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August 21, 2023

Rust Diaries, Day 24: The engine

If you know your Subarus, you should know that with those flat fours, it’s a tale of “when”, not “if”. With a slight summer delay, I’m reporting the pickup of the Impreza from Nowy Sącz. It started innocently enough, but ended the way it always does. The list consists of 59 items, and the bill… a bit more than 59 PLN. The cylinder hone to the first oversize, and everything associated with it, was done properly, without cutting corners on costs.

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August 15, 2023

Rust Diaries, Day 23: On its own wheels

We’re wrapping up this project. Floor pan splash shield and the rear diffuser. Exhaust.

Front and rear bumpers with lights. Wheels. And after a month, the car is back on its very own BBS forged alloys.

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August 14, 2023

Rust Diaries, Day 22: The end is in sight...

…or maybe: The end is near!

The front and rear brakes are installed, and while we were at it, the handbrake shoes were replaced.

The front wheel arches, mudguards and rocker panel covers are installed. All the missing clips have been replaced.

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August 12, 2023

Rust Diaries, Day 21: Fuel filler neck

The fuel filler neck is assembled. It might sound like a silly little part, and it is, but there are plenty of components to put together, not to mention all the pipes going in and out of the vapor canister.

The rear sway bar and a pair of new links have been installed because the old ones had an encounter with an angle grinder.

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August 11, 2023

Rust Diaries, Day 20: Rear axle II

It’s starting to look really nice. The rear suspension is finally reunited with the car.

And the most important thing, we figured it out — well, actually Tomek’s Dad figured out how to save the snapped bolts in the chassis beam. He welded two small plates to each of the two nuts, which we inserted through the service holes into the correct position. Then, we secured them with screws so that the plates were positioned against the lower plane of the beam. We then drilled a hole through both the beam and the plate, so that a rivet could be inserted through. It turned out perfectly — the rivet held the nut in the correct position so that we could start the thread, and thanks to the plates, we could properly tighten the bolt (without having a wrench on it), as the plates wedged inside the beam. It was done without cutting or welding anything.

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August 10, 2023

Rust Diaries, Day 19: Rear axle

Well, now we’ll see. Anyone can take something apart.

Today, we assembled the complete rear axle, including the differential and its housing, subframe, and trailing arms.

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August 9, 2023

Rust Diaries, Day 18: The last day of painting

Cobra in the engine bay.

Final touches on the gearbox housing (a keen eye might notice that Tomek decided to celebrate the end of painting with a rather cute sweater):

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August 8, 2023

Forester, busy as usual

A wee anniversary.

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August 7, 2023

Rust Diaries, Day 17: Black and pink

Following up on the work done on Day 15, we finished with all the large and small parts; they received a final coat of Cobra. Black for the most and pink (STI pink, if you like) for the smaller bits. This was inspire by those iconic trailing links ST2027055000, that’s RAL 4010, if you’re wondering.

A quick look at the home paint shop.

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