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johndej
johndej UltraDork
6/6/24 9:26 p.m.

Good vibes for the recovery process!

GameboyRMH
GameboyRMH MegaDork
6/6/24 9:29 p.m.

Oh another bit of news, Grimmspeed actually was willing to sell a replacement airbox alone, at a reasonable enough price that it's worth not fabricating a substitute from scratch. When I tried to bend the wrecked one back into shape I tried a magnet on it and got no reaction, so it seems to be made of some super-hard aluminum alloy, I'd assumed it was steel from how hard it was.

GameboyRMH
GameboyRMH MegaDork
6/8/24 7:53 p.m.

The shop's started work on fixing up the front of the engine. No concrete bad news yet but no good news either. The crank pulley spacer was messed up (pin was sheared off for one thing) and the front timing cover to crank spacer seal is leaking. Also the tensioner pulley was bent, and again they don't sell that pulley separately so I should have quite the collection of spare tensioners soon.

dean1484
dean1484 MegaDork
6/9/24 9:25 a.m.

Have you tried measuring the run out on the crank?  If it was in spec I would be much more confident that the motor would be ok. 

GameboyRMH
GameboyRMH MegaDork
6/9/24 4:47 p.m.

In reply to dean1484 :

I asked the shop to do that, they want to have all the parts needed to make the car potentially somewhat driveable together before they push it onto a lift inside the shop to start the real work on it though. The front main seal and tensioner pulley should be the last parts needed so I should find out in the next week or so.

dean1484
dean1484 MegaDork
6/9/24 6:26 p.m.

You can do it in the parking lot in a couple minute. If they are not engine builders there is a good chance they don't have the tool needed to measure it.  A magnetic base and a dial gauge a bolt and a pry bar and a small dead blow hammer  is all you need.  Most repair shops won't have the dial gauge and the base.  I would have done that before doing anything else. 

dean1484
dean1484 MegaDork
6/9/24 6:28 p.m.
Apexcarver
Apexcarver MegaDork
6/9/24 8:06 p.m.

If they set up ring and pinions they would have one I would think. That's why I have one knocking around my shop.

GameboyRMH
GameboyRMH MegaDork
6/9/24 9:06 p.m.

I think the crank spacer (the part with the sheared pin in my last pic, it's a small cylinder that goes on the end of the crank, the pulley then sits on it and the crank bolt passes through it and screws into the crank) would need to come out first since it's taken some damage.

It's a shop that does some of everything but the bulk of their work is collision stuff. I'll see if I can get the runout test done any sooner.

I took apart the oil cooler today and confirmed it looks like just the core with its mounts & brackets are trashed, I just need to clean up some damage I did to the sandwich plate trying to get it off the engine. The oil filter actually got dented in the crash and I think that force kind of jammed the whole assembly together, unfortunately I caused some gouges near the sandwich plate's sealing surfaces trying to break it loose with different tools before I tried jiggling the whole thing by hand. After I did that it unbolted easily...weird.


GameboyRMH
GameboyRMH MegaDork
6/13/24 7:32 p.m.

So the shop confirmed today that the crank threads are messed up, they want to try cleaning up the threads for the stock bolt but they don't have a tap long enough to reach it, normally they'd call a mobile machine shop for this but to save some money they're giving me the opportunity to find the correct tap. Looks like it's an M13x1.5 thread, bolt shaft is 110mm long and about the last 30mm is threaded, so that's how deep into the engine it has to reach. A bottoming tap would work best.

The serpentine belt tensioner was also messed up and the AC compressor pulley might be tweaked too, but in Canada I only use the AC a few times per year anyway.

GameboyRMH
GameboyRMH MegaDork
6/18/24 9:24 p.m.

Tried the boiling water trick on the front bumper today and got some improvement. Before:



After:

Next time I'm going to try more force on it while it's hot.

I should get some info on the crank threads soon, so far we haven't found any more signs of potential damage, I had a look at the threads with a cheap borescope/endoscope and didn't find any obvious damage, just some crud:

GameboyRMH
GameboyRMH MegaDork
6/25/24 3:34 p.m.

Crank thread repair was a success, just waiting for news from the shop now, but I'm not rushing them, the sooner they're done the sooner I have to pay up...

It took a lot of shopping around but I got this to my door for less than half the base price of the cheapest new one I've seen:

These are very specific, some BRZ airbags will fit although they will look wrong, but then the 86 also has another steering wheel variant with a different airbag cover shape that won't fit at all. It looks like the plastic covers are permanently stuck to the airbag itself and can't be swapped at all, which is really too bad as being able to swap covers would open up a lot more interchange options. This one has a lot more blemishes than my old one did, they'll remind me to keep my guard up around hard obstacles and avoid unnecessary hoonage.

 

Apexcarver
Apexcarver MegaDork
6/25/24 6:40 p.m.

In defense of Toyota/Subaru and their airbag supplier, you would be astounded the amount of engineering that goes into one of those covers and how the weakened internal part lines (and their exact placement) affect the deployment of the airbag. 

 

Glad things seem to be looking positive! Hope it keeps going that way!

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