Restoring my Evo

[JeeperCreeper]

I've had this Evo X for 6-7 years now. Its starting to get crusty underneath, and Im going to fix that. This has been and will continue be an ongoing project. I have a whole shell, ready to cut it up for body panels. My rockers are gone, thanks to side skirts that hold salt and dirt. I also need to repair the driver rear quarter from an accident from 5 years ago.

Today, I am replacing the front subframe, steering rack, and control arms. I'll also be using my newly acquired sand blaster to start restoring the body underneath, and prevent the rust from getting worse.

Stay tuned, this is gonna be a long project.

[Memornix]

Subscribed.

i have always been on the subie side of STI vs Evo debate but a few years back I was right where you are now with a 98 impreza. That was my first real car project and I learned alot and I now it is my daily and puts a smile on my face every day.

The funny thing is, after building the car, I now have a better respect for everyone's builds and even waved at someone driving an Evo a few days ago from the subie.

Looking forward to seeing the struggles/progress.

[JeeperCreeper]

I wanted to talk smack to the subie guy I saw at the gas station, until I could taste the E85 in his exhaust 😆. I'll always chose team Evo, but I also have a certain respect for the Subarus. I do always say, anyone can get an STI, but not everyone can Evolve.

[Meleager7]

subbed as well.....let me know when you get to the rust remediation steps!

[JeeperCreeper]

The bigger stuff like cutting and welding rocker panels will definitely be a while, because once I get that deep, I'll also need a paint job for the whole car. Good winter stuff

[ChuckLove]

I was hoping you still own this!

[JeeperCreeper]

Sand blasting, priming and painting. I'm just focusing on everything above the subframe for today. The main body isn't as bad as I originally thought, but from the skirts to the pinchwelds is pretty roached. That will be another days work though, probably after my Jeep is alive again.

Also, sandals are not proper PPE for using a sand blaster, contrary to viral videos from the middle east.

[otar]

Itchy toes? Just a lil bit of sand media can scratch that for ya!

[JeeperCreeper]

Going back together now. I'll be addressing that rusty oil pan next, the gasket is leaking anyway.

[JeeperCreeper]

Almost finished, then this one bolt snapped. It must have been weak because it was barely getting snug and it broke. Otherwise, I need an alignment. I got it close, but it feels like it needs just a little more toe-in so the steering self centers like it should. The new rack feels tight, no more dead spot in my steering.

[Memornix]

I had a few bolts that looked identical to that one, only mine were seized and wouldn't come out and snapped. I ended up drilling most of it out then using a carbide Dremel bid to get the rest of. It was touchy work to not mess up the threads but eventually got it out.

Hopefully yours is easier since it snapped going in.

[JeeperCreeper]

Yeah Im confident it will come out easier than if it snapped of while tight. It barely felt tight with a short 3/8 ratchet. I have extractors, I'll drill it and get it out tomorrow.

[1shot_Dave]

How do you like that sandblaster for rust removal? I bought the same one with the intent of cleaning up the underside of a 26 yr old Audi this summer.

[JeeperCreeper]

So for heavier rust, you're going to need a needle scaler, wire wheels, wire brushes and elbow grease. But this will take off a surprising amount of rust. I picked up 70 grit aluminum oxide and it was taking parts that were fully coated with rust back to shiny metal. Well worth it. I think Im going to make a mount for the hopper to sit on my compressor, so the vibrations keep the media flowing. When you start to get low you have to give it a shake because it all comes out the one side on this setup. Overall, it was a huge time saver. But remember to grab a tyvek suit and sealed goggles and a respirator, that stuff will go everywhere. I had everything but the suit and definitely regretted it.

[JeeperCreeper]

Got the alignment done. I wasn't too far off just using a tape measure in my dirt driveway. But lasers don't lie, and this car drives so smooth through the corners now. Also when I had it apart, I sand blasted the hubs and the mounting surfaces on the wheels, and I have no more vibrations in my brakes.

Next task will be the front bumper. Most of the bolts are snapped off. I'll also be cleaning up the radiator support while I'm in there, and hopefully finishing it off with an aluminum undertray to get rid of the plastics and the 40 clips that hold it together. I hate those things. I also have an Evap purge valve coming in, hopefully that clears my code.

[JeeperCreeper]

Well, my bumper was being held on by hopes and dreams essentially. I had 4 bolts I needed to extract from the rad support. I had to epoxy the fog light mounts back on, and tomorrow I'll be sand blasting the rusted brackets and repainting them. I also deleted the big plastic diamond logo from the top grill. I might buff the headlights while I'm here, too.
Eventually I want a different bumper, but this one needs to last for a while still while more important issues are addressed. At least now it won't be held on by 3 bolts.

[JeeperCreeper]

I revisited this headlight I started to polish a while back and never got to finish. Now it looks brand new again.

[JeeperCreeper]

I fixed up the front bumper. The fog lights were falling off, and most of the bolts that held it were snapped off. So after drilling and a lot of swearing, I got all the bolts out. No extractions, I had to drill every one until I could pry and chisel them out. But not I don't feel like the bumper will fall off. I also painted the grills and removed the huge plastic badge from the top grill.

[JeeperCreeper]

Well, today had to change my plan on this car. The clutch just went out. No stock replacement for me, this thing has some go fast parts already. Hopefully my lightweight flywheel didnt burn up. Sadly, I dont have twin disc money ($2500 for that kit) so I ordered a decent ACT street performance clutch. It should be just fine for occasional spirited drives, and daily use. I also managed to add the valve cover I need to the order. Its been leaking for a long time, so Ill be happy to get that fixed up. Plus I might as well get the cover powder coated since its shiny raw aluminum.

A double rainbow appeared after the clutch died. Not sure what to make of that.

I guess pictures will happen when I take it apart. Stay tuned

[Cunha]

Sweet dude. Worthy ride.

[JeeperCreeper]

Parts day! I spent a little extra on the titanium bolts for my valve cover. If any of you have watched my builds, I think you will know what's going to happen to them...

[JeeperCreeper]

I love titanium