Classic wagon, full rebuild getting out of hand
 

So the poor old wagon has bneen sat for 5 years in a heap after suffering head gasket failure. With other projects (mainly the house) at an end I've finally managed to gain a load of spare time. Cue project wagon!
This was my first Subaru
https://cimg1.ibsrv.net/gimg/www.sco...2c212b0c03.jpg

However a shot in a classic soon had me selling up and buying this wee beaut

https://cimg4.ibsrv.net/gimg/www.sco...a442f20d97.jpg
https://cimg6.ibsrv.net/gimg/www.sco...44403635c7.jpg

Just a 1995 gf8 wrx with a polar chip and other basic goodies.

It for perfectly until the dreaded head gasket failure struck, and with pressurised hoses and ultimately hose failures and heater matrix failure.

So the car has been parked up for a long timI have, but i have now decided to rebuild the whole car and document progress on here with as many pictures as possible. So here goes nothing!

OK so let's face it, the standard wrx wagon blue interior is just gash. So that's been binned along with the doorcards some fool has butchered for 6*9's.
Interior stripped and trying to find a way into the heater matrix. F&%k me its buried deep in there.
https://cimg5.ibsrv.net/gimg/www.sco...fcf015998a.jpg
https://cimg1.ibsrv.net/gimg/www.sco...4d9e276795.jpg
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Progress with this build is gonna be slow as parts purchasing and money to burn don't seem to go hand in hand.

I feel the need to rectify a lifetime of bodge fixes from previous owners as I progress. Namely wiring!

Why do folks fit stereos, gauges etc and persist on twisting wires together and taping, using scotch locks and tapping into bizarre power sources.
​​​​​​​https://cimg2.ibsrv.net/gimg/www.sco...0d2ad2afb8.jpg

My pet hate is rushed jobs done poorly. So out with the solder and heat shrink! Time to return the interior wiring loom back to a factory state.

https://cimg1.ibsrv.net/gimg/www.sco...b23756e42d.jpg

​​​wiring sorted, I managed to get my filthy paws on a flocked dash. Given the Subaru rally history it would have been rude not to.

I'll ge​​​​t the rest of the interior back in once its had some minor bodywork.

​​​​​​​Engine updates coming soon

Nice project.
Subscribed :thumb:

Why is it once you start digging about you find something else to do?
The engines coming out for the head repair and already im thinking "iI'll just quickly paint the engine bay, subframes etc"
Honestly think I should have taken up a crystal method addiction....would be a damn sight cheaper.
Anyhoo moved the car into my shed and engine is whipped out.
Every sensor, lead, bolt has been bagged and labelled.
Mandat​​ory before shot
​​​​​​​https://cimg0.ibsrv.net/gimg/www.sco...cc870da1f8.jpg

https://cimg4.ibsrv.net/gimg/www.sco...05642ed9fb.jpg
https://cimg0.ibsrv.net/gimg/www.sco...36a8a25d07.jpg
Moved the car into the garage.....not quite sure what's happened to my photos, lol.
some bolts are proving to be in a pesky location but my trusty lidls electric rattler makes short work of them once they've soaked overnight in wd40.

https://cimg3.ibsrv.net/gimg/www.sco...eb5e73e868.jpg
https://cimg8.ibsrv.net/gimg/www.sco...53232370a2.jpg
That's the engine out and hanging like my big set of balls for taking a job like this on!

The more I think about it, now I've come this far it would be a sin JUST to replace the gaskets and go again. Think I might just rebuild the engine while its out.
I'm guessing other owners have been in this position before hahaha

https://cimg8.ibsrv.net/gimg/www.sco...49fc1ce35d.jpgSump pan off, and defo had a head gasket issue.
https://cimg1.ibsrv.net/gimg/www.sco...bab811783a.jpgTime to split the block and assess damage if any, hope not.
Tidyness and a good filing system is the order of the day
https://cimg2.ibsrv.net/gimg/www.sco...08b7dce848.jpgThats the block split ready for cleaning
oh well, so much for a simple head gasket replacement, looks like since I've come this far I may as well rebuild the whole car and engine for peace of mind.

A bonus is the closed deck block is in great condition, although I'd be happy to freshen up the bores think I'll send it away for machining.

great work there m8. not so many of these threads these days will be watching your progress. nice one :thumb:

https://cimg7.ibsrv.net/gimg/www.sco...f4b1e71bfc.jpgStarted cleaning the block halves, spray gunk and elbow grease with the wifes steam cleaner turned out to be .....well ..crap.
https://cimg9.ibsrv.net/gimg/www.sco...e5720b7e0f.jpgThats better!
spray on gunk with a steam cleaner didn't cut the mustard as much as I'd liked.
So it was a wee trip down to get it vapour blasted, with a fine non abrasive medium suitable for aluminum.

Much better now. Think I deserve a bud light and a single malt

https://cimg2.ibsrv.net/gimg/www.sco...08ce9c6931.jpgBlock getting palleted up to send to the machine shop
https://cimg0.ibsrv.net/gimg/www.sco...da9f2b08c8.jpgNice home made crate to protect the block
https://cimg1.ibsrv.net/gimg/www.sco...999e0ef716.jpgMay as well get a start on the heads
it would have been soooo much easier just to replace the head gasket or bought a 2nd hand engine, but with so many imprezas being broken or sacrificed to the scrapyard and rust gods I've decided to give this one a new lease of life the proper way.
The block is away to precision engineering Inverness for skimming of all mating surfaces, and crucially rebore and hone to 92.5mm to suit a new forged setup.

​​​​​​I'm not looking for crazy power as its just not usable on the roads without risking your licence or a public accident.
im not into "scene" cars which are lowered on coilovers, I've never understood why the youth of today slam the cars on coilovers to end up creating cars with stiff, unpredictable handling. More than often a worse spec of damper than OEM.

The primary target for this build is one thing. My car my rules....I've never been one to please the crowds haha

Anyway less typing I have cylinder heads to refurb, check clearances, lap valves ........and If I get time I'll re paint the inlet manifold phew!
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good work m8, go enjoy that beer while theres some sun.

Cheers yabba!
beer and whisky ends up in a vicious circle for me. It seems to kick start the part of the brain that generates modding ideas....if only it worked with the money budget part of the brain.
Never mind that's what overtimes for lol

https://cimg2.ibsrv.net/gimg/www.sco...9ea4ad1c36.jpgThe first cut is the deepest
https://cimg4.ibsrv.net/gimg/www.sco...569522a3b6.jpgCheeky wee trial fit
https://cimg9.ibsrv.net/gimg/www.sco...98ad053e90.jpgPrimed, with rivnuts in
https://cimg3.ibsrv.net/gimg/www.sco...f1a4dc1f7c.jpgFresh lick of paint
https://cimg7.ibsrv.net/gimg/www.sco...ab99fe1f12.jpgNot too bad at all
soooo while I'm waiting for machine work to the block and umpteen engine parts to be saved up for, thought I'd get a start on freshening up the body. And you guessed it I'm rectifying years of neglect and also reparing as much as I can at the same time.
406 silver just didn't seem to float the old boat, so I've gone for a lovely glossy white seeing as its a classic JDM colour and I haven't seen many classic wagons in white.
Taking some inspiration from the old forms rs and cosworth range and painted the arch flares black, should look the part once its all done.
The paint work is stunning for a home diy spray job, given its a dusty old shed (damped down before spraying) the paintwork has come out near perfect. No dust or bugs captured, just smooth glossy finish. Still need to wet sand and polish but you get the idea. ......need to stop drinking beer, its leading to silly ideas

Epic stuff. Did you do the spraying yourself?

Yeah was all me thanks. I'm doing pretty much everything on this build myself.
best bit of advice I was given as an apprentice (pipefitter) was "don't get greedy with it" and I've listened to that my whole life lol.
Just did many light coats of colour, then 2-3 coats of clear with the last a wet/heavy coat. Once I've wet sanded it, it should be better than a factory finish.
Not bad for cheapass electric hvlp diy spraygun.

looking good mate I'll be checking in on this every so often. always good to see love for the wagons. flocked dash looks the dogs. something I'm keen on getting done on mine.

https://cimg4.ibsrv.net/gimg/www.sco...7687d50ffb.jpg
I do love a flocking myself. Best £30 spent on eBay yet for a flocked dash. Can't stop touching it lol

What did you use to blast the panel ready for spraying?

Sandpaper and a block. Wasn't difficult or time consuming to be fair.
rubbed panel with 320 grit first
Few coats of primer, left to fully cure
Then a sand with 400, then 600
The panel was pretty smooth and felt nice on the hand just before painting.

Between colour and clear coat I gave it a wipe with a tack rag, and that was it really

30 quid on ebay! jammy git! im off to have a look for one now :thumb:

https://cimg4.ibsrv.net/gimg/www.sco...c7d1e1c2de.jpgFog covers after a wet sand look terrible
https://cimg2.ibsrv.net/gimg/www.sco...8b5d27dd72.jpgA wee polish up and they are spankin!
https://cimg8.ibsrv.net/gimg/www.sco...4dfcd043ee.jpgDecals going on
https://cimg6.ibsrv.net/gimg/www.sco...78ed806ce2.jpgHappy with the finished product
another fine eBay find. Preface fog covers for £8.00.
Hit them with a spray can of satin black (all I had lying about) and a few coats of clear. Cheeky wet sand and a smack in the face with g3 cutting and meguiars polish.
Super smooth glass finish.
The build is shaping up nicely. Think it's time for a beer

https://cimg6.ibsrv.net/gimg/www.sco...3e27565636.jpgFlatted down
https://cimg1.ibsrv.net/gimg/www.sco...dc1343dd50.jpgLiberal coating of barcoat before i prime
found an alloy face lift bonnet at the scrappy for £20 so got a chance to flat the bugger down and a good slap in the ass with barcoat isolator coat just in case its some stupid paint that's on it.
I'll let that dry off before giving it the white.

....so it looks like I'll be face lifting the wagon.
Best get onto eBay for some more bargains

https://cimg8.ibsrv.net/gimg/www.sco...1d80d7ff56.jpgFreshly painted bonnet, before a wet sand and polish
https://cimg1.ibsrv.net/gimg/www.sco...6adfef2429.jpgThis stuff is amazing!
https://cimg4.ibsrv.net/gimg/www.sco...fd2938a474.jpgAfter a wet sand and polish
you can tell its summer, had a really productive few days. Got the bonnet painted, wet sanded and polished.
Paint I'm using is upol 1k RFU acrylic and is so easy to use. I've had no training for painting and this stuff just lays on so well, no orange peel, seems to smooth out by itself and goes super hard. Not bad given I am doing it in a dusty shed with no spray booth or oven. Just a crappy oil heater from lidl and a diy electric sprayer. Very pleased with the results.

More to follow once I've demolished some more beer

https://cimg8.ibsrv.net/gimg/www.sco...599bbc9fb2.jpgEsl board!
ooh lala another cheeky eBay find. £70 for the ESL board. Looks like I'll get the soldering gear out tonight and fit a socket onto the ecu, and cut the j1 resistor.
I'm keeping my hi flow sports cat on the 3 inch downpipe so I won't be enabling anti lag.

Really nice work :thumb:

The ESL board you have bought isn't mappable unfortunately,you have the old v1.2 board for the early car,and no als,launch,ffshift etc possible on the newer v2 ESL board 92-96.

appologies
It seems it's the earlier v1.0 which isn't mappable,just an eeprom,i think the v1.2 is live mappable?
the latest ESL is v2.0

Ah OK I see. That's fair enough regarding the Al's feature.
am I right in thinking the v1.2 board doesn't do live mapping but it CAN still be mapped?
I was told it had a map on for td05 16g, 440s and mafless.
I assume with this board you can still map the car with whatever mods is on the car. Just not live mapping?

Haha u had me panicking there. Thought I'd have to sell it and get the v2. Phew!