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Paul Magyar's 1995 Subaru Impreza L - Street Mod/Track build

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  • Paul Magyar's 1995 Subaru Impreza L - Street Mod/Track build

    Update: This thread is cross-posted to the following forums/threads:


    Project Introduction, June 2009: Paul is an old college buddy, good friend of mine who happens to be a long time autocrosser and now a NASA Time Trial competitor here in Dallas, TX. After stints in old Pontiacs, then autocrossing in modern BMWs, he's become an AWD Turbo Subaru fanatic. He has owned and raced both a 2005 STi and a 2008 STI, in SCCA's STU class. He's also tracked the '08 STI in NASA TTB:



    This '08 was well setup on AST 4200s, Vorshlag camber plates, custom swaybars, 18x9.5" wheels and sticky ST rubber (and R88s for track use). There's also a racing seat, COBB bits and pieces, even a custom after-cat exhaust I built. After a few "warranty issues" on the '08, with a little encouragement Paul decided to build a more serious autocross and track effort with a more dedicated and "replaceable" race car. By that I man an inexpensive Subaru chassis that is somewhat "disposable", so he's not running a $35-40K, nearly new, daily driven street car on track. It only takes one incident to really ruin your day.


    The "gem" of a Subaru he bought, with the parts piling up

    So after literally minutes of looking at other Subaru track car projects and autocross build-ups, he decided on a class to build around: SCCA Street Modified (I'll call it "SMod" here for short). This generous ruleset allows him to do all of the update/backdate swapping necessary to run the latest/greatest Subaru STi drivetrain (300+ hp 2.5L intercooled turbo and 6-spd AWD transaxle) in the cheapest/lightest/most disposable Impreza chassis. He picked up a 1995 Impreza L "stripper" with manual windows, teal green paint, FWD and automatic drivetrain from local hot shoe autocrosser/drag racer/Bonneville top speed addict Brianne Corn. This car is a real "diamond in the rough" (emphasis on rough), and here's what it looked like starting this weekend in August 2009:


    Starting weight of 2440 pounds is pretty good! The STI starts closer to 3200 in stock form

    He had also picked up the transaxle, rear subframe/axle, fuel tank, brake/fuel lines, dash, interior and pretty much everything from a 2007 STI from another local racer who had totaled their car. He still needs to source the motor but he has a hot lead on a 2004 STI motor and turbo. The entire STI drivetrain is going into the old FWD Impreza chassis with a custom harness that allows for full DCCD diff control, like the late model cars have. Its going to have the late model dash as well, which should look pretty slick.


    The 6-spd transaxle and various other drivetrain parts are from a donor 2007 STI; the 2.5L motor is from an '04 STi

    The car sat for a several weeks (with parts piling up on the roof!) so I dragged my 4 corner scales by Paul's home garage to force him to remove the 100+ pounds of trash and dead bodies from the interior "to get a starting weight" on the car, and hopefully kick-off his build project. That worked.


    Somehow I got drafted into re-wiring his garage!? More lights, plus 220V and 110V outlets were added

    While I was there I noticed that his giant air compressor I helped him pick out almost a year earlier was still sitting, unused and un-powered. He still had no 220V circuits and outlet in his garage, and had almost no lighting or usable 110V outlets... typical track home with one outlet and one 60W bulb, but luckily it was a 3 car garage (the reason he bought this house), and as a bachelor he could do with it as he saw fit. In its current state he couldn't get any work done in there - in the dark without power or compressed air. One thing leads to another and we ended up spending the entire weekend adding lots of 110V and 220V outlets and fluorescent lights to his garage, moving all sorts of junk out of there, re-arranging the car, and more. It was hotter than hell outside (101F) and even hotter in his attic, but at least now he can run his compressor, plug in some power tools, and have enough light to work (3 x 8' fluorescent lights).

    Paul's Project Pictures from this buildup are located here: http://vorshlag.smugmug.com/Projects...aru-Impreza-L/

    More soon!
    Last edited by Fair!; 01-14-2014, 07:59 PM.
    Terry Fair - www.vorshlag.com
    2018 GT / S550 Dev + 2013 FR-S / 86 Dev + 2011 GT / S197 Dev + C4 Corvette Dev
    EVO X Dev + 2007 Z06 / C6 Dev + BMW E46 Dev + C5 Corvette Dev

  • #2
    Re: Paul Magyar's 1993 Subaru Impreza L - Street Mod/Track build

    Update for August 21, 2009: Went by Paul's this weekend to get some furniture and saw the Impreza L. Paul's been busy and has all of the old interior, drivetrain, suspension and crossmembers out. The added garage lighting and compressed air did indeed kick off this project as I had expected. The "L" is now stripped down almost to the bare shell - which is how all real race cars should be started. He has acquired a 2.5L STi motor (thanks, Henry Lin!) and all sorts of other bits and pieces for that. Still looking for a stock STI turbo and intercooler...

    We've been both pouring over the rules for SCCA Solo Street Prepared and Street Modified, looking for changes and areas to maximize. Paul noticed that SP (and SM by default) now allows for full weld-in 8-point roll cages, which is a big change from before (it all had to be bolt-in style, before) and now he and I are both planning cages for our project auto-x/track cars. This will let us both run the cars in NASA Time Trials safely and still maintain SCCA Solo class legality (we've since decided to delay this for both f our cars).

    While I was there Paul mocked up a wheel and tire on the L (no rear subframe or suspension in the way):



    This is a TR Racing 18x9.5" wheel with 245/40/18 tire. Its almost touching the inner fender sheet metal and is pretty much touching the outer section as well. So it would likely need some baseball bat rolling to fit this tire initially, which I think is the route he's going to want to go with. I keep telling him - get it together with the major parts initially, and worry about the tires/wheels last. This way he can get it running and driving and sorted using his HUGE selection of used ST tires and wheels, before blowing $3500+ on any custom wheels & tires (CCW?) needed for SMod. When its time for 18x10's its going to need flares, too.

    As for the other upcoming body mods, he's going with some sort of GC8 2.5 RS or STI front end:



    Personally I think the stock, 2 door GC8 STi look is pretty damn sharp. I think we can custom make flares that look good, maybe even similar to the profile in that picture, but just make them wider to clear the 285/30/18 tires.

    Next up Paul is going to finish prepping then painting the front fender wells and engine bay. After that he is installing the stock '07 STI fuel tank, subframes and suspension, then plumbing new brake lines for the ABS. Hopefully the built motor is going together in the next 30 days....

    More soon!
    Last edited by Fair!; 12-15-2010, 05:06 PM.
    Terry Fair - www.vorshlag.com
    2018 GT / S550 Dev + 2013 FR-S / 86 Dev + 2011 GT / S197 Dev + C4 Corvette Dev
    EVO X Dev + 2007 Z06 / C6 Dev + BMW E46 Dev + C5 Corvette Dev

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    • #3
      Re: Paul Magyar's 1993 Subaru Impreza L - Street Mod/Track build

      That is not a 'stock STi front bumper' It is either the STi Sport front bumper (can be purchased as an aftermarket part from STi, not an OE option) or a true 22B front bumper.
      Jon D. Simmons
      1988 E30 M3 - STX #88
      AST-USA | Bimmerworld | Butler's C&D | D-Force | Russ' Garage | Import Specialists

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      • #4
        Re: Paul Magyar's 1993 Subaru Impreza L - Street Mod/Track build

        Project Update for Oct 26, 2009: Not much to report yet. Paul has been piddling around with the car and after borrowing some tools to get some stubborn seat belt bolts (pinhead torx) removed last week. All he has left in the interior is the old dash to remove, then the new '04 STi chassis harness can go in, and the '08 STi dash can be trimmed and installed over that. Once that happens the rest of the interior starts to fall into place. Should?

        I just noticed a few flared Impreza pics and thought I'd post:


        OK, this is a little bit much, but you get the idea...



        Being a 2 door the flares on the rear will be easier to do on Paul's '95 Impreza. Which is a plus since I'll probably be doing those...

        More soon,
        Last edited by Fair!; 12-15-2010, 05:10 PM.
        Terry Fair - www.vorshlag.com
        2018 GT / S550 Dev + 2013 FR-S / 86 Dev + 2011 GT / S197 Dev + C4 Corvette Dev
        EVO X Dev + 2007 Z06 / C6 Dev + BMW E46 Dev + C5 Corvette Dev

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        • #5
          Re: Paul Magyar's 1995 Subaru Impreza L - Street Mod/Track build

          Project Update for Nov 23, 2009: We've been tearing into our GRM $2010 E30 project for the past 2 months, but Paul's project has been a bit slower going. As I said in my September update, Paul was busy for a while there and got the stock drivetrain, front suspension/brakes/subframe, and the entire rear suspension out. I just finally got a chance to snap some pics. Here's how the car looked Nov. 22 when I went by to help him on the car for about 4 hours...


          The stock '93 Impreza drivetrain and suspension were all removed in September

          Unfortunately the project has been totally stalled out for the past 6 weeks, so he needed a "jump start" (literally!) to get going again. His old truck hadn't been started in 2 months and it was dead as a doornail. I dropped by with the jump box, we got it fired up, then headed to Henry's house to pick up the 2004 STI longblock (used for a core) that he had sold Paul. This will be dropped off soon at COBB Plano (actually it went to The WattShop), along with the new pistons, cams, ARP bolts and other assorted bits for reassembly.


          Motor parts ready to go to the engine builder

          Paul's garage was a bit cluttered and hard to work in, so we started out by doing some cleanup. We also hung a new, ginormous "white board" and I made some "to do lists" for this project as well as 2 other vehicles he needs to sell. The old '95 front seats went in the truck to take to the dump, then we disassembled the rear subframe and suspension and it all went into the recycle bin (the steel).



          Next we pulled the stock fuel tank, which was a 2 man job since it still had 8+ gallons of old, nasty fuel inside. We managed to get it out and only cut one line, and didn't spill a drop. Once it was out we pulled the fuel pump/pickup/sender assembly and drained the contents into a 5 gallon bucket, then poured that into two 5 gallon fuel jugs using a cardboard funnel (reminder - go buy some damn funnels, Paul!). Then the tank was allowed to air out; later it will get recycled, too.


          Left: the used 07 STI rear subframe was totally bent. Right: New replacement subframe from Subaru will bolt-in

          The other big step planned for today that needed 2 people was the stock dash and main harness removal. The stock '95 Impreza dash was coming out and a '07 STI dash is going back in its place. A wiring harness from an '04 STI is going to power the car and dash, or so the plan goes. We removed dozens and dozens of screws, bolts and removed the old dash in pieces. The main support beam came out next, then the HVAC components came out in 3 separate sections - blower motor, evep coil and heater core.



          Next we discombobulated both the main dash/HVAC/circuit breaker harness and the engine harness, which ran from the dash area to the engine compartment in two separate runs. The '07 STI dash was then mocked up and its a really good fit. After some minor trimming it should "look factory" and will improve the layout and interior considerably, not to mention it will house all of the diff control switches and other differences between the '95 Impreza and an '07 STI.


          Left: both wiring harnesses removed. Right: '07 dash mocked up

          Lastly I showed Paul how to clean up a section of the underhood bud disaster area, using my top secret cleaning techniques. "We made a clean spot" so now he has to finish the rest. By day's end, a good chunk of work was knocked out and Paul is back on track, with plenty of sub-projects planned for the 2009 Winter Holiday break.

          More soon,
          Last edited by Fair!; 12-15-2010, 05:17 PM.
          Terry Fair - www.vorshlag.com
          2018 GT / S550 Dev + 2013 FR-S / 86 Dev + 2011 GT / S197 Dev + C4 Corvette Dev
          EVO X Dev + 2007 Z06 / C6 Dev + BMW E46 Dev + C5 Corvette Dev

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          • #6
            Re: Paul Magyar's 1993 Subaru Impreza L - Street Mod/Track build

            Do this.

            http://www.youtube.com/watch?v=ulxgwQ6lGu4


            Costas
            cars and such...

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            • #7
              Re: Paul Magyar's 1993 Subaru Impreza L - Street Mod/Track build

              Trying to schedule a bi-weekly work night for both Paul and McCall's cars. This Teusday Dec 22 = Paul's car!
              Terry Fair - www.vorshlag.com
              2018 GT / S550 Dev + 2013 FR-S / 86 Dev + 2011 GT / S197 Dev + C4 Corvette Dev
              EVO X Dev + 2007 Z06 / C6 Dev + BMW E46 Dev + C5 Corvette Dev

              Comment


              • #8
                Re: Paul Magyar's 1993 Subaru Impreza L - Street Mod/Track build

                Yep, that is one of the cars that has inspired this project.

                This Tuesday is putting in the new wiring harness (from the 2004 STi). I think this is the hardest part of the whole project, there are no directions.

                -Paul
                '11 Mustang GT / '95 Frankenpreza

                "A turbo: exhaust gasses go into the turbocharger and spin it, witchcraft happens and you go faster."
                - Dr. Clarkson

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                • #9
                  Re: Paul Magyar's 1993 Subaru Impreza L - Street Mod/Track build

                  Originally posted by Paul View Post
                  Yep, that is one of the cars that has inspired this project.

                  This Tuesday is putting in the new wiring harness (from the 2004 STi). I think this is the hardest part of the whole project, there are no directions.

                  -Paul
                  What time are we starting?
                  McCall

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                  • #10
                    Re: Paul Magyar's 1993 Subaru Impreza L - Street Mod/Track build

                    I will be starting at 6. Pizza order at 7.
                    '11 Mustang GT / '95 Frankenpreza

                    "A turbo: exhaust gasses go into the turbocharger and spin it, witchcraft happens and you go faster."
                    - Dr. Clarkson

                    Comment


                    • #11
                      Re: Paul Magyar's 1995 Subaru Impreza L - Street Mod/Track build

                      Update for Jan 20, 2010: Paul and I did some engine bay painting last night, using a POR-15 brand product. It was recommended to use a specific multi-step cleaning process (that sucked) and foam brush to apply the product on in 2 coats (the brushes REALLY sucked). This was a huge frakking mess, and the cleaning supplies they sold Paul really didn't cut it. Brake Parts Cleaner to the rescue!



                      After a partial first coat was showing massive fish-eyes from oil still on the surface, this still tacky coat was removed via brake cleaner. Next, all of the engine bay sheet metal was really de-greased with brake cleaner. Then we applied a fresh coat of white, waited 2 hours, and applied the other. Looks pretty good, for a brushed on finish (some drips & runs), but its not as nice as it should have been for all the work that went into prepping this engine bay. There are still a few areas I would have cleaned and prepped better, but you don't really see those once the parts are back in. Paul was happy with it; I was indifferent. If you go to a POR-15 coating, PREP THE METAL PROPERLY. All surfaces should be thoroughly degreased with the proper solvents.



                      In hindsight... probably should have gone the extra effort and sprayed the engine bay with a proper 2-part urethane automotive paint finish. I won't be recommending this brush-on POR-15 crap to anyone, personally. Short cutting the proper preparation process always ends up with compromises.



                      Next up: painting the front inner fender structures. Paul has spent some quality time with "The Crudbuster", a whirling dervish of a power tool with nasty metal brushes, and removed "20 years of crud" from the underside of the front fender sheetmetal. Let's vote for "spraying" on some product this time, please? And the AST shocks are finally about to be ordered.

                      I cannot wait to see this thing back on 4 wheels...
                      Last edited by Fair!; 12-15-2010, 05:22 PM.
                      Terry Fair - www.vorshlag.com
                      2018 GT / S550 Dev + 2013 FR-S / 86 Dev + 2011 GT / S197 Dev + C4 Corvette Dev
                      EVO X Dev + 2007 Z06 / C6 Dev + BMW E46 Dev + C5 Corvette Dev

                      Comment


                      • #12
                        Re: Paul Magyar's 1993 Subaru Impreza L - Street Mod/Track build

                        Originally posted by Fair! View Post
                        Let's vote for "spraying" on some product this time.
                        New flavor of the day for painting wheelwells and other high abrasion or rock-chip prone areas is Macropoxy.

                        http://protective.sherwin-williams.c...3Aproduct-6842

                        There's a thread on RallyAnarchy and/or Special Stage showing it's application with brushes and rollers. Apparently spraying it takes special equipment.

                        Comment


                        • #13
                          Re: Paul Magyar's 1995 Subaru Impreza L - Street Mod/Track build

                          Update for Jan 26, 2010: Went by to work on Paul's car after earlier taking some measurement's on McCall's Z3 LS1 project. Paul didn't have many parts to install onto the '93 that night, so I took the chance to document a little of the work he'd done earlier that week. The engine bay brake lines, ABS hydraulic unit, and some other bits from the '07 STi bolted right into the '93... gotta love a long lived chassis with tons of carryover! There's a couple of holes to drill, and a few broken plastic retainer clips he needs to replace, but for the most part everything bolted right up. Even the '07 brake booster is going to fit. The pedal assembly? Not so much. More on that in another installment.



                          We also mocked up the '07 HVAC under-dash modules. The center section contains the heater core and evap core, so we removed the evap core (this car won't have air con, but it will have a heater and defroster), which came out cleanly. A small block-off plate from sheet aluminum will cover the hole in the HVAC box that the evap core's intake/exhaust lines left behind. We then realized we needed to drill new holes in the firewall for the 2 heater lines, so Paul was tasked with rounding up some hole saws and unibits, which he has since acquired.

                          Later this same week Paul started to reinstall the engine bay harness (the '93 cbody harness and the '07 engine harness). He also had a windshield guy come by and remove the front windshield, cleanly and intact (he could have re-installed the old, uncracked stock windshield, but a new one will only be a few bucks more, and new windshields always look clearer than 18 year old stock units). Having that out of the car gives us ample access to be able to fit the '07 STi dash into the '95 unImpreza. The '07 unit is longer and has to be trimmed ever so slightly at the lower edge of the windshield to line up. He's also sourcing some 2 door Impreza 2.5 RS door panels, which better line up to the '07 dash contours.

                          Fitting the newer STi dash bar, HVAC modules, wiring harness/ECM, dash/gauges and making the new and old interior bits fit together is the trickiest part of this swap, but it will look factory when finished - if done right. The drivetrain and brake system swaps are themselves fairly straightforward and mostly "bolt-in" affairs. There's probably 25-30+ dash mock-ups/mod steps in our future. Entire companies exist to create these types of new-into-old Subaru drivetrain, wiring and interior swaps.

                          More soon...
                          Last edited by Fair!; 12-15-2010, 05:24 PM.
                          Terry Fair - www.vorshlag.com
                          2018 GT / S550 Dev + 2013 FR-S / 86 Dev + 2011 GT / S197 Dev + C4 Corvette Dev
                          EVO X Dev + 2007 Z06 / C6 Dev + BMW E46 Dev + C5 Corvette Dev

                          Comment


                          • #14
                            Re: Paul Magyar's 1995 Subaru Impreza L - Street Mod/Track build

                            Project update for Feb 2, 2010: Paul took a quick picture of some work he did on the dash.

                            Here is a picture of everything mocked up except the dash bar. The heater box/blower motor unit and dash were easier to install than I originally thought. I have figured out how to install the dash bar correctly thanks to a thread on rs25.com.


                            '07 STi dash in '95 Impreza - mock-up
                            Of course the dash bar was more difficult to install than he originally thought. We ended up modifying the brackets a bit and got it to bolt in. I think we show that in a later post.
                            Last edited by Fair!; 12-16-2010, 10:23 AM. Reason: resized/cleaned up picture
                            '11 Mustang GT / '95 Frankenpreza

                            "A turbo: exhaust gasses go into the turbocharger and spin it, witchcraft happens and you go faster."
                            - Dr. Clarkson

                            Comment


                            • #15
                              Re: Paul Magyar's 1993 Subaru Impreza L - Street Mod/Track build

                              Looks great Paul!
                              Thomas
                              AST '04 S2000 (STR)
                              '04 R32 with AST 4100s

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