tweedbean's Subaru BRZ Rebuild - Page 8 - Toyota GT 86 Forums UK
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post #71 of 79 (permalink) Old 15th July 2020, 10:03 Thread Starter
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Originally Posted by BRZ View Post
Looks nice James! Well done for all the hard work of stripping the car and good luck on putting it back together.

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Thanks, the bodyshop wanted to challenge me, for the few minor bits they removed, they threw everything in a box, bolts/clips/parts. This is a contrast to me putting everything I removed in clear plastic bags with labels so I knew what went where. So I have the fun of working out where those bits went but it adds to the fun of doing something like this.

The only part I have had an issue with so far is the passenger side door handle, the inner plastic mechanism has come away from the door, so need to work out a way of bolting that back in place with out removing the glass, but I expect some hurdles like that and im sure there will be a few more surprises when rebuilding the front end.
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post #72 of 79 (permalink) Old 16th July 2020, 09:29 Thread Starter
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My second evening of work was a little shorter but got plenty done before it rained.

The passenger door handle plastic section that holds the lock on the inside of the door had come away not allowing me to fit the door handles. It was a tight squeeze but I managed to undo the bolt, manoeuvre it back into place and bolt down so no future issues. Also the interior door handle had become disconnected at the door latch end so I had to remove the locking mechanism from the its mount and use long nose pliers to re-attach the yellow cable. That meant my issues with the doors were fixed.

So I refitted all the door seals, door mirrors, front triangular window glass, door cards, wind seals and bits of interior trim next to the doors. All went back perfectly with no left over screws/bolts which is always a bonus.

Untitled by James Baker, on Flickr

The door mirror caps are with the body shop still, they are going gloss black and the central dash piece they are filling the hold the BRZ has for an alarm LED and painting that green to match the other section. Please ignore the dusty interior, thats getting blitzed this weekend now that the doors/windows seal properly.

Ive also built the side trims back up after clearing off all the old glue from the black pieces and treating them to a layer of Gtecniq C4 plastic restorer to keep them looking tip top:

Untitled by James Baker, on Flickr
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post #73 of 79 (permalink) Old 20th July 2020, 16:13 Thread Starter
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A quick update on progress with the BRZ, had very little time to work on it however its gone pretty smoothly so far. The only major issue I have so far is the fact facelift washer jet covers for the front bumper do not fit pre-facelift headlight washer jets themselves, which is annoying as I had bought them separately as they were missing off the car. Solution is to do away with headlight washers and just stick the covers to the bumper, or a more sensible solution is to source facelift washers, very hard to come by and expensive from the dealer.


Sundays job involved stripping the front end down:

- Removing the wings as they werent bolted on properly, they were only on for ease of transport

Untitled by James Baker, on Flickr

- Refitting the wings

- Fit headlights

- Fit HID kit for headlights

- Fit bonnet struts from Fensport

- Wire in the new aftermarket yellow fog lights

- Wire the drivers side repeater as that was destroyed

- Sort panel gap

Untitled by James Baker, on Flickr



- Fit bumper under tray

- Fit front bumper

- Refit a load of plastic engine bay trim

Untitled by James Baker, on Flickr

Untitled by James Baker, on Flickr

Untitled by James Baker, on Flickr

I still have a pile of stock bits to fit like wheel arch liners, number plates etc then its ready for an MOT and back on the road. Then the modding can begin.
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post #74 of 79 (permalink) Old 27th July 2020, 09:05 Thread Starter
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Life has got in the way a little over the last week, so not touched the BRZ, however one update I had was a picture from Grigul Design/LederManZ. *I sent them a stock BRZ/86 wheel a couple of weeks ago now for them to retrim. *Its looking much tastier now, I cant wait to get my hands on it. *Due for delivery in the next 3 days:

Untitled by James Baker, on Flickr

Its looking a top job from what I can see so far with the alcantara/leather mix, red stitching/centre marker, flat bottom and a little bit of extra padding.
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post #75 of 79 (permalink) Old 31st July 2020, 09:33 Thread Starter
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MOT Prep

So yesterday afternoon I managed to blitz the car in preparation for its MOT which is booked in for next Tuesday. As its a Cat S it needs a fresh MOT before it gets back on the road and can have its new plates applied to it. I wanted to get the MOT done before I started modding the car, as it will be easier having it taxed/insured and on the road. For example it needs to go to the bodyshop for a final polish now its rebuilt, that will be so much easier and cheaper if I can drive it there myself instead of paying £50 a time to the transport company, plus once thats done I can get the side skirts etc fitted as I didn't want them to have to faff with taping up the new parts to avoid getting polish on them. So dont worry plenty of aftermarket parts coming soon for interior, exterior, suspension and engine bay.

I fitted the wheel arch liners so I could secure all the wiring for the new HID kit I fitted previously. I also cleaned up the overspray which ended up on the door glass when the door skins were painted, I used fine wire wool which removed it super easy.

I fitted the Geraldjustproject controller for the 2017+ cluster so I can control the LCD screen and at the same time I switch out the grey switches for black JDM ones, I also fitted all my black door handles, gaiter surrounds etc. Fitting video for the controller here:



I also sorted the TPMS light which would have impacted the MOT. As my car doesnt have TPMS sensor the car flashes the light thinking they are damaged/faulty, I opened up the cluster, only a couple of clips, lifted the dial face forward and places a piece of foam backed tape across the opening for that single LED so no light can get through. I'm sure this light could be mapped out but this was a quick a free option with the same result, no flashing warning light.


Untitled by James Baker, on Flickr


I picked up my painted dash and wing mirror caps from the bodyshop, they did a great job so I got those fitted alongside wiring up the new shark fin aerial. I like the contrast of black mirror caps:

Untitled by James Baker, on Flickr


I hate sending a car for MOT with an untidy interior so it finally got a good clean to remove all the dust and grime from the previous owner:

Before:

Untitled by James Baker, on Flickr

After, notice the dash is in without the hole for the subaru alarm flashy light which I had smoothed over:

Untitled by James Baker, on Flickr

I also fitted these gates rubber mats, super cheap, £10 from ebay and adds a little splash of colour and a grippy rubber surface.

https://www.ebay.co.uk/itm/Gate-Slot...72.m2749.l2649

Untitled by James Baker, on Flickr

I addressed the remaining white in the engine bay, as the engine didnt come out the body sprayed as much as they could green. For the rest like the fire wall, I masked bits off, degreased and painted it matt black. In degreased most of the engine bay and cleaned up the battery while it was out.

Untitled by James Baker, on Flickr
I also wanted to finish off the head unit install:

- So I threw in the new USB retention cable which worked a treat, only cost £13: https://www.ebay.co.uk/itm/OE-Car-St...72.m2749.l2649

- Wired the reverse camera up, connected to the pink wire in the passenger footwell, 5th wire down on the left in this block to get a reverse signal to the head unit:



- I ran the camera cable down the passenger side of the car, under the back seat, through the boot, up into the wire rubbers between the boot and the boot lid, using a coat hanger to pull it through so no wires exposed for the OEM look. I then used a dremel tool to cut a square out next to the boot handle opening button and used the mount that came with the camera to fix it to the inside of the boot handle, I hate reverse cameras you can see from the back of the car, so its tucked away for the stealth look and can only be seen when the boot is fully open.

Installed Pioneer Nd-bc8 reverse camera



Untitled by James Baker, on Flickr

Also the steering wheel retrim arrived back, Grigul Design did an amazing job:

Untitled by James Baker, on Flickr

I also had to change the battery in the spare remote as it didn't work, so I decided to record a how to video, super easy, it turns out the previous owner had installed the incorrect battery, no wonder it didn't work:


Finally I fitted the front removable plate holder and rear plate. Then I took it for a quick drive around the neighbouring car park to check brakes etc work as it was the first time I had driven it more than a couple of meters, all was good and now back in my garage until the drive to the MOT station next Tuesday:

Untitled by James Baker, on Flickr
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post #76 of 79 (permalink) Old 31st July 2020, 13:55
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The fuel filler cap seems missing James. What happened to it?

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post #77 of 79 (permalink) Old 31st July 2020, 17:44 Thread Starter
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Originally Posted by BRZ View Post
The fuel filler cap seems missing James. What happened to it?

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The body shop removed its to paint it, it was riveted on and they had to drill them out. They are massive rivets and I donít have any big enough here to refit it. Iím going to look at some riv nuts asa solution to refit it, just not had chance to measure them
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post #78 of 79 (permalink) Old Yesterday, 14:20 Thread Starter
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Nearly Back On The Road

So I set out to give a true reflection of what it would take to get the car back on the road. *I have done all the work myself minus the frame shop straightening the front end/welding on the new slam panel and the respray itself. *If you take out of the consideration any mods I've purchased that weren't needed such as rear lights/headunit/STI parts etc and just look at what it would take to get a similar 86/BRZ back on the road with similar damage I have spent as follows.

Exactly as I've done it with facelift front end and new bumper/wings plus full colour change:

Total on the road cost: £8930.46

That includes:

Crash Damaged BRZ £4200

Used Bonnet £150

Used Crash Bream £50

Used Rad £20

Used A/C rad £20

Used Fans £20

Used Airbox and washer bottle £100

Odd used and new clips, brackets, fog lights, wiring, rear bumper etc £200

New Slam Panel Subaru £306

New Front wings and brackets, top plastic grill trim, 4x rubber bushings for rad assembly Toyota £309

New Vland Headlights £380

New Facelift front bumper with all the brackets, grills etc £617.92

New Headlight rubber seals(BRZ Only) Subaru £58.14

New Headlight washer jet covers Subaru £70

New Various bolts Subaru £29.24

Labour for frame shop to straighten the car £380

Respray in Porsche RS Green £2000 (Note for those that ask why so cheap I did all the labour in terms of stripping the car minus the bonnet/doors/boot lid



For that above cost I have a 2013 BRZ with around 40k on the clock, spotless interior, heated seats, spotless exterior which is unique and you wont see another one in that colour, black headlights etc. *Yes I could have bought a working 86 for that sort of price (Only seen very rough BRZ's sub £10k) but it would possibly have higher mileage, not as in good condition and certainly not unique. *It would also have the pre-facelift front end which im not a massive fan of. * So for me I am more than happy with it as it stands and gives me a solid base to start modifying.**



Getting it on the road even cheaper:

Now I could have got it on the road for much cheaper if I had waited around for used parts that matched the body colour and didn't insist on retro fitting a facelift front end. *This would have avoided £2000 in bodyshop costs straight away, plus the used body parts would have been a lot cheaper than the new bits I went for like the front bumper and wings.

Total on the road cost: £6383.54



That includes:

Crash Damaged BRZ £4200

Used Bonnet £150

Used Crash Bream £50

Used Rad £20

Used A/C rad £20

Used Fans £20

Used Airbox and washer bottle £100

Odd used and new clips, brackets, fog lights, wiring, rear bumper etc £200

New Slam Panel Subaru £306

Used Front wings and brackets, top plastic grill trim, 4x rubber bushings for rad assembly *£300

New Vland Headlights £380

Used Front Bumper £150

New Headlight rubber seals(BRZ Only) Subaru £58.14

New Various bolts Subaru £29.24

Labour for frame shop to straighten the car £380



Yes I was lucky with some of the used parts coming up super cheap, but if I can find bargains, others can.* *Sam Nadeem from SJ Autosports is a great source of well priced used parts for 86's/BRZ's in the UK.* I did all the work with a Halfords tool kit and a Ryobi impact gun. *I've never rebuilt a crashed car before so have learn't a lot along the way. *Now its time for its MOT tomorrow, then tax and insurance. *Once thats done its off the bodyshop for its final polish now its all back together then modifications begin.**



Very happy its gone from this:

Untitled by James Baker, on Flickr



To This:

Untitled by James Baker, on Flickr
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post #79 of 79 (permalink) Old Yesterday, 18:00
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Quite a turnaround! Good luck for the MOT tomorrow, although I'm sure you don't need it!!!
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