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-   -   2001 Impreza L | WRX swapped | Rust repairs and weight reduction! (https://www.rs25.com/forums/f145/t204801-2001-impreza-l-wrx-swapped-rust-repairs-weight-reduction.html)

RavensFan77 01-18-2014 01:49 AM

2001 Impreza L | WRX swapped | Rust repairs and weight reduction!
 
This is mostly the progress of my srp 2001 L coupe, but also some 98L and 2018 brz stuff.



Backstory:


I got the car in August 2011 with 100,500 miles. It was my first car, and it had lots of problems at the start. Almost sold it a few times, but once I read about all the swap stuff, I decided I had to keep it.

I messed with weight reduction, and fixing/upgrading the suspension while I gathered funds for the swap...lots of maintenance too...although the ej22 ran strong the whole time. It really was bulletproof. I had to have the transmission rebuilt, but was finally was able to start the swap summer 2014 and I got an ej205 in and running.

Fall of 2015 it was totaled (not my fault) and I spent a year slowly fixing the car myself with no collision experience. After tons of spot welds, test fits, wiring, and double checking......I got the car inspected and legal to drive again in November 2016, with a reconstructed title.

2017 and on will be dedicated to rust repairs,weight reduction, and self tuning.




Here are some up to date pictures, regardless of the different seasons:

https://c4.staticflickr.com/1/712/31...3da98a34_c.jpg


https://farm6.staticflickr.com/5443/...73d82c2b_c.jpg

https://c6.staticflickr.com/6/5567/3...ffffca2d_c.jpg

https://c1.staticflickr.com/6/5610/3...10fbc00e_c.jpg








The goods:


ENGINE:


-USDM 02/03 ej205 (6/28/14)

-TGV deletes

-Grimmspeed catless uppipe, ceramic coated

-Cobb catted downpipe, ceramic coated

-02-05 wrx, Invidia q300 catback

-STi oil pan

-KillerB oil pick-up tube

-Avo turbo inlet

-lighter crank pulley, and no p/s or a/c pulleys

-Protune by Jermaine @TurboXS

-v3 accessport

-iWire merged harness



TRANSMISSION:


-'01 5mt (3.9) and cable clutch;
AndrewTech rebuild

-custom reinforced clutch fork

-'01 (oem) TOB, and pivot ball

-'06+ wrx clutch

-'06+ wrx pressure plate

-'06+ wrx flywheel

-TiC shifter linkage update and pivot bushings



SUSPENSION / HANDLING


-KYB excel-g struts (2/2/14)

-Eibach pro-kit springs 2/2/14)

-Group N front top hats (2/2/14)

-3/8 saggy butt spacers (2/2/14)

-18mm Outback rear sway bar

-20mm WRX wagon front sway bar (6/28/14)

-JDM GC8 crossmember (6/28/14)

-Whiteline steering rack bushings (6/28/14)

-Whiteline rear endlink bushings

-group N front-of-trailing arm bushings

-power steering delete



WEIGHT REDUCTION&DISTRIBUTION:


-Currently about 2690~ lbs.
-***Was at 2590, but the turbo engine swap and a full-size spare added well over 100 lbs back.

-Aluminum jdm gc8 hood

-USDM front bumper beam cut in half

-deleted a/c

-deleted power steering

-washer fluid tank relocated to trunk

-battery relocated to back seat

-removed hunk of metal from glovebox and under dash

-removed most sound deadening

-stripped trunk besides spare

-lighter wheels

-removed keyless entry system

-random little things. More soon.



----------



Here's the progress from the beginning mostly in order. I'm going to add in some dates/mileage later on. Bear with the potato pictures for the first few pages. I eventually got a digital camera, and now a DSLR, so the pictures get progressively better in quality.







Warning, picture heavy:







-Bought late August of 2011, bone stock.















--some actual wheels to replace the steelies and decent tires too.







16x7 with 205/50-16 Conti DW















--This is the oldest pic I have of my car, and the only pic from the beach driving I have left.







http://i1171.photobucket.com/albums/...1354256219.jpg















--Rally armors, which get used on a daily basis on PA's crazy roads :unamused:







http://i1171.photobucket.com/albums/...ps34e9df1e.jpg















--Homemade light bar that mounts 2 hella 500's







http://i1171.photobucket.com/albums/...ps8f1ec3ea.jpg















How it looked last winter:







http://i1171.photobucket.com/albums/...ps0a7eb72e.jpg















--Polyurethane rear end link bushings







This is when I learned how hard pressing bushings is.....















--New outer tie rods, ball joints, and front wheel bearings.







This is when I learned to hate wheel bearings and ball joints......















This is a ball joint removal tool......mine were really stuck.







http://i1171.photobucket.com/albums/...ps8283f577.jpg







http://i1171.photobucket.com/albums/...psfbbf6fbe.jpgj

RavensFan77 01-18-2014 01:49 AM

--ALL axles have been replaced at least once, some multiple times.

--New trailing arms, with group N front-of-trailing arm bushings already pressed in.

--Valve cover gasket, tube seals + grommets replacement.
http://i1171.photobucket.com/albums/...psfec39e3e.jpg

--Picked up an RS hood, scoop, vents, and all painted SRP, REALLY cheap. I was gonna get one when I do the swap anyway, so why not?
http://i1171.photobucket.com/albums/...psd5aa8d6f.jpg


--A deer ran into the drivers side of my car, yea ran into me. Right into the side, dents from the front fender to the rear 1/4 panel.
All fixed up, new door, and half the car repainted. Here it is after the body work:
http://i1171.photobucket.com/albums/...psf64f4ee9.jpg

--Ended up rattle-canning the wheels. Don't like the machined lip, dark spoke, style.....

How I bought them (unfortunately)
http://i1171.photobucket.com/albums/...ps8370c177.jpg

http://i1171.photobucket.com/albums/...ps7557771a.jpg

http://i1171.photobucket.com/albums/...psc6749f63.jpg

Better than how I bought them....and somehow the spray paint is holding up to the gravel roads.

--Dealer I got it from put some water-thin oil in the gearbox that left me with all gears grinding for over a year.
The transmission was rebuilt and new clutch installed by Andrewtech. They did an awesome job. Got the TIC shifter linkage update, and 5mt pivot bushings installed at the same time.

No more shifter slop or grinding gears! :banana:
http://i1171.photobucket.com/albums/...psaab742f0.jpg


--New "taco link" front lateral links with new bushings, new rear wheel bearings

--here's how it sat at 130,000
http://i1171.photobucket.com/albums/...psc2c0a421.jpg

RavensFan77 01-18-2014 01:49 AM

2001 Subaru MoneyPit (Impreza L)
 
--Picked up an 18mm swaybar from a '98 Outback for $25. Direct bolt-up and easier to find than one from a WRX. It was at a u-pull-it place and the bolts were rusted, so I found another way to remove it:
http://i1171.photobucket.com/albums/...ps159dc0bc.jpg

The Outback was sitting on its brakes, so I couldn't get underneath to pull the bar out the normal way....instead I had to pull/wiggle/wrestle it out from the drivers side. Took like an hour of turning/pulling/yelling/more pulling to free it completely.
http://i1171.photobucket.com/albums/...ps6fb45318.jpg

-Got my a/c discharged and deleted the system. Getting to this bolt on the compressor was the most difficult part.
http://i1171.photobucket.com/albums/...psff83b6a2.jpg

-Compressor out:
http://i1171.photobucket.com/albums/...pse87f5729.jpg

-Pulling the condenser:
http://i1171.photobucket.com/albums/...ps6233573f.jpg

-After looking at all the bent fins on the condenser I concluded the radiator needed some protection from bugs and stuff:
http://i1171.photobucket.com/albums/...psa28988be.jpg
I have some black mesh material mounted in front of the radiator where the bumper and grille open up. It gets gunked up from bugs after a while, so I just make another. I made a stencil so I can just cut a new piece of mesh quickly.

--Here's all my weight savings:
http://i1171.photobucket.com/albums/...ps2c93c1e0.jpg

Total weight dropped: ~31 lbs. This was just the start of my weight savings. Next was the trunk:
-no donut
-no tire well cover thing
-no carpet
-some paneling removed
-some metal removed
-sound deadening removed

--Changed up my aux. lighting set-up. Moved the hella 500's to the bumper and bought some rigid industries LED's...and they are bright!
Stock headlights:
http://i1171.photobucket.com/albums/...ps320bcc7b.jpg

Headlights + LED floods:
http://i1171.photobucket.com/albums/...ps9d8ae81a.jpg

On two SPST switches:
http://i855.photobucket.com/albums/a...ps71a3477b.jpg


--picked up an RS wing
http://i855.photobucket.com/albums/a...psa933c9d2.jpg

--More sound deadening removal. I used dry ice:
~under rear seat
~passenger side floor
-drivers side floor
http://i855.photobucket.com/albums/a...ps4f61e8d0.jpg
http://i855.photobucket.com/albums/a...ps99bd6ada.jpg

The only stuff left is on the firewall and trans tunnel.
http://i855.photobucket.com/albums/a...psd1ec0378.jpg

*more weight savings
--deleted washer fluid tank
--removed hunk of metal from glovebox
--lightweight crank pulley
--power steering delete
--lighter intake

Last time I got it weighed it was 2590....but since then I've added the full size spare which is around 35 lbs. Once I get a lighter battery and remove some more stuff I hope for mid 2500's with the full size spare.

Stuffing the rack with wheel bearing grease:
http://i855.photobucket.com/albums/a...ps31c6c54f.jpg

Empty engine bay:
http://i855.photobucket.com/albums/a...psb6b0fa58.jpg

RavensFan77 01-18-2014 01:51 AM

2001 Subaru MoneyPit (Impreza L)
 
--rattle-canned the wheels a darkish gold for winter.
http://i855.photobucket.com/albums/a...ps77547da6.jpg

--Michelin x-ice xi3's on right now.
Been getting use out them this winter:
http://i855.photobucket.com/albums/a...pse5f735af.jpg
http://i855.photobucket.com/albums/a...psa270c580.jpg

I have new struts, springs, group N front top hats, and all the other stuff waiting to go on in the next few weeks...just waiting on a few more parts.

...and since I decided on a swap a LONG time ago, I finally got started on that. :banana:

Blown up ej205:
http://i855.photobucket.com/albums/a...ps05c78983.jpg
Bought that 2 weeks ago, and I've been tearing it apart in my house with hand tools. Got the heads off last weekend, and finally got the damn pistons out tonight. Gotta go get a 12 point socket to finish removing the case bolts and I can split the block tomorrow, well today now. Lol it's pretty late.
http://i855.photobucket.com/albums/a...ps4faf9268.jpg
http://i855.photobucket.com/albums/a...ps82f955eb.jpg

Had to get creative for the c-clip things:
http://i855.photobucket.com/albums/a...ps9bf698b4.jpg

Looks/feels like it was rod bearing from #4 that died. This is my first Subaru engine teardown, but everything else looks pretty clean to me. Cross hatching is good right?
http://i855.photobucket.com/albums/a...ps5adc1ffd.jpg

Hoping to have it all ready to drop in, harness and all, by spring.

Evaded 01-18-2014 07:36 AM

Nice.... Looking forward to more.

Evaded

RavensFan77 01-18-2014 06:23 PM

2001 Subaru MoneyPit (Impreza L)
 
Thanks! Today I finally got the block apart:
http://i855.photobucket.com/albums/a...ps80d625e8.jpg

#4
http://i855.photobucket.com/albums/a...ps9b43366e.jpg

Everything else looks pretty good. Just gotta get it all to a machine shop next, to see how it looks in the nitty gritty and see what needs to be replaced.

Now here's a problem I ran into while splitting the block.
I broke this:
http://i855.photobucket.com/albums/a...ps49c1ecee.jpg
http://i855.photobucket.com/albums/a...ps13641398.jpg
The oil cooler bolt threads into there.....and too many threads broke off so the bolt isn't long enough to tighten down.
Since those threads are on the block itself, is this bad?? The ONLY thing I can think of is finding a longer bolt...or even having one made.

Also broke this little bracket off whatever this piece is:
http://i855.photobucket.com/albums/a...ps49b029c7.jpg

Atleast that is replaceable and I can just bolt another one on....the oil cooler bolt issue may be a real problem....

RavensFan77 02-10-2014 05:46 PM

2001 Impreza L | WRX swapped | lightweight daily driver project
 
--The other week was single digits everyday, and a fuel leak developed. I smelled gas occasionally, but the super cold days allowed me to see exactly which hose was leaking....so I replaced this little guy: http://i855.photobucket.com/albums/a...psnfpue56q.jpg

--Since the ej205 is completely torn down I've been cleaning up the parts to get it ready for the machine shop.
Got the valve covers almost all the way clean:
http://i855.photobucket.com/albums/a...ps638b3be0.jpg

--FINALLY got rid of the stupid accordion shifter boot. Also cut the shifter down and re-threaded it back to 12x1.25 so I can use my stock knob. Got bored and made a few "knobs" out of random stuff....but this is the only one that turned out OK: http://i855.photobucket.com/albums/a...psd5d0e8da.jpg
It's from that ej205. Not permanent.

--2 weekends ago, my impatience got the best of me and I decided to do my struts and springs myself. I rented some spring compressors and used all hand tools....wasn't too bad! Had to get some special sockets and wrenches but me and another friend got it done. http://i855.photobucket.com/albums/a...ps999bc37b.jpg http://i855.photobucket.com/albums/a...psc69f8ddd.jpg

My car had the original L model struts/springs which were all blown, except one...which was like half blown, lol:
http://i855.photobucket.com/albums/a...ps37db757f.jpg

Since mine is about 200 lbs lighter than an RS, I think the RS stuff would lift me. I also didn't want to go too stiff because I really like the gravel roads around here. So I went with:
-KYB excel-g struts
-Eibach pro-kit
-Group N front top hats
-standard rear top hats
-cut bump stops
-3/8 saggy butt spacers
http://i855.photobucket.com/albums/a...ps5c8693ea.jpg
Broke all these: http://i855.photobucket.com/albums/a...ps7c99d042.jpg

Really evened out the ride height....not too low, and not too stiff.Maybe an inch drop. Maybe. Before, I could EASILY fit a full fist up front and the back sagged a lot...The 3/8 saggy butt spacers were the perfect size.
The whole set-up took out some body roll, less squat/dive on accel/braking. Much improved cornering and turn-in. Very happy so far.
Before:
http://i1171.photobucket.com/albums/...psa1e7e0eb.jpg

Now. It actually sits really even, this is on uneven ground:
http://i855.photobucket.com/albums/a...psb2ab9516.jpg

After working on it for waaaayy too long, I was able to just barely make it on time to my alignment. I swear, as soon as I tightened down the last lugnut I started the car and left :lol: :http://i855.photobucket.com/albums/a...psbdc593d1.jpg

--Finally found a bottle that I can use for my re-located & smaller windshield washer set-up. It's not the color I want, but is the right size so it'll work for now.
This is just a mock-up....I will paint the silver strap black or red, and run the hose and wire neatly:
http://i855.photobucket.com/albums/a..._zps6c6251.jpg

No need for a gallon on de-icer and that huge container. This smaller one shouldn't really be visible since its behind those brake lines.

RavensFan77 02-14-2014 06:03 PM

2001 Subaru MoneyPit (Impreza L)
 
Had some fun before the big snow came through: :projectsti.com:
http://i855.photobucket.com/albums/a...ps3a5c2118.jpg
We got tons of snow here yesterday, this was the beginning of the storm:
http://i855.photobucket.com/albums/a...psbc592864.jpg
--The snow stopped for a little and I ran out to get some all weather floor mats. The nicer ones seriously weighed like 30 lbs. so I got the cheapest, thinnest ones I could find. These will definitely get the job done, and weigh next to nothing. :D
http://i855.photobucket.com/albums/a...ps8365dd91.jpg
--It cleared up today so I was able to finish the washer tank relocation. I still need to find a better container but I wanted to make sure my mount would work...and run the wires and hose to the other side. Just had to swap the hose set-up around to make the factory hoses reach the passenger side.
Need to go back and use black zipties....but yeah it doesn't look the best up close, although you can hardly tell its there being behind the brake lines.
http://i855.photobucket.com/albums/a...ps79813799.jpg
http://i855.photobucket.com/albums/a...ps93ee08ec.jpg
http://i855.photobucket.com/albums/a...ps511fba6a.jpg
http://i855.photobucket.com/albums/a...psc5c33084.jpg

See....its pretty hidden behind those brake hardlines.

RavensFan77 02-15-2014 08:11 PM

2001 Subaru MoneyPit (Impreza L)
 
Almost forgot about weight reduction....although I'm kinda running out of stuff to remove. A lighter battery is in the plans but I'm working on little stuff. Hope to be back in the 2500's soon, since the full-size spare bumped me back up a little.

Got started on removing some metal from the trunk. I already kinda started this before but I got more of it out today. There's some rust on the right corner so even more will probably come out later....not sure if that was any type of "bracing" but if so I could easily add some vertical structure back (3rd picture, lol).
After that I want to remove the jack bracket/mount, and the two tabs that held the spare tire cover. There's also some wires + their connectors I can trace, pull back, and cut.
http://i855.photobucket.com/albums/a...ps1e0b7c4f.jpg
http://i855.photobucket.com/albums/a...ps51add9c0.jpg
http://i855.photobucket.com/albums/a...ps05d98290.jpg
Also removed both the broken cup holders. Kept the front part for the one on the dash so it looks nice and neat like one is still there....the one in the center console was all messed up and always fell off the little track. Probably going to remove the entire center console and get the rest of the sound deadening soon.

Formed a mud flap back in shape too....it was bent in a "U" between the tire but luckily didn't get ripped off....stupid snow. Here's a random shot from today, usually they don't even plow the gravel roads:
http://i855.photobucket.com/albums/a...ps5c093c21.jpg
Might get around to cleaning up more of this ej205 stuff tomorrow. I wrapped it up as soon as it was apart. :D
http://i855.photobucket.com/albums/a...ps29374281.jpg

RavensFan77 02-23-2014 07:32 PM

2001 Subaru MoneyPit (Impreza L)
 
Cleaned up the block halves and valve covers. Used chlorinated brake cleaner and probably turned my driveway into an EPA disaster.
http://i855.photobucket.com/albums/a...pse082d376.jpg
Missed some spots and ran out of brake cleaner but most of the gunk is off.
http://i855.photobucket.com/albums/a...psdb8414e3.jpg
http://i855.photobucket.com/albums/a...ps3ce227d6.jpg
http://i855.photobucket.com/albums/a...psbd27531f.jpg

The heads are supposed to be good, but I think I want to check them out and maybe refresh them too. Going to try to get the valves and springs out this week/weekend and finish cleaning everything off.

Started taking the glovebox out so I can remove the evaporator thing under the dash I forgot about.
Just want to be in the 2500's...


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