72 Ultra Orange - Bucket List Restomod

[72ultraorange]

Owen, i purchased the CX Racing IC and Radiator kit with bracket only. I didn’t get the hose kit — not knowing what my setup would be. I have not found a suitable radiator shroud yet; and most likely will make one — the radiator is about 10.5”H x 22”W (fin area) 26”W (total) x 2”D. The IC fits nicely inside the front grill in front of the radiator and there is a brushed aluminum bracket in the kit that could be used to mount the shroud. I had to get some longer hardware…but it was easy to install — zero cutting. The shroud would need to be able to support 2 -10” or 2 -9.5” fans connected in the center. Overall looks to be decent quality but have no idea on overall functionality yet…

Here is the part I purchased:
https://www.cxracing.com/racing-radiator/IC-RAD-D5-KIT

Install pictures…. Easy install. Bolt holes were already in front fascia. Probably will change out bolts to minimize interference later…. Not sure if holes were put there by PO or OE…

[72ultraorange]

Finally have a new cross member back from powder coating. (Thanks Troy and Don and Dave!!) along with all the bolts and fasteners to put this together. I hope to get the rear wheels back on it soon.

Here is a mock up of the rear … and some updated pics of ongoing assembly

[ostaylor]

Nice setup - is that a Subaru STi R180 rear differential?

[72ultraorange]

Nice setup - is that a Subaru STi R180 rear differential?

Yes - it's a Subaru R180 from a 2017 WRX STi with ~60K miles on it -- looks brand new inside. It has 3.545 (39:11) ratio gears with a Torsen LSD. I did clean up the outside and repainted it with VHT primer and paint - will make a post for this. I have been debating upgrading the 5 speed FS5W71C transmission and the differential but for now - I think we will go with this setup as "good enough".

Found a great transmission / gear calculator - here: https://www.blocklayer.com/rpm-gear.aspx
Tire Calculator Here: https://tiresize.com/calculator/ (more fitment work to do on the tires - TBD)

Need the gear ratios for your transmission, your diff gear ratio, and your tire diameter and you can virtually "try out" different setups. It has a nice graph of shift points and speed calculations. Am no expert here --- but validated "when" I get this running - it might actually work Plan to further address this while body work is being done.

I used the gear ratios from this website for the transmission: http://z31.com/wiki/doku.php?id=informa ... ansmission

FS5W71C 5 Speed Manual Transmission Ratios:
1st: 3.321
2nd: 1.902
3rd: 1.308
4th: 1.000
5th: 0.759
Rev: 3.362

Tire Diameter: Dunlop 205/50/R15s - Diameter ~23.1" (these came on the car)

R180 Diff Ratio: 3.545 (39/11 = 3.545)

[ostaylor]

I just bought an STi Torsen LSD with the same gearing. Hoping it arrives this week but all things delivery seem slowed down right now. Hoping for great condition when I pull the cover and will definitely clean it up and paint it as well as my rear cross member (and soon rear trailing arms) have been sandblasted and powder coated.

[72ultraorange]

Finally have a new cross member back from powder coating. (Thanks Troy and Don and Dave!!) along with all the bolts and fasteners to put this together. I hope to get the rear wheels back on it soon.

Here is a mock up of the rear … and some updated pics of ongoing assembly

Updated - cross member assembly and differential assembly

[RONSLYCHUK]

Very nice!

[72ultraorange]

Finished the trailing arm installation and the rear differential install:

Here are my notes:
1) The R180 requires the pinion flange to be removed to install into the 510 rear cross member. Uses a 27mm socket. Remove and set aside. Reinstall after you have the R180 installed in the cross member. Torque specs are 134 ft-lbs. Found a great reference for the R180 here: http://ken-gilbert.com/wrx/STi_Manual/0 ... ential.pdf

2) The differential fits into the crossmember with no mods. Getting the shims reinstalled takes some patience..and a BFH depending on the cross member. Put in fronts or backs and move to other side. Use pry bar to open spacing slightly if required. Thanks - Eastbaysolo!

3) Inserting the stub axles requires that the internal C-clips be oriented so that the “C” was oriented like a “U” — letting gravity help…then took some persuasion with a dead blow hammer — Thanks Dave!

4). The standard R180 mustache bar studs are the wrong size and required 2 - M12x1.75x 40mm bolts to mount mustache bar.

Latest progress - Axles are next !

[Heinrich]

very pretty!

[72ultraorange]

very pretty!

Heinrich, thank you! Now the proofing will be if it actually WORKS! I am so ready to get this thing moving! But know I have many months to go!!!

[72ultraorange]

Very nice!

Thank You!! Hoping to make this nice enough to show — but certainly fun enough to have some track time! Long way to go - but having the wheels back on it will be a major accomplishment at this point

[72ultraorange]

Finally — after about 10 months - She’s a Roller

Made some good progress over past few weeks - had some rework to do on the mustache bar clearance and CV axle grease boots.
Celebrating this milestone!!— Roller (April Wine) - https://youtu.be/usWQOPTORn8.

A few build notes; but past all of this now!!!
- Initial alignment issue with differential mustache bar - added spacers behind Diff Cover / longer bolts
- Swapped out the red bushings for black bushings
- Tight clearance on the lower mustache bar bushing and differential hub adapter axle bolts; may need smaller diameter lower mustache bushing washer.
- Alignment of crossmember bushings took a few tries with 2 jacks to get rear end aligned
- Installing the rear axles with the trailing arms unsupported - I pinched the CV joint grease seals and tore them — had to replace them. Fun times! Recommend installing axles AFTER rear cross member and trailing arms are in. Just my experience.

- Next up will be rear sway bar, pedal box, brake/clutch cylinders, and steering linkage — followed by the the big engine “test fit”!

[72ultraorange]

Got the Troy Ermish Racing rear sway bar kit in. Overall relatively easy install; requires simple modification to trailing arms.

Install notes:
- Would have been much easier to install on a lift; and recommend installing with rear suspension / trailing arms
- A 3/8” hole must be drilled in the trailing arms between the shock mount and the axle hub; cobalt drill bit worked well
- Drilling after cross member install allowed for the hole to be drilled with the bracket as a guide
- Adjust hangers left and right prior to tightening
- There are MANY adjustments on this bar; will need to check setup in a track condition

Moving on to completing the front steering linkage and pedal box with brake and clutch cylinders to prep engine fit test - for exhaust fabrication.
On the engine front; may need to replace the intercooler with a larger setup based on initial discussion with my tuner.

Here are pics of the sway bar install: (and yes it is powder coated orange!)

[72ultraorange]

Had the pedal box modified to support performance braking system with dual cylinders - 1 for front and 1 for rear brakes.
Modifications and kit by Don from DPRacing.co.

Relatively simple installation. Firewall requires simple modifications. Installing now to finalize cutting on the firewall prior to paint and body — and most importantly checking clearance on turbo down pipe.

Update: Fluid reservoirs will be installed remote; working to find best location near master cylinders to mount them along with mounting solution. Looking at a couple of options.

Some install notes:
- Used reinforcement plate as template for metal work - will have welded in at body shop
- Used drum sander on drill to open up the firewall; good enough
- Tightened bolts down to close gap between firewall and pedal box; and then installed cylinders
- Reservoirs don’t have sufficient clearance on gutter above firewall - remote mounting will be required
- Pedals and balance bar will be installed after paint and body work is done.


Pre Powder coating

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Powder Coated

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Reinforcement Plate as Template

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Firewall Modified

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Plate fitment

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Cylinders Installed:

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Pedal Box Inside

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[KiKiIchiBan]

Very tidy. I have undercarriage envy