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Project Phoenix: 05 Wagon Restoration


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As things currently stand we've got 457 man hours into the project. Paint and body needs plenty of work still, but the drivetrain is brand new and the blackstone report from our first break in oil change came back great.

 

Engine:

 

2018 Subaru EJ257 Type RA Shortblock

MAP Stage 1 D25 Cylinder Heads w/ OEM Cams, BC

Valves/Springs & Supertech Guides/Seals

ARP Head Stud Kit - ARP 260-4701

Subaru EJ257 11mm Oil Pump - 15010AA360

Killer B Motorsport Oil Baffle and Pickup Tube

RCM EJ257 HKS Timing Belt Kit

Hill Country Forced Inductions VF40 Turbocharger

IAG Turbo Oil Feed & AVCS Line

Torque Solution Air Pump Delete Kit (D25 Heads)

Cobb AccessPort V3

GrimmSpeed Top Mount Intercooler Kit

Tomei Expreme Unequal Length Exhaust Manifold & Uppipe

CNT Catted Downpipe

STi Genome Axle-back Exhaust

ProTuningLab Catback Exhaust T304 Stainless Steel 3" Piping

Perrin Lightweight Crank Pulley

K&N Panel Filter

Group N Motor Mounts

Go Fast Bits Diverter Valve

IAG TGVs

Free Range Racing Engine Hose Kit

GrimmSpeed V2 Turbo Heat Shield - GRI 092007

Cobb Tuning Turbo Inlet - 724400-BK

 

Drivetrain:

 

JDM S402 Spec B. 6 Speed Transmission w/ 1.1:1 Output

2011 STI R180 3.545 Rear Differential w/ Spec B. Axle Shafts

Spec B. Driveshaft

Clutch Masters FX100 HD 6 Speed Clutch Kit

Whiteline Rear Differential Mount Bushings - KDT903

JDM Forster STI/Spec B. 6 Speed Shifter Assembly

Cobb 6 Speed Front/Rear Shifter Bushings - 211330

Cobb 6 Speed White/Stealth Shift Knob - 213350

Cobb 6 Speed White/Stealth Reverse Lockout Pull Kit - 244310

Group N Transmission Mount - D1010-FE000

Torque Solution Pitch Stop Mount

Torque Solution Solid Shifter Linkage U-Joint - TS-SU-474

Torque Solution Shifter Pivot Bushings - TS-SU-703

Torque Solution Positive Shift Kit - TS-SU-PSK

Torque Solution Drive Shaft Carrier Bearing Support Bushings - TS-SU-DSB

 

Chassis:

 

KW V2 Coilover System - 15245006

Spec B Aluminum Front Control Arms

Perrin Positive Steering Response System LCA Bushings

Whiteline Front Control Arm Bushings - W0506

Whiteline Roll Center/Bump-Steer Adjust Kit - KCA313

Whiteline Rack and Pinion Mount Bushings - KSR207

Cusco Front Control Arm Mounting Brackets

Cusco Powerbrace Crossmember Brace - 692 492 M

Cusco Front Lower Arm Brace - 684 475 A

Cusco Power Steering Rack Brace - 692 026 ALHD

Whiteline 22mm Front Swaybar - BSF30Z

Whiteline Front Swaybar Endlinks - KLC139

 

Spec B Aluminum Rear Trailing Arms

Whiteline Front Trailing Arm Bushings - W63398

Whiteline Rear Trailing Arm Bushings - W63394

Spec B Aluminum Rear Lateral Links

Whiteline Outer Lateral Link Bushings - KCA399

Whiteline Inner Lateral Link Bushings - W63396

Whiteline Rear Control Arm Set - KTA124

AVO Rear Subframe Underbody Brace Kit - S1B03G1GH002T

AVO Sway Bar Reinforcement Brackets - S1104M1HT001T

Whiteline 20mm Rear Swaybar - BSR39Z

Whiteline Rear Swaybar Endlinks - KLC144

 

Brakes:

 

DBA 4000 Series Front Rotors - STI 5x100 Fitment - 4654S-10-GRP

DBA 4000 Series Rear Rotors - LGT Hub/Brembo - DBA42657S

KNSBrakes V1.1 Conversion Caliper Bracket - KNS-005

DBA XP650 Track Performance Front Brake Pads - DB1678XP

DBA XP650 Track Performance Rear Brake Pads - DB1521XP

Stoptech Stainless Steel Brake Lines Front - 950.47005

Stoptech Stainless Steel Brake Lines Rear - 950.47505

Motul RBF600 Brake Fluid Synthetic DOT 4 500ml - 100949

2004-2007 STI Brembo Brake Calipers Powder Coated Hyper Silver:

2007 WRX 1" Brake Master Cylinder Assembly

GrimmSpeed Master Cylinder Brace

 

Interior:

 

Prosport 52mm Supreme Electric Boost Gauge

Prosport 52mm Supreme Electric Oil Pressure Gauge

JDM Spec. B Silver Pedal Assemblies

Black Interior Conversion

 

Exterior:

 

RallyArmor Mud Flaps

JDM Wagon Tail Lights

 

 

Wheels/Tires:

 

Rota Gravel 18x8 +44 Wheels w/ Custom Matte Gunmetal Powder Coat

Rota Matte Black Center Caps

Muteki Black Closed End Lug Nuts

 

Misc:

 

GrimmSpeed Radiator Shroud - 096030

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Edited by Chocoholic005
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It's about time I document my progress as I try to coerce this wagon to rise from its rusty ashes, if just so I can remember all the hard work we put into it. Long story short, I purchased this example from a forum member in November after 203k hard Chicago/Detroit miles.

 

The motor had low compression on cylinder 4, suspension was shot, paint poor and interior tired (and tan)... basically the car needs everything; a complete rebuild.

 

So the plan is for my girlfriend and I to completely strip down this wagon, repair any rust and basically turn this thing into a brand new car, with plenty of upgrades thrown in along the way. Black interior, 6 speed swap... still no idea what I want to do with the motor or color (maybe Polestar blue?), but i'm sure I'll figure it out along the way.

 

I'm also documenting every part I buy, every dollar I spend and every hour we work, in case anyone cares... I fully expect this project to cost every bit of $25k. (Spoiler... that was way low)

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Edited by Chocoholic005
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On 1/5/19, we began stripping things down. I am fortunate enough to have a drive on hoist with bridge jacks to make all this work possible.

 

We managed to spend almost a combined 45 hours removing the front/rear suspension and rear subframe. Everything fought us. Probably a dozen bolts broke or had to be cut off, one of the forward trailing arm to body bolts broke off inside the unibody and had to be removed by drilling out an access hole in the interior, and I spent four hours cutting apart an axle nut until it physically fractured under force. The brake lines were so rusted out at the fuel tank, i'm surprised I made it home... but that probably surprises no one. Rust sucks.

 

Surprisingly, the underbody was in very good shape. Only a few spots with surface rust, and nothing that required patches to be welded in. Every brake line in the car needs to be replaced, the fuel tank is garbage and literally nothing from the suspension, including either subframe, is salvageable.

 

Pulling the engine and trans. comparatively took no time. We dropped the assembly straight out the bottom by lifting the body right off it. After about 70 hours, we had the car fully stripped, minus the dash and moved on to protecting the underbody.

 

The entire underbody was cleaned, wire wheeled, removed of rust/treated and prepped for undercoating. I went with 3M rubberized undercoating as its the best alternative to oil based products I'm aware of, and it looks really nice when properly applied. This process took the better part of 25 hours, but was well worth it in my eyes. I don't know how much salt/snow this car will see, but now at least it's protected.

 

After 123 hours of teardown and treatment, the wagon is finally ready to start going back together. I've got the whole car laid out in my basement as a reference, and it's time to start ordering parts!

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Edited by Chocoholic005
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To date we've spent 144 hours on the project in total. I recently had shoulder surgery, so the progress is slow; but the parts have been rolling in:

 

We sourced a new fuel tank and all new rubber lines, coated/painted it and swapped over the existing fuel pump assembly. I slapped some buytl patches on it to mimic factory. I sourced a complete set of Spec B suspension arms and am going with Whiteline bushings all around including the adjustable rear arms. The trailing arm bushings were a giant PITA to remove as they wouldn't line up to be pressed out; had to spend almost 2 hours drilling them out.

 

I have everything for the suspension outside of coilovers and swaybars, including new subframes, wheel bearings, and a rebuilt steering rack. New brake lines and associated parts have come in, but I haven't sourced a brake setup yet. All things considered my dining room has turned into quite the part stockroom. There are some other misc. parts I've picked up, including a replacement set of doors and half my interior conversion, which brings the total investment to almost $10k:

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Edited by Chocoholic005
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IMO don't bother painting the engine, you can't it once its in the car.

 

Looking forward to seeing your updates.

 

Oh, when you begin putting parts back on, use anti-seize compound on all threads.

305,600miles 5/2012 ej257 short block, 8/2011 installed VF52 turbo, @20.8psi, 280whp, 300ftlbs. (SOLD).  CHECK your oil, these cars use it.

 

Engine Build - Click Here

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$171 six speed? Deal of the century.

 

Consider that more of a running total haha. Only sourced a handful of parts for that section of the project yet. I'll keep the tally updated in future posts, but if anyone knows where I can get a $171 transmission, by all means!

 

White F-type Coupe is so sexy. IMO the prettiest car on the road.

 

Thank you! I wholeheartedly agree.

 

IMO don't bother painting the engine, you can't it once its in the car.

 

Sorry... separate thoughts. Considering painting the exterior blue.

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I commend you for all the work to breathe a new life into the wagon, but.... you would be able to buy a low-mileage rust free example for much less $$$, not to mention the time you put into it.
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I commend you for all the work to breathe a new life into the wagon, but.... you would be able to buy a low-mileage rust free example for much less $$$, not to mention the time you put into it.

 

You're probably not wrong. I wanted a project and I certainly got one. Wagon's aren't exactly the most common thing here in Michigan, but it helps that the car came with some upgrades like brembos, an exhaust, etc. to help make the cost more reasonable... but this whole project definitely isn't a wise financial decision haha.

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I've also tallied the cost of fixing every little last thing on my wagon and making it showroom minty fresh. Was also $25k.

 

I pumped the still stock brakes on that plan, but really glad to see it happening!

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Do you have subledgers for performance and oe part totals?

 

Sorta. I have all the parts listed/color coded based on the table above. I've also got everything detailed based on area (suspension/steering, underbody/fuel tank, 6 speed swap, etc.) including part numbers, cost to purchase, and source. Happy to share if desired.

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I spent $32k on my wagon new, I'd say rebuilding this one better then new for $25k is a bargain, nothing can touch it for the same $$$ plus it's a wagon. You two build on. I hope you'll have front and rear JDM bumpers. I look forward to see the finished product.
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I like what I see! Save the wagons!!! I am jealous of the lift, would have made my work (similar to what you are doing) a lot easier. If you need some more ideas to go down the rabbit hole check out my thread Here. I would remove the plastic guards at the front of the rear wheel wells by the rear doors. Check for rust under those (again reference to my thread).

 

 

If you have any questions feel free to message me, our work looks like it over laps a bit.

Wagon is LIFE! - 265,000 miles and climbing

Unofficial Build (Restoration) Thread

Steering Rack Rebuild

 

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I spent $32k on my wagon new, I'd say rebuilding this one better then new for $25k is a bargain

 

We'll see how it goes but the $25K budget may well be a pipe dream. Still haven't sourced anything significant for the engine/drivetrain. And who know where paint will end up...

 

I would remove the plastic guards at the front of the rear wheel wells by the rear doors. Check for rust under those (again reference to my thread).

 

Did do that; had a bit of rust on both sides, with a small hole on one side. Didn't bother with a patch panel for now; just cut out the bad metal and treated the area.

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You're probably not wrong. I wanted a project and I certainly got one. Wagon's aren't exactly the most common thing here in Michigan, but it helps that the car came with some upgrades like brembos, an exhaust, etc. to help make the cost more reasonable... but this whole project definitely isn't a wise financial decision haha.

 

careful. it's a slippery slope. once you start sliding down, life as you know changes. could have bought a small country for what i have in mine. but dam it, have fun.

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