wagon fettle
 

SN has always been a source of good advice, so even though this is not jaw dropping thread like Dinges, E_M_B, Zen, Frayz etc I thought I’d share my wagons evolution so far and try to give a little back :)

I brought it when it was just over three years old, early 2004 and it looked like this
http://img.photobucket.com/albums/v4...ilscoob2-1.jpg
http://img.photobucket.com/albums/v4...mailscoob3.jpg
http://img.photobucket.com/albums/v4...lscoob10-1.jpg

After a couple of years and your average modding (the majority of the mechanical work was carried out by XS as I had nowhere I could work on the it); full decat, panel filter, ported headers, flex fit up-pipe, samco turbo hoses, three port boost solenoid, TEK3 etc…and of course the obligatory external mods I ended up with this

http://img.photobucket.com/albums/v4...940cropped.jpg
http://img.photobucket.com/albums/v4...939cropped.jpg
http://img.photobucket.com/albums/v4...3cropped-1.jpg

I really liked the way the car drove but wanted to go faster, up-rating the supporting components in line with increasing the power and doing as much of the work myself as I could. Starting with the brakes and suspension to try and retain the same sort of feel, optimising it to try to make it quicker without losing the drivability. I moved late 2006 and found myself with a garage and enclosed space I could work on the wagon so began to acquire bits for a low budget DIY upgrade…

Ian

I started with the brakes; using one of Dyney's brackets upgraded from a sliding calliper to 03WRX two pots

http://img.photobucket.com/albums/v4...s/IMG_3314.jpg
http://img.photobucket.com/albums/v4...s/IMG_3317.jpg

270mm vs 290mm
http://img.photobucket.com/albums/v4...s/IMG_3315.jpg

For the fronts, I sourced a pair of the original Scooby Sport Bembos and two piece 325mm disks from Godspeed.
http://img.photobucket.com/albums/v4...s/IMG_3461.jpg
http://img.photobucket.com/albums/v4...IMG_4193-1.jpg

I also installed a CDF's brake stopper to stop the bulkhead flexing where the master cylinder is fitted. The new set up improved the brake pedal feel no end and I have yet to experience brake fade; in conditions where with the previous set up wilted this set up keeps working :notworthy

I then moved onto the suspension; installing Whiteline solid drop-links all round and a Whiteline 22mm adjustable rear ARB. I already had Eibach springs fitted, but the drop links and especially the ARB tightened up the way it felt allowing you to get onto the power earlier when cornering.

http://img.photobucket.com/albums/v4...s/IMG_3770.jpg
http://img.photobucket.com/albums/v4.../IMG_3772p.jpg

As I had faired very well -for a mechanical simpleton at least- I decided to get brave and did this; 22B Bulletin Board: bolt on stage II mods...

After much cursing and scrapped knuckles I ended up with this
http://img.photobucket.com/albums/v4...s/IMG_5744.jpg
http://img.photobucket.com/albums/v4...IMG_7043ps.jpg

:luxhello: i love wagons!

It now went pretty quickly and had a brake set up that was not over whelmed by its speed. I was very happy with the results and rather proud of myself so I’ve continued to fiddle since then and (after splitting a rubber hose whilst fitting my fmic and it not working anyway:cuckoo:), have removed my air con

http://img.photobucket.com/albums/v4...s/IMG_7479.jpg
http://img.photobucket.com/albums/v4...s/IMG_7218.jpg

I had a bit of a moment and made an impulse ebay purchase of a v5 re-trimmed wagon interior. I liked the way it lifted the interior but I didn't like the colour or the v5 drivers seat...so I bit the bullet and got my v6 interior re-covered by Concept Interiors.

v5
http://img.photobucket.com/albums/v4...s/DSCF4756.jpg
http://img.photobucket.com/albums/v4...s/DSCF4757.jpg

v6
http://img.photobucket.com/albums/v4...s/IMG_6604.jpg
http://img.photobucket.com/albums/v4...IMG_6601-1.jpg
http://img.photobucket.com/albums/v4...s/IMG_7480.jpg
http://img.photobucket.com/albums/v4...s/IMG_7481.jpg


Being a little obsessive I wasn't happy with the big-ass Momo wheel and I managed to source a MY03 sti wheel, paint strip it:eek: and clean it up to get it to match.

http://img.photobucket.com/albums/v4...IMG_7280ps.jpg

Recently though I have been acquiring parts to upgrade my suspension; my wagon has just done 70k so the standard struts are getting a little tired. A good excuse at the very least :D

I managed to get hold of some rusty but refurbished mechanically KYB Group N tarmac struts, Cusco top mounts, alloy wishbones, front super flex bush set and a lower brace. Everything was (with the exception of the lower brace and bushes), second hand and I wanted to clean it all up before fitting.


More pics later...I need a PC break :lol1:

I quite like them too :D:lol1:

You removed the air con :eek: you wait till we have a really hot summer this year :cool:

Looking good though Ian :thumb:

thanks ian:)

well I'd split the pipes and lost all my gas when I pushed too hard on the fmic hard pipes :( so as its only a toy now thought I may as well go the whole hog and bin it..we shall see how I deal with those pod traffic jams this year :wonder::lol1:

the struts had been refurbished, used for a couple of thousand miles and then just left in a garage. So they were mechanically sound but looked a mess.
http://img.photobucket.com/albums/v4...s/IMG_6708.jpg
http://img.photobucket.com/albums/v4...s/IMG_6715.jpg

I set about cleaning them up; the dremel lasted all of 10mins:mad: so i switched to a drill and wire brush head. Quite pleased with the results, especially considering how bad the corrosion was on the bases.
http://img.photobucket.com/albums/v4...s/IMG_7291.jpg
http://img.photobucket.com/albums/v4...s/IMG_7292.jpg

I had to hand paint them with this toxic stuff, horrible to use but did the trick.
http://img.photobucket.com/albums/v4...s/IMG_7298.jpg

Two coats later; milk chocolate struts :freak3:
http://img.photobucket.com/albums/v4...s/IMG_7432.jpg
http://img.photobucket.com/albums/v4...s/IMG_7435.jpg

After letting the paint go off for a couple of days I repainted them with a slightly less edible looking colour.
http://img.photobucket.com/albums/v4...s/IMG_7437.jpg
http://img.photobucket.com/albums/v4...s/IMG_7442.jpg

Not the best finish but much better than they were, ready to go
http://img.photobucket.com/albums/v4...s/IMG_7448.jpg

Top mounts next...unfortunately I neglected to take any pictures before I cleaned them up. There was some corrosion on the bottom of both plates which needed finishing and protecting, so I decided to take them apart and do it properly:smug:
http://img.photobucket.com/albums/v4...s/IMG_7248.jpg

Prepared to paint
http://img.photobucket.com/albums/v4...s/IMG_7246.jpg

I re-assembled them after painting and was pleasantly suprised with the results:cool:
http://img.photobucket.com/albums/v4...s/IMG_7453.jpg
http://img.photobucket.com/albums/v4...s/IMG_7455.jpg

Wishbones then...second hand as always :lol1: so I cleaned them up...

http://img.photobucket.com/albums/v4...s/IMG_7215.jpg

http://img.photobucket.com/albums/v4...s/IMG_7221.jpg

Originally i was going to purchase an anti-lift kit but with all the adjustment from the top mounts and the struts I elected to retain the standard fittings and invest in uprated bushes. So, you guessed it; I cleaned up the originals :norty:
http://img.photobucket.com/albums/v4...s/IMG_7450.jpg

New bushes, off to Mocom (thanks for making time for me with no notice Zak), on Wednesday to remove the old ones and press fit these puppies :cool:
http://img.photobucket.com/albums/v4...s/IMG_7461.jpg

Hey - nice story Ian. Anyway - it's bloody quick!!!

Bloody quick sideways so i've heard :lol1:

thanks Keith :thumb: I'm sure you will back me up when I say it was totally controlled and safe sideways :D

Nice wagon there! Looking forward to parking next to it at the NBO :)

Dave

Thanks Dave, I'm looking forward to having a nose around your cashmere beast; the stroker kit sounds interesting :notworthy

ian

gazebo up and back wheels off...ready to start tomorrow :)

http://img.photobucket.com/albums/v4...s/IMG_7493.jpg

looking good :thumb: :thumb: :thumb: dont worry about air con just get an ra roof scoop like ive done to my pimp wagon project:) :)

If i didn't have a sunroof I'd have a vent:norty:

seen your thread, looks like a decent job...how's it going now?

made reasonable progress today; removed both rear struts, refitted one and fitted braided brake lines. I could only refit one of the struts because the spring seat was missed from the N\S :Whatever_

First things first, remember to loosen the strut bolt before you remove the strut...else you will end up ruining the strut.
http://img.photobucket.com/albums/v4...s/IMG_7518.jpg
http://img.photobucket.com/albums/v4...s/IMG_7523.jpg

Once you have loosened the strut bolt, you can loosen the two lower bolts (19mm socket).
http://img.photobucket.com/albums/v4...s/IMG_7509.jpg

Then the three top mount nuts...removing your strut brace mount if fitted.
http://img.photobucket.com/albums/v4...s/IMG_7506.jpg

You can then carefully remove the strut
http://img.photobucket.com/albums/v4...s/IMG_7512.jpg
http://img.photobucket.com/albums/v4...s/IMG_7510.jpg

Now you need to compress the springs so you can remove the top mount (nice and easy if you loosen the bolt while the strut was fitted :mad:)
http://img.photobucket.com/albums/v4...s/IMG_7513.jpg

Preparing the two struts shows how much beefier the KYG's are.
http://img.photobucket.com/albums/v4...s/IMG_7514.jpg
http://img.photobucket.com/albums/v4...s/IMG_7515.jpg

Re-assemble the strut in reverse order...easy :thumb:
http://img.photobucket.com/albums/v4...s/IMG_7543.jpg

Brake lines are even easier, just make sure you purchase a 10mm brake line spanner or you will round the fixings off
http://img.photobucket.com/albums/v4...s/IMG_7541.jpg

Shweeeeeeeeeet :)

Nice looking work there, who said Subarus arent green..... Recycling at its finest. :thumb:

Ian
(I am noticing a lot of people called Ian, with Wagons...:Suspiciou )

Could be another member of Team Ian :lol1:

Ian

kinder to my pocket and the planet :D

You are not wrong...seems to be an indication of excellent personal taste :lol1:

I have now taken the wagon out for a drive over some roads I know very well and the rear damping seems much stiffer, although that could very well be the placebo effect...anyway I'm happy so far although the N\S strut is quite noisy :lol1:
http://img.photobucket.com/albums/v4...s/IMG_7545.jpg
http://img.photobucket.com/albums/v4...s/IMG_7550.jpg

Though I'd post a pic of my advanced strut top nut fastening system...:freak3:
http://img.photobucket.com/albums/v4...IMG_7537-1.jpg


Drove down to Kent yesterday to pick up my roof rail delete trim from the now defunct Jolly Green Monster and have seen the new Jolly Peppermint Monster; thanks Simon :thumb:

http://img.photobucket.com/albums/v4...s/IMG_7564.jpg

its gotta be good for the RS day :norty::D

A short update...I took the roof bars off on Sunday and fitted the blanking trim. It was a lot less fiddly than I imagined and only took 90 minuets or so.
http://img.photobucket.com/albums/v4...s/IMG_7567.jpg

After you have removed the roof bars (four 12mm bolts each side), you can slide the section trim forward to stop breaking the fasteners. There is a retaining piece of trim near the screen which you can just pop out with a flat head screw driver. After cleaning the gully I used silicone bathroom sealer to plug the holes, cleaned up the trim and clipped each piece in place.
http://img.photobucket.com/albums/v4...s/IMG_7569.jpg

Makes a big difference to the perceived roof line...well in my head anyway :D
http://img.photobucket.com/albums/v4...s/IMG_7570.jpg

I'm really pleased with it; makes the most of the black roof now too
http://img.photobucket.com/albums/v4...IMG_7581ps.jpg
http://img.photobucket.com/albums/v4...s/IMG_7584.jpg

Weight saving of just under 3kg too :norty: :lol1:
http://img.photobucket.com/albums/v4...s/IMG_7575.jpg

Looking good Ian, i ordered the bits today to do my roof rails :norty:

its a really good mod with one major downside; you will wish you had removed them years ago :lol1:

will this make it the only debarred blob wagon?

Removed the front struts and WD40'd everything last night.
http://img.photobucket.com/albums/v4...s/IMG_7593.jpg

I completed assembling and lubing the bushes for the wishbones (Luke at Mocom did the hard bit last week :notworthy).
http://img.photobucket.com/albums/v4...s/IMG_7610.jpg
http://img.photobucket.com/albums/v4...s/IMG_7613.jpg

Removed the old ARB bushes...
http://img.photobucket.com/albums/v4...s/IMG_7599.jpg

...and fitted the SuperFlex replacements.
http://img.photobucket.com/albums/v4...s/IMG_7633.jpg

Made a little pile of stuff to fit to in the garage too:D
http://img.photobucket.com/albums/v4...s/IMG_7608.jpg