Grcygtr

[FooSchnickens]

This will (rather poorly) document the timeline of events surrounding the acquirement, repair and subsequent modification of one 1997 Subaru Impreza Outback Sport, codenamed 'GRCYGTR'.

--11/25/2010--

SUBJECT: INITIAL DISCOVERY

After searching the far reaches of craigslist, autotrader and ebay, I had found several potential candidates for a suitable subject to fulfill the parameters of this mission. After several failed attempts at communication with various parties, and one encounter with a wholly unacceptable subject vehicle, I was finally able to locate a specimen that fulfilled a majority of the myriad requirements bestowed upon me by my superiors. These factors included: sound chassis, proper function of various accessories and, above all, proximity to our headquarters. It was on this afternoon that I discovered test candidate 006. Contact with the owner was made and a time was set to view the vehicle later that week. There would be one hurdle to surmount higher in the chain of command regarding its mobility, but I am confident that I will be successful in my proposition.

Test Candidate 006:
http://i143.photobucket.com/albums/r156/FooSchnickens/3o23p23l85O65T45R2abr9de05758fcd8133f.jpg

--11/28/2010--

SUBJECT: INSPECTION AND RETRIEVAL

Upon initial inspection of Candidate 006, all major conditions appeared to be met. The chassis possessed no signs of excessive, nor even minor oxidation. All major systems were confirmed to operate correctly and within designated parameters. The one flaw to Candidate 006 was its motivation unit, which had suffered damage to which the extent is unknown. Approval from command had been received to proceed with the Candidate regardless of this fact, and arrangements were made to have it transported back to headquarters.

Candidate 006 as found:

http://i143.photobucket.com/albums/r156/FooSchnickens/2010-11-28150432.jpg

Candidate 006 prepped for transport:

http://i143.photobucket.com/albums/r156/FooSchnickens/2010-11-28165818.jpg

Candidate 006 staged at headquarters awaiting phase I:

http://i143.photobucket.com/albums/r156/FooSchnickens/DSC_7293.jpg

[FooSchnickens]

--11/29/10--

SUBJECT: INITIAL DOCUMENTATION OF SUBJECT CONDITION

Upon arrival to headquarters, Candidate 006 exhibited no signs of rejection from its previous habitat, and, in fact, welcomed its new surroundings. We took advantage of its placated demeanor to gather as much data regarding its current condition as possible:

Our attention was first placed on its Motivation Unit in an attempt to begin to diagnose its malfunction. No data was discovered on an external evaluation, a more thorough exploratory procedure will be required.

http://i143.photobucket.com/albums/r156/FooSchnickens/DSC_7295.jpg

Moving on, we went to the interior. Everything was found to be in order as all window units and ingress/egress hatch locks performed as intended. One fault was found with the audio system as only the rear output units appeared operational. The receiver unit appears to be functioning properly which suggests an electrical fault or malfunctioning front output units. Additionally, no severe damage was found to the cockpit or passenger areas with minimal stains that would be easily removed at a later date.

http://i143.photobucket.com/albums/r156/FooSchnickens/DSC_7300c.jpg

The only visible damage to the interior came in the form of a slightly peeled-back vinyl cover on the driver door fascia.

http://i143.photobucket.com/albums/r156/FooSchnickens/DSC_7315.jpg

The rear cargo area was as spacious as we had hoped, and will prove to be a valuable asset moving forward. The exterior-mounted cargo beams suffered damage during the previous ownership and were removed. Repairs can be easily made by replacing the aging hardware with new weather-resistant units.

http://i143.photobucket.com/albums/r156/FooSchnickens/DSC_7304.jpg

Upon completion of the internal inspection one technician noted the gesture of goodwill extended by its previous owner, a 'Royal Pine Car-Freshener'.

http://i143.photobucket.com/albums/r156/FooSchnickens/DSC_7314.jpg

[FooSchnickens]

--11/30/2010--

SUBJECT: PHASE I EVALUATION

Upon the completion of the cursory external examination of the motivation unit it was determined that a more invasive exploratory procedure was required. Access covers to the motivation unit's timing equipment were removed and the inspection began. What was discovered confirmed our suspicions of incorrect timing being the root cause of the unit's current inoperative state.

Upon aligning the main timing mark:

http://i143.photobucket.com/albums/r156/FooSchnickens/DSC_7320.jpg

We discovered that one timing bank was aligned properly:

http://i143.photobucket.com/albums/r156/FooSchnickens/DSC_7329.jpg

While the other bank was not:

http://i143.photobucket.com/albums/r156/FooSchnickens/DSC_7330.jpg

Also of note was the fact that the timing belt appeared to be out of adjustment which may have caused it to slip and throw off the entire system.

A further exploratory procedure has been planned for a later date.

[RotorNutFD3S]

Above received 1429 30 November 2010. Forwarded to interested parties. Awaiting further information.

[nickt93]

Will be awesome if you just need to swap the belt and set the timing properly. Keep us updated! How much did you pay for that thing?

[Stealth97]

Is it an interference motor? If not you might have lucked out, however I'd expect it to run like crap, rather than not at all.

[jester911]

--11/31/2010--




Clearly this must be some sort of time machine since you are at 11/31 and November only has 30 days.:lol:

[CharlestonMX5]

--11/31/2010--

SUBJECT: PHASE I EVALUATION

Upon the completion of the cursory external.........

HOLD IT...... Today is the 30th, so you did this tomorrow ? But November only has 30 days...... :p

NICE....... so you went straight to the timing...... sweet, if that's the only issue.

[CharlestonMX5]

LOL Jester....

[iscariot]

oops.

http://lh4.ggpht.com/_XkxLua5W3H0/RsdIic1f9rI/AAAAAAAAALI/t5lM-vpCPXI/MVC-032S.JPG

Fun car, I made the AWD mistake of lifting off the throttle mid slide on an off-camber sweeping turn after a hurricane blew through. Backwards into a ditch at 60mph. Cut my hand climbing out the shattered window, managed to bruise my bicep from my arm whipping back, but otherwise fine. I still have dreams of one day owning a WRX driveline'd RS...

[FooSchnickens]

Will be awesome if you just need to swap the belt and set the timing properly. Keep us updated! How much did you pay for that thing?
Yeah, I'm really hoping that's all it is. Paid $400 for it.


Is it an interference motor? If not you might have lucked out, however I'd expect it to run like crap, rather than not at all.
I haven't been able to get a definitive answer on this yet. Some people say all EJ22s are non-interference, and some say that only a specific year range are non-interference. I haven't tried starting the motor yet until I get the timing reset just in case it is an interference motor and I damage it even more. Even if it runs like crap, if I can get it to run under its own power I can limp it to the shop and not have to pay to have it towed or rent a car dolly again.

Clearly this must be some sort of time machine since you are at 11/31 and November only has 30 days.:lol:
Oops, finger slipped.

[FooSchnickens]

--11/30/2010--

SUBJECT: PHASE I EVALUATION <SUPPLEMENTAL>

Additional time was cleared to preform a more detailed exploratory procedure and a surprising discovery was made upon removal of the main timing assembly cover.

As the cover was removed, several small bearings fell to the floor, indicating a broken pulley.

http://i143.photobucket.com/albums/r156/FooSchnickens/DSC_7332.jpg

A closer inspection of the pulley system indicated that the tensioner pulley had failed, causing the belt to lose tension and subsequently go out of the specified timing alignment.

An attempt to locate a replacement part locally was made, but none were found. With this part sourced, the motivation unit may be able to run and move Candidate 006 under its own power.

[FooSchnickens]

--11/30/2010--

SUBJECT: PHASE I EVALUATION <SUPPLEMENTAL>

The initial assumption that the tensioner pulley was damaged was found out to be false as the wrong part number was referenced when determining the components of the timing system. The correct component was the timing belt idler gear. This fact was discovered all too late as the local parts warehouses have already been shut down for the evening. Another attempt will be made tomorrow morning to acquire the part and hopefully restart the vehicle's motivation unit.

[FooSchnickens]

--12/1/2010--

SUBJECT: PHASE I COMPLETION

Upon acquiring the correct part for repairs the motivation unit was able to be resuscitated and showed no signs of internal damage. Its maiden voyage to procure a celebratory snack from a local fast food vendor proved that all major systems were functioning perfectly with no untoward noises, smells or other obvious signals that something was amiss.

Efforts have now been redirected towards establishing proper titling and licensing for the vehicle as it is now fully functional.

It is with this milestone being reached that the plan moves into Phase II and Candidate 006 becomes officially designated: GRCYGTR.

[nickt93]

Congrats - that's awesome!

[Dr.Drew]

I'm digging the build thread. Since wikileaks is fubar'd today it's the next best thing.

[RotorNutFD3S]

Good job! $400 well spent!

[FooSchnickens]

Yeah, I just looked back at what I've spent so far:

Car: $400
Tow Dolly: $56
Pulley: $43
Tank of gas: $26

Total: $525

:butt:

[Bernie]

Sweet! I used to have a buddy that claimed that the universe would reward people with "their extra 10% for the day" and you sir, have gotten your 10% from the universe this day...

BTW, what does GRCYGTR stand for? "Greasy Getter" since it's first voyage was a fast food run? :lol:

[RotorNutFD3S]

Grocery Getter?

[scandmx5]

from what little i know and have seen of Taylor this is gonna be an urban assault vehicle. it will probably be loaded with mountain bikes and NATO small arms :lol:

[Stealth97]

Dude that is so freaking cool. Now flip it for a big profit!

[FooSchnickens]

Rip nailed it.

And yeah, the end result will be a UAV that's still up to the task of being somewhat comfy. Throw some forester suspension on it, skid plate and light bar and call it a day.

I considered selling it now that it runs, but this particular model is kinda hard to find and even the base models around here are beat to hell. Though tripling my investment ain't half bad.

[Reverend Greg]

That is the exact vehicle I was looking for,I now have my eye on a legacy wagon...might be hard to buy now tho....
(G)

[FooSchnickens]

--12/1/2010--

SUBJECT: PHASE II RESTORATION

With Phase I complete the project will now move into Phase II where GRCYGTR will receive it's proper government badging and licensing as well as receive a more scrutinous evaluation and applicable repairs of its functions in a real-world environment. One step forward was made with the Audio Receiver Unit (ARU, or more commonly referred to as the Nixon Module (http://norwegianity.files.wordpress.com/2009/08/richard_nixon27s_head.jpg)) which was originally to be thought to be malfunctioning. As it turns out, the unit's antenna was not fully deployed and causing only a partial signal to be received. Fully extending the antenna fixed the issue and has not reoccurred since.

[FooSchnickens]

--12/5/2010--

SUBJECT: PHASE II - Road Worthiness Testing

With the motivation unit functioning properly, a medium-range excursion was planned to field test all vehicle functions. Lighting, climate controls, steering, suspension and cargo hauling were all tested. A total of 500 miles were traveled and no failures were noted. The only features found not to be operational at this point are the rear defroster and rear accessory outlet. As of yet the fault has not been determined as the fuses for both features are not burned out. Further investigation will be necessary to determine the fault.

[FooSchnickens]

--12/24/2010--

SUBJECT: YEAR-END EVALUATION

Based on initial assumptions when first acquiring GRCYGTR, the results have exceeded our expectations, even with the motivational unit now inoperable. All major necessary systems performed within specifications and no faults presented during this time period other than the timing belt failure.

Current available resources have been diverted from smaller projects to this one in an effort to repair or replace the motivation unit in a timely manner. Initial disassembly should begin today to determine the extent of the damage. It is our hope that the damage is limited to the valvetrain as replacement parts are both readily available and cost-effective especially when compared to an entirely new motivation unit. Depending on the findings of this procedure we are expecting to have the unit operational either by the end of period twelve 2010 or at the end of period one 2011.

[FooSchnickens]

--02/18/2011--

SUBJECT: MOTIVATIONAL UNIT ADDENDUM

Progress has been slow on evaluating the motivational unit's condition due to numerous external factors that were beyond our control and issues with disassembling the unit itself.

Initial disassembly was met with resistance when the cylinder head was being removed. Several bolts were frozen in place and took longer than expected to remove. One bolt caused further issues when the forces holding it in place proved to be higher than the tensile strength of the bolt itself, causing it to shear off with most of it still inside the motor block.

This was not cause for much alarm as this behavior is typical of older units. However, the condition of the top part of the bolt after it was extracted was indeed troubling.

A typical removed cylinder head bolt appears wet with oil and may have some amount of grit in the threads. The bolt removed the GRCYGTR's cylinder head was drastically different:

http://i143.photobucket.com/albums/r156/FooSchnickens/FxCam_1297896636594.jpg

Not only was it completely dry (rust and other debris fell from the hole as the bolt was extracted) but the bolt itself is heavily pitted and shows signs of extreme degradation.

With the cylinder head removed a closer inspection was made. This inspection revealed that there were several hairline fractures in the block that appears to have caused either a leak in the headgasket or through the motor block itself into the cylinder head bolt channel.

In either case, the motor has been deemed "unusable" and scheduled for immediate removal and subsequent replacement. Several donor units have been located and arrangements are being made for delivery.

While Acquisitions is busy selecting a new unit, technicians will begin removing the remainder of the now-defunct motivational unit in preparation for the impending transplant.

[VitaminD]

Sucks, this was the gamble on a on a rough running car. I wish you the best , I bet you come out ahead of a running car. The real benefit is being able to trust the car when you finish.

[doombastic]

Nice subie! That sucks that the engine is no bueno but seems like you will still be ahead of the game with a replacement.

(i heard robot voice when i read your posts lol)

[epilonious]

I am loving these writeups.

Doombastic: I, too, and imagining a robot voice... specifically Glados from Portal

[Blackmamba]

You must melt down unsuitable propulsion unit into usable armored plate or ammo.

[Imaginhate]

I hear James Earl Jones


Tapatalk, son.

[FooSchnickens]

Sucks, this was the gamble on a on a rough running car. I wish you the best , I bet you come out ahead of a running car. The real benefit is being able to trust the car when you finish.
Well, that's the thing. When it was running, it ran perfectly. No stumbles, smoke, codes, nothing. The only external sign that anything was wrong with the engine was, well.... nothing. :\ Had I known there was this internal damage from the get-go I'd have forgone replacing the timing belt and sourced a new engine immediately. And yes, I will still be very much ahead in the end. I've got just over $500 invested in it and even with the new motor (about $400) would still put me well under the normal asking price for an OBS in good condition ($4-6k).

[FooSchnickens]

-- 9/25/11 --

SUBJECT: MOTIVATIONAL UNIT ACQUISITION

Following a period of severe lack of funding, facilities and manpower HQ has realized the true use of our branch and have supplied us with a new base in which to conduct our operations. We anticipate to be fully transferred to this new location in no more than 60 days. In the meantime, a suitable replacement for the motivation unit has been sourced and is pending budget approval by HQ.

In the meantime, the majority of our resources will be devoted towards the transfer of materiel to our new location. During that time, however, the initial removal of the motivation unit and driveline apparatus will commence in preparation for the new motivation unit to be installed.

Morale is high as we pack up equipment and begin the transition phase. We anticipate this new location to be much more conducive to the completion of this project and are eager to begin work once again after a long hiatus.

[FooSchnickens]

-- 12/06/11 --

SUBJECT: HQ TRANSFER AND PROJECT CONTINUATION

Having fully transferred our headquarters to their new location we were ready to have GRCYGTR moved to its new service facility. The process went smoothly and we eagerly await the time to finally begin work yet again. A tentative start date of 12/10/11 has been chosen as it coincides with work on another project, BLKMBA. If all goes to plan, we will have the old motivational unit removed and the chassis prepped for the new motivational unit when it arrives.

[DecoyOctopus]

lol@motivational unit

[FooSchnickens]

-- 12/10/11 --

SUBJECT: MOTIVATIONAL UNIT REMOVAL

Today's Motivational Unit removal went faster than anticipated. The old unit was removed without incident and placed into temporary storage while we await the arrival of the new unit. It appears that some work will need to be done to the transmission as it seems to have a leak around the input shaft. The repair will require the transmission to be removed so we are trying to source a transmission already mated to a new motivational unit, or a transmission from the slightly more desirable WRX model.

In either case, progress is moving along rapidly and we hope to have the project completed no later than the end of P1 of 2012.