What the World needs now is... a progress thread, An update after 2 years? Unpossible! Yet, true. Options

[VaccaRabite]

So, when I started this restoration in October of 2005, I started a progress thread on the Subaru Board (NASIOC) that I active on. I have been meaning to create a thread here, but I never got around to it. I figured the kids over in ricer land would find it more amusing to see a classic resto in action then the folks here that have lived it.

But, I now post more here then I post in NASIOC OT, and feel more involved in the community then I did when I started. So, for the sake of ease, I am going to port over my posts from NASIOC, and posts from today on will be unique here.

As I get ready to paint (JUNE 9th - 13th are PAINT DAYS!) this thread will get more active. :-)

Zach

PS, it kinda fun for me to do this. Looking over the old posts brings back memories of the ride...

[VaccaRabite]

Posted 12-8-2005

Other stuff done since the 10-12-05 update:

The floor pans were found to be in really good shape. I wire brushed them, hit them with Metal Ready and then 2 coats of silver Por15. I used the silver as it is supposed to fill pits a little better, and be a little stronger.

The only bits still left on the car right now are the suspension. Everything else is out.

It ended up being a very good thing that the car would not start when I bought it. The fuel ring on the passenger side was very cracked and was leaking fuel. Looked like the driver side had been updated, but not the passenger. I am converting the fuel system to stainless steel through the tunnel, but will probably stay with (new) rubber injector hose out of the tunnel.

I ended up cutting out that section of the rear trunk with the rust. I have not found a replacement for it yet, but am looking.

The front trunk also ended up being pretty rusted. I took out the A/C condenser in the front, and was going to weld the hole closed. However, while cleaning up the area around it (getting rid of the "rust proofing") my angle grinder went right through it a couple of places. Luckily, the trunk panel that I picked up to replace the A/C can be used to replace the front trunk floor. :-) All of the A/C stuff is out of the car (including all the hoses and fittings), and I don't think that it will be going back in.

There was also some battery tray rust, so I am planning on cutting out the battery tray and welding a new one in after that is fixed.

The only other bit of significant rust that I found was on the engine firewall. tree debris, mud, and probably battery acid had collected in the bottom passenger corner of the firewall. It rusted through an area 2inch tall by 3inch wide. The only thing keeping it together was paint. When I touched the angle grinder to it, the whole section exploded. But that has been the only significant spot. Its totally flat, so that will just be a sheet metal weld.

The engine did not start due to the fact that the wire harness was burned at the ignition coil. Given the fuel leak, this was a good thing. Several wires on the engine wire harness were scarred, bald and somewhat burned, so I am going to pony up for a new one.

I have the engine out and mostly stripped. I have not taken the heads off, and probably won't at this time. The entire power robbing exhaust system on that car is going to be binned. Initially I wanted to put headers on it, but Erin convinced me that heat was a good thing. :-) I have not decided what I want for the actual exhaust. I know that the Bursch 2.0 exhausts are supposed to preform the best, but I really like the looks of the 4 tipped Monza (indulge the little ricer in me - the both flow about the same). Either way, it will be a while before the engine is back in the car, so I have time to ponder it.

It looks like all of the 75/76 model year smog stuff had been capped off, but left bolted in. I am going to find out what I can get away with in PA, and try to avoid putting back all that back on when I re mount the engine.

I ground all the paint bubbles down to bare metal. No rust was found, looks like a crappy respray. Not an issue, as I was going to repaint anyhow.

So far the biggest goof up on my part was the windshield. The rear glass was just about ready to fall out on its own. But the front took more time. I spent a lot of time slowly cutting away the butyl tape around the windshield. But it sealed behind me again. Needless, I ended up cracking the windshield. Doh.

The last big disassembly task is to remove the suspension, and then scrape the bottom of the car down to bare steel. This will also be por-15ed. I know I will probably find some surprises, but I doubt it will be through. About the only place that I have not been able to inspect is the center tunnel.

Now it is getting really cold in the garage, so I will probably take a break on the car and work on setting up some heat in there. It will take me a while, but the car is going to be in top notch shape by the time that I am done with it.

Zach