Jay762

WRX STI Hatch - Project Dotty

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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 🤔

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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

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

Test fit

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Trimmed, drilled and bolted down

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

 

 

 

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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...

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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

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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. 

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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.

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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

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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 .

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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 😊

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

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

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Initial positioning of the panel

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OCD much

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Convenient hole for wiring

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adding trim to protect wiring

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Trim trimmed

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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

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Now adding the fuse supply

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

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Fuses and relays in place

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

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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

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Extending the existing loom

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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

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wrapping the new loom

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Final underseat with cables in a shroud post wrapping

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Routed up c pillar into boot space

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

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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!!

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Board in situ time to start connecting

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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

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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.

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Everything back in place

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Now onto the fuel lines...

 

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Tools arrived this week for the fuel system plumbing

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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 .

 

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

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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

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

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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.

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View from Rear

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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.

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