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General >> Rally >> New to Me Project - 05 WRX!
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Message started by Dave Cotie on 03/12/15 at 14:07:32

Title: New to Me Project - 05 WRX!
Post by Dave Cotie on 03/12/15 at 14:07:32

Just signed the papers today. Blown Motor - Plan Rally-X and maybe Rally Sprints.

Build will be slow - only as "play" money and labour allows.

I am planning on trying to re-build myself. It will be my first motor re-build. PO blew the timing belt. Move to my garage happens tonight.

Title: Re: New to Me Project - 05 WRX!
Post by RyanHuber on 03/12/15 at 15:02:19

Dave, if the timing belt blew that means most likely bent valves, which means at least heads. It may be cheaper overall to try to find a running used engine to put in, either another USDM or a JDM.

Looks good though!

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 03/12/15 at 15:09:14

Thanks Ryan. That is plan B. I am going to tear the motor down and look. It already has 245k kms on it so it may be pretty used up.

Going to have some fun with it.

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 03/12/15 at 15:12:02

Oh and I have to give the PO back the wheels. They weren't included in the deal.

He will be trying to sell them, so if anyone is looking to buy a set let me know.

They are OZ's - he valued them a lot more than I did!!!

Title: Re: New to Me Project - 05 WRX!
Post by RyanHuber on 03/12/15 at 16:32:06

Yeah, look like OZ Prodrives, very nice for sure. Good luck with the tear down, a good learning experience for sure.

Let me know if you need help with anything.

Title: Re: New to Me Project - 05 WRX!
Post by Bruce VA3BRS on 03/12/15 at 19:54:24

Looks Like Somebody is going to be busy for the next while. Does that mean you not running the Volkswagen this year.

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 03/12/15 at 20:23:55

I think the VW might be seen at a Rally Sprint or two. That kind of makes changing the seats around and stuff likely not worth it. Anthony will probably keep it the way it is. I couldn't sit in Anthony seat if I sawed myself in half!!! ;D

Still might be possible, but the play budget will be going into this thing. It is safe in my garage tonight. Start working on it on the weekend!

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 03/13/15 at 17:33:03

Hmmm! - Yea that doesn't look good!

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 03/14/15 at 08:13:10

RyanHuber wrote on 03/12/15 at 16:32:06:

Yeah, look like OZ Prodrives, very nice for sure. Good luck with the tear down, a good learning experience for sure.

Let me know if you need help with anything.

Thanks Ryan - you know I will be bugging you for information at some point!!!

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 04/12/15 at 12:24:36

Well the wife's Cabriolet was awoken from its winter hibernation and moved out of my "working" spot in my garage.

WRX moved in courtesy my kids, a neighbour and a floor jack (garage door on that side is broken). Time to get that engine out and assess the damage.

Title: Re: New to Me Project - 05 WRX!
Post by Anthony_T on 04/13/15 at 19:37:03

Dave Cotie wrote on 04/12/15 at 12:24:36:

WRX moved in courtesy my kids, a neighbour and a floor jack

I knew jacks were useful - good to know the same can sometimes be said of kids and neighbours ;D

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 04/18/15 at 13:22:04

Engine hoist borrowed. Pull begins as soon as I can get away from the new puppy!!!

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 04/18/15 at 17:26:14

Here we go . . . .

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 05/03/15 at 20:43:04

Well, I am no Ross Wood but there was a reason I did not make it to LHFR. Today, I went a haulin'!

This is the 5th Subaru that I have owned. Unlike the others that have lived on in the hands of other people, this one is destined to have it's heart ripped out, it's carcass pillaged for anything useful and its skeleton hauled to the boneyard. That's right it's an Engine Donor (and soon to be part out). The PO was informed that it has terminal rear subframe and strut tower rot and the car could not be certified.

So I ventured to the wilds of downtown Toronto and the chaos that was the roads around the Toronto Marathon, loaded it while sitting on a side street with the hazards on and the Parking Enforcement officers lurking and headed north!

Bonus points for low mileage engine that replaced the original 40k kms ago (shell has over 300k), with timing belt and new clutch. The car also has a new battery and alternator!

So Subaru #4 will live - once I get some wrenching time (wife's current schedule and the new puppy are killing the garage time).

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 05/07/15 at 22:34:48

So yeah, here is a look under that 02 donor wagon:

So failing that safety was probably a good idea!!!

Title: Re: New to Me Project - 05 WRX!
Post by RyanHuber on 05/08/15 at 13:47:13

Looks like it's growing stalactites...

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 05/08/15 at 17:12:01

Looks good from above but it is ugly below!!!

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 05/11/15 at 12:27:02

Worked all afternoon on Saturday trying to get the downpipe off the car. 221k kms and 10 years - it's not coming off without a fight!!!

All of the bolts and nuts off the turbo. Two bolts on the flange in front of the 2nd cat. Had to attack with the grinder. One is off. The 2nd one still won't budge. It's drill time.

My dad told me a long time ago, NEVER work on exhaust systems. That is why muffler shops exist. Some days I ought to listen . . . . . .

Title: Re: New to Me Project - 05 WRX!
Post by Alexei S on 05/11/15 at 13:00:54

Exhaust work usually means getting out the big red wrench i.e. a torch, and heating up what the bolt goes through.

If it's a bolt into a captive nut or something, the other option is to cut off the bolt, then weld a nut onto it. Usually welding a nut on will give it that thermal shock it needs to break the rust.

But yes, in my experience, I've never had a good time with exhaust fasteners. It's usually some combination of Liquid Wrench + Heat to get things to go at least.

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 05/11/15 at 15:20:50

Best I have is a propane torch ie. a small warm wrench :(

I have been hitting it with lubricant and heat. The grinder put some heat into though!

Title: Re: New to Me Project - 05 WRX!
Post by Anthony_T on 05/11/15 at 17:22:36

You can get a very small oxy/ace torch set up at C.T. that works better than propane. Or you can borrow mine if you wish.

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 05/12/15 at 08:39:23

Might need to take you up on that offer Anthony.

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 07/07/15 at 22:34:25

Well I finally won the battle with the one exhaust stud that would not let go. So the following items got done tonight:

- Exhaust stud removed
- Downpipe removed
- Remaining engine-to-transmission bolts removed
- engine mount nuts removed

Cherry picker goes into place tomorrow night, pitch mount gets removed, transmission jack will get positioned and then the non-running lump should be out.

After that the 05 will go back out in the driveway and the rusty 02 will get rolled into the garage to get gutted!

Finally some progress!

Hoping that the parts I can sell off the 02 will free up some cash. I am hoping to pick-up a downpipe and a Cobb AP with the proceeds.

Title: Re: New to Me Project - 05 WRX!
Post by Momo cars on 07/08/15 at 21:33:48

Hey,

Any chance those rims are still for sale?

Awesome project by the way. Is she up and running yet?

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 07/09/15 at 22:23:21

I can try to reach out to the former owner to see if he still has the rims.

Not running yet but making progress after a long hiatus due to wife's schedule.

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 07/21/15 at 23:05:51

Time for a beer!

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 07/22/15 at 22:28:18

The next part of the swap - change positions - 05 to the driveway (had to put the bumper cover and grille back in to keep the neighbours off my back - I should move to the country!) and the 02 to the garage!

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 10/17/15 at 06:07:38

Well I haven't updated this in a while. Here is what the parts car looks like now:

Someone is coming to get the remains this weekend, so in the interim, it's get working on the replacement lump. Only my 2nd timing belt and my first on a Subaru and on a DOHC engine:

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 10/17/15 at 21:05:40

The transplant patient is back in the operating room! (Pushing cars by yourself that have no engines really sucks :( )

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 05/04/16 at 22:44:05

Well I haven't updated this in a while!

This goes back to November as I fought to get prepped for Pines.

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 05/04/16 at 22:45:40

This was about a week before Pines:

But I kept at it and a couple of days before leaving for Pines 15:

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 05/04/16 at 22:48:31

But alas there was a problem. Car started misfiring on the trip to get it safetied. I had to go to Plan B.

After Pines, I replaced the fuel filter but one of the fuel fittings got broken and in order to fix it out came the rear subframe and fuel tank!

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 05/04/16 at 22:52:00

It sat like that most of the winter. I just couldn't get motivated to get out into the garage in the cold. However I got back at it a few weeks ago! Here is the result:

When is the last time you saw a rear 1/4 this clean on an 11 year-old Subaru???

More shots!

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 05/04/16 at 22:53:45

In the next couple of days it's safety time!

Nice clean, low mileage EJ205 idle!

http://vid680.photobucket.com/albums/vv169/NGTD/WRX%202005/VID_20160429_200439_zpsigxq7ok2.mp4

Title: Re: New to Me Project - 05 WRX!
Post by John_Vanos on 05/05/16 at 07:29:50

car looks fabulous, nice work Dave!

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 05/05/16 at 11:50:05

John_Vanos wrote on 05/05/16 at 07:29:50:

car looks fabulous, nice work Dave!

Thanks John. It is a really clean car - now to the classifieds! I am hoping to fund a 2wd rally car with the proceeds. ;)

Title: Re: New to Me Project - 05 WRX!
Post by Dave Cotie on 05/09/16 at 23:43:52

She's legal!!!