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Thread: chuckthefuk - 97 BDGT/Track | Sept 13' - Rollcage is DONE !!

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    SLi Supporter chuckthefuk's Avatar
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    chuckthefuk - 97 BDGT/Track | Sept 13' - Rollcage is DONE !!

    I am trying my flickr account so look for the album links after each update.
    -----
    So I finally took delivery of my soon to be track car. Heres the story...

    1997 BD9 Legacy GT Limited
    5MT / Sunroof
    Originally from Quebec, Canada (No SALT)
    Purchased from a local member in Ontario
    Price $2000 CAN


    Flickr Album -> http://www.flickr.com/photos/43663513@N ... 481034969/


    Anyways I'll start my list of items:

    **Complete 04' STi Swap no Merging"

    Engine: 04' STi EJ257 (NO IMMOBILIZER)
    1. - Royal Purple 10w30 oil
      - 04' STi EJ257 long block
      - 04' STi ECU tuned @ 19 PSI w/ Cobb AP
      - Turbo - none
      - Turbo Manifold - none
      - Up-pipe - none
      - 04' STi 3" down pipe w/o cat (hangers modified for BD chassis)
      - 3" straight through v-band axle back
      - A/C Delete
      - Cruise Delete


    [list=2:3e949qrv]Maintenance items:
    - Blown head gasket, needs a rebuild.
    - Wastegate was cracked on the turbo
    - stock manifold/up-pipe to be upgraded[/list:3e949qrv]

    --------------------------------------------------------------------

    Fuel System:
    [list=17:3e949qrv]
    - BD gas tank removed
    - BD rubber/metal fuel lines removed
    - BD rubber/metal brake lines removed
    - BD gas tank filler neck remobed
    - BD gas door removed/welded
    - SS brake lines (body -> caliper)
    - SS brake lines (body -> ABS unit) [unsure about ABS delete][/list:3e949qrv]

    --------------------------------------------------------------------
    Drivetrain: 6MT 3.90FD
    - 04' STi 6MT
    - 04' STi f/r axles
    - 04' STi R180
    - 04' STi DCCD
    - 04' STi stock bushings at the moment.
    - 04' STi f/r yokes + legacy driveshaft (custom welded, balanced) Chassis has be modified to clear flange
    - Group N 6MT Transmission mount (going to order eventually)
    --------------------------------------------------- -----------------
    Chassis/Suspension: BD9
    - Group N engine mounts (in a box with the Noltec stuff)
    - 04' STi lateral links
    - GC/GD Noltec adjustable lateral links
    - 04' STi f/r Subframes
    - 04' STi front aluminium control arms w/o ALK
    - 04' STi quick ratio steering rack
    - 04' STi + 97' BD intermediate shaft (custom linkage)
    - 97' BD steering column w/ 04' STi control stalk custom welded
    - Noltec f/r adjustable camber plates (track version) [Adjustable in any direction providing proper camber)
    - Noltec f/r camber bolts
    - Noltec front endlinks (dogbone)
    - Group A subframe locking bolts
    -
    - Whiteline 25mm swaybar locking collars
    --------------------------

    Interior:
    1. - 1x Zero/Sport Carbon Kevlar fixed seat w/ aluminum rails/sliders. (not certified) [driver]
      - 04' STi Cluster CDM in KM->MPH
      - 04' STi complete body harness w/ legacy accessory connectors (soldered & shrink wrap)
      - 97' BD Legacy ignition cylinder
      - 04' STi airbag ECU removed
      - 97' BD climate control delete (going with aftermarket heater box)
      - GC' Cusco 12-point Bolt-On Roll Cage
      - 04' STi pedal assembly w/ sti pedals
      - 04' STi shift knob
      - BD column cover modified for aftermarket wheel hub.
      - 04' STi ebrake w/ chrome button
      - 04' STi DCCD + C.DIFF buttons mounted to ebrake cover plate [/list:3e949qrv]
      --------------------------------------------------------------------
      Exterior:
      - GD RS/WRX front fender flares
      - Rolled + flared quarter panels
      - GD ARP W-I-D-E--B-O-D-Y rear quarters (replica fiberglass)
      - Carbon FX GT style hood
      - BD L' Trunk w/o spoiler
      - 04' STi bumper w/ fogs + spats (merged to BD GT bumper Half&Half)
      - JDM BD tail lights
      - 97' GT trunk lens
      - JDM Projectors w/ right lens removed for air duct

    --------------------------------------------------------------------
    Wheels:
    - ?????????????? 17+ x 8+ @ 45+ offset
    - Tires?
    --------------------------------------------------------------------
    Brakes:
    - 04' STi Front Brembo 4-pot w/ EBC Green Stuff
    - 04' STi Rear Brembo 2-pot w/ EBC Green Stuff
    - 04' STi f/r hubs / spindle
    - SS brake lines f/r
    --------------------------------------------------------------------
    Audio:
    - Boxer rumble

    --------------------------------------------------------------------
    Carbon FX Hood


    Flickr Album -> http://www.flickr.com/photos/43663513@N ... 622002056/

    Zero/Sport C/F Kevlar Fixed Seat



    Goal is to fit into a 36/38 before I can track.. Current 40/42

    [GUT N' STRIP]
    --> Quick blurb.. removed most of the interior.. found an ebay short shifter and a 10 disc cd changer. as well as 2 mis-matched speakers..The previous owner was to cheap to buy an aftermarket wiring harness and decided to hard wire it directly.. Fucking nightmare!!




    Flickr Album -> http://www.flickr.com/photos/43663513@N ... 619314100/

    [GD 04-05 Fender flares]
    --> Quick blurb.. test fit with self tappers... still need to trim, rivet, weld, fiberglass, bondo, prime


    Flickr Album -> http://www.flickr.com/photos/43663513@N ... 743847414/
    -Need to hammer in the arch lip.
    -Need to trim a bit more
    -Need to bring out the bumper mounting point by 1" so it can flow with the flare.


    ----------------Mar/13th/2010------------------------------------------------------
    Picked up a set of fiberglass 02-07 GD Impreza ARP (replica) rear quarter panels. Bought these from a local member for $250 and found out that they were made by Vince from VKinnovation.

    Here are a few pics of the fenders + the body shop process (for an Impreza not Legacy!) + Finished look



    Above are the fiberglass replicas. My Flickr link below had the photos of the the under layers. There basically a 1" x 2mm outline of all the panels that get "glued" down to the quarter panel and then the fiberglass panel can get screwed into place which gives a "flush" look. But since this is a legacy and nothing from a GD actually fits I am going to toss them and go with a full fiberglass molded quarter panel.

    Flickr Album -> http://www.flickr.com/photos/43663513@N ... 612496460/

    This widebody kit is out of this world but IMHO its just to wide and boxy for my taste.

    So.... The plans...
    0) Fiberglass both sections together and cut the new door line.
    1) The combined length of both door skin and quarter panel is almost 5 foot. So I plan on shorting it by 1-2 feet at the same time .
    2) This should shorten the depth of the arch by 1-2" The original ARP arches are almost 4" and that's a tad big for me.
    3) I might delete the gas door and go with a fill-in-trunk fuel cell OR use the gas door and go with a standard filler-neck fuel cell.
    4) Not sure if I am going screw/rivet/sheet metal brace the underside.. there are so many options..

    Expect photos of the the "mock-up" stage by April-May..


    I couldn't help myself... Rough mock up. Fits pretty good. Thanks 3M :-D

    87/ [/b]
    ----------------May/3rd/2010------------------------------------------------------
    Cusco Safety 21 Around-dash 8-point Roll Cage *GC8*

    So... I scored a GC8 Cusco 8-point roll cage thats missing one chromoly bar for the low price of $200 CAN. I don't know what I am going to do with this...

    Options:
    a) Get the chromoly bar, test fit and bolt together
    b) Get the chromoly bar, test fit and weld it together
    c) Use the cusco design and weld a custom cage then sell the cusco to my buddy with that white gc8.

    http://farm5.static.flickr.com/4066/457 ... fed9_b.jpg
    http://farm5.static.flickr.com/4028/457 ... e84a_b.jpg
    http://farm5.static.flickr.com/4053/457 ... 9dd0_o.jpg

    Flickr Album -> http://www.flickr.com/photos/43663513@N ... 853762127/

    ----------------June/6th/2010------------------------------------------------------
    Rolling Adjustable Body Dolly

    ... So space in my garage is a little tight so I decided to go "ALL-OUT" and build a Rolling Adjustable Body Dolly.

    NOTE: I am going to remove EVERYTHING from the car. Wire wheel, sand blast, paint strip the entire car! This will take many days if not months. So expect slow updates.

    The Parts.


    8x2" Swivel Steel caster with Rubber liner (helps to reduce noise and resistance)


    8x2" Swivel Steel caster with Rubber liner with Foot Brake (helps to prevent the body dolly from rolling around when working)


    3-ton Jack stands (I could of used 2 but these were on sale)

    The Mockup



    The Example

    Example of the car on the dolly (not exactly to scale. Since I'm 6'3" and much taller then the final height measurements of the dolly.

    The Cost
    Everything has been purchased from http://www.princessauto.ca (local supplier for Canada)
    2x 8x2" Swivel Casters @ $43 CAD
    2x 8x2" Swivel Casters w/ brake @ 45 CAD
    2x 3-ton Jack Kit @ $35
    Raw metal @ $100
    4x Ratchet Straps @ $36
    -------------------------------------------
    $382 + 13% Tax
    Total $431.

    The Process
    1) Raise car body from rear and front subframes to appropriate height with pump jack and stands.
    2) Roll body dolly under car body
    3) Adjust cross bars to proper length/width and tighten locking bolts
    4) Adjust Jack height and affix locking pin
    5) Lower car body on to Jacks
    6) Remove subframe pump jack and stands and roll the dolly around in the direction needed.

    Not bad for a custom made dolly.











    and to celebrate the sturdy acomplishment we decided to pull the rear end.



    All pics uploaded to flickr.. check below
    [b]Flickr Album -> http://www.flickr.com/photos/43663513@N ... 6236054317


    ----------------Oct/11th/2010------------------------------------------------------
    Quick summary..
    - Bought a complete Turn-Key Legacy wired 04' STi swap from member DIP @ $7500
    - Zak bought the chassis from DIP @ $450
    - Remove STi component and replaced with stock Legacy component from my track shell.
    - Labelled all connectors from harness to component
    - Complete 04' STi swap put into storage until chassis is ready next year.
    [b]Flickr Album -> http://www.flickr.com/photos/43663513@N ... 5020884603

    ---------------May/9th/2011--------------------------------------------------------
    So it been some time and I have been busy with life and helping other subaru friends with their projects.

    I finally got around and pulled the entire STi harness!! YAY!



    more pics in the flickr album from my last post.

    Also UPDATE!!

    The cusco bolt-in rollcage is gone.. SOLD .. c'ya!!

    Time for a proper weld-in cage from Ronie O'brian Motorsports.

    ------------------------ April/2nd/2012-----------------------------------------
    So things are starting to roll..

    Dropped $2000 on a deposit for my rollcage.

    specs:
    - Builder = Ronnie O'Brien Motorsports / Brampton, Toronto
    --- He makes cages for CamJam Canada and most ORC/CRC rally cars.
    - TiG Welded
    - un-painted
    - cage will be tied into rear subframe
    - cage will pass through the firewall and tie into the shock towers.
    - 10-point = $3300
    - chromoly = $500
    - gussets on pillars = $150
    - air jack tubes = $200
    - undertray/pan mounts = $200-400
    - jack points = $200

    Ronnie let me take some photos of his current setups.. he didn't let me take pics of certain things like his shop / door bar design / and other custom trade secrets. Here is a E46 M3 he was about to finish and paint. Sorry for the sloppy shots.. it was iffy with my smartphone acting up and constantly talking to Ronnie.

    --------------> Pics below :-D no img tags since they are huge and so many :-D <--------------------------------------

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    aftermath of the final strip and moved the 6MT/EJ257 back home for now.


    Rolling her out.
    Removed
    -windows/sound deading/dash/heatercore/blower
    -unroof/doors/engine/trans/diff/suspension/fuel tank
    -brake lines/fuel lines/seatbelts/interior/door sensors/
    - EVERYTHING except the brake booster/master & slave clutch/wiring harness




    Backing her up





    Slowly rolling her up the ramps.



    Shes loaded and ready to go!







    Watching her while we drive




    View out the back of the truck



    Unloading @ O'Brien Motorsports




    Her new home for the next few months.






    Till next time.

    -Chuck

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  3. #3
    t3h ub3r m3mber 2.5GT's Avatar
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    Re: chuckthefuk - Satin Black 97' BD6 GT (Track Car)

    A little bit of elbow grease and you're good to go!

  4. #4
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    Re: chuckthefuk - Satin Black 97' BD6 GT (Track Car)

    Just wondering if its got a 2.50" exhaust why are you going to a 2.25? I'm thinking of doing exhaust on my car and was going to go with 2.50 is there something wrong with that?
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  5. #5
    SLi Supporter chuckthefuk's Avatar
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    Re: chuckthefuk - Satin Black 97' BD6 GT (Track Car)

    Quote Originally Posted by 02_Legacy
    Just wondering if its got a 2.50" exhaust why are you going to a 2.25? I'm thinking of doing exhaust on my car and was going to go with 2.50 is there something wrong with that?
    2.5" produced less back pressure and causes lag during low rpm acceleration. I found that 2.25" is the sweet spot at least in my configuration.

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    Re: chuckthefuk - Satin Black 97' BD6 GT (Track Car)

    Quote Originally Posted by chuckthefuk
    Quote Originally Posted by 02_Legacy
    Just wondering if its got a 2.50" exhaust why are you going to a 2.25? I'm thinking of doing exhaust on my car and was going to go with 2.50 is there something wrong with that?
    2.5" produced less back pressure and causes lag during low rpm acceleration. I found that 2.25" is the sweet spot at least in my configuration.
    i can agree with you on that, do you plan on doing anything to get the torque back in the low end of the powerband? I find that it would be more effective to go with a supercharger if you plan to do forced induction or go hybrid with the CAI and keep the snorkle so you don't lose the torque
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  7. #7
    SLi Supporter chuckthefuk's Avatar
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    Re: chuckthefuk - Satin Black 97' BD6 GT (Track Car)

    Quote Originally Posted by evolegacy
    i can agree with you on that, do you plan on doing anything to get the torque back in the low end of the powerband? I find that it would be more effective to go with a supercharger if you plan to do forced induction or go hybrid with the CAI and keep the snorkle so you don't lose the torque
    no plans really since all the engine stuff is temporary, I never did feel the difference between snorkle/snorkless. I plan on doing a few events with the EJ25D then swap a JDM Ej205 head w/ a JDM EJ208 bottom end. And the transmission I plan on using is undetermined at the moment.
    -Chuck

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    Re: chuckthefuk - Satin Black 97' BD6 GT (Track Car)

    Looking forward to it chuck!
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    Re: chuckthefuk - Satin Black 97' BD6 GT (Track Car)

    Quote Originally Posted by chuckthefuk
    no plans really since all the engine stuff is temporary, I never did feel the difference between snorkle/snorkless. I plan on doing a few events with the EJ25D then swap a JDM Ej205 head w/ a JDM EJ208 bottom end. And the transmission I plan on using is undetermined at the moment.
    -Chuck
    I never tried the snorkle idea I only heard the possibilities from doing it, so figured i'd ask. what would the benefits be from using the 205 heads on a 208?
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    SLi Supporter chuckthefuk's Avatar
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    Re: chuckthefuk - Satin Black 97' BD6 GT (Track Car)

    204/205 blocks are known for breaking. 204/205 heads are better flowing the 206/207/208 heads. The 208 bottom end is much stronger then the previous generations. I am only choosing this combination since this is a known fact on the inter-webs and my buddy with a GC8 just went through this nightmare.


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  12. #12
    t3h ub3r m3mber 2.5GT's Avatar
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    Re: chuckthefuk - 97' BD6 GT (Track) *update* GD flares....

    There's a old member(s) here that did the same impreza flare. It does look good if done right. Hardest part is getting everything line up. I would like to see the final results

  13. #13
    SLi Supporter chuckthefuk's Avatar
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    Re: chuckthefuk - 97' BD6 GT (Track) *update* GD flares....

    Ya I'v seen that thread. He actually lived 20 minutes away from me. I am still debating going with a 1 - 1/2" gap between the original fender and the gd fender, this would create a fender vent from behind similar to widebody fenders.. OR just mount them flush by using just the flare and not the GD wheel arch.

    Hmmmm.. I'll decide this weekend when i mock up the other side and restock some cutting discs.

    My biggest concern is wheel fitment after this fender upgrade.. I am running 205/55/R16's now... I know I can fit 225's no problem with some rolling of the fender lip and the right alignment..

    Any suggestions?

    -Chuck

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    Re: chuckthefuk - 97' BD6 GT (Track) *update* GD flares....

    Just don't get sidetracked with other projects/Miatas/Cameros/STIs....and everybody will love you.
    You can only get so far with a warm spoon

    Dial 5 for teH Niteclub!

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    SLi Lurker )2edline's Avatar
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    Re: chuckthefuk - 97' BD6 GT (Track) *update* GD flares....

    Quote Originally Posted by MoclovFlop
    Just don't get sidetracked with other projects/Miatas/Cameros/STIs....and everybody will love you.
    oh no he didn'tttttttttttttttt - yes, yes he did =]
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  17. #17
    SLi Supporter MoclovFlop's Avatar
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    Re: chuckthefuk - 97' BD6 GT (Track) *update* Nov/6/09

    I like you better already.

    Looks good.
    You can only get so far with a warm spoon

    Dial 5 for teH Niteclub!

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    "Proby" aurelius's Avatar
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    Re: chuckthefuk - 97' BD6 GT (Track) *update* Nov/6/09

    brb, wiping the drool off my keyboard when I saw this.
    Project Domo

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    t3h ub3r m3mber 2.5GT's Avatar
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    Re: chuckthefuk - 97' BD6 GT (Track) *update* Nov/6/09

    That's pretty cool

    Any plans for the rear?

  20. #20
    SLi Supporter chuckthefuk's Avatar
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    Re: chuckthefuk - 97' BD6 GT (Track) *update* Nov/6/09

    not sure yet... my options are:
    1) GD STi rear quarter cut outs and door cut outs
    2) GD STi widebody fiberglass add-ons
    3) GC 22b rear quarter replica (similar to xXGTBspecXx wagon)
    4) SF Forester rear quarter cut outs and door cut outs

    -Chuck

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    SLi Lurker slaytalera's Avatar
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    Re: chuckthefuk - 97' BD6 GT (Track) *update* GD flares....

    Quote Originally Posted by MoclovFlop
    Just don't get sidetracked with other projects/Miatas/Cameros/STIs....and everybody will love you.

    oh he went there


    looks great so far, cant wait to see what you do with the rears

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    SLi nOOb chaksq's Avatar
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    Re: chuckthefuk - 97' BD6 GT (Track) *update* Nov/6/09

    Those GD flares look HOT. If I ever find a WRX in the yard...
    1991 Toyota MR2 │ Black │ 2.2l 5S-FE
    2006 Acura RSX Type-S | Blaze Orange Metallic | 2.0l K20Z1


    Previous: 2007 Mazda 6, Bright Island Blue | 1998 Subaru Outback, Blue/Gold | 1991 Toyota MR2, Red | 2000 Ford ZX2 S/R, Zinc Yellow | 1996 Ford Escort LX, Cayman Green

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  24. #24
    SLi Supporter chuckthefuk's Avatar
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    Re: chuckthefuk - 97' BD9 GT (Track) *update* Dec/28/09.. :-

    Where to start... Good new... or bad news.......... Good news it is!

    Good news:
    -Sold my EJ25D for $400-ish.
    -Sourcing out a chargespeed (replica or original) rear quarters and doors
    -removed most of the insulation and interior paint.
    -prepping for seam welding and bracing with gussets.
    -debating going with a weld in cage from http://www.customcages.co.uk (local dealer can offer there product line up) http://www.customcages.co.uk/Rollcage/M ... rer=Subaru
    or going with a custom cage made by a local shop. I have no real purpose for this car so certified cages are not my concern.
    -Priced out carbon/kevlar single racing seat, harness, fire suppression system, and fuel cell.


    Bad news:
    -My father passed away in his sleep on Nov 21st 2009 @ age 58 from cardiac arrest.
    -I am forced to sell my fathers body shop, since I can not become a full time body tech currently.
    -I have lost the ability to work on my car in the winter.
    -I have lost most of my ambition/motivation to complete the chassis prep this year/winter.


    Please do not send your condolences.. I've had a month + of people reminding me.... I appreciate the thought, but lets just keep it strictly legacy in this thread.

    From the bitter north.
    -Chuck

  25. #25
    SLi Supporter chuckthefuk's Avatar
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    Re: chuckthefuk - 97' BD9 GT (Track) *update* Mar/13/10.. :-

    Check 1st post ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^
    ----------------Mar/13th/2010------------------------------------------------------
    Picked up a set of fiberglass 02-07 GD Impreza ARP (replica) rear quarter panels.


    -Chuck

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    SLi O.G. httrdd's Avatar
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    Re: chuckthefuk - 97' BD9 GT (Track) *update* Mar/13/10.. :-

    That should look really good!
    TJ

    99 LGT H6 Limited OBP

    A little bit of Wrx, a little bit of 2.5RS, a little bit of STi, a LOT of SVX!

    Will I ever supercharge this Eg33???


    Quote Originally Posted by chuckthefuk
    Cheers and the Baja is not the bastard child.. The Legacy is :-D -Chuck

  27. #27
    SLi O.G.
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    Re: chuckthefuk - 97' BD9 GT (Track) *update* Mar/13/10.. :-


    trim the fat and get to the good stuff.. all while keeping it simple. I like. You're definitely off on the right foot and running.
    BD GT

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  29. #29
    SLi nOOb B's Legacy Wagon's Avatar
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    Re: chuckthefuk - 97' BD9 GT (Track) *update* Mar/29/10.. Oh

    Looking great nice that you update the first post alot with all the new stuff. Cant wait to see more.
    Keep up the good job chuck..

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    SLi O.G. anothernord's Avatar
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    Re: chuckthefuk - 97' BD9 GT (Track) *update* Mar/29/10.. Oh

    Now this is a member's ride thread!

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