The Winter Project

ML · 11-13-2009, 02:18 PM

2002 WRX Rally build!

My friend's son blew up the motor in his WRX. It turned out to be cheaper to buy a wrecked complete car at auction and take the motor out of it than to buy a motor with around 70,000 miles on it. I ended up picking up a 2004 WRX motor with a spun bearing on ebay about a month ago for $250. So, the motor's getting rebuilt and so is the car... to rally.

Here's the car. There's no damage on the other side of the car. And, as incomplete as it looks, we have all the parts, except for the hood and fender. Now we just have to get it moved to my house.

Rachel · 11-13-2009, 02:43 PM

I dig the white. Are you really gonna Rally it?

ML · 11-13-2009, 02:47 PM

The first season will probably just be rallycross. After that, yes.

Dr_Jones · 11-13-2009, 05:04 PM

wow...couple coats of wax and you should be good to go

arrutled · 11-14-2009, 08:12 AM

well i think your insane, but try not to blow this motor up too.

ML · 11-14-2009, 09:40 AM

Quote:

Originally Posted by arrutled

well i think your insane,

Welcome to my world... What? It actually took you this long to figure that out?

Quote:

Originally Posted by arrutled

but try not to blow this motor up too.

I didn't blow up the last one but I'll try not to blow this one up.

ML · 11-14-2009, 09:42 AM

Quote:

Originally Posted by Dr_Jones

wow...couple coats of wax and you should be good to go

Oh yeah baby! I also hear that an extra coat of wax will take 10 seconds off your stage times.

and 1 · 11-14-2009, 01:39 PM

mike you bamf...way to be. can't wait to see how this thing turns out. how long do you think it's gonna take?

ML · 11-14-2009, 03:46 PM

Quote:

Originally Posted by and 1

how long do you think it's gonna take?

Not entirely certain. April or May is the goal. Money will be the biggest deterrent.

ML · 11-14-2009, 03:50 PM

The first step in the project is done... build a workbench.

arrutled · 11-15-2009, 11:30 AM

Nice bench! save a weekend in march for my car!

amybang · 11-16-2009, 09:08 AM

So, I know that you all know more about cars than I do, but um, that looks like a stack of tires not a motor to me...

amy!

mkPOTO · 11-16-2009, 09:20 AM

very nice.. subscribed to see progression

ML · 11-16-2009, 09:28 AM

Here's two to choose from. Does either resolve the tire issue?

ML · 11-16-2009, 10:10 PM

Disassemble the front subframe so the crossmember can be cleaned up and powdercoated

ML · 11-16-2009, 10:15 PM

and new parts, like these along with a STi steering rack and replacement right front steering knuckle and subframe, can start going back together.

jtsherri · 11-16-2009, 10:23 PM

Have you considered running the RPM (or other similar) subframe(s)? You can save nearly 40 lbs and get a more rigid design.

FYI: those steering rack bushings make a HUGE difference. '04 STi rack, right?

ML · 11-16-2009, 10:29 PM

Correct, 04 ST rack. For the time being, we're just going to run the stock subframe because I was able for pick one up for just a little over $100. We are going to be running GTSpec frame bracing, which the other guy working on the car with me can get at cost from a local parts shop. So it has been considered but will end up being a future upgrade.

jtsherri · 11-16-2009, 10:41 PM

Quote:

Originally Posted by ML

Correct, 04 ST rack. For the time being, we're just going to run the stock subframe because I was able for pick one up for just a little over $100. We are going to be running GTSpec frame bracing, which the other guy working on the car with me can get at cost from a local parts shop. So it has been considered but will end up being a future upgrade.

Ah, can't beat the cost on that subframe... And you also can't go wrong with GTSpec bits either (especially at cost!).

Have you looked in to picking up an X-brace for the rear, at all? They're a bit pricey, but make a HUGE difference. Based on the looks of things, you probably even have the means to fab your own up (assuming you're not simply planning to run a full cage, in which case it's not really necessary).

Lastly, did you stick with the EJ20 mostly because of how cheap you picked it up (vs. running an EJ25) or are you also sticking to a 2.0L due to some sort of rally regulation.

By the way, I'm just curious. I'm HUGE Subie fan here... Previous car was a big turbo STi with ton o' mods.

Here's a pic in the glory days:

(Click for a larger image)

And here's a pic from one of the meets. I still run it bi-weekly, regardless of picking up my 1er.

ML · 11-16-2009, 11:23 PM

We stuck with the EJ20 because it matches the ecu in the 02 WRX body and the motor was picked up for $250. The initial intent is to keep the car road legal and maintaining the stock ECU that matches the VIN on the body will help. Because the car currently has a salvage title, it has to be inspected by the state police to ensure that it wasn't stolen or been through a chop shop before it goes for the safety and emissions inspection. Assuming that the all of the receipts are kept, it can be demonstrated that the structural body work was done and the stock restraints are not removed (airbags and seat belts), it should go relatively smoothly.

We are building the car to the NASA Rally Sport rule book and making sure that the Rally America specs are also met (or can be relatively easily where difference exist). So, it will be getting a full cage. The other guy on the project has a friend that is going to do the cage for us.

I also had an 04 STi. I really liked the car but got very tired of living with it. It had an APS intake and and turbo back exhaust, dyno-tune and some basic suspension mods. The exhaust was guaranteed to get me pulled over about once every six weeks, although I never actually got a ticket. It was really starting to verge on harassment. As a daily driver, I'll take my M any day over the STi.

ML · 11-17-2009, 09:23 PM

We learned today that the bearing on the #4 cylinder connecting rod spun in the $250 motor, which is exactly what I was told. The crank is pretty badly scored, so its good that the crank that came out of the blown motor is still good. We also learned that the compression in all cylinders is very low at less than 20 psi. This was by hand turning the motor. I was expecting low numbers, but not that low. Time to spit the cases. :-(

The reason for the spun bearing: an improperly torqued connecting rod bolt

arrutled · 11-18-2009, 05:00 AM

wow you guys are moving quickly

11-13-2009, 02:18 PM	#1
ML Change for a Nickle? 14 Rep 875 Posts Drives: 2006 M3, Mazda truck Join Date: May 2008 Location: Westfield, MA iTrader: (1)	The Winter Project 2002 WRX Rally build! My friend's son blew up the motor in his WRX. It turned out to be cheaper to buy a wrecked complete car at auction and take the motor out of it than to buy a motor with around 70,000 miles on it. I ended up picking up a 2004 WRX motor with a spun bearing on ebay about a month ago for $250. So, the motor's getting rebuilt and so is the car... to rally. Here's the car. There's no damage on the other side of the car. And, as incomplete as it looks, we have all the parts, except for the hood and fender. Now we just have to get it moved to my house. Attached Images __________________ "I tasted death many times on the river today. Do you want to know what it tasted like? Do you REALLY want to know? Well I'll tell you then: it tasted like BEEF JERKY." - unknown paddler 8/1/09
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11-13-2009, 02:43 PM	#2
Rachel Dangerous Curves 96 Rep 1,148 Posts Drives: better than the boys ;) Join Date: Apr 2008 Location: Shirley, MA iTrader: (1) Garage List 2011 Ducati 848EVO [0.00] 2008 135i [0.00]	I dig the white. Are you really gonna Rally it? __________________
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11-13-2009, 02:47 PM	#3
ML Change for a Nickle? 14 Rep 875 Posts Drives: 2006 M3, Mazda truck Join Date: May 2008 Location: Westfield, MA iTrader: (1)	The first season will probably just be rallycross. After that, yes. __________________ "I tasted death many times on the river today. Do you want to know what it tasted like? Do you REALLY want to know? Well I'll tell you then: it tasted like BEEF JERKY." - unknown paddler 8/1/09
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11-13-2009, 05:04 PM	#4
Dr_Jones Major 70 Rep 1,027 Posts Drives: Join Date: May 2008 iTrader: (0)	wow...couple coats of wax and you should be good to go __________________ Just like Indiana...I love my whip
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11-14-2009, 08:12 AM	#5
arrutled Colonel 103 Rep 2,474 Posts Drives: Olsa Join Date: Jun 2008 Location: Western Mass iTrader: (0)	well i think your insane, but try not to blow this motor up too. __________________ AW 135i w/ blackette, performance short shift kit, BMW alarm, Performance rotors, APEX ARC-8 wheels, Direzza Star Spec 235/275, Dinan stage 3 suspension, M3 wishbones/tension rods/front sway/rear subframe bushings and thats all folks!
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11-14-2009, 01:39 PM	#8
and 1 winter mode 62 Rep 2,057 Posts Drives: 08 135i, 88 M3 Join Date: Aug 2008 Location: Somerville, MA iTrader: (0) Garage List 1988 BMW M3 [0.00] 2008 135i [7.50]	mike you bamf...way to be. can't wait to see how this thing turns out. how long do you think it's gonna take? __________________ 88 M3: BMWCCA J Sport 08 135: because streetcar
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11-14-2009, 03:50 PM	#10
ML Change for a Nickle? 14 Rep 875 Posts Drives: 2006 M3, Mazda truck Join Date: May 2008 Location: Westfield, MA iTrader: (1)	The first step in the project is done... build a workbench. Attached Images __________________ "I tasted death many times on the river today. Do you want to know what it tasted like? Do you REALLY want to know? Well I'll tell you then: it tasted like BEEF JERKY." - unknown paddler 8/1/09
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11-15-2009, 11:30 AM	#11
arrutled Colonel 103 Rep 2,474 Posts Drives: Olsa Join Date: Jun 2008 Location: Western Mass iTrader: (0)	Nice bench! save a weekend in march for my car! __________________ AW 135i w/ blackette, performance short shift kit, BMW alarm, Performance rotors, APEX ARC-8 wheels, Direzza Star Spec 235/275, Dinan stage 3 suspension, M3 wishbones/tension rods/front sway/rear subframe bushings and thats all folks!
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11-16-2009, 09:08 AM	#12
amybang ... and Orca too! 29 Rep 845 Posts Drives: 128i Convertible (AW/CR) Join Date: Apr 2008 Location: Belmont, MA iTrader: (0)	So, I know that you all know more about cars than I do, but um, that looks like a stack of tires not a motor to me... amy!
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11-16-2009, 09:20 AM	#13
mkPOTO Mr. Nice Says Hello 635 Rep 16,662 Posts Drives: BMW M3 \| X5 xdrive 35i MSport Join Date: Dec 2008 Location: USA iTrader: (25) Garage List 2002 Lexus GS300 [0.00] 2008 BMW E92 M3 [5.58]	very nice.. subscribed to see progression
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11-16-2009, 09:28 AM	#14
ML Change for a Nickle? 14 Rep 875 Posts Drives: 2006 M3, Mazda truck Join Date: May 2008 Location: Westfield, MA iTrader: (1)	Here's two to choose from. Does either resolve the tire issue? Attached Images __________________ "I tasted death many times on the river today. Do you want to know what it tasted like? Do you REALLY want to know? Well I'll tell you then: it tasted like BEEF JERKY." - unknown paddler 8/1/09
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11-16-2009, 10:10 PM	#15
ML Change for a Nickle? 14 Rep 875 Posts Drives: 2006 M3, Mazda truck Join Date: May 2008 Location: Westfield, MA iTrader: (1)	Disassemble the front subframe so the crossmember can be cleaned up and powdercoated Attached Images __________________ "I tasted death many times on the river today. Do you want to know what it tasted like? Do you REALLY want to know? Well I'll tell you then: it tasted like BEEF JERKY." - unknown paddler 8/1/09
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11-16-2009, 10:15 PM	#16
ML Change for a Nickle? 14 Rep 875 Posts Drives: 2006 M3, Mazda truck Join Date: May 2008 Location: Westfield, MA iTrader: (1)	and new parts, like these along with a STi steering rack and replacement right front steering knuckle and subframe, can start going back together. Attached Images __________________ "I tasted death many times on the river today. Do you want to know what it tasted like? Do you REALLY want to know? Well I'll tell you then: it tasted like BEEF JERKY." - unknown paddler 8/1/09
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11-16-2009, 10:23 PM	#17
jtsherri Major 144 Rep 1,262 Posts Drives: TBD Join Date: Aug 2008 Location: Metro Detroit, MI iTrader: (14) Garage List 2008 135i [10.00]	Have you considered running the RPM (or other similar) subframe(s)? You can save nearly 40 lbs and get a more rigid design. FYI: those steering rack bushings make a HUGE difference. '04 STi rack, right? __________________ -Jason My review(s): cp-e™ Cat Back Exhaust, cp-e™ SS 3" Downpipes, TPLSM3 Custom Fiberglass Subwoofer Enclosure, P3 BMW 135 Vent Integrated Digital Interface
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11-16-2009, 10:29 PM	#18
ML Change for a Nickle? 14 Rep 875 Posts Drives: 2006 M3, Mazda truck Join Date: May 2008 Location: Westfield, MA iTrader: (1)	Correct, 04 ST rack. For the time being, we're just going to run the stock subframe because I was able for pick one up for just a little over $100. We are going to be running GTSpec frame bracing, which the other guy working on the car with me can get at cost from a local parts shop. So it has been considered but will end up being a future upgrade. __________________ "I tasted death many times on the river today. Do you want to know what it tasted like? Do you REALLY want to know? Well I'll tell you then: it tasted like BEEF JERKY." - unknown paddler 8/1/09
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11-16-2009, 11:23 PM	#20
ML Change for a Nickle? 14 Rep 875 Posts Drives: 2006 M3, Mazda truck Join Date: May 2008 Location: Westfield, MA iTrader: (1)	We stuck with the EJ20 because it matches the ecu in the 02 WRX body and the motor was picked up for $250. The initial intent is to keep the car road legal and maintaining the stock ECU that matches the VIN on the body will help. Because the car currently has a salvage title, it has to be inspected by the state police to ensure that it wasn't stolen or been through a chop shop before it goes for the safety and emissions inspection. Assuming that the all of the receipts are kept, it can be demonstrated that the structural body work was done and the stock restraints are not removed (airbags and seat belts), it should go relatively smoothly. We are building the car to the NASA Rally Sport rule book and making sure that the Rally America specs are also met (or can be relatively easily where difference exist). So, it will be getting a full cage. The other guy on the project has a friend that is going to do the cage for us. I also had an 04 STi. I really liked the car but got very tired of living with it. It had an APS intake and and turbo back exhaust, dyno-tune and some basic suspension mods. The exhaust was guaranteed to get me pulled over about once every six weeks, although I never actually got a ticket. It was really starting to verge on harassment. As a daily driver, I'll take my M any day over the STi. __________________ "I tasted death many times on the river today. Do you want to know what it tasted like? Do you REALLY want to know? Well I'll tell you then: it tasted like BEEF JERKY." - unknown paddler 8/1/09
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11-17-2009, 09:23 PM	#21
ML Change for a Nickle? 14 Rep 875 Posts Drives: 2006 M3, Mazda truck Join Date: May 2008 Location: Westfield, MA iTrader: (1)	We learned today that the bearing on the #4 cylinder connecting rod spun in the $250 motor, which is exactly what I was told. The crank is pretty badly scored, so its good that the crank that came out of the blown motor is still good. We also learned that the compression in all cylinders is very low at less than 20 psi. This was by hand turning the motor. I was expecting low numbers, but not that low. Time to spit the cases. :-( The reason for the spun bearing: an improperly torqued connecting rod bolt __________________ "I tasted death many times on the river today. Do you want to know what it tasted like? Do you REALLY want to know? Well I'll tell you then: it tasted like BEEF JERKY." - unknown paddler 8/1/09
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11-18-2009, 05:00 AM	#22
arrutled Colonel 103 Rep 2,474 Posts Drives: Olsa Join Date: Jun 2008 Location: Western Mass iTrader: (0)	wow you guys are moving quickly __________________ AW 135i w/ blackette, performance short shift kit, BMW alarm, Performance rotors, APEX ARC-8 wheels, Direzza Star Spec 235/275, Dinan stage 3 suspension, M3 wishbones/tension rods/front sway/rear subframe bushings and thats all folks!
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