Slow weeks for a fast car.

The past couple of weeks have been the slowest ever. A constant feeling of dread keeps me company every time I have thought about this GC. Especially when I remember my target at the start of the year was to get it up and running before August. We all know about the best laid plans....

A few choice parts came through in the post. Thanks to the guys over at Import Performance Parts . So let's get right to it as I bring you up to speed on this not-so-fast-today GC.

LONG POST ALERT: this will have to be delivered in two parts.

The final piece of the Brake jigsaw puzzle.

Stop tech steel braided brake lines. We shall put these to the test soon. Quicker, firmer more consistent brake pedal feel among other benefits are expected. I am sure this will provide a dramatic improvement from the stock rubber hoses that came off the assembly line in this GC.

Bye Bye hard lines!

In the last post, I gave a lengthy update on the perils of these OEM hard lines for the oil cooler. They introduced major fitment issues. This was the parting shot.

We love braids. Braided lines.

The selected replacement for the hard lines. These are built to withstand high blistering heat and temperature as well as high pressure. In normal operation of the EJ207 motor, the oil temperatures can get to well over 100 degrees celsius and pressure can surge beyond 8 bar. This needs to be contained and these braided lines are the best suited for the job. They may not exactly look pretty, but this is a case of function over form.

PS Cooler

The power steering fluid cooler was also length adjusted and repositioned. Another advantage of the braided lines is that they are quite malleable and can be made to fit even in that cramped bay.

Test Fit:

The initial plan was to have the cooler "side mounted"as we had a slew of space issues to deal with. However, Bharat over at Diastar attempted this "center mount" which was a deviation from plan but I think it turned out quite well. It will require some minor fabrications to hold firm and also to have the PS cooler at the right height. With this fit, the wiring harness will be routed in front of the radiator and away from the heat of the exhaust headers. I see plenty of custom brackets coming up.

Oil Lines Close up

Here is a close-up of the oil lines. This was still during mock fit so in the final setup, a few things will have changed. New jubilee clips for one and lower mounting brackets.

Lights, camera...

Here's a view from an angle with the grill and headlamps fitted. Everything falling nicely into place.

Dusty much?

Don't let the dust fool you. With the two coolers in, the mechanical components were now in full running condition. Ready to roll into the body shop.

END OF PART 1: MECHANICAL

PART 2: BODYWORK BEGINS

Many moons later...

So this week the bodywork finally started. I managed to get a few shots of the progress. A bit of focus on the rust removal as the car is prepared for paint.

The Arena:

Well folks, this is where it will all happen. Old scars will be opened, and new ones acquired. Cutting open and sealing and binding and joining. Arc welding and panel beating will carry the day.

Identified rust spots: hell

The tail section had accumulated an alarming amount of rust. Around the trunk lining where the rubber seal sits to keep out the elements, a job it had failed in spectacular fashion.

Rust spots: 2

It was really bad in this area. Cut away and replace work already in progress here. The old metal is cut and ground down and fresh sheet metal spot welded in place. Shaping in progress.

The first level of joinery looks rough and untidy, but is a necessary step towards renewal of this section.

Rust spots: 3

Right hand side was not spared. The damage had reached this sector. At this point I had to take a moment and really question myself on the decision to buy this car, but that's a story for another day.

To repair this section, the rear windscreen will have to come off or risk damage. But then again, taking it off has a 95% to 100% chance of breakage. May the odds be in my favor.

Close up clip

See through:

There is a hole through the car. I did not need to be a scientist to deduce that the water which leaked in through the trunk seal neatly collected and sat here, undisturbed. Long enough to cause severe corrosion.

All this was going to get cut out. Real soon.

All in all, that tail section still manages to look good. The bumper comes off this week. Hopefully it's reveal will not bring with it too much work, but we are not taking any short cuts here. That exhaust will also need some adjustment work after all the bodywork is done.

RSR

RSR 3 cat-back stainsless steel exhaust 3 inch bore. This will end up a few inches shorter than the manufacturer intended, but will be a perfect fit here. Higher flow should yield some interesting power figures.

I had my gopro with me and this presented a unique opportunity for some dramatic shots off that wide angle lens.

LHS view: work area

From here, you can see a bit of the expanse of the workshop. Lots of work in progress; some kind of testament to the demand that Diastar Auto sees.

RHS

I like this shot as it brings into focus the really wide stance of the XXR530 wheels coupled with the wider track from the MY05 GDB Impreza drivetrain that we are running. I plan to replace these with some OZ superleggera with a "close to stock" offset for a flush fit.

Bare Interior

Looks like so much space but it's not really. When you strip away all the padding and fittings, this is what you are left with. In full race mode, I imagine the only addition in here would be a 12 point roll cage and a bucket seat. That would be quite a racket to drive!

Cockpit:

This center line is usually selected to hold the various G-sensors and yaw sensors as the center-most position in the car. These are used by the ABS and DCCD computers to help you stay on the road.

Driver view:

Exciting to imagine that bucket seat hugging you as you mash that pedal and the acceleration pushes you back into the seat, fists tightening on the steering wheel. This particular wheel will have to be replaced with something more modern. At least with radio controls.

Co-driver view

Not too shabby.

RHS view 2

Another view from the rear showing how meaty that stance is. I would have kept the wheels but this would have made the bodywork a tad too complicated for my liking. These are on sale!

Locked in the Trunk

A good position to get a view of the main power conduit. as a result of the battery relocation to the trunk, the wiring is routed on the left hand side, the two thick cables, sharing the same path with the fuel and IC spray lines to the front.

Bent

Front end starting to come together. Hopefully this week the mounting work for the crash bar will begin. That should give a bit of bump protection in case of any incident as well as additional bracing to these floating chassis legs.

RHS wheel well

The size of the gopro allowed some good views inside the wheel well. This is the right hand side wheel well. The BC coilovers seem much at home here. Some coats of paint expected in these wheel wells once the undercarriage is being attended to.

LHS wheel well

The tool

That red thing there with a metal tip is the hot end of the arc welding machine. Plenty of work for it coming up.

Dirt:

These wheels have gathered some dirt over the weeks. With the pace and traction picked up in this week, hopefully they shall not gather anymore.

Panels: Trunk lid

In parallel, surface prep work had already began for the other panels. Trunk lid and doors. By the time these are bolted on, they will be ready for paint.

Top side. This was all period-correct including 555 livery. It shall be redone in full white.

Panels: Doors

These were getting their fair share of treatment. I can't wait to see them on. The past week has been very productive. Now on to the next one.

Closing Shot: Grimmspeed 3-inch stainless steel down pipe

Quick dash over to Import Performance Parts and I happened to stumble upon this well executed customization on stainless steel. Props to Pindri(IG @weld_hack_). Basically a grimmspeed 3 inch stainless steel downpipe with divorced dump pipe for the waste gate. The dump pipe was touching on the steering knuckle and had to be rerouted. Beautifully executed.

Alcohol?

Alcohol...because no great story starts with a glass of milk. Water-meth mixture injection kit. Talk to IPP for your dose.

That's all folks! Next blog post: Bodywork part 2