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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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August 5, 2023

Rust Diaries, Day 16: Truck Bedliner

The work’s picking up pace. Today, we opened the first can of Cobra – a textured truck bedliner coating based on two-component polyurethane resins, which is going to make the final layer on the underside of the car. I was a bit apprehensive about this moment and wasn’t sure how RAL 5017 would look on the car. But I think it turned out quite well. Yes, it’s brighter than 02C - World Rally Blue, but once everything that the roads have to offer covers it, it will look class. Cobra on the rear wheel arches and up to the gearbox line:

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August 4, 2023

Rust Diaries, Day 15: Subframes II

Following up on the work done on Day 12, we continued with all the large parts that didn’t make it to the powder coating: Dinitrol and the primer.

I spent some time and effort on the lateral link set — steel wool works wonders on those aluminum pieces.

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August 3, 2023

Rust Diaries, Day 14: Halfway point (?)

The theoretical halfway point (I gave myself a month to finish this), but we’ll see how it turns out in the end. The engine bay won’t be stripped; we wouldn’t have had enough time, plus some of the work required could have been too much for us to handle — like rerouting the fuel and brake lines. After all, our technical consultant deserves our respect and we would not want to over work him. As a result, brown packing paper in hand, it’s time to start packing things up. We’ll finish stripping at the chassis beams level.

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August 2, 2023

Rust Diaries, Day 13: From big to samll

The next logical step was to tidy up all the remaining small parts, and that’s exactly what we did. Quite a few of them went through zinc plating.

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