Subaru Impreza GC8 & RS Forum & Community banner

41 - 51 of 51 Posts

·
Registered
Joined
·
47 Posts
Discussion Starter #41
So now the patch is in and welded; weld, grind, weld......

83114





This is now ready for duraglass and bondo

83116




The next panel is in
83115



Now the final panel is in. All the rot has been repaired on the left side.
83117




So to put in the square hole for the rocker fastener I made a scribe template our of an Orange Juice bottle
83118




I needed to make a hole like shown
83119





I used the rocker as the guide where to put the hole. Notice the rocker will hide most of the repair.
83121



83120




Here is the hole in the rocker. I drilled it out then used a dremel bit to clear the corners. Notice the hole drilled in the rocker flange, this is to allow the water channel in the rocker drain out of the the flange
83122


YES the rear fascia is trialed with its fasteners looking good.
83123
 

·
Registered
Joined
·
47 Posts
Discussion Starter #43
Ok some more updates. I made a "plug gauge" out of some ABS strips and sanded it until it fit the stock square hole then used it to tune the holes I had to put into the metal.
83556




Looks good
83557


So the Ebay fenders I bought are NFG - don't buy these, they really don't fit the car. With lots and lots and lots of fiddling the would probably fit but it was less work to just fix the OE fenders. I used part of the lower from the new to patch the original then used the rest to practice dent pulling.
83558


83559


83560


83561


83562



Most of it is hidden but it turned out quite nice when I was done.
83563


Bay clean up day. Wow was it a mess. Now on to make new ones.
83564


$300 Worth of bits. In the end this will not be cheap. I will tally up the cost of it all in a later post.
83565
 

·
Registered
Joined
·
47 Posts
Discussion Starter #44
I fabbed up some jacking reinforcements so the pinch flange would not get all "jacked up" when changing to race wheels.
83566

Welded in and all sealed up
83567



Ok now getting to it with Evercoat Glass Lite to cover the welding areas.

83568



Smear, sand, smear , sand, smear, sand......you get the point
83569



Evercoat RAGE!
83570



Guide Coat
83571




Coming together
83572


A little dent repair. It actually turned out not too bad.
83573



All prepped
83574


Final masking for the overspray
83575
 

·
Registered
Joined
·
47 Posts
Discussion Starter #45
Finally Epoxy Primer!!
83576


83577


83578



So the metal is all done on the left side. I have the finish the fender and prime it then undercoat the car and put the mechanicals back together then start over again on the right side. Fortunately it isn't as badly rusted.
 

·
Registered
Joined
·
47 Posts
Discussion Starter #47
NEED HELP!! I need a photo(s) of the body metal around the fuel filler neck. I can't tell what it is supposed to look like and our car is really NFG. I will post pics soon. A couple of photos in with the fuel filler door open would help a lot. Help a brother out!
 

·
Registered
Joined
·
47 Posts
Discussion Starter #48
Well lots to catch up on. Still along way to go but we are making progress. Good to get some of the bits off the floor and replaced. Some pics of the brake rebuild. When we got the car the brakes were really weak. After the tear down I could see the rears were totally frozen with dirt, rust etc. Fortunately the caliper pins were not corroded in the slide pockets.

83835


Yes I have a small medial blaster too. Can't really seeing rebuilding brakes without one.
83836



Afterword looks better than new. I use the VHT caliper paint and have had good results with it on street cars. Down the road this will all likely be replaced with race brakes.
83837


Another comparison, blasted vs not blasted.
83838


One corner done. :) The rotor and pads looked fairly new. Probably should replace those too but will try to see if I can get by with these. Already have cubic $$ in this.
83839


So three of the corners had some parts I could carry over but the right rear the jounce pad was complete disintegrated and the dust boot had a crack in it. All new OE Subie bits for the pins, seals, bleed screws, and bolts.
83840


Just for reference I have these guys too
83841


83842



All the hardware is cleaned and ready for reinstall
83843
 

·
Registered
Joined
·
47 Posts
Discussion Starter #49
OK back to the body. I thought the right side would be better but whoa was I wrong. I can't believe how many schlock mechanics are still out there. The repairs on this car have been mind blowing to say the least. (BTW watch this, I feel for these guys
)

The lower rear quarter looks similar to the other side was. I was trying to figure out how to work around the fuel filler neck but that will sort out later in this post.

83844



So I start to deep dive the fuel filler area and started shaking my head on how it was looking, "Wow that is a lot of rust", I removed the "fuel Saucer" I know that name because that is the Subaru part name for it. :-(
83845



This is an interesting pic, I will explain what is going on here:

83846


So it isn't really apparent but I have a light shining from the hole in the lower rear quarter (out side of the car) and it is illuminating the gas cap from the inside. Hmm doesn't really seem to be sealed. OK "HOW DOES IT WORK?"

So lets look at the saucer, Hmm I see the drain and drain tube but there isn't any type of seal on the back SOOOO that could only mean that in a fuel overflow the gas will run right into the rear quarter and fill up the right side of the trunk. JUST AWESOME! WTF!!
83847


This is when I put the shout out for pics of what it is supposed to look like. BTW HUGE THANKS TO md00150028 for the pics. That really helped.

More weirdness from the schlock repair guys.
83848


I though that was an OE doubler at first but after walking this through I realized it was another NFG repair job.

Just to make it super confusing there is also this:
83849


That is an OE vent or drain of some type in the lowest part of the rear quarter. That indicates to me Subaru had this as a countermeasure in case the rear filled up with fuel.

So I took a look at the "fuel saucer" and see it was all cut away in the repair. (WTF! Why do this!? How dangerous!)

83850



At this point it all had to come out. It was apparent the fuel filler neck was removed before in. It was super easy to remove.

Let's hear it for pigeon rubbers!
83851


Capped it all off and removed the fuel filler neck.
83852


83853

Just to the right of the "A" and above it is a plug for the fuel hose. I happened to have an old aluminum plug gauge used to size intake ports for porting. Fit like a gem!
 

·
Registered
Joined
·
47 Posts
Discussion Starter #50
Check this out:
83854



Looking good! ;-)
83855


Just getting better!
83856


That hole you see in the center goes right into the trunk,

OK now for the clean up. Can't forget this one, the inner shock tower hole where it all got started. This side was worse that the left.
83857


Rotted metal cut away
83858


On the floor to be discarded;
83859



So after ordering a "Fuel Saucer", kinda a pricey part too here is the comparison:

83860


The left one is the new one and had a the proper flange and it comes with the fuel filler gasket too.

Here is the "B" side and you can see the gasket ti supposed to "kiss up" to the sheetmetal.

83861


The fuel fuller has this gasket:
83862

I have deduced it all sandwiches together with sheet metal between this gasket and the Fuel Saucer gasket. This is what it looks like without the sheet metal and plastic shroud from the fuel saucer:


83863
 

·
Registered
Joined
·
47 Posts
Discussion Starter #51
One more reference pic
83864


83867


OK I am off to do some welding. Patched several of the bits in the rear quarter yesterday so it is slowly moving forward. Making a little relief for that goofy vent.

83866
 
41 - 51 of 51 Posts
Top