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R56 Cooper S
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Discussion Starter #1 (Edited)
Hi! I'm Marcus, and this will be the chronicle of my '99 Rally Blue RS. I have dubbed this car, Project FEELZ, because my intent is to just make the whole car feel better. Better feeling brakes, suspension, power, etc.

I've had this car since 2010, and I friggin love it, it's awesome. This is my 4th car ever, my second Subaru (my first being a 1996 Legacy Brighton that I got off Craigslist for $700. Damn I miss that car), and by far the best car I've ever owned.

I don't remember when exactly it was that I fell in love with these GC chassis cars, but I remember I joined the forum and started searching hardcore to find one right before I left for USAF Basic Training. I couldn't find one by the time I had to go, so I ended up selling the two cars I owned at the time ('92 240sx and the Legacy), and spent the next 6 months in Texas. Once I got back, I lucked out and found this blue beauty on Craigslist up in Berkeley, so ASAP I drove up there with my cousin, drove back down in this beast, and got home just in time to change and barely make it to work on time.

Aaaaanyways... let's throw up some pics because people like pictures! Right?!



Wait a sec...that's not right...



Ahh...there she is! In all her sexy blue-ness.


First post of this journal complete. Accomplishment achieved.
 

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R56 Cooper S
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Discussion Starter #2 (Edited)
How she currently sits:


Posts of interest:

-Crossmember Shimming.
-Transmission mod for 06WRX clutch fork.
-First start after swap.

Mod list:

Exterior:
-V6 Replica front lip
-Ver. 5/6 grill w/ pink stars badge
-Rear spats
-Headlight Armor yellow foglight cover

Interior
-V5/V6 STI seats
-Depo Racing 52mm Boost Gauge
-Depo Racing 52mm Oil Pressure Gauge
-STI Duracon shift knob
-Trunk Light kit (my favorite mod ever!)
-05 STI Steering wheel

Engine/Drivetrain
-06WRX EJ255 Swap
-06WRX Clutch Fork
-Exedy Stage 1 Clutch for 06 WRX
-GroupN Engine and Transmission Mounts.
-Kartboy Front and Rear Shifter Bushings
-Kartboy Short Shift Lever
-eBay 3" Shifter Extension
-Perrin Lightweight Crank Pulley
-Steel braided clutch line
-Tomei Timing Belt Guide
-TurnInConcepts Transmission Crossmember Bushings
-Walbro 255 Fuel Pump
-Differential Outrigger bushings
-Rear subframe lockdown bolts.
-Beatrush differential brace.

Exhaust
-Invidia G200 Catback
-Helix catted DP

Suspension/Wheels/Brakes
-Bilstein/Prodrive WR struts/springs
-Whiteline steering rack bushings
-Crappy steel braided brake lines that need to be replaced
-4/2 pot calipers
-Stoptech Street Performance pads Front/Rear
-Rota G-Force wheels (17x7.5)
-Hankook Ventus V12 Evo tires. (215/45/r17)
 

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R56 Cooper S
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Discussion Starter #3 (Edited)
So as I stated, I'm working on an 06WRX swap.



After having owned it for like 8 months, I finally have the funds to get this party started.

Throw in some new gaskets, a timing belt kit, a little bit of this...


A dash of this...


A pinch of this...
(Cause I'm a baller)

Bake at 400*F for a couple hours and you end up with this...

A terrible picture of a pretty nice looking engine.
 

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R56 Cooper S
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Discussion Starter #4 (Edited)
A couple points of concern however.

I made a thread about this a while back, but when I was pulling everything apart, I found a mass amount of oil inside the turbo.



I pretty much cleaned it all out, but I didn't take it apart or anything like. I'm hoping it'll be ok and make just be really smoky for a while, but does anyone have any thoughts about any potentially detrimental effects this might cause?

Also, the oil cooler on the engine was absolutely filthy:



Does anyone know what might have caused this thing to get so gross? It doesn't really look like there's any obviously failed gaskets or seals around there, but I'm not really sure.

I guess I'll find out if there's any failed gaskets once the thing starts running huh?
 

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R56 Cooper S
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Discussion Starter #5 (Edited)
Last Thursday I sent my wiring out to Brian @ iWire to get the merge done. In the mean time, I got the party started with the car while the wiring was out.

I disconnected everything a few days ago in anticipation of removing the engine, so today after work all I had to do was get it out of there.

Now you see it:


30 minutes later.

Now you don't!


And that's pretty much where I'm sitting at at the very moment. Tomorrow is going to be a long day doing many many things before I go and install the EJ255. I have to clean up the engine bay a little bit since it's filthy, I have to install my new awesome Group N transmission mount, and trans crossmember bushings, and swap out my old funky shifter joint.

Tomorrow will be fun.

Any tips on anything else I should do while the engine is out?
 

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1998 Subaru Impreza 2.5RS
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I wish I would have gone with a EJ25 motor =(. GL on the build! I would suggest hosing down the bay and making it clean while the motor is out, might as well right? lol
 

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R56 Cooper S
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Discussion Starter #9 (Edited)
Not as much accomplished today as I had hoped. :(

I did some cleaning, took the steering rack out (and I think i screwed up my steering wheel/rack alignment, damnit), and disconnected the control arms from the crossmember. All that's left to do is remove the crossmember, but the bolts are not cooperating at all.

And of course I don't have a 17mm deep socket, and the short socket won't work. Stupid tool set has a deep 19, 18, and 16.
 

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R56 Cooper S
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Discussion Starter #10
Oh my god those fuckers were on tight.

After a 45 minute drive to the only auto parts store near here that closes at midnight to get a 17mm deep socket, and with the help of my cheater bar and a whole lot of grunting, I broke the 4 crossmember bolts loose. Now don't anyone tell me I missed any or anything like that.
 

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R56 Cooper S
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Discussion Starter #11 (Edited)



Seriously? Well what the hell am I supposed to do about this? Anyone have a part number for a replacement? And does it just bash in and out or what?

*edit* I ended up just hammering that thing back in to place. It's more or less back where it needs to be, and it took the torque of the crossmember bolts just fine.
 

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R56 Cooper S
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Discussion Starter #12 (Edited)
Got the crossmember in last night. I used a WRX crossmember, and for those of you wondering about shimming the control arms, this is how I did it:



Just shove em in there. You can see I have 2 washers on one side, and 1 washer on the other. FWIW the 2 washers are towards the rear, but it doesn't matter.

These are the washers I used, purchased from O'Reilly Auto.




Plan for today: Install these bad boys.

 

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MY99 OBS
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shimmying the control arms mean? just adding washers? Subscribed! looks like an awesome project. I am about to start my own, 03 wrx into 99 OBS. Most likely will be putting on the wrx X-member, hence me asking about shimmying the control arms :lol:
 

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You know what I did for the control arms that works....use WRX bushings and put them into your control arms, it fills in the gap and serves it purpose as a bushing =), just food for thought if you want to do it my way.
 

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Discussion Starter #17
shimmying the control arms mean? just adding washers? Subscribed! looks like an awesome project. I am about to start my own, 03 wrx into 99 OBS. Most likely will be putting on the wrx X-member, hence me asking about shimmying the control arms :lol:
What this means is that, the WRX uses wider bushings for the control arms than the RS does, and thus the WRX crossmember is wider where the control arm goes into it than the RS is. The washers are there to take up that extra space, so you can still use the RS control arms.


You know what I did for the control arms that works....use WRX bushings and put them into your control arms, it fills in the gap and serves it purpose as a bushing =), just food for thought if you want to do it my way.
I totally would, but I sure as heck don't feel like taking all that stuff apart again. Haha, it was irritating enough the first time. Good tip though.
 

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Discussion Starter #18 (Edited)
Installed all that shifter stuff last night successfully. Much to my surprise, it turns out my car already had a Group N transmission mount, what the heck.



So that'll be going up for sale if anyone wants to buy it (the old one that is).

Here's some comparisons between the OEM and Kartboy rear shifter bushings.








Plan for today: Get under the car AGAIN; take off transmission crossmember AGAIN; replace my old shifter linkage. I had to buy some punches specifically for this job, so that crap better come off.

Plan stage 2: Put my steering rack back in.
 

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Discussion Starter #19 (Edited)
Shifter linkage in.
Steering rack in.

And because I love doing comparisons:

The new vs old linkage. My old one really wasn't all that bad.


Aw man I love when things are clean!


So on my swap, I decided to go with the 06WRX clutch/flywheel combo, instead of the RS one. The reason I did this was because the WRX stuff is already designed to handle the power that the engine puts out, and the slightly uprated Exedy Stage 1 I bought should be just a little bit better.

The alternative reason why I decided to go with the 06 setup is because the 06WRX uses a much thicker and beefier release fork. I saw many posts about people breaking the release forks on the RS, and even though I doubt I'd ever have that problem with only an Exedy kit, I didn't ever want to have to deal with that.

As some of you know, the problem with using the 06WRX fork on an RS transmission is that it sometimes comes in contact with a bit of webbing inside the trans bellhousing, causing the fork to not work quite right. My plan is to cut back some of that webbing so I won't have any issues with the thicker fork.

I will post pics later of what I did, so others who want to do this will know what to do.
 

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Discussion Starter #20 (Edited)
Ahh, breakfast of champions! Fuel for this most auspicious of days.



As promised, here are the pictures of the modification I did to the trans bellhousing to fit the 06WRX clutch fork. I actually ended up shaving off more than was necessary, but in the end, if it were smoothed out a bit more, it would ALMOST looks like the transmission webbing was designed that way, don't you think?

Before:


After:




Plan for today: Get the engine in! Yeah!!
 
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