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This is a discussion on DirtyImpreza.com Project Rally RS (2001 2.5RS) within the Motorsports Talk forums, part of the Community - Meet other Enthusiasts category; More odds and ends getting done on the car. Nothing too exciting but since I like to take pictures of ...

  1. #16
    Registered User 409industries's Avatar
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    More odds and ends getting done on the car. Nothing too exciting but since I like to take pictures of everything, here it goes!

    Autometer Pro Shiftlight. Yeah they are a bit ricer, but i've always been a fan of shift lights. Not having to keep a close eye on the tach has always been a big plus whether it be racing in autocross, rallycross, or eventually on stage where taking your eyes off the road for a second is sketchy. This guy will just give me a quick heads up before i bounce off the rev-limiter. I still need to get the right RPM pill, as this one is from another car and is way past the redline of the RS. So this was the install.

    Extend the wires to reach the ECU, a good ground, and a power source.


    Drill holes on the top of the steering column cover to mount the light and allow the wires to pass through.


    Mounted.


    Tap into the RPM signal wire off the ECU.


    Good spot for a ground (behind where the stereo usually is)


    There's lots of potential power sources to use, i took the easy route and used an add a fuse on the radio spot (since i don't have a radio). :-(


    Done!


    As you can see, the position of the shift light does not block my view of water temp, or the tach... only partially on the lower end of the speedometer.

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  3. #17
    Registered User catsfan222's Avatar
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    God that is awesome. What a fun project! I bet that thing is a blast to drive off-road. Really enjoyed reading through this.
    -Stink-Eye Mob #999-

    2008 WRB WRX, Rally Armor Mud-flaps, ERZ Catless 3" exhaust, Tsudo DP, COBB AP (Stage 2)

  4. #18
    Registered User 409industries's Avatar
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    Before you read this. Please let me tell you that no matter how easy you think putting in racing seats is going to be, it's not going to be easy. Nothing about these seats was easy to do, from acquiring the right hardware, to getting everything aligned and installed. If you want to rally though, you gotta have em so just try to smile when everything goes annoyingly wrong over and over again.

    I picked up these seats from a Cobra distributor in Southern California. The labels on the side of the seats might throw you off a bit. The Cobra Imola S was replaced with the Imola Pro, so the sticker says one thing, but the embroidery on the seat says another.


    They are actually very light, and probably the most affordable Kevlar seat out there. Spent a pretty penny on the seats and the sexy aluminum side brackets (unfortunately they do not export the cheaper steel side brackets out the UK) and set out to source the remaining hardware. I found a guy in San Diego that had a passenger side sparco seat bracket, swooped on that quick... used saves a lot of money. The driver's side one on the other hand was much harder to acquire. Sparco ran out right as geekmonster was going to hookabrothaup and they didnt arrive the following week with their next shipment. I poked around for a while on the big Subaru forums, but was getting bought out from underneath, and dealing with people who didn't have Paypal accounts, etc. Not rad. So i bought one from a store i won't name at this time because I am currently working on getting a refund from them.

    So when you buy a Sparco DRIVER side seat base for a 01 RS / 02 WRX this is what they send you.


    Are you f!@$%ing kidding me? A Wedge Engineering base, for a Buick Skyhawk / Chevy Cavalier... and its a passenger side? Seriously retarded. I didn't get a Wedge unit because they decided to not return my emails about getting a quote for one. Their loss. Needless to say i was furious because this shop's distributor's shipping sucked too (i couldn't change the delivery options so FedEx would only let me pick it up at the damn warehouse of theirs). geekmonster came though in a pinch again and was able to pull off getting one from me super last minute. I met up with him, and jetted over to Jackson Rally that same night. Seriously, thanks so much Chris you rock!

    Rolled up to JR, car smoking like crazy... ripped another CV boot somehow that's another fix for another day. After the usual bribing of Kyle with pizza of his choice and multiple containers of Dr. Pepper we got to work. Pulled the old Impreza L seat out. It found its way to the dumpster later that night.... finally!




    If its one thing Kyle hates, it's installing seats and I now know why. Nothing matches up. The seat manufacturer makes side mounts for their seats that don't really fit (we turned one set of them around backwards) then the bottoms of the side rails don't match up with the Sparco seat bases, and then these don't really line up with the OEM holes in the car all that well. So, how do you fix a problem like this? We'll you have to have to have a guy that knows how to make anything work with metal... and a lot of patience.

    One of the many test fittings of the smaller driver side Imola. We got the distance for my short ass legs pretty good, i can still push the clutch to the floor, that's kind of important.


    The Imola GT is the wider version of the Imola and is the co-driver seat. This thing BARELY fits in an RS. Its probably the biggest seat that will fit in a caged GC


    Clamping things down and marking holes that need to be drilled to attach the side rails. (It would be too easy to make them just match...WTF!)


    The Sparco bases are pretty weaksauce, they need additional gusseting to make em strong!






    So we ended up finishing around 3am, but that is how most of my install projects work out. The seat feels GREAT i must say. I took the liberty of driving Ortega Highway on the way home and was amazed at how much more connected i felt to the car (all that padding on the stock seats is like a dead zone for feeling what the car is doing under your ass). Even though the Imolas have very low sidewalls, the still hold me in place very well, and the shoulder support is awesome. To all the haters that were claiming the harness bar was way too high, it actually worked out perfect, just as we knew it would. Here's the finished install.






    Thanks goes out to Kyle at Jackson Rally again for the millionth time that he has gone above and beyond for the project RS. It would not be where it is today without his tireless efforts. Now i can finally get on to a bunch of other smaller projects now that i know exactly where the seats are going to be staying. Sparco 6pt harnesses are not in yet because i need some additional hardware to adapt them to the harness bar. Ill be running my Schroth Profi 2's in the meantime. More updates to come...

  5. #19
    Registered User wrxnews's Avatar
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    Let me start by saying what an awesome build on such a tight budget. It must have been a blast hanging out at the event and answering questions.

    I'm going to try my hand at RallyX for the first time when I get home from this deployment...any suggestions? The club that is putting on the race has a class for me, street tire awd.

    Also sorry to hear about your run-in with wedge...I had the unfortunate pleasure of them making my brackets for my old tC...those suckers didn't work for piss. The mounting holes were dead on but they used round stock bar where the sliders mounted. I promise to not give them any business ever again.
    Last edited by wrxnews; 09-18-2009 at 04:23 AM.
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    wholesale real cheap sneakers

    welcome to our website: www no spam com
    Last edited by Weasel 555; 09-18-2009 at 06:36 AM.

  7. #21
    Registered User 409industries's Avatar
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    Quote Originally Posted by wrxnews View Post
    I'm going to try my hand at RallyX for the first time when I get home from this deployment...any suggestions? The club that is putting on the race has a class for me, street tire awd.
    It wasn't so much a run-in with Wedge rather that they just didn't want my business. After checking out the seat base that came to me in error, i am glad i didn't go with them. Their bracket is extremely heavy. Even though the Sparco base needed modifications, in the end it fits very well.

    I've got tons of information for you about doing your first rallycross here: Rallycross Prep

  8. #22
    Registered User 409industries's Avatar
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    Its been a while since i've hit up this thread. This doesn't mean that nothing has been going on with the RS. To be honest, all of the crazy working on the car has slowed down a bit to focus on a few other things going on, and DI in general. One good thing though is that I have actually been driving the car a lot more, and taking it to events (including meets, photo shoots, etc). Generally using the car as its second main purpose in life... to expose the general public to what rally and DirtyImprezas are all about!

    After we got the seats in, i was able to try them out up at the first ever California City rally cross. Tore a CV boot on the up there, so it was a stinky mess all over the place with burning grease on the exhaust headers. I did my best to ghetto fix things with a mess of duct tape and zip ties.



    Despite the constant smoke / smell... what a blast, i mean the car was a ton of fun out there (I still need to figure out how to keep her from understeering like a pig) but it was great fun getting some seat time up there. This venue has so much potential because its very large and close to gas stations, food, ice, and well... even a bar Looking forward to racing here again in 2010. It'll be up to our friend Rally OBXT to see if this is going to happen. I really hope it does, its a great time out there and a huge lot!





    Going to try to get this thread up to date over the next couple of weeks so stay tuned for more pics!

  9. #23

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    I Support ClubWRX
    nice job with the duct tape and tie wraps and cool pics from the rally x, thanks for the updates
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  10. #24
    Registered User 409industries's Avatar
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    Finally it was time to deal with that busted inner CV on my passenger side axle. I decided to tackle it on my own because taking axles out is usually a piece of cake. Well, it is when you don't completely smash the axle nut into the axle groove that its pinched in. As i tried to un-pinch it, it got smashed in and there was quite a bit of material preventing the nut from backing off. Figured i had nothing to lose because i had a spare axle and nut. I started drilling it out. That didn't work and it was totally screwed after that, i even managed to drill into the axle quite a bit! Good thing was though, the nut was going anywhere so the axle was still securely on the car. I headed out to Jackson Rally shortly after to see if Kyle could help me with me with my new predicament.

    Turns out he has a specially modified chisel tool that he uses only for "axle nut un-pinching". I now have one of these, however it didn't do us any good with the condition that the nut was in now. After about 45 minutes of grinding with a special narrow grinding bit, enough material was removed so that the damn thing could be snapped off.



    With the nut off, the axle could finally come out.



    THIS is exactly why CV boots are not made out of duct tape.



    The "replacement" axles that i got had different outside rings (the teeth were different for the ABS sensors i think?) but with some slight modification the passenger side one fit just fine and i was on my way again without smokey axle grease flavored cabin air. I think ill be buying new axles from now on to get fresh stretchy CV boots to avoid tearing. With the gravel coilovers, i'm getting much more droop and i think it just over stresses the brittle old CV's and they break. Its not worth saving the extra couple bucks... i'll be getting new ones from now on.

  11. #25
    Registered User 409industries's Avatar
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    The RS went to two separate events recently, coincidentally they were both at the same location! Forman Performance had their grand opening shindig so i though this would be a good opportunity to take the rally car down there and show it off a bit. It definitely got some good attention, and there were a few people that were interested in its construction, etc. So it was nice to talk to some people that were curious about what rally is all about. The event was way fun too, a DJ was playing music the whole time, and the street tacos were super good and spicy. Can't ever complain about that! Car was actually washed sometime before this event, it looks weird semi-clean.





    We wish Forman Performance good luck with the new shop. If you have any questions for them, post up in their vendor forum here: Forman Performance - DirtyImpreza Forums

    Several weeks later, i got word about the NASIOC SCIC 3rd annual photoshoot at the same shop. I headed down there with Bug-I Newk and mousemanthormx in their cars to get some DI representation along side all of the "hellaflush" garage queens. Don't get me wrong, there were plenty of nice cars there but i made sure to not wash the RS after our fun out in the desert the week before. The vibe at these meets is so different than that of a rally event. Take Parc Expose for example, you could talk to anyone about their car and 99% of the time they are going to be more than happy to answer any questions you might have. Smiling faces everywhere. At this street meet, there were really only a few people that looked or even acted like they wanted to socialize with someone that might not know, nothing but hard looks all the time. Reminds me of lame trendy socal bars. I did meet some cool people (you know who you are) but overall, i pretty much just hung out with the guys we rolled up with. Regardless, every car there got a "DirtyImpreza.com - Dirt is for Racing, Tarmac is for getting there" sticker left on their car, or on their driver's seat if the window was open! Kickass. :lick:


    Yes, that is a Buick Grand National to the left of the RS :headbang:


    Yes, we all know that car shows are somewhat boring, but its good exposure for the site, and also for my generous sponsors. Gotta be out there working it with the local clubs and meet goers! I'll have another update coming shortly. Made it back out to Jackson Rally for some minor fab work...

  12. #26
    Registered User 409industries's Avatar
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    More fun out at Jackson Rally! Minor stuff, but sh*t that needs to get done...



    As much as i didn't want to deal with seats anymore, it had to be finished. Nothing too bad though. I've had these Sparco 6 point harnesses sitting around for a long time. If i'm going to get any use out of them before they expire, i figured they best get put in the car soon. The only spot that really needs and custom work is the two crotch strap mounts under the seats. Since we kept in the stock beam under the seats that runs along of the front of the seat from the transmission tunnel to the door sill, we had a good study piece to weld onto. The factory shape of the beam had some big holes that needed to be plated over, the paint was removed and prepped for the welding.



    Kyle sizing the plates.



    Welding those bad boys in.





    Here's the completed passenger side plate and anchor rings.



    Here you can see both of them installed.



    Installing the harnesses was pretty easy, Schroth Racing has some great videos on YouTube that show how to properly wrap belts over harness bars, etc. (YouTube - hmsmotorsport's Channel), however the biggest PITA was adjusting the crotch straps to the right length in the car. This is especially hard to do because i had to guess how long they needed to be, put them through the seat, have Kyle hold the seat up while they are clipped in, bolt the seat down, sit in the seat, and then do it all over again to adjust as necessary! Getting the camlocks to release the crotch strap to invert the bracket was fun to figure out too. My iPhone definitely helped with this part, finding YouTube videos was key! Anyway, they are in and i am now even more looking forward to trailering this car. 6 point harnesses are good for racing, but sure to suck for driving to and from events.



    Trunk Tiedown mounts:
    I had my spare tire fly up and hit the inside of my trunk and slam down into the spare tire well upside down once when i was out in the desert. Time to get some proper mounting points to secure things in place. Kyle welded this one up front, pretty epic welding as the underbody coating likes to catch on fire near the gas tank. I got to hang out down there and blow out the flames as they appeared. See... that's teamwork right there.



    The rear two (towards the back of the trunk) are simply drilled and secured in place with washers and a locknut. The tiedowns will be arranged in a triangle formation.



    Its a good setup and i am stoked to be able to rip around knowing i don't have to unload everything before i can get sideways. Next on the list is to get some tool bags that can be secured on top of the spare.

    Got some more goodies in the mail since this visit to the shop, we're going to get some electronic stuff put in the car soon! Subscribe to this thread to get the next update!

  13. #27
    Registered User 409industries's Avatar
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    Over the weekend i set aside some time to really focus on getting things hooked up that we'll need rallying. Nothing too difficult, just a lot of stupid things that just need to get done. First off was finally getting the co-driver harnesses installed and tidy up the slack in the car. I had to guesstimate the size for my co-driver, so hopefully these fit as adjusting the crotch straps is a pain in the ass.





    Before i could get the next batch of electrical items taken care of, i needed to get some 12V constant wired up in the car. I picked up this nifty fuse block online, and wired it to the battery. Wiring in the engine bay was run tidily across the firewall strut braces. The fuse block was mounted in close proximity to the center console, and has 6 terminals that can be connected to any devices that need to have constant power which use standard automotive fuses. There are several devices that i know will need this, including the Terratrip, maplight, horn, and interior lights. The nice thing is that i know i'll have extra terminals for anything later on that might need to be connected up and its easily accessible





    I needed to get a horn working. Rather than deal with trying to hookup the lame horn piece on my removable steering wheel, i installed a push button toggle on the toggle panel. This is easily in reach of the co-driver if i need to have him honk at someone while im busy driving, etc. Anyway, i decided that it would be fun to have some of those annoyingly high pitched airhorns in the rally car. I had a set on one of my first cars back in high school and figured it would be a laugh to hear them again. For some reason the dumb horn trumpets came in red, so i painted them black before putting them in.

    I found a good place to mount the air compressor, on this OEM bracket. I drilled a hole in it, and mounted it up. It looks really clean here, almost as if it came with the car.


    I decided to do this the long way (the right way) and took the front fender off so that i could put some lock nuts on the back of the bolts that secure the horns inside the engine bay. Mad amounts of jumping and slamming this car around shouldn't dislodge the mount points. If anything the plastic horns will break off before the bolts come loose.



    Here is the whole setup. Its loud as hell. This will be fun honking at spectators, etc!


  14. #28
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    Really love your car and your write up. Great read! Thanks for keeping us updated!

  15. #29
    Registered User 409industries's Avatar
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    Quote Originally Posted by Lorak View Post
    Really love your car and your write up. Great read! Thanks for keeping us updated!
    More updates coming this week too. I took quite a few pictures of the new goods that went into the car recently, i'm just getting caught up with my writeups!

    Thanks for the compliments.

  16. #30
    Registered User 409industries's Avatar
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    One of the bigger electronic tasks I was avoiding was the rally computer. I'm not too good with wiring and all that so this was a bit intimidating as i have heard some horror stories about people splicing ECU wires incorrectly and frying components... (leave the magic smoke inside the box!). I picked up a used Terratrip 202+ for a good price.



    After quick chat with Barret at All Wheels Driven i jotted down some notes about what to look out for. He pointed me in the right direction like usual and suggested picking up the Terratrip DSI (Dual Signal Interface) box, so that instead of using a regular magnetic probe for the odometer we could splice into the computer's ECU to get the information the rally computer needs that way. The wire you need to connect to (in a 2001 RS) is on the B135 harness #24 - Vehicle Speed Signal (its green with a small yellow stripe) which is located right off the ECU mounted on the floor by the co-drivers feet. This can be tapped using a simple radio shack style crimp splice.





    A good way to check that you've spliced into the correct wire is to first jack up your car and put it on jack stands (or use a lift if you are cooler than I am and have access to one). Once this is done you can run the motor and put the car in gear to get all tires moving.



    Next hookup a voltmeter, or even a cheap test light to the spliced wire into B135 #24. As the wheels rotate, the test light will blink on and off. If you rev the motor and make the wheels turn faster, the light will blink faster as a result of this. If you have a constant volt reading (or constant test light) then you are probably on the wrong wire. It should pulse a very low voltage off and on (between 0 and 5v) while in motion.



    Here is the DSI box all wired up (to provide power, ground, and pulse information to the Terratrip). This part was a little bit confusing, but not too bad. I found this great diagram over at Susquehanna Motorsports (Susquehanna MotorSports - High Performance Vehicle Lighting and Competition Accessories):



    Basically, here's how it all breaks down:

    -Pin 1 is your constant power from the battery, which is also spliced into the power of the Terratrip. When you buy your rally computer you have to get the 12 pin molex adapter to make all this work ($5.00 at Sube Sports)
    - Pin 3 runs from this terminal in the DSI box to pin 2 (I believe Probe 1 input on the Terratrip, it has a diagram on the back of the rally computer for reference)
    - Pin 4 is the pulse wire that is spliced into the ECU of the Subaru (B135 harness #24)
    - Pin 6 is the ground for both the Terratrip and also the DSI box.



    There is a quick calibration process that is done on the DSI box (by adjusting a small screw) that is supposed to get everything to work properly. Once this is done, you can see that the rally computer is counting the pulses coming from the ECU. The complete instructions for calibrating everything is online. I have still yet to verify if everything is working properly but will soon. Hey look, the back lit display works too! It got dark before i completely finished.



    I don't have a mount built yet for the rally computer, so for now it is disconnected and the wires have been taped up as ill be doing a rallycross this weekend. The DSI box has been mounted in the glove box bezel, pictured here on the right side. A Jackson Rally computer mount is definitely planned for the near future.


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