DirtyImpreza Project RS (2012 Rally Prep)

[409industries]

This thread will be used to document the progress of the DirtyImpreza RS rally car.

Recent Video Clip:
Gorman Ridge Rally 2011 - Stage 12 Wheatfield / Powerline
http://www.youtube.com/watch?v=ewJTxn6mC5A
Recent Action Pic:
Gorman Ridge Rally 2011
http://www.dirtyimpreza.com/hosting/imagehosting/DIRT_maxey_clockwise.jpg

Prescott Rally 2010
http://www.dirtyimpreza.com/hosting/project_rs/2010-10-1-prescott_recap/Prescott_LT_FMP_1.jpg


Recent Still Pic:
2011 SEMA Show Featured Vehicle - Baja Designs (Booth #22486)
http://www.dirtyimpreza.com/hosting/project_rs/2011-11-3-SEMA_show/SEMA_CSF_model.jpg

First GC Purchased: 7/16/07
Second GC Purchased: 5/1/2008

Table of Contents:
7/17/2007 - Sticker Removal (http://www.dirtyimpreza.com/forums/showpost.php?p=6403&postcount=8)
7/21/2007 - Applied DirtyImpreza Decals (http://www.dirtyimpreza.com/forums/showpost.php?p=6748&postcount=24)
7/27/2007 - Trunk Stripping (http://www.dirtyimpreza.com/forums/showpost.php?p=7251&postcount=33)
7/28/2007 - O2 Sensor Fix (http://www.dirtyimpreza.com/forums/showpost.php?p=7332&postcount=37)
8/02/2007 - Knock Sensor Fix
(http://www.dirtyimpreza.com/forums/showpost.php?p=7707&postcount=42) 8/02/2007 - Trunk Sound Dampening Removal (http://www.dirtyimpreza.com/forums/showpost.php?p=7777&postcount=47)
8/09/2007 - Hood Vent Cover Removal (http://www.dirtyimpreza.com/forums/showpost.php?p=8082&postcount=60)
8/11/2007 - Rear Cabin Stripping (http://www.dirtyimpreza.com/forums/showpost.php?p=8174&postcount=66)
8/16/2007 - Cabin Carpeting / Console Removal (http://www.dirtyimpreza.com/forums/showpost.php?p=8430&postcount=75)
8/20/2007 - Cabin Sound Dampening Removal (http://www.dirtyimpreza.com/forums/showpost.php?p=8801&postcount=83)
8/25/2007 - Rear Seat / Rear Dash Dampening Removal (http://www.dirtyimpreza.com/forums/showpost.php?p=9178&postcount=94)
9/02/2007 - Trunk / OEM Wing Debadging (http://www.dirtyimpreza.com/forums/showpost.php?p=11232&postcount=102)
10/27/2007 - RallyArmor 3/16 Front Skidplate Install (http://www.dirtyimpreza.com/forums/showpost.php?p=16033&postcount=109)
11/14/2007 - Team Dynamics ProRally1 Wheels (http://www.dirtyimpreza.com/forums/showpost.php?p=18290&postcount=119)
11/25/2007 - Soltek HID Install (First Position) (http://www.dirtyimpreza.com/forums/showpost.php?p=19974&postcount=136)
12/18/2007 - DirtyImpreza Windshield Banners (http://www.dirtyimpreza.com/forums/showpost.php?p=27293&postcount=155)
12/28/2007 - OEM Stereo / Front Speaker Removal (http://www.dirtyimpreza.com/forums/showpost.php?p=28986&postcount=164)
1/9/2008 - First Time In The Dirt / Punctured Oil Pan (http://www.dirtyimpreza.com/forums/showpost.php?p=32433&postcount=179)
1/16/2008 - Repairs Planned (http://www.dirtyimpreza.com/forums/showpost.php?p=34656&postcount=184)
1/19/2008 - AUX HID Light Wiring (http://www.dirtyimpreza.com/forums/showpost.php?p=36520&postcount=190)
1/22/2008 - Jackson Rally Main Lightbar Installed (http://www.dirtyimpreza.com/forums/showpost.php?p=37129&postcount=198)
1/25/2008 - Emergency Rally Spill Kit (http://www.dirtyimpreza.com/forums/showpost.php?p=38453&postcount=217)
1/28/2008 - Sparco 6 Point HANS Compatible Harnesses (http://www.dirtyimpreza.com/forums/showpost.php?p=39948&postcount=223)
2/2/2008 - Clutch / Flywheel Replacement (http://www.dirtyimpreza.com/forums/showpost.php?p=44458&postcount=228)
2/13/2008 - Gorilla Acorn Bulge Black 3/4" HEX (19mm) Lugnuts (http://www.dirtyimpreza.com/forums/showpost.php?p=49578&postcount=245)
2/24/2008 - Custom OEM HID Brackets (http://www.dirtyimpreza.com/forums/showpost.php?p=55813&postcount=256)
3/28/2008 - RA Roof Vent Delivered (http://www.dirtyimpreza.com/forums/showpost.php?p=60521&postcount=263)
5/1/2008 - Second RS Purchase (http://www.dirtyimpreza.com/forums/showpost.php?p=67238&postcount=311)
5/10/2008 - Second GC Gutting / Stripping (http://www.dirtyimpreza.com/forums/showpost.php?p=69432&postcount=335)
5/20/2008 - Windows Pulled / Trunk Removed (http://www.dirtyimpreza.com/forums/showpost.php?p=71545&postcount=347)
6/11/2008 - Doors Removed / Scraping / Coilovers Arrive (http://www.dirtyimpreza.com/forums/showpost.php?p=75448&postcount=366)
6/18/2008 - Dashboard Removed / Airbags Out (http://www.dirtyimpreza.com/forums/showpost.php?p=76881&postcount=383)
6/26/2008 - Seam Welding Prep (http://www.dirtyimpreza.com/forums/showpost.php?p=78639&postcount=395)
7/2/2008 - B pillar Plates (http://www.dirtyimpreza.com/forums/showpost.php?p=80101&postcount=410)
7/8/2008 - A/C and Cruise Control Removed (http://www.dirtyimpreza.com/forums/showpost.php?p=81404&postcount=412)
7/19/2008 - Rally Tires Mounted (http://www.dirtyimpreza.com/forums/showpost.php?p=84249&postcount=417)
8/27/2008 - Trunk Seam Prep / Coilovers Installed (http://www.dirtyimpreza.com/forums/showpost.php?p=90042&postcount=427)
9/15/2008 - Main Cage Bars Bent and Tacked In (http://www.dirtyimpreza.com/forums/showpost.php?p=93667&postcount=442)
9/17/2008 - More Cage Bars Fitted (http://www.dirtyimpreza.com/forums/showpost.php?p=94241&postcount=459) / Top Of Cage Welded (http://www.dirtyimpreza.com/forums/showpost.php?p=94289&postcount=462)
9/24/2008 - More Cage Work (http://www.dirtyimpreza.com/forums/showpost.php?p=95914&postcount=480)
9/25/2008 - More Cage Progress - Motor Pulled
(http://www.dirtyimpreza.com/forums/showpost.php?p=96263&postcount=484) 9/28/2008 - B Pillar X Welded (http://www.dirtyimpreza.com/forums/showpost.php?p=96459&postcount=486)
10/9/2008 - Front Strut Plates and Bracing / A Pillar Gussets (http://www.dirtyimpreza.com/forums/showpost.php?p=98978&postcount=504)
10/14/2008 - A Pillar to Front strut tubes / Interior Seam Welding (http://www.dirtyimpreza.com/forums/showpost.php?p=100004&postcount=514)
10/23/2008 - Transmission Pulled / Underbody Seam Welding Prep (http://www.dirtyimpreza.com/forums/showpost.php?p=102154&postcount=518)
10/26/2008 - Doorbar X's / A Pillar Reinforcement Bar (http://www.dirtyimpreza.com/forums/showpost.php?p=102470&postcount=521)
10/27/2008 - Final Underbody Seam Prep / OEM brakelines removed (http://www.dirtyimpreza.com/forums/showpost.php?p=102955&postcount=524)
11/6/2008 - Jackson Rally Rollcage Install Complete / Seam Welding Complete (http://www.dirtyimpreza.com/forums/showpost.php?p=105010&postcount=532)
11/30/2008 - Safety Equipment from Safe Drives (http://www.dirtyimpreza.com/forums/showpost.php?p=109102&postcount=541)
12/2/2008 - Engine Bay Cleaned and Degreased (http://www.dirtyimpreza.com/forums/showpost.php?p=109763&postcount=547)
12/10/2008 - Roll Cage / Engine Bay / Cabin / Trunk Painting Complete (http://www.dirtyimpreza.com/forums/showpost.php?p=111195&postcount=565)
12/22/2008 - Old RS to New RS Everything Swap (http://www.dirtyimpreza.com/forums/showpost.php?p=113275&postcount=589)
1/27/2009 - Cage Film / Odds and Ends Things (http://www.dirtyimpreza.com/forums/showpost.php?p=119417&postcount=625)
2/15/2009 - Quick Release Steering Wheel Install (http://www.dirtyimpreza.com/forums/showpost.php?p=123082&postcount=639)
3/5/2009 - Valve Adjustment / Header Stud Repair (http://www.dirtyimpreza.com/forums/showpost.php?p=126316&postcount=643)
3/7/2009 - Project Rally RS's First Time in the Dirt (http://www.dirtyimpreza.com/forums/showpost.php?p=127093&postcount=650)
3/15/2009 - RS Trunk Debadged (http://www.dirtyimpreza.com/forums/showpost.php?p=128274&postcount=659)
3/18/2009 - Logbook Issued (http://www.dirtyimpreza.com/forums/showpost.php?p=128411&postcount=665)
3/25/2009 - Axle / Torn CV Replaced (http://www.dirtyimpreza.com/forums/showpost.php?p=129743&postcount=686)
3/29/2009 - Painted A Pillar Support Bar (http://www.dirtyimpreza.com/forums/showpost.php?p=130809&postcount=692)
4/3/2009 - Vinyl Graphics Installed (http://www.dirtyimpreza.com/forums/showpost.php?p=131500&postcount=703)
4/4/2009 - RA Roof Vent Installed (http://www.dirtyimpreza.com/forums/showpost.php?p=131568&postcount=711)
4/9/2009 - Group N Mounts / Catback Exhaust (http://www.dirtyimpreza.com/forums/showpost.php?p=132264&postcount=718)
4/14/2009 - Brakes Inspected / RA Vent Latch / Scissor Jack Modification (http://www.dirtyimpreza.com/forums/showpost.php?p=132946&postcount=726)
4/19/2009 - California City Shakedown (http://www.dirtyimpreza.com/forums/showpost.php?p=134403&postcount=737)
4/25/2009 - Glen Helen 2 Rallycross Footage (http://www.dirtyimpreza.com/forums/showpost.php?p=135337&postcount=742)
5/3/2009 - Roof Scoop Installed (http://www.dirtyimpreza.com/forums/showthread.php?p=135910#post135910)
5/18/2009 - RallyArmor Mspec Mudflaps (http://www.dirtyimpreza.com/forums/showthread.php?p=137883#post137883)
5/22/2009 - Fender Wiring Protection (http://www.dirtyimpreza.com/forums/showthread.php?p=138537#post138537)
5/24/2009 - Day Stages Bumper (http://www.dirtyimpreza.com/forums/showthread.php?p=139193#post139193)
5/30/2009 - First Car Show (http://www.dirtyimpreza.com/forums/showthread.php?p=140225#post140225)
6/2/2009 - Proper Alignment (http://www.dirtyimpreza.com/forums/showthread.php?p=140423#post140423)
6/20/2009 - Front Grill Aesthetics (http://www.dirtyimpreza.com/forums/showthread.php?p=142836#post142836)
7/7/2009 - Hoodpins / Endlinks / Windshield Banner (http://www.dirtyimpreza.com/forums/showthread.php?p=145156#post145156)
7/26/2009 - HID Wiring (Re)Installed (http://www.dirtyimpreza.com/forums/showthread.php?p=150308#post150308)
8/10/2009 - Autometer Pro Shiftlight (http://www.dirtyimpreza.com/forums/showthread.php?p=156614#post156614)
8/23/2009 - Used Michelin Rally Tires (http://www.dirtyimpreza.com/forums/showthread.php?p=156615#post156615)
9/11/2009 - Cobra Imola Pro Seats (http://www.dirtyimpreza.com/forums/showthread.php?p=157803#post157803)
9/20/2009 - Cal City Rally X (http://www.dirtyimpreza.com/forums/showthread.php?p=178314#post178314)
11/6/2009 - Axle / CV replacement (http://www.dirtyimpreza.com/forums/showthread.php?p=178748#post178748)
12/6/2009 - Forman Performance Opening / SCIC Photoshoot (http://www.dirtyimpreza.com/forums/showthread.php?p=179131#post179131)
12/11/2009 - Sparco 6 Point Harness Install / Trunk Anchor Mounts (http://www.dirtyimpreza.com/forums/showthread.php?p=181584#post181584)
3/20/2010 - Ghetto Air Horns Installed (http://www.dirtyimpreza.com/forums/showthread.php?p=209626#post209626)
3/27/2010 - Terratrip 202+ Rally Computer / DSI Box Installed (http://www.dirtyimpreza.com/forums/showthread.php?p=209852#post209852)
3/28/2010 - Peltor FMT110 / Hella Map Light Installed (http://www.dirtyimpreza.com/forums/showthread.php?p=210707#post210707)
4/1/2010 - Personal Safety Items (Helmet / Shoes) (http://www.dirtyimpreza.com/forums/showthread.php?p=216102#post216102)
5/20/2010 - DRTY RS License Plates (http://www.dirtyimpreza.com/forums/showthread.php?p=220229#post220229)
6/13/2010 - New Plates On / Soltek Light Covers (http://www.dirtyimpreza.com/forums/showthread.php?p=225116#post225116)
8/3/2010 - HANS Posts / Race Suit (http://www.dirtyimpreza.com/forums/showpost.php?p=232347&postcount=970)
8/17/2010 - Feal Suspension Coilover Servicing (http://www.dirtyimpreza.com/forums/showpost.php?p=235033&postcount=988)
9/11/2010 - Prescott Prep 1 - Brakelines / Front Axles / Pads / Other Stuff (http://www.dirtyimpreza.com/forums/showthread.php?p=239430#post239430)
9/18/2010 - Prescott Prep 2 - Transmission Swap / Front Skid / LASSA Tires (http://www.dirtyimpreza.com/forums/showthread.php?p=240744#post240744)
9/25/2010 - Prescott Prep 3 - Reinforced Front Skidplate / Front Towhook / Terratrip Mount (http://www.dirtyimpreza.com/forums/showthread.php?p=245849#post245849)
10/22/2010 - Prescott Rally Recap (http://www.dirtyimpreza.com/forums/showthread.php?p=246450#post246450)
12/4/2010 - DIRT 2010 Photoshoot (http://www.dirtyimpreza.com/forums/showpost.php?p=254305&postcount=1082)
2/24/2011 - Glen Helen 1 Rallycross (http://www.dirtyimpreza.com/forums/showthread.php?p=269942#post269942)
3/19/2011 - Skidplate Bars (http://www.dirtyimpreza.com/forums/showthread.php?p=280229#post280229)
5/4/2011 - Battery Tender (http://www.dirtyimpreza.com/forums/showthread.php?p=283308#post283308)
5/14/2011 - Peltor G78 Helmet / Mock Rally Stage Practice (http://www.dirtyimpreza.com/forums/showthread.php?p=285964#post285964)
7/2/2011 - Interior Cleaning / Trunk Wiring Fix (http://www.dirtyimpreza.com/forums/showthread.php?p=294839#post294839)
7/9/2011 - Coilover Service / Sabelt Harnesses (http://www.dirtyimpreza.com/forums/showthread.php?p=295359#post295359)
7/16/2011 - Underbody Protection (http://www.dirtyimpreza.com/forums/showthread.php?p=296875#post296875)
7/23/2011 - Battery Cleanup / Trunkpins (http://www.dirtyimpreza.com/forums/showthread.php?p=297013#post297013)
7/30/2011 - Quick Release Bumpers (http://www.dirtyimpreza.com/forums/showthread.php?p=298342#post298342)
8/6/2011 - Front Fenderliners / Coilovers Serviced (http://www.dirtyimpreza.com/forums/showthread.php?p=300144#post300144)
8/20/2011 - Coolsuit Cooler Install
(http://www.dirtyimpreza.com/forums/showthread.php?p=303955#post303955)8/21/2011 - Trunk Ratchet Strap / Day Bumper / Misc Prep (http://www.dirtyimpreza.com/forums/showthread.php?p=304012#post304012)
10/4/2011 - Gorman Ridge Rally 2011 General Recap (http://www.dirtyimpreza.com/forums/showthread.php?p=307103#post307103)
10/11/2011 - RS Repainted White (http://www.dirtyimpreza.com/forums/showthread.php?p=308647#post308647)
10/25/2011 - Glen Helen #4 / SEMA Show 2011 Preparations (http://www.dirtyimpreza.com/forums/showthread.php?p=310916#post310916)
11/3/2011 - SEMA Show 2011 Featured Vehicle (http://www.dirtyimpreza.com/forums/showpost.php?p=313014&postcount=1238)
1/3/2012 - Peltor FMT-120 / ZerodegreeC Interface Box (http://www.dirtyimpreza.com/forums/showthread.php?p=320522#post320522)
2/2/2012 - Modified Magazine - March 2012 (http://www.dirtyimpreza.com/forums/showthread.php?p=325024#post325024)
2/19/2012 - CRS Rallyschool and Rallycross (http://www.dirtyimpreza.com/forums/showthread.php?p=329741#post329741)
2/27/2012 - Spare RS 5sp Transmission (http://www.dirtyimpreza.com/forums/showthread.php?p=330171#post330171)
3/5/2012 - Windshield Tint Banner (http://www.dirtyimpreza.com/forums/showthread.php?p=330591#post330591)
3/11/2012 - Prosport Premium 52mm Gauge Install (http://www.dirtyimpreza.com/forums/showthread.php?p=332611#post332611)
3/25/2012 - Steering Column Reducer Install (http://www.dirtyimpreza.com/forums/showthread.php?p=335516#post335516)

Modifications:

Engine:
Stock EJ25
K&N Drop-In Filter
Custom Magnaflow Catback

Suspension:
AllWheelsDriven (http://www.allwheelsdriven.net/) Bilstein/H&R 40mm Gravel Coilovers
RalliTEK Rear Swaybar (http://www.rallitek.com/rafrreswbars.html)

Wheels / Tires:
Team Dynamics (http://www.teamilluminata.com) Pro Rally 1 Gravel Wheels (White) 15x6 +40
LASSA (http://www.rally-tire.com) Rally 3 Rally Tires 195/65x15 (Stage Rally)
Hankook Ventus R201 G51 Rally Tires 195/65x15 (Rallycross)

Interior:
Jackson Rally (http://www.jacksonrally.com) FIA Spec Roll Cage
Sabelt 6pt HANS Compatible Harnesses
NRG Innovations Short Hub
NRG Innovations Quick Release
NRG Innovations 350mm Sport 3 Steering Wheel
Cobra Imola Pro Seat (Driver)
Cobra Imola Pro GT Seat (Co-Driver)
Cobra Alloy Sidemounts
Sparco Seat Bases
Custom Battery Mount
Custom Coolsuit Cooler System
Terratrip 202+ Rally Computer
Terratrip DSI box
Peltor FMT120 Intercom
ZerodegreeC Phone / Radio Interface Unit
Amerex 2.5 Lb. Dry Chemical Fire Extinguisher (x2)
52mm Prosport Premium Oil Pressure Gauge
52mm Prosport Premium Oil Temp Gauge
52mm Prosport Premium Water Temp Pressure
OEM Center Dash Gauge Pod
Autometer Pro Shiftlight
LifeHammers (x2)

Exterior:
Jackson Rally (http://www.jacksonrally.com) Custom Stainless Lightbar
Jackson Rally (http://www.jacksonrally.com) Reinforced 1/4" aluminum front skid plate
Jackson Rally (http://www.jacksonrally.com) Front Towhook
Front Bumper Slide Latches
HDPE Front Fender Liners
UHMW-PE Underbody Protection
Rally Armor (http://www.rallyarmor.com) Mspec Urethane Rally Mudflaps
Rallispec Roof Scoop
RA Roof Vent
JDM RS Roof Skin
OEM Rear Differential Protector
Mesh Radiator Screen

Lighting:
Soltek 4" Fuego HID (https://www.bajadesigns.com/NET/C-381/FUEGO+LIGHTS) Driving Lights (x4)
Soltek 4" Fuego HID (https://www.bajadesigns.com/NET/C-381/FUEGO+LIGHTS) Wide Cornering Lights (x2)
Soltek LED Interior Domelights (x2)*
Hella Codriver Light

Misc:
Braille (http://www.braillebattery.com) Endurance Series B6034 Battery
Group N Motor Mounts
Group N Transmission Mount
Oil Sandwich Plate Adaptor
Airhorns

Results:
Stage Rally
8/27/2011 - 1st Place CRS-GT / 1st Place USRC Production AWD (4th Overall) - 2011 Gorman Ridge Rally
10/2/2010 - 1st Place CRS-GT / 1st Place USRC Production AWD (10th Overall) - 2010 Prescott Rally

Rallycross:
2/19/2012 - 4th Place Overall - Ridgecrest Rallycross
2/13/2011 - 2nd Place Overall - Glen Helen 1 Rallycross
10/10/2010 - 3th Place Overall - Glen Helen 2 "Gymkhana This!" Rallycross
4/4/2010 - 3th Place Overall - Glen Helen "Follow the White Rabbit" Rallycross
3/7/2009 - 7th Place Overall - Formula Rally X (FRX) Glen Helen 1 Rallycross
4/25/2009 - 3rd Place Overall - Formula Rally X (FRX) Glen Helen 2 Rallycross
9/20/2009 - 3rd Place Overall - California City Rally X

Media:
2/2/2012 - Modified Magazine, March 2012 Issue page 79 SEMA Coverage

[409industries]

Well, i picked up a Black 2001 Subaru Impreza RS tonight for $6800. I bought it off a very nice guy named Kevin that works at SRT Motorsports in Yorba Linda, CA. I was stoked that he was interested in my plans for the car even after he sold it. Way cool. I can tell this is the beginning of a very big project, but i cant wait to document all the steps along the way. So heres my first thoughts:

The Bad

-The car has 120K miles on it
-The clutch is slipping.
-Passenger side front 1/4 panel has a nice dent in it.
-The clear coat is coming off all over the rear of the car.
-CEL is on because of a bad o2 sensor.
-5th gear likes to grind a bit when it goes into gear. (eep)
-The car is still registered in Illinois, so its out of state
-The brakes pads are dead and the brakefluid hasn't been changed in a loonnng time.
-Driver's side window doesn't roll up on the track without help.

The Good

-The car is black. I like black cars.
-The seller gave me a replacement Exedy clutch that he bought, but never installed.
-The Timing Belt was replaced at 94K miles
-The Oil / Diff fluids have been changed recently
-New spark plugs and plug wires
-The interior is in very good shape
-There are Hellas (500's i think) installed
-Not a salvage title

http://dirtyimpreza.com/hosting/imagehosting/RS_firstnight.jpg
First night in its new home!

Oh yeah, and the original owner sprung for the imitation CF trim... niiiice...

So first things first, i gotta get the damn thing registered in California, thats going to suck, since I have to get it inspected by the DMV since they have to actually SEE the VIN number, and it needs to be smogged. Then once i can legally drive it around, ill go get that clutch replaced...

The adventure begins...

[derf]

Congratulations, the car looks clean. I'm happy for you. I know you were looking for a while to find one. Can't wait to see what your going to do to this monster. :twisted: Keep the pics comming :D

[sebhockey]

Nice buy, can't wait to see what you have in store for it. I think you should spring for getting the entire body stitch welded and have a roll cage installed (tis what i want to do if i turn my wrx into a dedicated rally car). :mrgreen:

[MBasile]

nice buy. I don't know why I'd ask, but is this going to be a rally/rally-x car or do you have other plans?

[409industries]

The ultimate goal for this car is PGT stage rally competition (even though i havent figured out how im going to be able to drive in PGT w/o any experience yet)... but ill figure that part out soon enough.

First things first though. The car needs to be smogged and registered in CA. Its still from out of state with IL paperwork. Not rad... since i have to figure out when im going to have time to get the damn thing looked at by the DMV, then theyre going to rape me because its from out of state so i'm going to have to shell out a few bucks.

The car is definitely going to be caged, with a FIA spec roll cage. I already have an agreement with Coyote Fabrications in Orange, CA to do the work. The stitch welding part is up in the air, its a huge undertaking. I may have the strut mounting points reinforced, but to do the entire chassis might not be feasible. AP Boss in Los Alamitos would be doing the stich work.

Well see. Theres a lot of small steps to take before i can take on the bigger aspects of the project.

[Azewaldo]

Can't wait to see this RS in full DI paint/decal livery!

[409industries]

Got home from work today. Shouldnt drive the car on the street since theres a sheriff station literally across the street from me. The car has no plates, no registration and no insurance... yet.

So i took to the spot in my apartments where i could plug in my shop vac and clean it out a bit. Turns out i can subtract about $0.76 off the price of the car... BOOYA!

http://www.dirtyimpreza.com/hosting/project_rs/2007-7-17-sticker_removal/RS_found_change.jpg

After cleaning out the trunk I noticed that there is no factory jack in the side. no biggy, ill be getting a different one anyway. i wiped down the insides and things look much better.

I had to get rid of the stickers that were on the car already.

http://www.dirtyimpreza.com/hosting/project_rs/2007-7-17-sticker_removal/RS_sticker_removal.jpg

I didnt have any DI stickers on me (doh!) so ill slap some on tomorrow.

[BlueRu]

The girl looks really good! I wish I had mine but alas I dont have the cash. Hope you do us all proud!

[zebrasinamerica]

Aaron, you're really making me want to do this to my 97 OBS and make my 03 my daily driver. Why did you have to go and get a GC ;)

looks good and can't wait to see how it comes out

Zebra

[kreitz3]

Sweet car. I need to get an RS I can rally. My WRX hates me.

[lminette]

Out of state shouldn't be a big issue. Mine was from AZ and I had no problem registering it.

[409industries]

Yes the STi is getting a bit fussy (strange steering clunk?), but i've been trying to be nice to her. I know shes happy to have the RS around so i can beat the crap outta her instead.

[PSG Evo]

this is going to be an awesome car.

It would be good to have a timeline and milestones to hit so you know if you're on or off track with schedule.

I would love to see this car in a stage rally.

`Gus

[UP2MTNS]

well look what I found for you on CL today...

http://sfbay.craigslist.org/sfc/pts/376823920.html

just in case you want some spare parts cheap :)

[PSG Evo]

Looks like there's nothing really you need in that ad except for...

Type-R shift knob: 20 usd

hahaha...jk

`Gus

p.s. you probably want to look for a parts car with good condition suspension components (i.e. control arm, knuckle, hubs, etc)

[kreitz3]

Are the extra set of pinks going on this car?

[409industries]

I would love to see this car in a stage rally.

`Gus
Gus... you will. Definitely.


well look what I found for you on CL today...


lots of random bits on there... could come in handy sometime. I never know what could break...

Are the extra set of pinks going on this car?

Nope, those are going up for sale real soon... to cover buying replacement bits for the RS ;)

[Not All There]

awesome man, i think your going to have a ton of fun with this!

[409industries]

awesome man, i think your going to have a ton of fun with this!

your build up has really been an inspiration... its great to see what people can do with these cars.

[Not All There]

Awesome! Glad to hear.

Not to mention how cheap the buildup can be (in some sorts)

[409industries]

The new issue of subiesport has a pretty nice project going on with an L wagon. Its like a whole nother world tweaking the smaller suby motors. Its pretty cool.

[Blix666]

The new issue of subiesport has a pretty nice project going on with an L wagon. Its like a whole nother world tweaking the smaller suby motors. Its pretty cool.

hmm..i'll have to grab a copy :idea: :twisted:

[409industries]

So i cant enjoy driving this car around yet... (not registered still... im waiting on an o2 sensor to come in the mail so i can pass smog, etc.)

So what to do? Play with more stickers!

http://www.dirtyimpreza.com/hosting/project_rs/2007-2-21-di_decals/driverside.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2007-2-21-di_decals/driverside_close.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2007-2-21-di_decals/passengerside.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2007-2-21-di_decals/rear_window.jpg

w00t!

[sebhockey]

Wow a fricken huge one on the back. I might have to get more for mine as it seems people get confused why my car is dirty.

[Blix666]

hm...you could prolly make windshield banners w/that sticker

[409industries]

hm...you could prolly make windshield banners w/that sticker

The windshield banner stickers are tricky because they have to follow the curve of the top of the window... The one was straight, so i cut it into 2 pieces, it looked better that way :)

[JacksonRally]

hm...you could prolly make windshield banners w/that sticker

The windshield banner stickers are tricky because they have to follow the curve of the top of the window... The one was straight, so i cut it into 2 pieces, it looked better that way :)

Sold!! I got all kinds of room on my back window for a larger sticker :o

[Blix666]

hm...you could prolly make windshield banners w/that sticker

The windshield banner stickers are tricky because they have to follow the curve of the top of the window... The one was straight, so i cut it into 2 pieces, it looked better that way :)

nuthin' some stress relief cuts wouldn't fix. tsiss350 just put a banner on his windshield and with a lil' patience, got it to follow the curve

[409industries]

Yeah i did actually think of doing that between each of the letters, but didnt have the patience... this was to hold me over until i can get the full wrap ;)

[sebhockey]

Yeah i did actually think of doing that between each of the letters, but didnt have the patience... this was to hold me over until i can get the full wrap ;)

A full wrap huh? Someone's gonna be busy. You should get custom plates while your at it: RallyDI

[409industries]

yeah the wrap thing will come in due time...

[409industries]

I had some time to kill after work today. I was changing the oil on the STi and it was still way to hot to work on. So, i turned to the RS for something to do.

First i throughly documented the inside of the car for comparison purposes in the future, secondly i took a closer look at trunk.

Looks like the carpeting, etc was just thrown back into the car. Who knows why it was out in the first place when i bought it... going for the sweet racer look? i dunno. anyway it was nice not having to deal with the plastic clips to remove everything.
http://dirtyimpreza.com/hosting/project_rs/2007-7-27-trunk_strip/rs_trunk_strip_2.jpg

nice stain in the back... something spilled. woops!
http://dirtyimpreza.com/hosting/project_rs/2007-7-27-trunk_strip/rs_trunk_strip_1.jpg

Removed all the sh*t you typically find in the trunk of an impreza. turns out i DO have a jack, it was just with the tire. Things removed: tire, jack, carpeting, wood thingy. Ill be weighing these and keeping tabs on the weight reduction, trying to offset the roll cage weight.
http://dirtyimpreza.com/hosting/project_rs/2007-7-27-trunk_strip/rs_trunk_strip_3.jpg

everything's out... now to tackle the sound deading... perhaps another day this weekend.
http://dirtyimpreza.com/hosting/project_rs/2007-7-27-trunk_strip/rs_trunk_strip_4.jpg

discovered an unplugged hole in the floor of the trunk... "peace!"
http://dirtyimpreza.com/hosting/project_rs/2007-7-27-trunk_strip/rs_trunk_strip_5.jpg

Ill be leaving the back seats and everything in, until i pay a visit to the DMV. I dont want them giving me any BS for not having rear seats, seatbelts, etc.

[Blix666]

i wish i could gut my car

[Not All There]

driving a gutted car for a daily is fun! :roll: lol

Whats great is you hear every single thing you run over, as well as every part of your car breaking as your romp on it well before you would in a car with an interior.

[gibbo]

So I finally registered for the forums. The car is looking sweet.

Danny

[409industries]

So I finally registered for the forums. The car is looking sweet.

Danny

Whats up danny! glad you're checking up on the progress...

So heres what i accomplished over the weekend. Sure enough there was a CEL for one of the o2 sensors. This is a problem because to register a car in the state of california you have to have a smog check if the title is being transfered. They check for functioning O2 sensors during the smog check, Doh! Just to be sure i bought an Actron CEL code scanner. I figure that this wont be the only time i get a CEL in this car. A good investment for the future.

http://www.dirtyimpreza.com/hosting/project_rs/2007-7-28-o2_sensor_install/o2_sensor_replace006.jpg

P0136 - O2 Sensor Circuit Malfunction (Bank 1 Sensor 2)
oh and for fun it decided to drop another code on me, but ill worry about this one later...
P0328 - Knock Sensor 1 Circuit High Input Bank 1 or 1 sensor

The replacement dohickey
http://www.dirtyimpreza.com/hosting/project_rs/2007-7-28-o2_sensor_install/o2_sensor_replace002.jpg

The old bastard (the after cat one)
http://www.dirtyimpreza.com/hosting/project_rs/2007-7-28-o2_sensor_install/o2_sensor_replace003.jpg

disconnect the harness and spray it with some liquid wrench... i drove the car around in the parking lot by my house for a bit to get it warmed up, i heard they come out easier this way. It came out, piece of cake.
http://www.dirtyimpreza.com/hosting/project_rs/2007-7-28-o2_sensor_install/o2_sensor_replace004.jpg

the new guy in
http://www.dirtyimpreza.com/hosting/project_rs/2007-7-28-o2_sensor_install/o2_sensor_replace005.jpg

Reconnected the harness, cleared the codes and so far so good. I need to drive the car around a bit to make sure the CEL doesn't come back. I hope it doesnt! The sooner i can get this car smogged the better.... *crosses fingers*

[I Like It Sideways]

I found that even with that hole plugged. my trunk still leaks. After a rallyx and a drive thru the rain, I had a small puddle of dirty water in my spare tire well. No good!! Nice progress on the RS!! Can't wait to see what all of that weighs.

[409industries]

Drove the car around the block a few times, then parked the car and ran it at 3K RPM for about 3 minutes...

The Good News
The O2 sensor malfunction code hasn't come back yet. Thats good... i think i can rest assured i replaced the correct O2 sensor.

The Bad News
Goddamn P0328 code keeps coming back. Ordered a new Knock Sensor today. Hopefully it will get here by the end of the week...

im never going to get this damn car smogged

[lminette]

Thats what I thought about mine. I had to search forever for a stock cat assembly.

[Blix666]

my car threw a P0328 too...i didn't have the $$$ for a new knock sensor, so i had to wait...after 3 days, it just went away

[409industries]

UPS man is more like santa claus in August. He was nice enough to bring me my $92 knock sensor. grrrr more money on stupid sensors!

Can you guess what brand i bought?
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-2-knock_sensor_install/knock_sensor_replace_001.jpg

Theres the little bastard down there.
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-2-knock_sensor_install/knock_sensor_replace_002.jpg

Hes no match for some liquid wrench!
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-2-knock_sensor_install/knock_sensor_replace_003.jpg

These look suprisingly similar...perhaps replaced before, or do the OEM ones look the same?
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-2-knock_sensor_install/knock_sensor_replace_004.jpg

Hooked the new one up. Torqued it to spec with my torque wrench. I read that over tightening these things can cause problems.
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-2-knock_sensor_install/knock_sensor_replace_005.jpg

The other day after i replaced the o2 sensor, the knock code came on after about 30 seconds of holding 3K rpm sitting still. It didn't do it this time! I even checked the ECU for codes and there were none. (notice the lack of CEL under the brake light!) yay!
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-2-knock_sensor_install/knock_sensor_replace_006.jpg

Looks like im ready to pass Smog! W00t! :P

[sebhockey]

Saweet, go get it taken care of so you can start using the car all the time now.

[UP2MTNS]

will these fit in your tranny? kind of a good deal if they really are in good condition:
http://sfbay.craigslist.org/sfc/pts/388159858.html

[lminette]

I think that the JDM trannies use a push clutch, and ours are a pull type. I'm not sure if the actual trannies are the same or not.

[409industries]

will these fit in your tranny? kind of a good deal if they really are in good condition:
http://sfbay.craigslist.org/sfc/pts/388159858.html

an RA gearset would be tight as hell. ;)

[409industries]

So Pepboys sucks and their "master technician" is out for ANOTHER week and they cant do smog checks. I went in there this morning before work expecting my car to be registration ready by the end of the day but nooooo. They need a "master technician" to put an effing probe in the exhaust pipe. LAME. Its around the corner from me, but screw em.. ill go somewhere else.

So anyway on to bigger and better things. I bought a couple pounds of dry ice for $10 at Ralphs and decided to give the sound dampening goo in the trunk the freeze treatment. It worked remarkably well. Once i got the hang of how long to hold the ice on and spread it over, the stuff was breaking off all over the place. I barely even had to use the flathead screwdriver as a chisel. Just freeze and hit with the hammer... LOL

The first section was pretty much a test run...
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-3-sound_deadening/sound_deadening_002.jpg

Best thing about working with dry ice is that it keeps your drinks really cold!
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-3-sound_deadening/sound_deadening_003.jpg

Once i got the hang of it, the stuff was coming off in huge chunks
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-3-sound_deadening/sound_deadening_004.jpg

Center of the trunk behind the backseat
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-3-sound_deadening/sound_deadening_005.jpg

Driver's side trunk
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-3-sound_deadening/sound_deadening_006.jpg

Passenger side trunk
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-3-sound_deadening/sound_deadening_007.jpg

The finished product... mmm shiny.. well sortof.
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-3-sound_deadening/sound_deadening_008.jpg

Just the trunk filled a ziplock gallon bag to the top. Id say theres probably about 4 lbs of material in there, not a huge weight savings but every bit helps right?... Once i get into the cabin of the car and remove all of the dampening in there i will weigh it all and see! stay tuned!

[sebhockey]

I dunno about this car, but on mine theres an undercoating that is pretty much a thick rubbery white coating. Well it used to be black when it was covered by regular undercoating, now it's white. It's all under my car, I wouldn't be suprised if your RS has the same. If it does you could be looking at another 10+lbs of weight savings.

[BlackParis]

I dunno about this car, but on mine theres an undercoating that is pretty much a thick rubbery white coating. Well it used to be black when it was covered by regular undercoating, now it's white. It's all under my car, I wouldn't be suprised if your RS has the same. If it does you could be looking at another 10+lbs of weight savings.

Believe it or not, that stuff is Structural, it helps hold the car together... take it off and preapre to destroy the floor pans, evey little rock will make a dent... Unless you opt for FULL under body skid plates, which will way more than the rubber....


Hmm... i'll have to try this removal process.. im too poor for dry ice, think normal ice would work?

[sebhockey]

I don't think regular ice would be cold enough to make it work.

[Blix666]

what about sprayin' it w/a fire extinguisher?

[409industries]

no. normal ice will not work. Dry ice is 5x colder and causes the sound stuff to become brittle and crack.

Fire extinguisher would work maybe... but is more expensive to recharge than just buying the dry ice in the first place!

[Blix666]

recharge nuthin...ya buy a cheapie from the depot for $20 and use it to douse the entire trunk cavity...assuming it would work in the first place!

[Not All There]

nice! I read about using dry ice, will be doing it next week. No residue?

[409industries]

nice! I read about using dry ice, will be doing it next week. No residue?

barely any at all ;)

[sebhockey]

recharge nuthin...ya buy a cheapie from the depot for $20 and use it to douse the entire trunk cavity...assuming it would work in the first place!

Those el cheapo extinguishers aren't the kind of extinguishers that freeze stuff. You would want a CO2 extinguisher, thus making the dry ice cheaper.

[409industries]

Yeah arent the cheapo fire extinguishers just propelled baking soda? In anycase the dry ice was still around well after i was done, meaning you can work at your own pace. I even re-used ice pieces from the first section on the last one.

EDIT: paperwork appears to be in order for registering the car. Im going to the smog place tomorrow morning and have an appointment with the DMV on friday morning! *crosses fingers*

[I Like It Sideways]

hope that goes well. I didnt know dry ice was that cheap.
Curious to see how much everything else weighs in at

[409industries]

I found an extra shipping scale that im going to use for the weights... booya for accurate measurements under 5lbs!

[409industries]

Going to get the car registered (hopefully) tomorrow. Itll be a happy day if i have plates on this car by noon tomorrow.

Anyway, so heres whats up. Nothing big, I was bored and decided to ditch the stupid metal covers on the underside of the kickass RS hood vents. On a side note, i really wish they would have incorporated these vents into the GD chassis imprezas... but they didnt. I think they look sick. So let that heat out!

Closed configuration
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-9-ventcover_removal/ventcover_removal_001.jpg

Both closed
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-9-ventcover_removal/ventcover_removal_002.jpg

Cover removed
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-9-ventcover_removal/ventcover_removal_003.jpg

Now hot air can escape! What a concept!
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-9-ventcover_removal/ventcover_removal_004.jpg

Both open
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-9-ventcover_removal/ventcover_removal_005.jpg

I guess this is a dirtyimpreza because of all the dust that has been collecting on it since i cant drive it very far. LOL So yeah you can save the dusty car jokes. Something dawned on me as i removed the vent covers. I may want to relocate my battery since the driver side vent is directly over the battery. What puzzled me though is that the covers have holes in them to let the water that collects in there to drain into the engine bay anyway... silly.

[sebhockey]

Eh, your battery is fine with them removed, just make sure your terminals are in good order. If you're worried about rust on the terminals you can always waterproof with vulcanizing tape n electrical tape or just get some rubber covers.

[I Like It Sideways]

I kept the cover in that is over the battery.
But those vents were the first to go on my RS. Definitely good to remove

[Blix666]

i've had both my covers off for over a year now and still no rust problems w/battery terminals...through the winter too

[409industries]

W00t! the RS is now officially registered and insured in the state of California. They raped me on my USE tax, but that was to be expected. I think ill celebrate by ripping the **** out of the inside of the car this weekend... ;)

stoked.

[409industries]

Check the original post of this thread. I have started documenting the things that i have removed to try and keep track of the weight reduction efforts (and where the weight savings came from).

Vent cover removal
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-9-ventcover_removal/ventcover_removal_weight.jpg

Trunk Sound Dampening Material removal
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-3-sound_deadening/sound_deadening_weight.jpg

[409industries]

Heres the latest round of removing things to prep the car for the roll cage. I have updated the totals in the beginning on the thread for a quick summary of our overall progress. You can check it out here (http://www.dirtyimpreza.com/forums/viewtopic.php?t=767)

Rear Seat Support Beam
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_001.jpg

Rear Side Impact Support Beam
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_004.jpg

Rear Speakers
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_005.jpg

Rear Side Panels (x2)
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_006.jpg

Rear Dash and Hardware
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_009.jpg

Rear Seat Foam Backing
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_012.jpg

Rear Seat Bench Foam
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_014.jpg

Spare Tire
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_015.jpg

Trunk Carpet
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_016.jpg

Trunk Carpet Siding
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_019.jpg

Jack and Spare Hardware
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_020.jpg

Trunk Floor
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_021.jpg

B and C Pillar Molding
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_022.jpg

Rear Seatbelts
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-weight_reduction1/weight_reduction1_023.jpg

Total Weight Reduction: 87.40

[I Like It Sideways]

This iis incredibly useful information. Thanks for doing this!!
87 lbs... wow.

[lminette]

Looks like I've got some work to do. Need to start gutting mine to. Seats are alreay unbolted since I had to get a 9ft surfboard in my car the other day. No one ever rides back there anyways. I also need to chack with my contacts to see about paint.

[Not All There]

starts to show that all the little things really add up!

[409industries]

Put a pretty good dent in the amount of garbage in the rear of the RS the other day. I still have to take out the front seats in order to remove the carpeting. Under there is the rest of the sound dampening material that i will be removing with more dry ice...

http://www.dirtyimpreza.com/hosting/project_rs/2007-8-11-rear_interior_removal/rear_interior_removal_005.jpg

...moving right along!

[UP2MTNS]

every time I take my rear seats out, I also pull out about 5lbs of dog hair. LOL

that spare tire and jack is 30+lbs.....wow.....

[Blix666]

you gonna paint all that?

[409industries]

you gonna paint all that?

I probably wont pay to have it done, but yeah im sure it will be rattle can'd. The rear shock towers are going to be stitch welded so they will need some protection from rust, etc. (and noooo im not stitch welding the whole car, way too expensive and time consuming having to dismantle the entire car)

[sebhockey]

you gonna paint all that?

I probably wont pay to have it done, but yeah im sure it will be rattle can'd. The rear shock towers are going to be stitch welded so they will need some protection from rust, etc. (and noooo im not stitch welding the whole car, way too expensive and time consuming having to dismantle the entire car)

Eh, thats why you get yourself a mig welder and do it yourself. :FU:

[409industries]

So... the latest round of removing stuff. On the chopping block was the carpet (so i can get to the sound dampening material in the main cabin), center console, door moldings, mini-sub under the seat, and various other crap.

The console came out easy, i thought it would be a good idea to take of this metal bracket around the shifter...
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-16-carpet_removal/carpet_removal_001.jpg

I quickly realized that this is what hold this rubber bezel in place, essententially keeping water, dirt, and debris from flying off the driveshaft and into the cockpit. Yeah that thing will be staying there. Maybe down the road ill make a nice flat metal one.The stocker piece is nasty with all the things sticking off for the plastics.
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-16-carpet_removal/carpet_removal_003.jpg

WTF is that under the passenger side seat? LOL its Death Cab For Cutie - "Plans"...( actually my favorite album of death cab's) but the CD wasn't in the case.
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-16-carpet_removal/carpet_removal_004.jpg

One side done!
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-16-carpet_removal/carpet_removal_007.jpg

Fast forward to repeating everything on the other side. The driver seat is sitting where the backseat would be. Damn there is a lot of sound dampening material to remove.
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-16-carpet_removal/carpet_removal_010.jpg

More money! muuhahahah looks like dimes are the best at finding there way UNDER the carpet somehow. Ad another $0.51 to the tally...
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-16-carpet_removal/carpet_removal_011.jpg

Coming soon. More dry ice! Can't wait to hear the rattle of rocks hitting the frame all over... ;)

[Not All There]

haha, its soooooo loud!

[Blix666]

don't forget to subtract the weight of that cd case and put it on the tally...unless ofcourse you're leaving it in there...

[BlueRu]

Finally got back on to look at all the stuff Ive missed. You have done so much to the car in such a short amount of time! Its looking very nice! How loud is it in the cabin now?

[409industries]

Finally got back on to look at all the stuff Ive missed. You have done so much to the car in such a short amount of time! Its looking very nice! How loud is it in the cabin now?

I haven't driven it in about a week and a half. Ill definitely be driving it soon though, once all the sound stuff is stripped out. Maybe ill take my video camera so you guys can hear how loud it is in there! :)

[BlueRu]

I would be uber greatful! I want to know how much that stuff works (the sound deadening stuff that is).

[409industries]

I would be uber greatful! I want to know how much that stuff works (the sound deadening stuff that is).

It actually works very well in conjunction with the thicker carpet in the cabin to keep quite a bit of road noise out of the car.

[BlueRu]

huh. Who'd uh thunk it? It looks like just a thin sheet of tar.

[409industries]

Stick to your diet!

Bought another $10 worth of dry ice and got almost all of the remaining sound dampening material out that ive been working on. Up next was all the stuff under the seats. It was tough enough just getting there, but once there it was not as easy as the trunk to get all the stuff off. Ill explain why in a second.

The process is usually, wedge screwdriver under frozen dampening stuff...
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-20-cabin_carpet_remove/cabin_dampening_remove_002.jpg

Pry it up...
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-20-cabin_carpet_remove/cabin_dampening_remove_003.jpg

It comes out in big chunks.. usually.
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-20-cabin_carpet_remove/cabin_dampening_remove_004.jpg

Problem was, that under the seats and throughout the floor, there were these plugs in the metal. They were usually saturated with the glue that holds the dampening down. I accidentally popped some of them out (like this one)
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-20-cabin_carpet_remove/cabin_dampening_remove_005.jpg

Not too bad!
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-20-cabin_carpet_remove/cabin_dampening_remove_009.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2007-8-20-cabin_carpet_remove/cabin_dampening_remove_010.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2007-8-20-cabin_carpet_remove/cabin_dampening_remove_012.jpg

You might have noticed that i left the sticky stuff on the transmission tunnel. I started to chip away at it but then realized that it was probably a good idea to leave it on there to keep some of the heat away from the seats (and people in the car). Not only that, but its hard to keep the dry ice on it since its vertical, making it pretty difficult to remove. So that stuff is going to stay. I ran out of dry ice before i could do under the rear bench seat. That'll come out probably tonight.

[Blix666]

where do you buy dry ice?

[409industries]

where do you buy dry ice?

I buy it literally around the corner at the supermarket (in this case Ralphs). Most major supermarkets will carry it. Often people use Dry Ice to ship meat and other perishables through the mail.

Theres lots of other fun things you can do with it too though. Dry ice bombs, bubbling liquor drinks, etc. etc. etc. :)

[Blix666]

hmm...never new

[Not All There]

looks nice man, yea those plugs are a pain, i have been driving with holes in the floor for about a month now. I was going to either weld in some small sheet metal circles or simply attach them with some silicon or epoxy to attach them, looks like the dry ice worked well for you.

[409industries]

More stuff hits the scales!

Plastic door moldings
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-22-weighin_II/weighin_II_002.jpg

White plastic pieces under the door moldings that the carpet attaches to
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-22-weighin_II/weighin_II_001.jpg

Center console and hardware
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-22-weighin_II/weighin_II_003.jpg

POS under seat subwoofer
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-22-weighin_II/weighin_II_004.jpg

Main cabin carpet
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-22-weighin_II/weighin_II_005.jpg

Total from this lot: 19.6 pounds

[Not All There]

whats the absolute total so far?

[409industries]

whats the absolute total so far?

Gross Weight Savings Updated on first post...

...110.4 lbs ;)

[BlueRu]

Getting closer to that cage weight. Have you taken out the AC yet?

[JacksonRally]

Don't start getting all tweaker on us...pretty soon you'll be starving yourself. Fat cars need love too!!

[409industries]

Hahah yeah no tweakin goin on here. Shes gotta keep a dash in, and door cards...

I dont have any plans to mess with the AC just yet. Maybe once i know for sure that i can tow the car to rallies and sit in a truck thats air conditioned...

... or when i get a vent for the roof... :)

[409industries]

So i think im done freezling and scraping for a while. The last big pieces that I am planning on removing have been taken out (rear dash, under the rear seats, and on the rear wheel wells).

Check out the dry ice working its magic on the sound dampening goo! (http://www.dirtyimpreza.com/hosting/video/dirtyimpreza_projectrs_dryice.wmv) Right Click > Save As...
In the video you can really hear the ice freezing the stuff and it cracking. pretty cool.

Dry Ice doing its thing again
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-25-rearseat_dampening/rearseat_dampening_001.jpg

Patch of sound dampening that was on the rear dash between where the speakers would be mounted. This stuff was more plastic-like than the rest of the car. It cracked really easily once exposed to the dry ice. Fun stuff. You can see the bushes behind the car through that hole because my trunk was open a bit.
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-25-rearseat_dampening/rearseat_dampening_002.jpg

I thought the rear wheel wells were going to be a pain because there is no way to hold dry ice onto them. Howerver, i found that if i worked my way down with the screwdriver and a mallet that the thing came off almost in one piece.
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-25-rearseat_dampening/rearseat_dampening_003.jpg

The end result wasn't as tidy as the frozen patches, but its no big deal.
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-25-rearseat_dampening/rearseat_dampening_004.jpg

Same thing on the other side
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-25-rearseat_dampening/rearseat_dampening_005.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2007-8-25-rearseat_dampening/rearseat_dampening_006.jpg

A bag full of worthless sound material.
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-25-rearseat_dampening/rearseat_dampening_008.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2007-8-25-rearseat_dampening/rearseat_dampening_007.jpg

So the total for doing just about all of the inside cabin was 8.55 lbs of sound material removed. I thought it would be more (based on how long it took me to get all of it out) but any weight out is good news. Gotta have nice clean metal to weld to anyway.

[Drew84]

Hmm, I would have gone the opposite route with a heat gun. I've got sound deading material that the original owner put in the trunk and it doesn't be long there. Other STi's don't have it and I need to get rid of it. Where do you get Dry Ice?

[409industries]

Sounds like Dynamat in your car....

Where do you get Dry Ice?

Blix asked the same question a few posts ago:

where do you buy dry ice?

I buy it literally around the corner at the supermarket (in this case Ralphs). Most major supermarkets will carry it. Often people use Dry Ice to ship meat and other perishables through the mail.

The people at ralphs are pretty lame. I go in and ask for it as im checking out, and they always look at me crazy (even though the freezer that holds the stuff is sitting in plain view at the front of the store). Its pretty cheap, i get a big block for $10.

Heat gun is a suckfest compared to dry ice. I used a heat gun on my last car. Its a mess and it burns your fingers all the time! Remember, you can still get burned with Dry Ice because its REALLY cold, so wear gloves.

[Drew84]

I don't think my local supermarkets carry dry Ice. Mabey you should have asked for C02 in a solid state lol. Then they would look at you even weirder.

[shakes]

Sand that nasty lookin metal down and get to painting man!

[WRR]

POS under seat subwoofer


hey, I've got one of those in my WRX :mrgreen:



sorry Aaron, I havent been on here in a bit but Doug posted a link over at rallyxportal.com so I came over to have a look.... nice ride & nice project for sure!! & your STi will thank you!!

amazing how much stuff you can pull out but as someone mentioned earlier, daily driving a 'lightened' car is a biotch.. combine it with rally suspension and I can tell you that the trip to Ridgecrest was one long a$$ drive in the SRT4!! but still worth it!!

good luck and glad you got through the DMV..

Jack S.

[409industries]

Hey Jack! nice to see you posting up again.

Yeah this is not going to be a fun car to drive around town for more than 20 minutes, but its nice knowing that its completely paid off already!

[BlueRu]

That looks like fun. If one of your stores doesnt sell dry ice then go to a major chain store. They like having it in stock so they can ship frozen goods.

[409industries]

I actually got around to doing this at least a week ago, but just have been crazy swamped with work and well... DI updates to post in my journal. The badging on the RS was annoying me. For one the 2.5RS badge is sweet, but half the red paint was peeling off. So i said screw it, i'm gonna debadge the RS too so itll look just like its big sister thats usually parked right next to it (the STi)

So here it is!

Before:

http://www.dirtyimpreza.com/hosting/project_rs/2007-9-2-trunk_debadge/trunk_debadge_002.jpg

After:

http://www.dirtyimpreza.com/hosting/project_rs/2007-9-2-trunk_debadge/trunk_debadge_017.jpg

Removed 2.5RS Impreza Badge
Removed S-U-B-A-R-U
Removed AWD Sticker
Removed 2.5RS Stickers on OEM Wing
Removed some random URL sticker

Sorry about that blinding license plate! I kinda scratched under the RS a bit, but its not too bad (and i dont really care that much) since this car will be showered with rocks soon enough. Im sure my polisher could take some of the smaller ones out. Look for my full write up in the DIY forum soon for my method of debadging your suby!

EDIT: Heres the Debadging Thread: http://www.dirtyimpreza.com/forums/viewtopic.php?t=1186

So do you think it worth weighing the subaru emblems??? LOL :mrgreen:

[BlueRu]

So do you think it worth weighing the subaru emblems??? LOL :mrgreen:

WEIGH THEM! A whole 10 grams maybe lol!

[tomodojo]

Total Weight Reduction: 87.40

do you want to sell those interior parts and the emblems?

[409industries]

Total Weight Reduction: 87.40

do you want to sell those interior parts and the emblems?

PM replied.

[L and E Fab.com]

That car is going to look sick riding on Gold Speedline and rally tires.

What Suspension are you running?

[bergdh]

Laqure thinner, (however you spell it)

this worked great to remove the resuidue from the tar, pour it on let it sit for a few seconds and wipe it off yes wipe it off. clean as a wistle. I need to post up some pics of the westridge obs interior tear out, its looking good!

[BorkedWRX]

So... the latest round of removing stuff. On the chopping block was the carpet (so i can get to the sound dampening material in the main cabin), center console, door moldings, mini-sub under the seat, and various other crap.

The console came out easy, i thought it would be a good idea to take of this metal bracket around the shifter...
http://www.dirtyimpreza.com/hosting/project_rs/2007-8-16-carpet_removal/carpet_removal_001.jpg



I accidentally removed (read: lost after installing short shifter :-| ) that metal bracket like 4 years ago, no problem with dirt, water, mud, etc getting in my car, and i've been under the center console a dozen+ times for various reasons since.

Just FYI

[409industries]

Behold! RallyArmor's 3/16" front skid plate. I would have posted earlier about this product, but only recently was I able to get everything done. Here we go:

The product.
http://www.dirtyimpreza.com/hosting/project_rs/2007-10-27-front_skidplate/GC_skidplate_install_003.jpg

The GC skid plate (left) compared to the GD chassis impreza plate (right) I had the GD one off the STi and figured it would be cool to see them side by side.
http://www.dirtyimpreza.com/hosting/project_rs/2007-10-27-front_skidplate/GC_skidplate_install_002.jpg

The skid plate weighs in at 18.55lbs. Not bad for a piece of metal this size. Aluminum rocks!
http://www.dirtyimpreza.com/hosting/project_rs/2007-10-27-front_skidplate/GC_skidplate_install_001.jpg

Install is pretty much a piece of cake, I only ran into problems because my car had been neglected (ill explain in a bit more in a second). Jack up the front of the car and put it on jack stands. Remove the plastic under tray. IIRC there are 4 bolts and a bunch of snap connectors holding it on. With this out of the way you will have the stock headers exposed along with the oil pan, etc.
http://www.dirtyimpreza.com/hosting/project_rs/2007-10-27-front_skidplate/GC_skidplate_install_004.jpg

I like to do the rear two bolts first. You can do the front two first if you want, they screw into the radiator core support. Which ever ones you do first, be sure to slide the front of the skid plate up underneath the bottom of the plastic bumper piece. Using the jack to support the skid plate really helps if you are doing this yourself. It will keep the skid plate from falling on your face as you try to align the first bolts. Get the first bolts hand tight only, because you will need to be able to move the skid plate around a bit to align the remaining holes.

http://www.dirtyimpreza.com/hosting/project_rs/2007-10-27-front_skidplate/GC_skidplate_install_005.jpg

As you can see the GC skid plate is contoured to allow the headers to come down.
http://www.dirtyimpreza.com/hosting/project_rs/2007-10-27-front_skidplate/GC_skidplate_install_006.jpg
http://www.dirtyimpreza.com/hosting/project_rs/2007-10-27-front_skidplate/GC_skidplate_install_007.jpg

Once you get them all hand tight, go back with a 13mm socket and tighten them all down
http://www.dirtyimpreza.com/hosting/project_rs/2007-10-27-front_skidplate/GC_skidplate_install_008.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2007-10-27-front_skidplate/GC_skidplate_install_009.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2007-10-27-front_skidplate/GC_skidplate_install_010.jpg

Now, some of you observant guys are going to notice im missing a washer on the front passenger side bolt. Well, back to the neglected part. There was no plastic splash guard on this car when I bought it (used). So the front two holes where the skid plate bolts mount are very rusted. It took a lot of WD-40 and some gentle but persistent force to get the bolts to take. Well the passenger side one thought it would be cool to pull out some rusted threads. After almost admitting defeat, I jacked the skid plate up a bit right next to the hole, removed the washer, and got enough threads on the bolt to hold it up there (at least temporarily).

So that’s the RallyAmror 1/8" skid plate in a nutshell. Big thanks goes to RallyArmor for supplying the DirtyImpreza.com Project Rally RS with some protection up front! You can see their full line of skid plates for all year Imprezas here - RallyArmor Skidplates (http://www.rallyarmor.com/store/skid-plates-c-58.html)

[409industries]

That car is going to look sick riding on Gold Speedline and rally tires.

What Suspension are you running?

stock suspension for now. I'm not positive what im going to end up with. $ is a big factor (of course)

[Not All There]

awesome man, look real nice and clean, not only do those bends help fit the headers, but im sure they add a good amount of support/strength to the plate itself.

Your jacking plate is a lot different then mine I noticed. Also, your stock headers come out in the same location as my borlas, but the route the borla takes is a little different. But it ends and meeds the cat in exactly the same spot.

oh, almost forgot, Stock suspension FTW lol!

[Blix666]

i had the same problem with one of my front holes (so to speak). i had to use one washer on one side and two on the other to remedy though.

[I Like It Sideways]

Looks clean, nice install!
How come you didn't go with the 3/16"?

[409industries]

Looks clean, nice install!
How come you didn't go with the 3/16"?

I'm checking with RA, but i dont think they make a 3/16" for the GC's (anymore at least)

[I Like It Sideways]

Ah gotchya. I coulda sworn I ordered the 3/16th for mine... I'll measure it.

[409industries]

Ah gotchya. I coulda sworn I ordered the 3/16th for mine... I'll measure it.

It is indeed 3/16", i posted incorrectly. I would imagine that yours is 3/16" as well. Any less is kinda pointless IMO. 1/8 is pretty thin. Most of the stage rally guys rock a full 1/4". No THATS beefy!

[I Like It Sideways]

Ah gotchya. I coulda sworn I ordered the 3/16th for mine... I'll measure it.

It is indeed 3/16", i posted incorrectly. I would imagine that yours is 3/16" as well. Any less is kinda pointless IMO. 1/8 is pretty thin. Most of the stage rally guys rock a full 1/4". No THATS beefy!

No doubt about that. I'd love 1/4 thick... but 3/16's is fine for now.
I never tucked mine into the lip. I need to do that.

[dppaladino]

hmm mine was 1/8th. and I bent the hell out of it!

[409industries]

We struck a deal with Paul from Team Illuminata (http://www.teamilluminata.com) and are now planning to run all our events next year on Team Dynamics ProRally1 wheels!

http://www.dirtyimpreza.com/hosting/project_rs/2007-11-14-td_pr1s/TD_prorally1_006.jpg
http://www.dirtyimpreza.com/hosting/project_rs/2007-11-14-td_pr1s/TD_prorally1_007.jpg

Super excited to get some rally tires mounted on these. I haven't decided on which tires were going to get (a lot of it depends on what Americas Tire can get us) but it will most likely be a medium compound grave tire of some sort. BFG's would be idea, but might not happen anymore, so im looking at the hankooks or possibly the falken tires.

funny thing is that i was going to get black wheels and these showed up at my door. I was suprised to say the least... but they look pretty cool! They are 15x6 +40 offset. I am planning on running 16/64-15 tires. (195/65R15)

[I Like It Sideways]

Ahhhh dang you!! I've been wanting white Pro Rally 1's.

Those are tits. Very nice

[Not All There]

those are going to look beautiful! Lucky bastard lol!

[22b-righton]

The RS is coming along nicely..We've prepped a couple of twins to yours. Really like the black ones, until it's 100 out..Keeping the AC is a good idea down there.

When are you going to get it caged? It looks like its ready to get the prep done now.

Did the wheels (15x6) clear your brakes? Those are designed to clear 4 pots, not stock, so they can rub. Have had some issues with 6's clearing WRX and Leggy brakes. None with the 7s.

Also, as far as the suspension goes, we build a proven set up that would work well on your car..If you went to Laughlin, there were 2 of our clients running it on GC/GM cars.

Good luck with the build.

[409industries]

Did the wheels (15x6) clear your brakes? Those are designed to clear 4 pots, not stock, so they can rub. Have had some issues with 6's clearing WRX and Leggy brakes. None with the 7s.


So, for the record 15x6 +40 ProRally1 wheels will fit over stock RS brakes.

http://www.dirtyimpreza.com/hosting/project_rs/2007-11-21-prorally1_testfit/prorally1_testfit_006.jpg

Wish i had some rubber on this wheel...
http://www.dirtyimpreza.com/hosting/project_rs/2007-11-21-prorally1_testfit/prorally1_testfit_005.jpg

Plenty of space for rocks and stuff to fit through there. I have more space here than i do on my Rallyx wheels on the STi...
http://www.dirtyimpreza.com/hosting/project_rs/2007-11-21-prorally1_testfit/prorally1_testfit_004.jpg

Yeah i know im missing a lugnut. I actually found it in the glovebox but the threads are destroyed on it. I think i have some spare subaru OEM lugnuts in my spare parts box somewhere. On a sidenote, i finished sanding down under the driverside seat. So i think im finished sanding / scraping all the crap off the car for now. I took all my tools out, etc and actually threw the car around a bit last night.

She handles like a boat compared to my GD as expected on old stock suspension, but there is a lot of potential. Despite how the motor sounds when it idles, it actually runs very smooth even at 6000+ RPM. Once I replace the clutch ill have a good idea how it pulls off the line, but its hard to tell right now because the clutch engagement is virtually non-existant.

And caged??? we'll pretty soon! hopefully first quarter 08. I'm amped.

[lorenkb]

Just a heads up, don't use subaru OEM lugnuts with the ProRally 1 wheels, they are angled differently.

Gald you decided to stick with white ones, they look great!

[IneedRS]

YES!! YOU KEPT THE WHITES!!!
haha awesome! i was hoping you were gonna keep those bad boys

[L and E Fab.com]

Now I want white wheels for my street car for Recce... Thanks Aaron!

[subyspawn]

white wheels FTW. i am pickin up Isamu's wheels for spares for next year...

[409industries]

Just a heads up, don't use subaru OEM lugnuts with the ProRally 1 wheels, they are angled differently.

Loren, which lugnuts would you recommend / which are you using?

white wheels FTW. i am pickin up Isamu's wheels for spares for next year...

Isamu's wheels are sweet as hell! i have to admit though, i have grown pretty fond of your STi with those black ProRally1's... they look great...

[lorenkb]

Loren, which lugnuts would you recommend / which are you using?

Um, well... there's this mexican dude down the street a bit from Kyle's shop that mounted my tires and sold me lugnuts... yeah :lol:. Big help huh? I'm assuming most tire/wheel shops would have them, they are a little longer than OEM lugnuts, with a deeper and more shallow base.

[I Like It Sideways]

Those look so sexy.

Can't wait to see how they looked with tires mounted. Glad you stuck with the whites!!

Have you thought about how beefy of a cage you'll be having built?

[Team Illuminata]

Aaron,

The oem nuts should fit though for competition we recommend bulge lug nuts to fill the seats better. TD and Subaru should both be 60 degree conical seat.

For rally you probably want steel, open ones. Also, think about using longer studs to get even more thread engagement. Get them 17mm hex so your socket will fit in the wheel holes easier or get a small diameter socket:

http://www.teamilluminata.com/Shop/WheelAccessories/WhAcc.htm

[UP2MTNS]

Aaron, looks good man, keep it up. Let me know if you ever need a co-driver :D

[lorenkb]

The oem nuts should fit though for competition we recommend bulge lug nuts to fill the seats better. TD and Subaru should both be 60 degree conical seat.

I must be mentally challenged or something... coulda swore they were different when I tried them. :oops:

Why use open end instead of the bulge closed for rally?

[Team Illuminata]

:oops:

Why use open end instead of the bulge closed for rally?

I might be thinking like a Brit but I recall srutineers wanting to be able to see how much thread engagement there is and if you run long studs you will often have the stud be longer than the nut anyway.

[JacksonRally]

Cool I was actually wanting open ended ones...we use them on the race trucks but those are with 5/8 studs.

[409industries]

So i met up with Kyle (06drtywgn) over the weekend to just "take a look" at how we might mount the lights on the RS. Well one thing led to another and next thing we knew it was dark outside and we (well HE) was still drilling holes in my bumper beam. So far so good, though they look fantastic where we put them. The GC Imprezas have a beefy front beam that made it so we didnt have to weld on another bar to attach the lights. Enough talk, heres the pictures.

http://www.dirtyimpreza.com/hosting/project_rs/2007-11-25-soltek_install_p1/soltek_fuego_part1_001.jpg

License plate hanger has to go
http://www.dirtyimpreza.com/hosting/project_rs/2007-11-25-soltek_install_p1/soltek_fuego_part1_002.jpg

Drilled holes to mount the lights, and a big access hole on the bottom to get a socket in there
http://www.dirtyimpreza.com/hosting/project_rs/2007-11-25-soltek_install_p1/soltek_fuego_part1_003.jpg

Carefully measured
http://www.dirtyimpreza.com/hosting/project_rs/2007-11-25-soltek_install_p1/soltek_fuego_part1_004.jpg

Access holes
http://www.dirtyimpreza.com/hosting/project_rs/2007-11-25-soltek_install_p1/soltek_fuego_part1_005.jpg

Mounted up. The lights are maxed out in their upward tilt. Since I dont have them powered yet, we will need to make adjustments based on how the light pattern looks from down there.
http://www.dirtyimpreza.com/hosting/project_rs/2007-11-25-soltek_install_p1/soltek_fuego_part1_006.jpg

Bumper back on. The bumper had to be modified by removing all of the grill pieces that sit in this opening. The lower part of the opening was cut back too, so that the bolts holding the lights on don't pass through the plastic. This way in service we can remove the bumper without having to take off all of the lights.
http://www.dirtyimpreza.com/hosting/project_rs/2007-11-25-soltek_install_p1/soltek_fuego_part1_007.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2007-11-25-soltek_install_p1/soltek_fuego_part1_008.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2007-11-25-soltek_install_p1/soltek_fuego_part1_009.jpg

The stock foglight location is going to be used for the wide cornering HID's. The old cracked hellas in there would be pretty useless. I'll probably use the stock wiring to the foglight switch to power those two outside lights. Kyle is going to work his fab magic to make some brackets that will fit in there.

Big thanks goes out to 06drtywgn for taking time out of his weekend to mess around with my rusted ass GC :) :headbang:

[UP2MTNS]

nice work, kids! :D

[I Like It Sideways]

My jaw is on the fricking floor, that looks badass!!!!!

Very nice work!!!!! I can't wait for illumination.

Are their plans for a removable light bar? I'd hate to see it get stuffed before the night stages.

[RALLYxISH728]

Car is coming along good bro!

[dppaladino]

Wow looks great. Those are going to be ridiculous!

[JacksonRally]

No plans for a "removable" light bar for this one, but it can be done. We are planning though for more front end protection but everything we are going to do is going to be behind the bumper cover and under the car. So what you see is a clean setup, and the protection will be undercover!

[I Like It Sideways]

gotchya. yeah i'd hate to see him stuff it and loose the lights though. Especially with how nice (and expensive) those are. A lot (if not all) teams have removable light bars/pods... An off at even 30 mph will destroy those lights... :shock:

You aren't kidding about being a clean install... one of the cleanest I've ever seen.

[sebhockey]

Nice work. It will hurt when one of them gets broken.

[rllyrckt]

LOOKS SWEET cant wait to see how BRIGHT they are

[Not All There]

nice clean install, id still be worried about stuffing it, but for the rallyx's in your area it shouldnt be a big problem. But come rally time possibly. Hey Aaron, do you have alot of bad shadows forming with the lights so low?

Very nice install tho, nice work

[409industries]

Dont know just yet, im still figuring out how im going to wire all this up.

[sebhockey]

Dont know just yet, im still figuring out how im going to wire all this up.


Using wires I hope would help. :mrgreen:

[Dynapar]

that looks bad ass! hope you dont crash though. thats alot of $$$ in lights

[Drew84]

mess around with my rusted ass GC :) :headbang:

Rust? where? you live in Cali you guys don't know the meaning of rust.

[409industries]

Rust? where? you live in Cali you guys don't know the meaning of rust.

This car was originally from Illinois.

[sebhockey]

Rust? where? you live in Cali you guys don't know the meaning of rust.

Pssh, you land lubers don't know the meaning of rust. You want rust? Then come to my work and I'll show you more rust per square inch than you'll ever to to see.

[rollo]

I'm gonna side with the doubters I think. I'd think you'd want to run a pod or a bar so you could take them off whenever you don't need them (i.e. most of the time) since they're such a big ticket item and relatively vulnerable wherever they end up. (maybe something like this: http://www.roadraceengineering.com/lightpodinfo.htm)

Also they seem real low - seems to me that to get the most out of them you'd wanna mount them higher so as to illuminate as much of the road (and side of the road) ahead as possible. If you think about the light output as a cone extending from the lens (I know it's probably not an exact cone) then by having them so low you're 'wasting' a lot of that light illuminating road you can't see (or at least can't do anything about, if you see what I mean).

As far as wiring, hell yes to relays - rallylights.com (http://www.rallylights.com) has a bunch of stuff about this in their "Useful info" section.

[409industries]

Thanks Phil for the advice. Kyle and I already in the process of designing a simple but effective bar. I agree, lights higher up will provide better visibility (and less chance of destroying them!)

Rallylights.com also has a ton of useful information about relays, etc, but i am still not getting how to wire this stuff up real well. I just want to do it right the first time...

http://www.dirtyimpreza.com/hosting/imagehosting/yellow_aux_lightrelay.jpg

[409industries]

Oh the RS threw a new code. Yay!

P0420 Catalyst Efficiency Below threshold (bank1)

Does this mean there is a post cat 02 sensor going bad? or my cat is screwed up?

[409industries]

The huge DI windshield banners turned out great! I got these as samples for the RS and am accepting pre-orders now. These went on with no problems, and i even got all the bubbles out. Probably my best install to date!

In the future, ill be getting a black tint banner underneath the vinyl to make it "pop" a bit more on the car.

Front:
http://www.dirtyimpreza.com/hosting/project_rs/2007-12-18-windshield_banner/windshield_banner_002.jpg

Back:
http://www.dirtyimpreza.com/hosting/project_rs/2007-12-18-windshield_banner/windshield_banner_004.jpg

If you are interested in getting one of these too, more information is available here. (http://www.dirtyimpreza.com/forums/showthread.php?t=2359)

[Not All There]

im diggin the rear window, ill prob do that

What did you dimple die in the rear?

[donutking]

ya for new stickers now get a hood pod for some rally lights!

[Salvator Rizzo]

this rs is going to be awesome!

[wolfman79]

Car's looking good can't wait to see it finished.

[409industries]

What did you dimple die in the rear?

Pardon my n00b-ness. What is dimple die?

ya for new stickers now get a hood pod for some rally lights!

Wont be going with a hood pod... actually getting a custom light bar. oooh yeah!

[Not All There]

lol, its just a set of holes i see made in a piece of sheet metal under the rear side windows. Your answer answers my question tho, it must be stock. They are just nice countersunk holes to make sheet metal stronger. "Dimples"

[409industries]

lol, its just a set of holes i see made in a piece of sheet metal under the rear side windows. Your answer answers my question tho, it must be stock. They are just nice countersunk holes to make sheet metal stronger. "Dimples"

Yeah, i noticed these when i took off the interior panels... they definitely come with the car! I think they look cool too. :)

[409industries]

No money... but the mod bug is biting. What do to? Remove more crap! I had the driver's side door panels off previously to try to repair the window but was unsuccessful. I know what needs to be welded but have no way to do it right now. So I removed the speaker and put the panel back on.

Decided to do the same thing for the other door and remove the sweet tape and disc changer head unit. The rear speakers had already been taken out. Tunes? Who needs em. Ill be listening to rocks hitting the chassis all day. Music to my ears.

http://www.dirtyimpreza.com/hosting/project_rs/2007-12-28-stereo_removal/rs_stereo_removal.jpg

Stock stereo and head unit comes in over 9lbs.

This week I also ordered my NASA / Rally America approved first aid kit, and two window breaker / seatbelt cutting tools. I figured its never too early to start gathering all the small stuff I'm going to need.

[sebhockey]

Looks like you're making good progress there Aaron.

[wolfman79]

If your stereo needs a new home I happen to know of one. She can't afford to pay much more than shipping though.

It's amazing how much some of the little stuff weighs. Stereo doesn't seem like much on its own but the equivalent of only 10 of those is already 100 lbs.

[kainam00]

Oh the RS threw a new code. Yay!

P0420 Catalyst Efficiency Below threshold (bank1)

Does this mean there is a post cat 02 sensor going bad? or my cat is screwed up?

It's usually the cat. 90% of RS's have this code, now that they are getting older. You also are pretty much guaranteed to get it if you're using an aftermarket header or cat, or basically if you increase the flow in any way. There are a couple fixes, one way is to add a spacer to the sensor, moving it out of the way of the exhaust a bit, another way is adding an inline resistor... both seem to be hit and miss.

The upside is that there is none or negligible performance impact. My car has been throwing this code for two years.

You can do a search for it on rs25.com, there are quite a few threads about it.

[DR1665]

First of all, I have to say that I can't wait to see this car in person at Ridgecrest. I assume you'll be there, if not for rally school, for the rallyx action. I had to miss Ridgecrest last year, but it's the first event on my calendar for 2008.

I love this thread. You've got the lights, but no pod. I've got the pod, but no lights. Even so, we've both got our rally wheels eagerly awaiting tires. Haha. Granted, mine are just a used set off an old Galant GSX, but they will be fine for a while, imo. I'll be painting them and mounting a set of well-used rally tires to them for practice between now and Prescott. I've heard that the factory spares are mounted on the perfect wheels for rally snow tires, FYI. Don't know if you plan on getting too far north with the car, but food for thought, eh?

They look like this (only silver, these are not mine):
http://i106.photobucket.com/albums/m266/ggsxkid/100_0347.jpg
http://i106.photobucket.com/albums/m266/ggsxkid/100_0444.jpg

Back to the lights, unless I missed it elsewhere, I didn't see which ones you went with. When I saw that the 7" Hellas for the pod started at $150 each, I decided that I'll likely live with some KC Daylighters on a custom, removable bar. I was also under the impression that only 6 lighting surfaces were allowed on the front of the car (OEM high and low beam count as one per side), so your comment about a pair of HID in the corners inspired a trip to the 2007 RA rule book for clarification. Good deal! 8 is the official answer! I'm likely going to stick with the OEMs, (2) wide, (2) pencil, and then a couple of cheap projector fogs in the low, OEM positions. A buddy and I ran a couple of the Prescott roads Monday afternoon and, as evening descended, the dust was just hanging like fog.

Anyway, it seems there are a handful of us out there working to run a rally (or two) in 2008. Perhaps you and I will trade times at Prescott this year in PGT? That would be dope.

[409industries]

It's usually the cat. 90% of RS's have this code, now that they are getting older.

The exhaust is definitely showing its age, but there are no aftermarket components added to it. So its just age that is probably the cause of the CEL. It doesn't show consistently either is what is very strange.

First of all, I have to say that I can't wait to see this car in person at Ridgecrest. I assume you'll be there, if not for rally school, for the rallyx action. I had to miss Ridgecrest last year, but it's the first event on my calendar for 2008.

Super bummed! as much as it is a dagger in my heart, i will not be at Ridgecrest this year. Its just one event in the long line of sacrifices that i will be making to get the car stage ready by the end of the year.

Last years event was one of my very favorite of the whole year, and it really sucks to miss it, but doing the numbers, it doesn't make sense to go when i'm struggling to come up with money for a roll cage, a new clutch, and coilovers in the next 3-5 months.

Id love to see the galant too! your comment about me having lights and no mount and you having a pod and no lights had me literally laughing out loud. good stuff. Realistically, i dont see myself doing any of the first round events for CRS this year. Ill probably go to Glen Helen to help out, but some of the events that require staying overnight are pretty much just not going to happen. 2008 is going to be the year of scraping by to make the project materialize.

[DR1665]

Super bummed! as much as it is a dagger in my heart, i will not be at Ridgecrest this year. Its just one event in the long line of sacrifices that i will be making to get the car stage ready by the end of the year.
Tell me about it. I was hoping to make a run at the JV series this year (since I haven't been out since JV2.07), but you're absolutely right. You got to scare up the cash for the build somewhere. I'm dropping a stock motor in my beloved 97 Talon, selling her, and picking up a second job in order to fund this project. I've had that Talon over ten years and I literally shed a tear the night I pulled the cams. :(

At any rate, I've never made it to any form of proper rally training, so I feel that the structured training/info sessions will add enough value to the venue to make it worth my while. Your talking it up as one of your favorites of the year only cements my decision to attend, sir.

i'm struggling to come up with money for a roll cage, a new clutch, and coilovers in the next 3-5 months.
We can't all be trustafarians, meng. ;-) I'm pretty sure I've worked up a trade of said light pod for a set of blown GR2s and assistance with rebuilding them to the Bilstein curves. I'm not 100% sure yet, but I'm keeping the pod in the back seat just in case!

The good news is that the stock suspension bits on my now 17 year old Galant seemed to handle Perkinsville and Witty Tom without too much issue. By no means are they competition-worthy (front end actually lifts under boost), but considering how I'm merely pointing the car from corner to corner while staying in my lane the entire time, they handle the straight stuff alright.

My biggest concern is seat time. I need to get more familiar with how the car handles on the dirt. The Desert Storm/Qz stages are going to be the best spots to do that, imo, as there are usually high berms along the roadway and, unless I try to shove a Saguaro, I should just understeer into the scrub. Prescott, on the other hand, presents some pretty scary off potential. I figure I'm not entering any RA events this year and I can legally run Prescott up until the end of June to gain some confidence on those, more dangerous, roads.

My most pressing goals for the year are cage (Rumblesoft Racing in San Clemente), seats (Cobras seem to be the least expensive legal), harness (heard G-Force has some $170/set which are legal as well), and the logbook. Amidst all that, I've got the same hair-pulling maintence type thins as you do. Brakes that wobble, CVs that click, clutches that slip more than they should, and something you should be thankful you DON'T have to deal with, deletion of a factory installed 4WS system. It makes getting sideways a real PITA.

I'll keep watching this thread, boss. It's good stuff and I like good stuff. :headbang:

[409industries]

Tell me about it. I was hoping to make a run at the JV series this year (since I haven't been out since JV2.07)

Ill be sure to make one of the later season events out at JV. Its just a ton of fun out there.


My biggest concern is seat time. I need to get more familiar with how the car handles on the dirt. The Desert Storm/Qz stages are going to be the best spots to do that, imo, as there are usually high berms along the roadway and, unless I try to shove a Saguaro, I should just understeer into the scrub. Prescott, on the other hand, presents some pretty scary off potential.
Have you done all three of these events? I am still tossing around which events would be best to try first. Of course, the time it takes to get the car ready is really going to dictate what could actually be the first event to try... But some events are definitely better than others for newbies.

My most pressing goals for the year are cage (Rumblesoft Racing in San Clemente), seats (Cobras seem to be the least expensive legal), harness (heard G-Force has some $170/set which are legal as well), and the logbook.
Drop me a PM before you come out to Rumblesoft, I work in San Clemente, and would be down to check out their place!

[lminette]

I'd be down to check out Rumblesoft as well!!!

[DR1665]

This is your project thread and I don't want to detract from that with my ramblings. I've never done anything more than briskly shoot from corner to corner on what I consider to be a good handful of these roads. I'm, honestly, in no position to offer advice on which rally might be better than the other, but I can share a few thoughts with you on these roads as a relative newcomer to the sport, should the budget suddenly materialize in time for you to have your pick, sir.

Seed9 - Neat little 1-day event with some hard packed clay, bits of tarmac here and there, lots of turn-around stages, and no shortage of pointy rocks and ruts. I worked a couple of the turn arounds and rode out in an early 70s, RHD Mini Cooper, as the Galant was pulling HAM repeater duties on a mountain top somewhere. (I got to see it. It was cool.)

DS/QZ - Don't let their HQ locations fool you. They share 90% of their roads with each other, most of which are a good 60+ miles EAST of Quartzsite. I've been out on these guys more than a couple times and the roads are brilliant. Fast, smooth, minimal (if any) exposures, but still capable of bending your struts if you're not careful at the helm. Sorefinger, with it's long straights and multiple yumps, and Treasure Mine, a turn-around with breath-taking scenery, flowing technical sections, and surprising, off-camber !!'s through mini ravines, will definitely stick out as favorites. There's even another stage (sorry, forgot the name) used in some race called something like the "Bouse 400," which is at least 20 miles long. Most cars completed the stage in less than 16 minutes. ;)

Gorman - Can be a crusher, but I've never been. Heard it's a good place to lose the training wheels, though.

Rim - Cancelled, never been.

Treeline - Cancelled, never been. (Seen footage, though. Brutal.)

Prescott - My "local" event. I've heard numerous people say that, if they could only afford to enter one event per year, they would pick Prescott. Such a diverse group of roads at this one. Fast, smooth sections turn into twisty and loose and back again on single stages. There's washes, cattle guards (the big air), hill climbs, narrow cuts through mountain faces, downhill drag races, one lane bridges, tight switchbacks, and crazy mad sweepers with big exposures. Some areas are really rough and rocky, while others are like driving on silt. It's so much fun.

Laughlin - Apparently going to change somehow for 2008, but I don't know how just yet. MAJOR undertaking, as it's not only a 3-day event, but I do recall towing the Rallynotes Neon back to within 90 minutes' drive of the Phoenix city limits. (Crazy for an event "held" in Laughlin, right?) I have limited experience on roads for this event, as we only drove out to one of the stages north of Peach Springs, AZ to collect the battered Neon on a road that was like driving on baby powder. (If they made a road out of Johnson Valley, this is what it would be like.) There's also a unique opportunity to race into the Grand Canyon, but competitors have to haul their gear all over Arizona for this one, so it's a major investment.

And I know nothing about either Reno or Idaho, save Reno is a stretch and Idaho is supposed to be on gravel this year instead of tarmac. Kris and Christine (Rallynotes/Rumblesoft) have pretty much been my guiding light in the world of the CRS since October of 2005 when I first met them and I basically have them to thank for the vast majority of what I know and have experienced along the way.

No doubt, the next time Vanessa and I are in SoCal and hanging out with the Marciniaks, I will be sure to let Kris knows folks over here are interested in checking out the shop. (If he, as a member, hasn't already seen this post and dropped you a line.) At the same time, I have to tell you that I can't stop thinking about excited I am at the prospect of potentially trading times with you in PGT at Prescott this fall. Whether we're in the same class or not (I'm too tired to re-read this thread and consult the rules), it's becoming something of a driving force in my motivation to complete my project on time. You've got a good lead on me now, but I aim to catch up shortly, sir.

[409industries]

You've got a good lead on me now, but I aim to catch up shortly, sir.

Thanks so much for that awesome writeup on all the events im considering doing! Having only been to two of them its nice to hear your take on some of the other ones.

I wouldn't say that i really have a big lead on getting ready for stage rally. Tearing stuff out of a car doesn't really count as car prep. LOL. Time to start spending the money it takes to get the rig in shape! I got an OEM replacement flywheel on the floor here next to me... and its only a matter of time that clutch shows up!

I guess i get antsy when funds are low. At least i got something to show for the past few weeks! A Rally First Aid kit and two glass breakers / seatbelt cutters!

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-5-rally_firstaid/rally_firstaid_kit2.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-5-rally_firstaid/rally_firstaid_kit1.jpg

[DR1665]

Thanks so much for that awesome writeup on all the events im considering doing! Having only been to two of them its nice to hear your take on some of the other ones.
Not a problem! Happy to help!

What is it with these previous owners and maintenance? I tell ya, man. My TOB is "gronchy" and a 5000rpm 1st gear clutch drop right about now would result in more noise and smell than AWD launch. You have the flywheel and a clutch en route! WINNAR! :mrgreen:

This thread is fast becoming a daily favorite of mine. (Well, more like a late night snack of sorts...) I just picked up a nice reflective triangle (w/ weighted base and case), AAA first aid kit w/ extra bandages, and "Life Hammer" for Christmas. Go figure!

Have you recently re-done the brakes on your car? I'm currently collecting the parts from various sources to get the job done (using gift certs from Christmas among other things). Otherwise, my shifter bushings and case of Rustoleum (flat black) should be here within a week. ;)

[donutking]

aaron car looks good coming along quote nicely.

[409industries]

Have you recently re-done the brakes on your car? I'm currently collecting the parts from various sources to get the job done (using gift certs from Christmas among other things).

Brakes are definitely on the list of things to do! Plans for the brakes include resurfacing the rotors, new brakepads, stainless steel lines, and of course new brake fluid.

Much of the little things have been pushed onto the back burner for now. Some major developments have come together so i need to keep a much money available as possible for the project (down payment on some gravel coilovers, cash to buy roll cage material).

I saw some of those emergency triangles on sale through ACE hardware, a 3 pack. Those stupid things are expensive, but not too bad.

To bring people up to speed on the project car, I took it out romping for the first time last weekend and had a total blast. The little metal plugs in the floor board need to be re-welded as i had most of them off from the sound-dampening removal. This was bad as mud water liked to come into the car when crossing the waterbars and deep puddles! (i even had my legs splashed a few times... whoops!)

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-6-trabuco_canyon/trabuco_mudding_011.jpg

The car handled decent, but it was really hard to get the back end to come around sideways with my bad brakes, and without a good clutch to deliver power to the wheels, it was nearly impossible to left foot brake. Still driving around was tons of fun, and i was loving the sound of rocks hitting all over the car. Its SO loud inside!

Alas, the fun ended after standing outside our cars (Rally OBXT, lminette and his wife) we saw oil coming out from under my car. Despite my best efforts to fix the problem on the side of the road, i was no match for a punctured oil pan. And to think i almost didnt bring my toolbox! WTF was i thinking!!!

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-6-trabuco_canyon/oilpan_rs.jpg

It wasn't going to be fixed there, and rather than risk the motor running out of oil and destroying itself i called AAA and had them flatbed the car to my folks house, where i will attempt to temporarily fix the car this weekend. (so that i can drive it far enough to get to my buddy's house to do my new clutch / flywheel / and oil pan.

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-6-trabuco_canyon/di_rs_flatbed.jpg

Wish me luck! ;-)

[fattie92]

I remember jumping railroad tracks in my buddies dodge caravan when we were 16. The impact put a nice hole in the transmission pan. We were in a parking lot 30min from home. Luckily we had a friend girlfriend with us! We had duct tap, and tampons!! While we were under the van plugging the hole with tampons and then sealing it off with duct tape a few ran off to the gas station to score some ATF... Not a freaking leak!!

Moral of story.... Always carry a few tampons and duct tape!

[MetalNeverDies]

LOL nice save man and here i though just duct tape could solve all my problems

[409industries]

LOL nice save man and here i though just duct tape could solve all my problems

Dont forget the tampons. :)

[fattie92]

Tampons are key as they expand as they absorb to seal everything off.

[409industries]

So this is the little bugger that drained the RS of all its oil! lame.

http://dirtyimpreza.com/hosting/project_rs/2008-1-12-patched_oilpan/oilpan_hole1.jpg

I actually have a replacement pan purchased already, but needed to patch the old one so the car can be mobile. Theres plans to get the lightbar made this weekend at Jackson Rally, and the following weekend is the clutch and flywheel replacement and my buddy's house. If I have any extra time, ill do the oil pan then, but we'll see. Its the same day as the CRS banquet so we'll see how we do on time.

Quiksteel FTW!!! hahaha Thanks to Rally OBXT for the referral, so far it works great! Seriously looks like i patched it with gray chewing gum. I couldnt find the original drain plug so the @%^@^@^ing fumoto valve is still on there.

http://dirtyimpreza.com/hosting/project_rs/2008-1-12-patched_oilpan/oilpan_hole3.jpg

The new goods going in the following weekend:

OEM replacement clutch and new Subaru flywheel...

http://dirtyimpreza.com/hosting/project_rs/2008-1-15-clutch_flywheel_oilpan/clutch_flywheel2.jpg

New oil pan

http://dirtyimpreza.com/hosting/project_rs/2008-1-15-clutch_flywheel_oilpan/new_oilpan.jpg

SUBARU TOOTHPASTE!!!

http://dirtyimpreza.com/hosting/project_rs/2008-1-15-clutch_flywheel_oilpan/subaru_toothpaste.jpg

j/k, its the Subaru OEM version of 3 Bond 1215 Silicone Gasket.

Wish me luck! :roll:

[Not All There]

good luck, its not to bad of a job!

[lminette]

Good luck Aaron!! If you need an extra set of hands give me a shout!!

[I Like It Sideways]

Bummer about the hole in the oil pan, but good decision and good catch.

Good luck separating the transmission from the engine, that was the hardest part (rather, took the longest) when I swapped motors.
Two prybars get the job done though, and some careful chiseling around the bell housing.

[409industries]

Bummer about the hole in the oil pan, but good decision and good catch.

Good luck separating the transmission from the engine, that was the hardest part (rather, took the longest) when I swapped motors.
Two prybars get the job done though, and some careful chiseling around the bell housing.

Yeah this car is originally from Illinios, so theres some rusty spots. I bet its going to be on there pretty good. :roll:

[Galen]

ghetto repairs FTW!!! nice batch of new parts tho!

[409industries]

Another weekend at Jackson Rally! Theres more pics and they will be coming soon... Over essentially a whole day of work, this is all i have to show for it right now. Partially completed wiring for the HID's. I'm still sorting out the relays and all that stuff.

Heres the fuseblock for the aux lights, and the while wires are the wires from the toggles inside that are in turn hooked up to what i think is the highbeam stock switch.
http://www.dirtyimpreza.com/hosting/project_rs/2008-1-19-jacksonrally_inst_day/jacksonrally_inst_day_022.jpg

I finally have the toggles hooked up correctly though so thats good. Toggles will eventually be mounted.

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-19-jacksonrally_inst_day/jacksonrally_inst_day_020.jpg

I originally tapped the yellow and blue one, but i dont think its right. I spliced that little green and white one. This seems to be it, because when its off my tester shows power, and when i turn the highbeams on, the light on the tester goes off (reverse ground???)

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-19-jacksonrally_inst_day/jacksonrally_inst_day_012.jpg


confused? Yeah i am too, but im going to hopefully have it all sorted out by the end of the week.

Big ups to Kyle and Keith for helping out all weekend. The lightbar is actually on my car and done right now, but i need to take some pics!

p.s. oil is slowly seeping through my ghetto pan patch job... but the car is driveable. LOL

[rllyrckt]

that looks like the fun i had when i was wiring up my bar.....i wanna see pics of your bar!!!!

[Galen]

lets see that bar baby!!!!!!

[Not All There]

i agree, dont be gay, post it up!

[409industries]

i agree, dont be gay, post it up!

Got too dark by the time i got home. sucks balls. I will def have pics tomorrow, mocked up with the lights too ;-)

[lminette]

Sweet!! Can't wait to see it!!

[fattie92]

To dark?? Bitch you have like 6 Solteks! Its never to dark!

[409industries]

To dark?? Bitch you have like 6 Solteks! Its never to dark!

6 solteks that aren't wired up yet!

[409industries]

w00t! its on!:eek:

Check this beauty out, its absolutely gorgeous. The Jackson Rally GC light bar has been installed on the Project RS. Thanks goes out to Kyle (06drtywgn) for spending his free sunday working on my car to get this done. His attention to detail really shines through here.
http://www.dirtyimpreza.com/hosting/project_rs/2008-1-22-main_lightbar/main_lightbar_001.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-22-main_lightbar/main_lightbar_002.jpg

Custom plates had to be fabricated to allow the light bar to bolt into the main bumper beam with two bolts. This bar is on so solid you can rock the whole car by it (possibly pull it too...) Were still thinking of ideas regarding cutting the bumper a bit more and inserting a removable plug to allow us to quickly add and remove the light bar between day / night stages.
http://www.dirtyimpreza.com/hosting/project_rs/2008-1-22-main_lightbar/main_lightbar_003.jpg

Take a look at these insane welds!!! :shock: :shock: :shock: These tabs were custom sized to fit the base of the HID's perfectly. The lights have enough contact area to be mounted very solid.
http://www.dirtyimpreza.com/hosting/project_rs/2008-1-22-main_lightbar/main_lightbar_004.jpg

With the Soltek Fuego 4" HID's (http://www.bajadesigns.com) mocked up for now, i am going to complete the wiring very soon.
http://www.dirtyimpreza.com/hosting/project_rs/2008-1-22-main_lightbar/main_lightbar_005.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-22-main_lightbar/main_lightbar_006.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-22-main_lightbar/main_lightbar_007.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-22-main_lightbar/main_lightbar_008.jpg

Access to opening the hood is not blocked. The hood can be easily opened without moving the lights.
http://www.dirtyimpreza.com/hosting/project_rs/2008-1-22-main_lightbar/main_lightbar_009.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-22-main_lightbar/main_lightbar_010.jpg

Finally, these lights block nothing as far as view from the driver's seat...
http://www.dirtyimpreza.com/hosting/project_rs/2008-1-22-main_lightbar/main_lightbar_011.jpg

Again, thanks to Jackson Rally for putting together an amazing product. This thing is BEEFY! For more information on the light setup check out Soltek Light Systems by Baja Designs (http://www.bajadesigns.com) - 4" Fuego HIDs

Pics / Video with lights on coming soon! :twisted:

[rllyrckt]

very nice....i cant wait to see it all lit up. man that is a nice bar. have fun wiring up the lights

[subyspawn]

seessssssy!!!

LIGHT EM UP!!! :flamed

[409industries]

very nice....i cant wait to see it all lit up. man that is a nice bar. have fun wiring up the lights

Yeah i didn't get any nice and neat harnesses and plugs *cough cough* izzy! cough*... but i finally have it under control. Relays and such are a bitch if you don't know what the hell you're doing. Rallylights.com has been an invaluable resource, along with some other websites about basic electric circuits.

Electricity > Aaron

[WRR]

yup, that there is some workmanship!! nice job Kyle

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-22-main_lightbar/main_lightbar_004.jpg

[rllyrckt]

yeah gotta love the harness making process, but when it all comes together and lights up the dark like its day, its all worth it.

[lminette]

F-in sweet!! Now I need one!!!

[Not All There]

very awesome, nice job on the fab work, some awesome ****s coming out of that shop.

Good point about no obstruction of view from the driverseat.

[sebhockey]

Awesome work there on Kyle's part. I'm getting more and more impatient to get my light bar from him.

[Galen]

nice!!!!!!!! i want one!!

[Azewaldo]

That's some nice work. Lookin' good!

[409industries]

Awesome work there on Kyle's part. I'm getting more and more impatient to get my light bar from him.

Good things come to those who wait...

We had talked about getting this bar done a long time ago!

[I Like It Sideways]

Awesome awesome workmanship. The light bar looks amazing, as do the lights.

[JacksonRally]

GEE all you need now are some Fuegos in the stock fog light location.....ok ok I just need to weld them and their yours!!

[Blix666]

that looks awesome

[Soltek Lighting]

That is an incredibly clean install and the wide cornerings in the stock fog position should work excellent. Those welds are amazing! Big props to 06drtywgn. I can't wait to see them light up the night!

[vaderSTI]

06drtywagn you do some awsome work

[Galen]

soooooo clean! those welds are amazing!

[409industries]

GEE all you need now are some Fuegos in the stock fog light location.....ok ok I just need to weld them and their yours!!

Super stoked. Thanks Kyle!!! :eek:

[409industries]

Got a goodie box today in the mail from rallygrafix.com. Now i have this purdy little bag to put all my spill stuff into. w00t w00t!

http://dirtyimpreza.com/hosting/project_rs/2008-1-25_spillkit/rs_spillkit.jpg

Get the spill kit from rallylights.com (it doesn't come with a bag though). Get that at rallygrafix.com. :)

[409industries]

Wiring hooked up! I got 4 HID's working ATM. Pictures to come soon. Its ridiculous.

[lorenkb]

Wiring hooked up! I got 4 HID's working ATM. Pictures to come soon. Its ridiculous.

Soon? Bish you had better march your ass outside and takes pics now!

Please? :tongue:

[rllyrckt]

COME ON.....LET THERE BE LIGHT, i wanna SEE, or be blinded, which ever one is better....

[anaonbd]

ahh HIDs, please say you aligned them right. I hate people who put them on and think, damn I'll just point them up to see better.. That's what pisses me off.

[I Like It Sideways]

To truly appreciate how bright these are, i'm going to have to fly out to cali.

Can't wait to see pictures

[409industries]

The HID pics will come soon. I just need to find the time to take some shots. I kinda want to wait until Kyle has the OEM fog location brackets made... for the super debut!

I picked these up off of subyspawn the other weekend. He cut me an amazing deal and i am super thankful for the hookup. You rule Keith!

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-28-sparco_hans/sparco_hans1.jpg

http://www.dirtyimpreza.com/hosting/project_rs/2008-1-28-sparco_hans/sparco_hans2.jpg

Basically everyone is requiring HANS or a HANS style device for stage competition so i got these 6 point Sparco HANS compatible harnesses. FIA approved until 2011. I have yet to get a helmet and device, but that will eventually come. :)

[I Like It Sideways]

Nice snag!!! They look awesomely sharp

[Meachy]

my old car is really turning into something.....

its looking good aaron.....!

sucks about the oil pan though....!

[Meachy]

on the same note....... did you not have your skid plate on while going through gyms?

[409industries]

on the same note....... did you not have your skid plate on while going through gyms?

Yeah i did and that actually was part of the problem! Fumoto valves and skidplates do not mix.

[409industries]

Finally the clutch replacement! The clutch was slipping so bad on this car, i still have yet to feel how fast (or not fast it is) because everytime you mash the gas, nothing really hooks up. My buddy snwcrzy is insane and decided to help out with the replacement since he has done many. We decided to go the "remove the transmission" route to get some good pictures for another project of his. Thanks goes out to at CorruptMotors.com for getting me a great deal on the complete Exedy replacement clutch kit. Drt Suby used his hookups to get me a brand new OEM flywheel as well. Thanks guys!

Here lies the RS... sitting all happy on its jackstands as if to laugh at me in advance. I had no idea the terrors I was about to find underneath when doing the clutch replacement.
http://www.dirtyimpreza.com/hosting/project_rs/2008-2-2-clutch_replacement/clutch_replacement_002.jpg

First on the chopping block, the exhaust. We unbolted it from the headers after the cat and snapped both bolts easily. They were rusted as f-k... this was foreshadowing on the entire day. It doesn't look so bad in this pic, but just wait... it gets better.
http://www.dirtyimpreza.com/hosting/project_rs/2008-2-2-clutch_replacement/clutch_replacement_003.jpg

Nice hole.
http://www.dirtyimpreza.com/hosting/project_rs/2008-2-2-clutch_replacement/clutch_replacement_004.jpg

Completely seized bolts. thats a nice looking gasket in there!
http://www.dirtyimpreza.com/hosting/project_rs/2008-2-2-clutch_replacement/clutch_replacement_005.jpg

Jacked the backend up a bit to get the driveshaft out...
http://www.dirtyimpreza.com/hosting/project_rs/2008-2-2-clutch_replacement/clutch_replacement_009.jpg

Removed the exhaust manifolds, you might say that i have a leak there now due to destroyed gaskets and missing / broken posts in there. Its awful looking. I think my headers are on there by a total of 3 posts (for both sides!)
http://www.dirtyimpreza.com/hosting/project_rs/2008-2-2-clutch_replacement/clutch_replacement_011.jpg

Tranny is out! sweet.
http://www.dirtyimpreza.com/hosting/project_rs/2008-2-2-clutch_replacement/clutch_replacement_013.jpg

Old rusty POS clutch
http://www.dirtyimpreza.com/hosting/project_rs/2008-2-2-clutch_replacement/clutch_replacement_014.jpg

New shiny OEM flywheel (PGT rules say the flywheel hast to be original / original material) No lightweight one for me... :(
http://www.dirtyimpreza.com/hosting/project_rs/2008-2-2-clutch_replacement/clutch_replacement_016.jpg

Clutch in there, ready to rock... with the alignment tool.
http://www.dirtyimpreza.com/hosting/project_rs/2008-2-2-clutch_replacement/clutch_replacement_017.jpg
http://www.dirtyimpreza.com/hosting/project_rs/2008-2-2-clutch_replacement/clutch_replacement_019.jpg

Sun setting, and we still weren't even close to being done...
http://www.dirtyimpreza.com/hosting/project_rs/2008-2-2-clutch_replacement/clutch_replacement_020.jpg

So we worked from 8am till 3am doing a "simple" clutch and flywheel replacement. The amount of obstacles that we overcame was big. Everything on the underside has rust and i counted that we broke at least 13 bolts. Its a good thing that my buddy has lots of spare bolts lying around from his 3 other Imprezas! The two notable big problems were that one of the transmission crossmembers would not thread back into its hole because the thread piece had snapped off inside the chassis! We had to cut a hole to gain access to it. Dave literally caught himself on fire welding a new nut in to hold the beam. It was some pretty sketchy sh*t!

Secondly, the transmission did not want to go back in. First, because it was smashing that small piece of sheet metal that rests right below where the tranny bolts to the engine, it got mashed up in there and took forever to pound back out of the way. Then we discovered that the clutch alignment tool may have done its job initially, but something slipped and we were trying to pound the transmission shaft into misaligned teeth on the clutch plate. This damaged the clutch plate and required tedious and meticulous filing / chiseling to straighten out the teeth so it would fit again.

Once the tranny finally went back in around midnight, we were able to put the tranny supports back in, the driveshaft, axles, etc all back together. It was a race to get done before the overnight storm came in! I think i would have cried if it started raining on us. I ended up throwing my mangled exhaust inside the car, and drove home with just the headers on. Its so effing loud, but i was over it at the time. The poor girl is still smoking from the busted oilpan, and i dont think jacking up the engine by it helped either.

Fortuantely ill be taking a few weeks off from car madness to go enjoy some of the best snow conditions of the season, ill do some minor work on the car from time to time, but there wont be any more major repairs made until march probably. I did shoot a little bit of video during the day, and am going to start a video log of the build from here on out. Stay tuned for that!

The saga continues... :roll:

[rllyrckt]

gotta love the "ohh its gonna be easy" jobs, thats how all of mine start out and take way too long...ohh are there any pics of the light output from the light bar yet, im still waiting. have fun with the snow

[Meachy]

oh lord.......

[derf]

Well at least thats out of the way. I hope the rest of the project is much less of a headache.

[Team Illuminata]

Are you sure this is not a Jeep in disguise?

Sounds like one of my Cherokee stories.

[lminette]

This is why I moved the engine forward instead!! That looks like a total PITA!! Sorry about your troubles Aaron!!

[409industries]

This is why I moved the engine forward instead!! That looks like a total PITA!! Sorry about your troubles Aaron!!

The concern was that the bolts holding the motor in for sure are going to break. The next time we have to do something like this, im going to have new ones handy.

The removal of the tranny wasn't difficult at all, (aside from rusted bolts and nuts) we needed it out so my buddy could get some pics.

I read your write up lou! :)

[Meachy]

dang out of state cars :(

[Team Illuminata]

I'm in Michigan, my cars are always out of state. Or is that "in a state"?

Now I'm all confused but I know this: my nuts are all frozen too.

[anaonbd]

yeh, i've learned a few things from taking cars apart. always have bolts ready and replace even the good ones so that "you" know that you have stuff that isn't going to break.

[Not All There]

nice man, i was waiting for the post after talking with you!

[Galen]

Way to work through countless misfortune. Well done!

[sebhockey]

Nice job on the clutch, looks like fun.

[Not All There]

Dude, the pilot bearing is in backwards!! You have to do it all over again now!









jk jk!

[I Like It Sideways]

Nice work on overcoming the roadblocks. Glad its all back together and moving!! I would have been hosed if I came across those problems with my RS...
The stock exhaust is junk, I used mine to practice welding on :lol:

[anaonbd]

wow, you're much further on your car than i thought you were. i was like oh damn, he just took all that out. of course i'm leaving the sound proofing in because one, i already painted over it, 2 i really umm well i'm lazy, that's about it. hahhahaa

[Drew84]

Wow coming along. I hope to see that car running some events on the East coast one day,;-)

[409industries]

My lugnuts finally made it!

Gorilla ACORN BULGE BLACK 3/4" HEX (19mm) 12X1.25
http://www.dirtyimpreza.com/hosting/project_rs/2008-2-13-lugnuts/lugnuts.jpg (http://www.teamilluminata.com/Shop/WheelAccessories/WhAcc.htm)

These are going to look sick against the White TD Pro Rally 1's. Big thanks goes out to Paul at Team Illuminata (http://www.teamilluminata.com/Shop/WheelAccessories/WhAcc.htm) for getting these out to me. I opted for 25 to have some spares lying around. These are great lugnuts, i've been using them on my STi for 3 years now and have never had a problem with them. :)

If you want a set hop on over to the Team Illuminata (http://www.teamilluminata.com/Shop/WheelAccessories/WhAcc.htm) website today, they have great prices on these badboys...

[Blix666]

are those lugs painted black or are they anodized.

[409industries]

are those lugs painted black or are they anodized.

I couldnt tell you for sure, but my other set hasn't chipped or shown markings even after a whole season of rallyx tire changes.

[Blix666]

they must be anodized then.

i've got painted ones (got'em on ebay and were falsely listed as anodized) and they chip the second a wrench/socket touches them.

[409industries]

thats what i figured. I mean theres a bit of scratching in the grooves, but i've beat the hell of out my old set and they still look great.

[I Like It Sideways]

Those will look awesome with the white wheels.

Why didn't you go with open lug nuts?

[fattie92]

I got to get me some of them... I don't think the chromies will look to good on gold...

[409industries]

Those will look awesome with the white wheels.

Why didn't you go with open lug nuts?

Theyre cheap enough that if i need to go with open lugnuts / extended studs, ill just get more. LOL

[409industries]

Video documentation of the clutch install can be found here!

http://www.dirtyimpreza.com/forums/showthread.php?t=3549