger rotor than the stock one...
http://img401.imageshack.us/img401/143/imag0310q.jpg

[Grafton]

Hurray more progress, I got the gas tank, rear diff outrigger, rear sub-frame and the rear diff installed tonight

http://img833.imageshack.us/img833/7445/imag0312bj.jpg (http://imageshack.us/photo/my-images/833/imag0312bj.jpg/)

[nikolaus.conrad]

Woohoo!

[chrish8r]

That red looks really nice underneath of there

[Grafton]

^ thanks, it matches the brake calipers. Right now everything under the rear of the car is back together except for the vent lines to the charcoal canister. I just need to bleed the brakes and wheels can go back on in the back, I still need to torque the fronts and bleed the brakes first.

[Grafton]

Finally an action shot of my Dad welding up some rust holes on the car

http://img534.imageshack.us/img534/6061/imag0315k.jpg (http://imageshack.us/photo/my-images/534/imag0315k.jpg/)

right now the wheels are back on and the rear body work finished the rust holes around the windshield are almost fixed, it's getting close to paint time :D

[98legwag]

So what color is going to be?

[Grafton]

So what color is going to be?
it's a repaint, so it'll be arctic white.

SHE MOVED UNDER HER OWN POWER TODAY! WOO!

Finally got the rust repair finished, and moved on to fixing some broke off bolts, I went to tackle the broke off radiator mount bolt and broke off the other one. When I went to drill the broke off bolts the plate they are welded to bent so I had to drill out the spot welds and I'm going to have to plug weld new plates in

http://img38.imageshack.us/img38/1994/imag0322ko.jpg
http://img843.imageshack.us/img843/769/imag0323u.jpg

Finished, welding/grinding the rust holes around the windshield now they just need a coat of bond-o to smooth everything out.

http://img152.imageshack.us/img152/3236/imag0324n.jpg
http://img834.imageshack.us/img834/2069/imag0325xi.jpg

Got the wiring harness mounted back to the car

http://img822.imageshack.us/img822/5334/imag0330h.jpg

The passenger side needs some finishing sanding

http://img846.imageshack.us/img846/1775/imag0326i.jpg

but the drivers side is looking much better

http://img23.imageshack.us/img23/6228/imag0327u.jpg

Yea promoted to the main work bay

http://img580.imageshack.us/img580/3372/imag0328q.jpg

also NEVER weld with the battery hooked up it leads to some seriously crazy electrical issues (relay's clicking on and off with a flashing check engine light, and random injectors firing while the engine isn't turning), luckily they were corrected with an ECU reset

[Grafton]

She was painted last weekend and I'm just now getting around to putting pictures up.

Final prep work
http://img806.imageshack.us/img806/8718/20120721190501.jpg

http://img844.imageshack.us/img844/1037/20120721190509.jpg

http://img842.imageshack.us/img842/7475/20120721190520.jpg

http://img40.imageshack.us/img40/5688/20120721190531.jpg

http://img585.imageshack.us/img585/6294/20120721210424.jpg

http://img716.imageshack.us/img716/3591/20120721210515.jpg

http://img585.imageshack.us/img585/8808/20120721210524.jpg

after painting

http://img140.imageshack.us/img140/9903/20120722004048.jpg

http://img823.imageshack.us/img823/5862/20120722004100.jpg

http://img29.imageshack.us/img29/1420/20120722004106.jpg

http://img51.imageshack.us/img51/8751/20120722004124.jpg

http://imageshack.com/scaled/800x600/220/20120722004131.jpg

https://sl-i.net/FORUM/

@$$ hole Horse fly
https://sl-i.net/FORUM/

Gnat damage
https://sl-i.net/FORUM/

It's a very rough paint job. Definitely a "10ft / 10mph" style it's really rough, has a run or two, and the air hose made contact a twice. But I expect to be able to smooth over most of the issues with the paint work.

It seems during this oddesy the clear side markers lens' were cracked and the retaining clip for the trunk lid lock is MIA.

However I need to figure out what to use to seal the taillights, what to use to replace the rubber around the license plate plastic inserts, and a few other odds and ends

[Huffer]

Props.

[Grafton]

Adjustable Idlers installed

http://img217.imageshack.us/img217/897/20120730193045.jpg

[Grafton]

Here are the pictures that I've got from the tail of the dragon, I'm thinking about getting one as a print any suggestions?

https://sl-i.net/FORUM/ (http://img214.imageshack.us/i/215969.jpg/)

https://sl-i.net/FORUM/ (http://img546.imageshack.us/i/215970.jpg/)

http://img51.imageshack.us/img51/7732/215971.jpg (http://img51.imageshack.us/i/215971.jpg/)

https://sl-i.net/FORUM/ (http://img99.imageshack.us/i/215972.jpg/)

https://sl-i.net/FORUM/ (http://img214.imageshack.us/i/215973.jpg/)

https://sl-i.net/FORUM/ (http://img215.imageshack.us/i/215974o.jpg/)

http://img805.imageshack.us/img805/2641/215975.jpg (http://img805.imageshack.us/i/215975.jpg/)

https://sl-i.net/FORUM/ (http://img338.imageshack.us/i/215976.jpg/)

[Perdue]

That's awesome. How much did they charge you for the pictures? I would love to go down and run the dragon once I get my suspension squared away. Good job on the restoration project too.

[Grafton]

Thanks I feel like it took way too long though, but I'm happy to have the car back and running. Hell I'm hitting my first post rebuild autocross this Sunday. As for the photos It varies from place to place but I paid 5 each for these and they offer prints and the pictures on CD.

[Dead91silvia]

Nice work! I know the feeling with the paint. That happens when I paint also. Try painting a black car.. ugh... Looks good though!

[ElbryanWolf]

Wow so clean! Even if in your mind the paint ain't perfect, in my eyes and on the pictures it is. Great job mister!

[1996Battlewagon]

I'm glad you had fun up there. It can be a bit alarming at first, especially given its reputation for wrecks and police. Bikers can be kind of prickish to cars too. More often than not, cruisers won't pull over for fast moving cars and sport bikes will just cross double yellows.

Anytime you want to go again, PM me. I'm about 45 mins away and even if I took off my shoes, I wouldn't be able to count how many times I've been up there. That place holds a large part of my heart and soul.

[nikolaus.conrad]

I'm unearthing this thread. Any updates Grafton? Do you still had the car? What's the skinny? Talk to me bro.

[Grafton]

well for about 6 months she was a driveway queen, I had a work van that I did all my driving in. I never really went anywhere without the rest of my clan in tow so we were always in the Outback.

However thanks to my manager at that job being a complete ass and being overworked, 2 man crew in an area that was supposed to have 4 I got a IT job at the local hospital and am again daily driving her.

She's still loud and leaky but stupid fun in the corners after the rebuild.

I'm getting ready to fix the loud part, the leaky will have to wait till this is an autocross/track car because I messed up the sealant job between the 2 halves of the motor. The current timeline is that ~10-11 months from now we'll have a good chunk of our debit paid off and we'll have more than enough to pay for a new STi for me.

I am enjoying killing the last of my winter tires, mainly practicing cornering techniques, the occasional flat foot shift, and getting a consistent launch. I figure If i get the mechanics of this stuff down on tires that don't grip I wont get bad habits from having learning on gripy tires that would hide mistakes in technique. Plus 185/65r15's mean I can slide around corners pretty easy :D

[nikolaus.conrad]

Damn man, that sucks! But I'm glad to hear that you got a new job an you're driving her again! Hopefully I'll be getting a set of tires for when I get a new Legacy. Much better to practice on worn out tires than wearing out a brand new set lol

[Huffer]

Grafton's going to be a sugar daddy.

[Grafton]

Grafton's going to be a sugar daddy.
to whom? lol

[Grafton]

Chipped a tooth off of 1st gear, so I'm replacing the transmission, and I'm switching to a UEL header while i've got it apart

[Grafton]

new transmission is in and I can tell the "new" one has some OLD bearings in it, they whine a little.

installed a set of knock off UEL headers, mmmmm rumble

here's one of the teeth from the old transmission:
http://img843.imageshack.us/img843/4074/erjs.jpg (http://imageshack.us/photo/my-images/843/erjs.jpg/)

Also preformed a brain transplant:
new ECU from a 98 Outback, it should run the engine better, but it will always throw a EGR code.

old on the left new on the right
https://sl-i.net/FORUM/ (http://imageshack.us/photo/my-images/46/pu43.jpg/)

[Grafton]

Rebuilt the started with parts from an automatic starter:

http://imagizer.imageshack.us/v2/1024x768q90/5/bsrn.jpg (https://imageshack.com/i/05bsrnj)

have a new look with the hood scoop:
https://sl-i.net/FORUM/ (https://imageshack.com/i/0a5ez0j)

[Hinyo]

Really nice build. Loving the JDM bumper. Dont see one of those everyday. What happened to the snowflakes?

[Grafton]

Really nice build. Loving the JDM bumper. Dont see one of those everyday. What happened to the snowflakes?
gone for the winter, 15" steel wheels and snows are where it's at now.

Now for some new pictures, Battle scars from the bouncing between a WRX and a Ford Excursion
https://sl-i.net/FORUM/ (https://imageshack.com/i/mv64ihj)

http://imagizer.imageshack.us/v2/800x600q90/839/fv39.jpg (https://imageshack.com/i/nbfv39j)

Yay new trunk lid, with spoiler. The old one got a dent and wouldn't shut correctly
https://sl-i.net/FORUM/ (https://imageshack.com/i/mrlb38j)

http://imagizer.imageshack.us/v2/800x600q90/30/yga4.jpg (https://imageshack.com/i/0uyga4j)

https://sl-i.net/FORUM/ (https://imageshack.com/i/nrp6ofj)

got some cool stickers from Subaru:
https://sl-i.net/FORUM/ (https://imageshack.com/i/n9n0m9j)
http://imagizer.imageshack.us/v2/640x480q90/39/un9z.jpg (https://imageshack.com/i/13un9zj)
https://sl-i.net/FORUM/ (https://imageshack.com/i/mv45jfj)

Mock up idea: ,,,,,,,,lk
https://sl-i.net/FORUM/ (https://imageshack.com/i/5sijltj)

[Muse]

Hey, I saw you got new wheels in the What Did You Do thread... can't wait to see 'em on here!

[Grafton]

Sadly I never got the chance to get those wheels on the car. Due to the STi pooping pistons, and the amount of work the lego needed to get roadworthy again, I had to sell her to a local Legacy fanatic. The good news is that the decent parts are going to keep two other Legacy's on the road.

It was a blast, Hopefully Subaru decides to sell a real Legacy wagon by the time my wife's car is due to be replaced.