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Discussion Starter #21
25 cases in Warwickshire should not put a halt on this ...:eek:
even looking at a worst case
I’d crack on whilst there is still a functioning supply chain
A half built car is no good to no one, and I would hope complete you would get your money back for any upgrades to date
keep up the good work
Everything is ordered to get it back on the road, its any nice bits I wont be ordering just yet, sideskirts, suspension etc.

Biggest headache is the Slam panel, the hole front end mounts to it, so cant start the front end rebuild until its here, due in 28th from Japan.
 

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Discussion Starter #22
Day 10:
Collecting more parts

So yesterday I collected a used airbox and washer bottle with pumps, these are the last major parts I hadnt ordered.

Untitled by James Baker, on Flickr

Today I decided to fit the new head unit, it was super easy, as I hadn't bought new metal brackets I had to cut up the stock ones, the filler pieces fit really well, looking at other guides I think people are fitting them inside the metal brackets causing a fitment issue when they should be fitting them outside the metal brackets. I have a headunit fitting video to edit and I will get that uploaded to help others.

Untitled by James Baker, on Flickr

Have a couple of simple videos I created for removing internal bits like the dash panels and gear knob, I will ensure I do more as I remove bits for mods, again only easy jobs if you know how to do them, hopefully this video series encourages more people to do DIY jobs on their cars:



I also fitted a HT auto rear lip and Top Sage diffuser lip, super easy:

Untitled by James Baker, on Flickr

I also threw on the bonnet, passenger wing and air box to get them out the garage, starting to look more like a car now. Ignore the panel gaps as I havent bolted anything down properly yet:

Untitled by James Baker, on Flickr
 

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Discussion Starter #23
Day 14 Still Waiting...

Progress has slowed due to the current climate. I'm still waiting on parts from Subaru Japan, with the local Subaru dealership now closed, I am unsure if I will be able to collect the remaining parts for 3 weeks plus, although the manager gave me a glimmer of hope, they may be able to leave them outside if they do turn up for me to collect as they are literally on my daily run route.

My front grill turned up from the USA, big thanks to Quirkparts on ebay for getting it delivered really quickly. Its only a subtle change, with this piece not having any pre-cut holes the UK spec comes with for the front numberplate holder. For me its the little details like this:

Untitled by James Baker, on Flickr

Trying to source genuine STI parts in the UK is really tricky for the BRZ, I'm after the side skirts, rear bumper trims and front lip. These apparently are out of production now and USA stores want crazy money to deliver them. A company called Brayson do replica parts and at a really good price, so I may go for them as there shipping is reasonable too:

Untitled by James Baker, on Flickr
 

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Discussion Starter #25
Day 35

So its been a long wait for the slam panel, but its finally arrived from Japan. Subaru called today to say the parts are in but the local dealership was closed. They then offered an olive branch that they would deliver it FOC as they had a driver passing by house, so a contactless delivery happened this morning.

So excited as this was the final piece of the puzzle for the front end that I didn;t have alongside the little brackets/seals in the picture that also arrived. It means tonight I can start building the front bumper and bolting the brackets to the front wings etc.

Untitled by James Baker, on Flickr

I will also get the rest of the car stripped down ready for paint with all the mirrors, door cards, handles, seals etc to be removed. Will try and do removal videos for each items coming off the car to add to the "how to" content on my youtube channel. As mentioned the car will be getting a complete colour change so all door shuts etc need painting.

Once this is done I need to sort getting the car over to a friend to ensure it is all straight, he will also do all the welding to fit the new slam panel so we can test fit the lights, bumper etc to to help line up the front end before it goes over to the bodyshop which is 5 mins away from them. This is all dependent are who is still working or not through this as I know even getting the car there may be an issue as not sure what transports companies if any are still working and the car isn't in a position to be driven on the road.

So for now I will work on what I can get done at home to prep it all and see what responses I can get off the other links in the chain.

Also as I have gone for the USA spec front bumper bar cover with no number plate holes, I purchased a number plate holder that bolts to towing eye threads

Untitled by James Baker, on Flickr

Luckily I don't need any more body parts to go to paint, the genuine STI skirts, lip and rear bumper trim all come finished in black so no need to get them painted to match the car, decided to wait until all this blows over and order the genuine STI parts direct from Japan rather than go for rep parts.
 

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Discussion Starter #26
Day 37

So another £300 order put in at Subaru today for parts including:

- 84942CA010 Headlight seal left roughly £30 plus VAT plus 84942CA000 Headlight seal right roughly £30 plus VAT - These are small rubber seals that sit between the headlight and front bumper, needed if you are fitting brand new lights aftermarket or stock as they arent supplier with the lights. As my original lights were destroyed I didn't have the seal to swap over from my stock lights. Without them you will have a gap between the lights and bumper in the corner.

The green part in this image:



- Front washer jet covers for the facelift bumper, these were roughly £50 a side, pre painted and I couldnt find any used examples.

- Miscellaneous clips/bolts I was missing.

- Both front wheel arch liners roughly £50 plus VAT each

In other good news the car is booked in next Thursday if all goes well for welding in the slam panel and an alignment/check to ensure nothing else is bent. I've spoken to the bodyshop and they are closed as all the paint suppliers are also closed so they cant get any paint however as soon as they open back up, I'm first on the list.
 

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Discussion Starter #27
Day 38
A video that should have came on day 1 but I didnt have chance to record it back then. Its a video introducing the project BRZ to my youtube channel. Over the coming months there will be plenty of how to content uploaded to the channel as well as blog style videos providing progress updates as I work to get it back on the road then modifying it. This video covers why I purchased it, what I purchased and the plans for the future. Thanks for watching

 

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Discussion Starter #29
Good read thanks. I thought it was an old article at first.

Day 40
Updates will get more interesting, but at the moments its all around an accumulation of parts.

Today I received a Mishimoto Sound generator delete to clear that piping from the engine bay.

Untitled by James Baker, on Flickr

I also have purchased a used 2018 BRZ facelift instrument cluster to retrofit into my car. This will give me the additional little screen to give the dash a more modern feel. Not a lot of gain but I thought why not. I have also ordered the Geralds Just Projects retro fit kit to give me a controller joystick replacing the blanking plate behind the gear stick, I will be ordering black controls so it doesnt stand out like in the picture below. This gives me full control of the little screen without having to retro fit the facelift steering wheels, clock spring and wiring.


Untitled by James Baker, on Flickr

Hopefully if everything goes to plan I should have a SARD style spoiler delivered later this week. I think the tuner style look works well with what else I have planned for the car over the duck bill I originally planned to purchase. Here is an idea of what it looks like:



I'm also purchasing a new rear bumper as mine has damage to the centre diffuser section and I didnt realise it was moulded into the bumper, seems stupid to paint a bumper with damage that cant be repaired.
 

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Discussion Starter #30
Day 47: The repair process begins again.

So last week I had a contactless collection of the BRZ as its booked in at a crash collision centre to get the slam panel welded in and ensure everything else is straight. I'm waiting on an update from them this week. Once its done it will come straight back for me to start preparing it for paint.

Untitled by James Baker, on Flickr

I also purchased a used SARD style wing which I had delivered via courier. The clear coat has a bit of damage from a pigeon strike, however that will be repaired by my local bodyshop and the side brackets are in solid condition but needed a refresh so I removed the stickers, sanded them down and gave them a blast over with primer before they go full matt black. Once finished it will look like new for a fraction of the cost:

Untitled by James Baker, on Flickr

I also received another delivery from Subaru, this time the wheel arch liners, numerous clips, 1 of 2 washer jet covers (The other is on back order from Japan) and the headlight rubber seals (2 of the most expensive bits of rubber I will ever order, ridiculous but needed to bridge the gap between the headlights and the bumpers). I also purchased a used rear bumper as mine was damaged by the previous owner reversing it into something. It was damaged on the textured part which I didnt realise was moulded to the entire bumper, so decided theres no point painting a damaged bumper if I cant replace that textured bit at a later date, hence the new one. If anyone wants a cheap white rear bumper with a couple of marks on the textured part, give me a shout.

I have also joined the group buy run by Jordan for the HID setup for the Vland headlights to get some decent light output from them.

 

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Discussion Starter #31
Day 49

While the BRZ is away at the crash specialists, I decided to start work on the wing brackets. They weren't in the best visual condition, but it was all superficial:

Untitled by James Baker, on Flickr

  • So I used a heat gun to remove the GT86 stickers.
  • Followed by a light sand with fine grit to remove any minor surface imperfections or corrosion
  • I then cleaned down with a panel prep spray and clean cloth
  • I used a number of coats of grey primer
  • Finally finished in matt black
Sard style wing part refresh by James Baker, on Flickr

I am looking into what protection a matt clear coat over the top would provide as not used it before.

Also had a photo from the crash specialist who are busy working away, they have the slam pane in place and are currently working out if everything else is straight. Once, done it can come back for me to paint the slam panel and get the rest ready for the bodyshop to paint it.

Slam panel is on by James Baker, on Flickr
 

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Discussion Starter #32
Day 51 - More Progress
The car is now completely straight and panels aligned. The passenger leg was bent backwards, but this has now been rectified using the fancy jig setup they have. I'm just waiting to hear when the car can be transported back to me. Excited as its starting to actually look like a car again even if I know the front end has to come apart again.

Untitled by James Baker, on Flickr

Photos from when he was lining it all up:

Untitled by James Baker, on Flickr

Here you can see the gap left if you dont buy or re-use the stick on rubber seals from a BRZ especially if you are doing the 2017 facelift bumper retro fit like im doing. I have the seals on the shelf to stick on when the car gets back to me:

Untitled by James Baker, on Flickr

Finally I picked up a super cheap set of used Rota Grids 18x8.5 et44 they need a refurb and are currently sitting on a new set of budget tyres Avon ZV7 that came with them, these will keep me rolling while I work on the car and will allow me to sell on the stock wheels which have decent tread and have been painted black by the previous owner. Eventually I will replace the Grids but for now they look better than the stock wheels:

Untitled by James Baker, on Flickr
 

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Discussion Starter #33 (Edited)
Day 61
Last week the BRZ arrived back via contactless delivery. Fully aligned and ready to go. Ignore the bonnet gap, the bonnet is open as I needed to fix the lock before I close it:

Untitled by James Baker, on Flickr

However my first job was to start stripping the front end back down so I could fit the rads/aircon/fans. Super easy job now I have done it multiple times.

Untitled by James Baker, on Flickr

My make shift painting station where I painted everything within the engine bay/front that had come from other cars or had come from Subaru in the black primer type finish.

Untitled by James Baker, on Flickr

I decided to go with matt black for a simple clean look. I will eventually do the entire engine bay in matt black as it will tie in with whichever colour I do the exterior and the engine isnt coming out for the respray so its easier for me to paint it matt black and get a decent finish. Hence why you can see paint under where the front wings will go.

Next I fitted the radiator/air con/fan assembly, I had to swap over the air con metal hoses as mine were also damaged from the crash. I then followed the correct process to fill/bleed/test the radiators with no signs of leaks:

Untitled by James Baker, on Flickr

This was a relief as it means I can move the car with no fear of damaging everything as this now means I have a running car. Idles perfectly, the engine seems good with no error codes which is a bonus.

Once that was done I set about bolting up the front end, fitting the crash beam, crash sensors etc and accounting for all the hanging connectors. All went back perfectly. I also refitted the airbox, snorkel and the surround that sits between the two. New items added to the list of bits to buy include the radiator filler bracket and a new filler neck for the washer reservoir:

Untitled by James Baker, on Flickr

Next I plumbed in the new washer reservoir which had been destroy in the crash. Check for leaks and all good. Now I need to order some washer jets for the headlights but other than that the washer system is now fully functional again:

Untitled by James Baker, on Flickr

Prep for paint

Fixing wise there isnt much left to do so the car can now go for paint, however I need to strip the car to keep costs down. So I stripped everything needed to get the car painted including:
  • Both wings
  • Rear Lights
  • Door Seals
  • Window Seals
  • Aerial
  • Roof trim
  • Wing Mirrors
  • Kick Plates
  • Door cards (I will replace weather seal plastic once painted)
Untitled by James Baker, on Flickr

So the only things left that I need to do this week are the:
  • Rear Bumper
  • Door Handles
Then its ready for paint:

Untitled by James Baker, on Flickr

Untitled by James Baker, on Flickr

Also my bonnet lifters arrived, they will go on the shelf to be fitted once the car has been painted as they will only have to come off again:

Untitled by James Baker, on Flickr

Also a courier today is collecting a Boral Unequal length manifold and a Milltek Overpipe that came up for sale at a great price. I fancy a bit of Scooby rumble from the boxer while I save up for forced induction.

Removing Exterior Door Handles

If anyone has any tips for doing this on a BRZ/GT86/FRS that have the touch sensors, please let me know. Only way I can see so far is to remove the glass to get to the connector to disconnect it. Its super easy for cars without this feature as its one torx headed bolt and you are done, not so simple on the UK spec cars with the touch sensors.
 

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Discussion Starter #35
So what colour will it be ?
scooby blue ?
I'm, 90% sure on the colour, although there is still time to change my mind. I want to go for a colour the BRZ/FRS/GT86 doesn't come in from factory, I'm paying for a full respray so might as well make it unique. Therefore world rally blue is out as the BRZ comes from factory in this colour. Colours the BRZ/GT86 also comine in that I dont want include white, silver, dark grey, black and red. It also comes in orange and yellow but I have considered none factory versions of those colours below.

I'm sticking to non metallic colours as it makes paint matching etc. so much easier in the future if I want to get more parts painted. I am swaying towards Porsche RS Green at the moment, although its the same colour as the R53 I would use different accent colours and I like the idea of two matching coloured cars. Theres still plenty of time for me to change my mind, nothing is set in stone until it goes to the bodyshop. Another selling point for me on green is that there aren't many examples of green ones, the only factory green offered is the new limited edition GT86 one which is a dark, almost British racing green colour, there are no bright/light greens and people tend to go highlighter green on wraps. I have a number of photoshops drawn up of my plans for the car including wheel/brake colour combos etc however I dont want to share that just yet. I do it with all my projects, I have the original photoshops for my R53 and both Clubman's, all of which turned out around 95%-100% of the original image I had in my head. I am a visual person so need to see something on paper when it comes to things like this.

Colours I have considered:

Nitro yellow from the A90 Supra, a darker/stronger yellow than the mellow one the GT86 comes with:



Porsche RS Green 2D8, the same as the R53, but would go for a different accent colours, not yellow, probably red:


Porsche Miami Blue, considered but didnt work for me on a photoshop of the BRZ. Also similar to the Hyper blue the BRZ came in:



Porsche Lava Orange, love the colour but very similar to the colour the GT86 comes in from factory:



Nardo Grey, however there are just so many grey cars its too safe a choice for me:


I did look at a highlighter green but with me not going widebody, I think it will be too much.
 

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Is San Marino blue been on your radar? BMW M2

I have considered it for the roadster when the time is right.
ideally I would like you to paint the R56 in that colour ...when you get bored :ROFLMAO:

 

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Discussion Starter #37
Is San Marino blue been on your radar? BMW M2

I have considered it for the roadster when the time is right.
ideally I would like you to paint the R56 in that colour ...when you get bored :ROFLMAO:

Its a nice colour, but not for me. I'm not a massive fan of dark blue cars although that does pop nicely in the sunlight.
 
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