WRX STI Hatch - Project Dotty

[savage bulldogs]

Do like a clean bay , me 😊

Didn't know anywhere sold clutch slave kits , think mine needs a refresh as the biting point seems to shift a bit as it gets warmer 🤔

[Jay762]

On 11/7/2019 at 2:32 PM, savage bulldogs said:

Do like a clean bay , me 😊

Didn't know anywhere sold clutch slave kits , think mine needs a refresh as the biting point seems to shift a bit as it gets warmer 🤔

TBF I did not replace the seals as there was no leakage just de rusted, cleaned then chased the threads and replaced with stainless steel items to prevent further corrosion

[Jay762]

Surge tank kit assembled and mounted, next bit will be electrical string & relays plus fuel pipe

Test fit

Trimmed, drilled and bolted down

I may add a layer of rubber or part of the boot liner, post cut, for pump vibration isolation

 

 

 

[savage bulldogs]

Liking the boot installation,  very tidy mate 👍

[Jay762]

On 11/7/2019 at 1:32 PM, savage bulldogs said:

Do like a clean bay , me 😊

Didn't know anywhere sold clutch slave kits , think mine needs a refresh as the biting point seems to shift a bit as it gets warmer 🤔

Found recently you can get a whole brand new unit from ICP for £35...

[Jay762]

On 10/25/2019 at 4:44 PM, savage bulldogs said:

Hows the tear down going ,bud .

Is there much that can be salvaged from the original build or is it a complete restart with new parts ? 

The results are in and its not pretty - I will be posting a full breakdown with photos of the analysis. Unfortunately there is quite a lot to write. Parts have been salvaged and will be resold but for what I would like to achieve a build from scratch is commencing

[savage bulldogs]

Frustrating that the "built engine " wasn't very well built in the 1st place but at least you know it will be done properly this time around. 

[Tidgy]

6 hours ago, savage bulldogs said:

Frustrating that the "built engine " wasn't very well built in the 1st place but at least you know it will be done properly this time around. 

im wondering if its got the origional built engine in as i know who built it and the spec and it was pretty epic.

[Jay762]

On 12/20/2019 at 10:08 PM, Tidgy said:

im wondering if its got the origional built engine in as i know who built it and the spec and it was pretty epic.

It has been identified as the original engine

[savage bulldogs]

On 12/20/2019 at 9:08 PM, Tidgy said:

im wondering if its got the origional built engine in as i know who built it and the spec and it was pretty epic.

Tbh I only just re read the beginning once you posted and had forgotten who supposedly built the block in the first place .

Looking at the tear down results thread , Seems like it's the same spec block ,with the same parts and with sleeves fitted 🤔

Think this thread is more about the new build he's going to have to do and not what he's inherited from the previous owner /builder .

[Jay762]

3 hours ago, savage bulldogs said:

Think this thread is more about the new build he's going to have to do and not what he's inherited from the previous owner /builder .

Yes that was my intention - keep them separate, this one is about moving forward 😊

[Jay762]

Continuing with the surge tank installation - bits arrived to plumb into existing system

[Jay762]

And the associated electrical string, relays and fuse mounts, wire for the loom extension matches ok the green yellow isnt perfect but hey ho

[Jay762]

Initial positioning of the panel

OCD much

Convenient hole for wiring

adding trim to protect wiring

Trim trimmed

Starting to wire the fuse panel to the relay panel green yellow will go from being the original 12v feed for the Subaru fuel pump to being the relay trigger voltage

Now adding the fuse supply

12v main feed to fuse and relay inputs and outputs plus the -ve relay outputs installed

Fuses and relays in place

In preparation for the loom connection - x3 wires into a bullet crimp

Connecting heavier cable for the 12v supply - the crimps in the fuse panel and relay were not big enough to take the larger gauge even though they are all individually rated to 40A

Extending the existing loom

Used some of these heat gun solder things for the first time instead of messing with soldering irons - they work well but practice first as it is not as easy as the spam videos make out

wrapping the new loom

Final underseat with cables in a shroud post wrapping

Routed up c pillar into boot space

More electrical string - earth cables for pumps 2 & 3 in place

Terminated the main 12v Battery feed to a fuse purely as I needed to get x3 feeds out - all of the bus bars I looked at were too big - one I did order that came through was 15cm long!!

Board in situ time to start connecting

All in place, wiring wrapped and put in shrouds then routed appropriately, pumps 2 & 3 connected, couple of additional holes drilled to rout cabling through, this will hold cables in place to stop any potential strain on the fuse  / relay panel etc

Panel cut, trimmed and replaced - unfortunately the hole I cut is slightly too big, I just could not get the thing in place to get accurate markings, a bit of black rubber behind will sort it but in all honesty I will probably replace it in the future with one from a breakers and will be able to mark and cut a perfect hole.

I also re routed the 12v pump feeds out of the way and secured with tie wraps which made fitting the foam piece easier.

Everything back in place

Now onto the fuel lines...

 

[Jay762]

Tools arrived this week for the fuel system plumbing

[savage bulldogs]

Nice tidy installation jay 😎

Wish I'd have bought some decent cutters and an6 assembly tools , took ages to get a decent cut without them lol .

 

[Jay762]

Change of direction for the fuel system postponed progress there, so a minor change to the interior

[Jay762]

Completed the plumbing on the Surge Tank, couple of redesigns and a few stripped threads - Doing AN6 with ptfe hose is a fiddle, having the vice was a big help otherwise I would have trashed even more fittings than I did in the process

Before - Standard Subaru setup

 

Gently bent the hoses apart and got connectors that would go to existing setup

Foam / sponge surround was falling apart, may or may not have had something to do with the fuel leak that has happened at some point disintegrating the sponge under the carpet transforming it from yellow to brown (Replacement carpet required as no support for rear passenger feet so carpet will eventually tear). Replaced with rubber gasket and lid replaced holding the connectors in place as well.

View from Rear

View from Front - Over kill but I added some trim to the metal edge so if there is any movement it wont wear away the black outer coating and expose the steel braided underneath.

[savage bulldogs]

Proppa tidy install that mate ,  nice work Jay 👍

 

[Jay762]

Sorted the 12v fuel pump line, experience has shown cutting into bulkhead seals will let in water plus I wasn't happy with the blade fuse and electrical tape setup.

Before

Drilled bulkhead and sealed using a grommet then ran the line through a protective shroud to the cars fuse panel, sealed the cut with epoxy resin.

 

Nice hole under the fuse panel for routing the lines

After checking the fuse panel for blanks I decided to use the redundant air pump components, the 60amp fuse is the right size but the blades used are bigger than your standard stuff I have in the garage so used the OEM Subaru ones

Lines in place

Connection to Battery

 

 

[Jay762]

Lots of work for what appears to be very little progress.

Put in an additional wire from the fuel pump panel to the ECU which will give the option of individual pump control based upon conditions (boost / demand etc) as opposed to both internal pumps running constantly. This can be switched just by moving moving a single fuse in the panel from one location to another.

Testing the Fuel pumps showed some leaks from the Torques UK joints after some backwards and forwards with them and establishing I had assembled correctly I will be redoing the fuel lines with an alternate supplier, tried the cheaper option but I now have no trust in the other joints that didn't leak.

Fuel spillage in the boot lifted part of the sound deadening so lifted the rest - will replace with some dynamat

Dropped the rear subframe and differential to spruce up and replace all the bushes for polyurethane alternatives.

 

Discovered the fuel filler pipe rusting

 

[Jay762]

After a week of soaking in penetration oil (Plus Gas) and attacks with a lump hammer and bolster, SDS hammer chisel I resorted to the press

9 tonne to get the bearing out from the hub

Derusting

Undercoat

Top coat x 4

After trying several different methods described on the web, press, drillout followed by SDS chisel I opted for old school blowtorch

Stripped a thread due to rusted solid so a little bit of welding but even more grinding...

Diff spruce up

Rusted

Prepped

Painted

Other bits in gloss

 

[Jay762]

Gear linkage tweaked with replacement bushes and a quick shift kit

Before

This is where all the plastic bits go if you install a meter behind a panel but just go at the panel with a dremel in situ

Ball out of socket

Perrin QS installed

Socket nice and clean

After

Underneath - Standard Subaru support bush

and gear link bush

After with Whiteline rear support, Perrin front

[Jay762]

Progress being made on reassembly

Powerflex polybushes fitted to powdercoated and painted parts

Subframe powdercoated with Whiteline & Powerflex bushes in place

[Jay762]

Started pulling suspension apart to address split dust boots, they had not been trimmed on assembly so when compressed they rub on the springs and split - both fronts missing altogether. An argument could be made for running without them - cosmetic etc but I always tend to follow what the pros do and if motorsport teams run with them and Ohlins supplies them as part of the original kit they should be there IMO

Discovered that the units had also been incorrectly assembled (shouldn't be surprised really) with the front and rear set both having different springs

They should be 90Nm front and 70Nm on the rear - here are the fronts where you can see the difference in spring diameter and 70C (70Nm) labelled on the spring

Awaiting the dust boots but the springs have been blasted and powder coated ready for reassembly