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Old 03-22-2012, 10:46 PM   #16 (permalink)
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noiiceee!
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Old 04-02-2012, 03:21 PM   #17 (permalink)
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Still have her in the garage, sadly. As of the end of today, we have been able to:
- install the new exhaust system (headers, catted and mid sections, and new muffler)
- install the newer front SG struts
- install the passenger drive shaft with its new boots
- install the newer steering rack also with new boots
- replace both lower ball joints (not on original replacement list, but found old ones trashed)
- solder the 300 resistor on the clock (but still doesnt work...figures)

...All since last Monday, and STILL have plenty to do. I have to thank my wonderful girlfriend for always being willing to drive me around until its done.
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Old 04-07-2012, 06:26 PM   #18 (permalink)
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Default New Alpine Amp

A few days ago, I went on ebay and looked for an Alpine Flex 5 to add to my head unit and continue my sound upgrade. I didnt expect to find anything, knowing they aren't common since people hold onto them, but hit enter and poof! A used one for $77 BIN! I debated whether to get it, but caved. I liked how they sound and couldn't pass it up. So, now just waiting til Tuesday to arrive! Though I did forget to order an install kit at the same time, so im going to be waiting a bit more for that to come in... bullocks.
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Old 04-07-2012, 09:05 PM   #19 (permalink)
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I really like where this is going. Do you have any sound clips?
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Old 04-07-2012, 09:21 PM   #20 (permalink)
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I have the install kit for that amp! It's sitting in the garage!
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Old 04-07-2012, 11:22 PM   #21 (permalink)
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Quote:
Originally Posted by onemanzu View Post
I really like where this is going. Do you have any sound clips?
I do, but they are of when the exhaust just got put on (when it still had leaks). I'll be getting my next update written up soon of all that has been done, plus get some photos and audio clips.
Though I will say, it makes my heart race every time I hit the gas and hear the rumble...

Quote:
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I have the install kit for that amp! It's sitting in the garage!
Sweet! Now, should I go with to Durango, or wait for the amp to come in and install it...
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Old 04-07-2012, 11:34 PM   #22 (permalink)
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^^^ Durango. Amps can wait.
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Old 04-08-2012, 01:27 AM   #23 (permalink)
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Default Garage Down Time - Pt.2

As of yesterday, my foz is done with new part installing and out of the garage! I got her back from the alignment shop and noticed a HUGE difference in the driving and handling. The suspension was nice and stiff and didnt dive at each turn, the steering no longer squealed, and with all the ripped boots taken care of I can finally take it in the MUUDDD!!! April FOTM!! (If we ever get mud... ). Anyways, here are some shots of the work done:

Steering Rack and Boot Replacement

As my old rack was due for a swap once we looked at it, I searched around and got one off of a wrecked forester on ebay that had 125k miles on it (vs 190k on mine). Since I already had new boots I had ordered from Jackie@Annapolis for my old rack, I decided to put them on this newer rack.




The newer rack w/ original boots. Rusted, but not horribly.


Newer rack w/ new boots


Once installed

No more squealing and smoother turning, a very cool thing.

Passenger Drive Shaft (CV) Boot Replacement

This job was supposedly projected as an all day job... after doing it, I can see why. Though, I must admit, playing with grease is fun. It took some time to get the drive shaft free, but was fairly straightforward with the rest. Took the one end apart, cleaned out the other (after smacking it with a hammer and feeling like idiots once we realized it couldn't be disassembled like the other end), applied fresh grease and installed boots acquired from Jackie, and done.







(Continued below)
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Old 04-08-2012, 01:28 AM   #24 (permalink)
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Default Garage Down Time - Pt.2 (Cont.)

(Continued from above)

Exhaust Upgrade

With the old headers, cat, and muffler off, I went ahead a prepped the new exhaust system by spraying the headers with high-temp silicon (thinking I was going to wrap next).



Once that was done, we concluded the wrapping could wait since my engine was still leaking atf and engine oil and the fluids would simply absorb into the wrapping. We then proceeded to assemble the system piece by piece onto the foz and ran into a problem: the pipes were designed for the 2.5RS, not the Forester, thus the undercarriage kept the pipes from aligning just right and caused leaks. To resolve that, we just took everything aside and assembled it together to slap on as one piece. It worked, but had some other issues (message me for more details and tips if your trying this, too). It was a royal pain in the A**, but the rumble was worth it .





SG Suspension Upgrade

When I got the struts in, they were covered in rust bubbles and nastiness that didnt hint at them having only 50k miles on them. Regardless, I set out to cleaning them off before spraying them down with some leftover plastidip.

(Ill add before photos later)


All scraped off and sprayed over




Final Touches
With everything back on and in place (mostly), I drove it down to CSR garage for the alignment. Since I was stumped and tired of working on it, I asked them to find out why it was leaking so much atf onto the exhaust, as well as to find out what was causing a screeching when I turned the wheel a certain distance to either side.

It turns out that the transmission cooler line had a hole rubbed into the side of it from the steering shaft spinning, and was leaking directly onto the steering rack and making it look at fault. The screeching, I found out, was from the sway bar links rubbing the inside of the wheels... I had installed them to where the links were horizontal and not vertical... , so got that fixed and the hose replaced at home and it was finally and totally done! For now...

So here she is!


Just after the alignment... with almost no more butt-sag (without spacers)

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Old 04-08-2012, 03:10 AM   #25 (permalink)
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nice work!
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Old 04-08-2012, 08:50 PM   #26 (permalink)
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Default Bad luck... with brakes! Perfect.

Earlier today I was on my way to my folks house in a neary city to visit for Easter, when upon entering it, I found my brakes were more squishy then normal... then completely gone! As I was coming up to the stop light, I had to resort to the E-brake to bring myself to a semi screeching halt.

I couldnt figure heads or tails out of it! I knew my brake pads and rotors needed replacement and the system needed a flush, but it wasn't that bad! I figured I just needed to get to the where my folks were and see if we could all figure it out, so I proceeded cautiously and slowly with my hazards on.

After taking a look at it, I found a nik cut out of the driver side brake hose that was spewing fluid viciously every time the brake was pressed. Then I remembered:

While installing the new suspension, the mounts for the brake lines had to be cut off with a Dremel to allow us to swap it out. During the process, the hose was cut and shaved in various points, leaving one major gouge and plenty of scuffing. We observed that the line would hold for the time being and continued work.

So with that knowledge, I decided to go to autozone, get some rubber hose and some worm gear ties and try patching it (as they didnt have any hoses available in any stores in town). However! The patch didnt work and only seized the caliper in the closed position and didnt allow any movement of fluid at all. I decided "he** with it" and just drove back on low cruise and didnt use brakes, thanks to low gears. While I was driving, I realized there were several other options that could have been tried, but didn't bother to pull over and waste day light that was quickly leaving.

What an Easter. lol.
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Old 04-08-2012, 08:59 PM   #27 (permalink)
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Default New Brakes... SOON

Per the previous update, it's needless to say that I will be replacing a bunch on my brake system (new pads and rotors all the way around plus the new hose).

Oh and by the way...

Thank you, Josh (Blue Fox) for killing my brakes! I knew there would be a retaliation for rolling your 04 FXT, guess this was it. lol.
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Old 04-08-2012, 10:10 PM   #28 (permalink)
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^^ LOL. Sucks about the brakes. I completely forgot about the nic in the line we left from the Dremel, which we should have fixed before getting that thing back on the road. But it just got lost in all the projects I guess. Could have been a costly lesson, but lucky the car is safe and sound back in the garage.
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Old 04-08-2012, 11:37 PM   #29 (permalink)
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sweet progress man!
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Old 04-09-2012, 06:12 AM   #30 (permalink)
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Wow! Good thing your OK. That could have turned out bad...
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