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 Post subject: Mitch's project JDM BC GT
PostPosted: Fri Aug 21, 2015 8:42 am 
First Gear
Joined: Sat Aug 02, 2014 12:47 pm
Posts: 92
Location: Queenstown, New Zealand
So, I've been a bit busy, and not really present on the forums at all. My weekends have been taken up by me starting my own Businiess, now officially called "Subaru Specialists", working exclusively on subies. It's been good fun actually, I gotta say, it's been enjoyable. But last few weeks that's been put on the back burner, and my focus has been trained on my friend and flatmates GT. It's a facelift GT sedan, and for those not familiar with the JDM market, BC GT's were all auto, manual BC's (turbo) were only available as RS's. Wagons were all GT's, and avail in both manual and auto. Well, with two months before a road trip to the North Island for Flat-nats, NZ's first national Subaru meet, we decided it'd be a good time to start the project we have been accumulating parts for (yeah right...)!

So, said projeect. This BC, is mint. It's a bloody time capsule, and it wow's anyone who stops to take a good look, just goes to say how important good maintenance is! But it's done 250,000km, and was pretty much leaking oil out of every orifice, and the auto tranny was flogged. Well it worked great, but was slow on shifts, slipped sometimes etc, just not up to our standard. Shocks are also gone too, and timing belt due... It makes no sence to me to faf about doing a manual conversion and lining up a box to the engine with just a floor jack and axle stands, and doing a block re-seal in the confined engine bay, both jobs are far better with engine out, and lifting subie engines is so fucking easy (45mins with a friend is my record), so it's engine out to clean and re-seal, do the timing, replace perished hoses and sensors, and make the manual conversion a cinch

So, over this year mitch has been accumulating parts. Genuine parts for everything, but the shocks which are KYB excel g's, (pretty much genuine anyway), and an Exedy clutch (ditto).


Next to our friends V4 STi RA
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IMG_9684 by Reuben Horsley, on Flickr

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LET THE FUN BEGIN!

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CLEANING!

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New ERREY THING

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Last edited by Reuben on Fri Aug 21, 2015 8:55 am, edited 1 time in total.

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 Post subject: Re: Mitch's project JDM BC GT
PostPosted: Fri Aug 21, 2015 8:49 am 
First Gear
Joined: Sat Aug 02, 2014 12:47 pm
Posts: 92
Location: Queenstown, New Zealand
Tranny out! YAY!

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IMG_0130 by Reuben Horsley, on Flickr

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Engine bay also cleaned!

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So that's about where we're up to at the moment. Just need to install the clutch hydraulics, pedal box, wire the neutral switch, install diff and trans, re-install motor, then do the shocks! wooo!

I'll keep this thread updated.


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 Post subject: Re: Mitch's project JDM BC GT
PostPosted: Thu Aug 27, 2015 11:49 am 
First Gear
Joined: Sat Aug 02, 2014 12:47 pm
Posts: 92
Location: Queenstown, New Zealand
Update from Mitch:

Quote:
Big update time,

First of all big thanks to Dave (DacerX) and Baddock for the 4.111 LSD Diff. Almost was completely fucked without this! Turns out this is a good one!, both wheels turn evenly off the ground, so we are looking good.

Over the last week we had finished assembling the engine and getting the wiring sorted. Gearbox and sub frame are all in place. And of course the new struts went in. Photos of earlier in the week.

ImageIMG_3090 by Mitchell Lindsay, on Flickr


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IMG_3092 by Mitchell Lindsay, on Flickr


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IMG_3085 by Mitchell Lindsay, on Flickr


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IMG_3086 by Mitchell Lindsay, on Flickr

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IMG_3121 by Mitchell Lindsay, on Flickr

More success was had today, though it was tough for Reuben as I was at work. But completed was rear bushes as well as diff, drive shaft and exhaust. Interior is complete!


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IMG_3096 by Mitchell Lindsay, on Flickr

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IMG_3095 by Mitchell Lindsay, on Flickr

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IMG_3097 by Mitchell Lindsay, on Flickr

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IMG_3112 by Mitchell Lindsay, on Flickr

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IMG_3101 by Mitchell Lindsay, on Flickr

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IMG_3116 by Mitchell Lindsay, on Flickr

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IMG_3117 by Mitchell Lindsay, on Flickr

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IMG_3118 by Mitchell Lindsay, on Flickr


All that's pretty much left is fluids and to put the engine back in!


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 Post subject: Re: Mitch's project JDM BC GT
PostPosted: Thu Aug 27, 2015 11:57 pm 
Second Gear
Joined: Fri Jul 09, 2010 1:41 am
Posts: 353
Location: Bend, Oregon
sweet 8) looking great. keep up the good work

_________________
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 Post subject: Re: Mitch's project JDM BC GT
PostPosted: Mon Aug 31, 2015 1:29 am 
First Gear
Joined: Sat Aug 02, 2014 12:47 pm
Posts: 92
Location: Queenstown, New Zealand
Update from saturday

Quote:
So update for today. It was a long day and not everything went smoothly, however the engine is in!!!!

First thing we did was start on the steering rack bushes. The old ones were shot (no surprise) and incorrectly installed by the previous owner.

[url="https://flic.kr/p/xX8utg"]Image[/url][url="https://flic.kr/p/xX8utg"]IMG_3134[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr

They sort of clamped them in at the wrong angle.

The all important cambelt sticker is installed

[url="https://flic.kr/p/xEwcyy"]Image[/url][url="https://flic.kr/p/xEwcyy"]IMG_3140[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr

Engine is sitting and waiting to go in

ImageIMG_3138 by Mitchell Lindsay, on Flickr


Flywheel is installed!, all shiny and nice. We also installed a NTN bearing as the one supplied was a known brand. Can't have that on a build like this :lolz:

[url="https://flic.kr/p/xEwcBQ"]Image[/url][url="https://flic.kr/p/xEwcBQ"]IMG_3142[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr

Clutch is installed

[url="https://flic.kr/p/xX8uKD"]Image[/url][url="https://flic.kr/p/xX8uKD"]IMG_3144[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr

Engine is ready to go

[url="https://flic.kr/p/xWg8d7"]Image[/url][url="https://flic.kr/p/xWg8d7"]IMG_3147[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr

And of course my shit eating grin, finally having it ready to go!

[url="https://flic.kr/p/xX8ujt"]Image[/url][url="https://flic.kr/p/xX8ujt"]IMG_3151[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr

[url="https://flic.kr/p/xWg8fG"]Image[/url][url="https://flic.kr/p/xWg8fG"]IMG_3152[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr


Once the engine was in, we decided to get the complex clutch system bled. This is where things start to take a bit of a slow point. Reuben and myself had got the fluid in the reservoir ready to bleed. But we had issues where the fluid would not just come though. We managed to get a little bit on one of the bleed nipples but failed elsewhere. Thinking we needed more vacuum, we got ourselves a brake bleed system from Repco. Fluid would come though this no problem. However as soon as we tired to finish the job by pushing the clutch in and out, nothing would happen. Looking though the system we discovered there was an issue with the master clutch cylinder. The thing was shot (Thanks Tydon :lolz:), it would compress once, then would stay stuck open. Lucky we had a spare and managed to replace other damaged parts that I had bought to complete one functioning set.

Damn thing was stuck as!

[url="https://flic.kr/p/xEC99M"]Image[/url][url="https://flic.kr/p/xEC99M"]IMG_3156[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr

Once the issue was found, no worries as we got on with the rest of the days jobs.

By the end of the day we had most of the engine bay stuff all sorted.

[url="https://flic.kr/p/xEvE7h"]Image[/url][url="https://flic.kr/p/xEvE7h"]IMG_3160[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr

[url="https://flic.kr/p/xEwcZy"]Image[/url][url="https://flic.kr/p/xEwcZy"]IMG_3161[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr

YAY!!,

Tomorrows job is finish the engine bay with the airbox, radiator, battery etc and fluids for gearbox / engine.


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 Post subject: Re: Mitch's project JDM BC GT
PostPosted: Mon Aug 31, 2015 1:32 am 
First Gear
Joined: Sat Aug 02, 2014 12:47 pm
Posts: 92
Location: Queenstown, New Zealand
And Sunday

Quote:
So we are pretty much finished. The car runs!!

We did have a few problems with a few things.

[url="https://flic.kr/p/xYM27s"]Image[/url][url="https://flic.kr/p/xYM27s"]IMG_3176[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr

We started off by finishing the engine parts and fluids. Engine, gearbox and rear diff all got fresh oil. Fresh coolant went in as well.

Fitted a few nice parts as well!, Paint could have been matched better but it looks so much nicer now it has paint!

[url="https://flic.kr/p/xXjZa3"]Image[/url][url="https://flic.kr/p/xXjZa3"]IMG_3171[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr


[url="https://flic.kr/p/x3LsdM"]Image[/url][url="https://flic.kr/p/x3LsdM"]IMG_3172[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr

[url="https://flic.kr/p/y1jbAi"]Image[/url]
[url="https://flic.kr/p/y1jbAi"]IMG_3177[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr



Engine is complete, just getting ready for first turn over!

[url="https://flic.kr/p/xH9aHg"]Image[/url][url="https://flic.kr/p/xH9aHg"]IMG_3179[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr


This is where we had issues, the car had power and everything was lit up, but the starter would not engage. Not even a click. It was like it was unplugged. Tuns out this wire needs to be joined so the starter gets power rather than from the Auto TCU.

[url="https://flic.kr/p/xZDz7x"]Image[/url][url="https://flic.kr/p/xZDz7x"]IMG_3181[/url] by [url="https://www.flickr.com/photos/132229912@N02/"]Mitchell Lindsay[/url], on Flickr


Here's our first failed attempt

https://youtu.be/n2JLAgBeaO8

After that it started, here's a video

https://youtu.be/gbSUPueBqa4



We have a few things to sort.

Clutch get stuck down when depressing rapidly
Small coolant leak from the turbo, just needs a hose clamp
and a few other things. But to be honest, not too many issues.

I also am running a auto cluster as both manual faceplate's we had were faulty. One had a faulty temp gauge and the other had a fuel gauge that were faulty! so that was fun :lolz:


But the car drives great and all of the new parts work a treat. Just need WOF, Reg and wheel alignment / balance

Woooo!


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 Post subject: Re: Mitch's project JDM BC GT
PostPosted: Sat Sep 12, 2015 5:02 am 
Site Admin
Site Admin
Joined: Tue Oct 15, 2002 11:37 am
Posts: 26959
Location: Houston, Tx
Nice work!

Yeah, to get the car to turn over you need to jumper the sterter interlock pins on the AT connector of the trans. This is from my write-up and everything I had to do with it.

http://www.surrealmirage.com/subaru/swa ... #shiftlock

_________________
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
1997 Impreza OBS

If you need to get a hold of me please email me rather then pm


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 Post subject: Re: Mitch's project JDM BC GT
PostPosted: Sat Sep 12, 2015 5:02 am 
Site Admin
Site Admin
Joined: Tue Oct 15, 2002 11:37 am
Posts: 26959
Location: Houston, Tx
BTW,

Love the hand and googly eyes :lol:

Image
IMG_3095 by Mitchell Lindsay, on Flickr

_________________
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
1997 Impreza OBS

If you need to get a hold of me please email me rather then pm


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