Sleezer1533's 2005 Impreza 2.5RS GC

Pulled it into the store today to take a look underneath

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Found my exhaust leak
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Changed the belt
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And threw in a new air filter
 
Changed out my burnt out license plate lights
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And decided to re-work my aux outlet mod. Picked up these from the junkyard this morning ... two subarus live on!!
Ordering something new to go along with these too :)
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Decided to commence operation "**** You Rust" tonight. Just did a little to get it started. Began with the worst spot.
Thats a large pit!!
Hopefully I can save the metal and it doesnt come through from the back side, I can feel some bubbling back there.
Going to need a grinding wheel attachment for my cordless drill, this was all the wire cup brush could handle, that or a good ol fashioned metal hand file

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And we continue with operation **** You Rust. Since the rear arches have some rust all the way back to where the plastic of the bumper meets, I took off the bumper and guess what ... I found more rust. Go figure:P
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So I took everything apart and started with the bumper brace or whatever you call it, the actual bumper lol. Wire cup brush till my drill was out of juice then covered what I got done with rust reformer.
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These parts are going to be tedious
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Oh and who new there was metal built into the bumper :p
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Anyone got a part number for these? They are located under the taillights and hold part of the bumper on
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Lastly WTF is this, it fell out when I took the bumper off
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i am not trying to be pestimistic, but not matter what you do , that rust spot is going to comeback right after this winter. trust me i have done it lol. may not not be visible since its dark color.
 
I havnt finished with the spot in the arch yet.
All the rust uis being taken down to clean metal. Covered with rust reformer for good measure and then anything that isnt an exterior body panel will be coated in rubberized undercoating. I know its not a cure-all but it should tack on some extra years to its life.

As long as you remove all the oxidized metal down to nice clean sheet metal, then paint or coat it, the rust should be gone.
 
With the next two days off, I just decided to finish up the bumper beam tonight
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My game plan for tomorrow is to bring her to the car wash and clean the mud out from under the rear and the rear wheel arches. Then bring her back, lift up the rear, take off the rear wheels and go to town on the arches spending the most time there to ensure as best I can that the rust wont return. Also taking a wire cup brush to any surface rust under the rear, then spraying liberal amounts of undercoating where need be.
 
Got to work this morning-> Lunch/Gym break right now
Started on the arches, heart sank when this happened, not sure what to do now
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Then go the rear side undercoated:
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Last photo makes me really want to smoke my tails
Also makes me think the headlights may look better in black
 
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Bumper is back on!
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Shes dirty and needs a bath asap!!
Also this pic seals it ... I need to smoke my tails
As mighty mods would say, blaaaaaaack

Also whats going on here with this license plate thingy, I always just used zipties to hold the plate on since
this seems to have been down inside my bumper since I bought it lol
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Ill be starting the wheel arches asap
Just got my can of por15 in today
Just need to find time, since I got switched to afternoon shifts I no longer have my afternoons wide open :/
 
Car has been a bit neglected lately, other than a wash and interior detailing.
Had the day off today and was going to keep going on the rear arches. Stopped out to auto-zone to pick up a roll of masking tape and noticed on the shelf right below it this stuff called Evapo-rust.
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Kinda pricey but I got the small bottle and am going to give it a try.
For large areas that cant be soaked in a bath it says to wet paper towels and lay them on the area followed by plastic wrap to prevent drying and let sit for anywhere from 8-24 hours depending on the degree of rust. Since I woke up kinda late and the day is half gone, Im going to get cracking nice and early on my next day off, Monday.

What Ive already done is taken a small paint brush and hit the rusted hole on the passenger's arch with por15, let it dry, then filled it with liquid metal filler. Then sanded down the filler to make everything ready for the final steps
The plan is:
Hit the arch with a wire cup brush to prepare the metal for the Evapo-rust
Apply the evapo-rust, Im hoping it wont take too long since the rust isnt too terrible now that Ive taken an angle grinder to the bad spots.
Hit the arches and bad spot with some 60-grit overlapping about an inch onto the good paint
Then applying probably two thick coats of por-15 with a mini roller
Ill either leave it like that for the winter or hit it with a coat of clear to prevent peeling at the edges
Then work on the body filler to fix the bad spot in the spring when I hopefully start wrapping it

And Ive come down to two choices for color:
Matte black or Matte Grey
 
Update. All finished for today
Final thoughts, everything went according to plan, expect the finish of the POR15. No biggie, just means extra sanding/finishing to do :/

1) Evapo-Rust soaked towels held in place with painters tape and magnets. Put remaining evapo-rust in spray bottle and soaked the towels every half an hour for eight hours.
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2) POR15 applied. Three coats with 20 mins drying time in between. Applied with a mini roller. Let sit for three hours after final coat
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3) Removed tape. Notice the "popcorn" like finish. I think its fibers from the roller.
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4) Started a bit of sanding. I like this stuff, dries very hard but flexible at the same time. Should last.
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Wow, wish you did this before I crashed my protege. Looks like it's coming out great, good job man!
 
Cant believe I didnt read about that on here ... in truth im not on as much now that I have teh scoob
Anyway that sucks man, what are you in now?


Also picked up some oil today. Autozone had a sale so I went with Mobile1 full synthetic and matching filter.
Also grabbed a tube of copper RTV silicone to fix this pretty annoying exhaust leak while im under there.
 
No point in getting a new car until I get my license back. (6 months)

And if your exhaust leak is from bad eBay gaskets blowing up, RTV only helps for a little while. Especially with winter coming, the salt will erode that stuff away by next year.

http://www.flex-innovations.com/gasket.htm
^^
These guys looks like they have top notch DIY gasket sheets that should be nothing but a fun day for you. Not expensive either.
 
So I got the oil changed and "mended" the leaky exhaust gasket. Was going to switch out my O2 spacer but it looks like Im going to need an O2 sensor socket to get this damn thing to budge. Also looks like Im going to need to drop the midpipe to get the old 90* spacer off since its going to hit the underside of the car as I turn it.

Had to make a barrier to protect the wrapped header from oil:
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I noticed that the majority of the gasket was in tact and fine and wasnt too comfortable replacing the whole gasket with the rtv so this is what I did: As you can see after cleaning the gasket, just a small bit of the inside of the bottom of the gasket had worn out...
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Hopefully that should last a bit anyway
 
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Small change from this:
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To this:
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Hard to get shots in my dim garage, ill get outside pic tomorrow:
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Downside to the black is it really shows how badly etched and oxidized my lenses are. Jonesing to get a new set now.
 
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