2013 FR-S Rebuild Thread
 

So I rebuilt myself a 2013 BRZ for HPDE track events that I chronicled HERE.

After I had so much fun returning that car to the road, I came across another opportunity to do it again.

This time it is a 2013 Scion FR-S, M/T with 66k that hit a tree. I purchased the car from www.erepairables.com (Insurance Auction Broker).

I will be repairing this one as well, with as much of the work being done by myself that I can. Will chronicle the progress here.

First Day Home (Monday, Feb 26)

Plans for the car is basically give me something to do (car repair relaxes me), the body will be repaired, engine will be removed and resealed, car will be cleaned up and likely sold once it's all better...

And don't worry, the silver one in the background is still my track car, it's not going anywhere.

Car had been taken to a body shop and partially disassembled before it was "totaled", first thing I did when I got it home was check it for all the front end parts that were missing.

Thank goodness a bunch of the parts were in the car, less parts to buy!

Now on to the damage, besides the obvious body parts needed (hood, fenders, front bumper covers and headlights) what else is there?

Looks relatively minor...but the wiring to the headlights is sheared off...that is all part of the main bulkhead harness...a $1,200 part by itself. Likely why it was written off, that plus the body work, suspension parts & wheel put it over the 80% threshold.

How the body shop left the engine & front of car:

All washed up after the inspection:

/me puts his name on the wait-list for an @Opie restored 86 platform

Can't wait to see the progress, so cool!

I was considering a flood car for a track built car. I would seriously think of purchasing a car from you in the future since I don't want to deal with the time finding the car, shipping, and then trusting any body shop near me. All the mechanical I could take care of. Time and effort are worth $$ to some people.

Then again, new supra.:iono:

Day 7:
OK, so last week was crazy busy for me at work so I didn't have a lot of time to spend on the car until this past Sunday.

The car arrived with no keys, which as many know there isn't (usually) a real easy way to get the car re-keyed without a visit to the dealership. This weekend, with the help of a fellow FT86Club member; xxjprimxx hooked me up with a step by step on clearing all the old keys from the immobilizer system and programming new keys and it worked awesome!

I purchased 3 genuine keys from Toyota/Scion, 2 Master & 1 Valet, cost: around $400, then I used the programming instructions from xxjprimxx and registered all three new keys and the car started right up!

That allowed me to get started on reassembling and repairing some of the car. I cleaned out the entire interior, vacuumed and used Turtle Wax's new Odor-X to deodorize the car. Then I removed all the damaged parts; fender hood and then organized and labeled all the parts that came with the car. Now, I'm ready to start.

Started reassembling the engine area, A/C lines, body supports. Measured the body clearances to confirm the front end was plumb & square. All checked out after a few adjustments. I plan on pulling the engine front timing cover and resealing it before I reinstall the radiator & condenser, it's leaking at the bottom corner where they all start leaking. All the parts are here, will likely finish next weekend.

Reinstalled the front exhaust pipe and removed the damaged left front lower control arm, luckily the control arm took the brunt of the damage, strut looks fine. Touched up some bare metal exposed during the accident.

Mocked up the front left support brackets before the welding starts next weekend!

Day 9


Still waiting on parts so not much progress. Looks like this weekend will not include any welding or bodywork as I want to get the engine reseal done before putting any of the body components back on. So that will be the focus this weekend. Lower control arm did arrive today so I knocked that out this evening. Went right on without an issue so I know I got everything lined up correctly last weekend!

Here we go again!:party0030:

Day 10


Picked up a used wheel & bulkhead harness. New headlights, turn signals & corner lights arrived as well as all the O-rings and sealant to reseal the timing cover.

Day 12


Re-sealing front timing cover...found lots of interesting bolts missing off the motor...off to order more parts...lol.

Wire repairs start tomorrow.

Day 13


Actually completed the timing cover reseal today, what a bear of a job. I can't imagine doing it with the front of the car attached...lol.
New tires arrived
Broke an exhaust stud when removing the exhaust manifold to get the front cover off, hope to get it drilled out and replaced tomorrow.














Found one of the transmission mounting bolts missing and a small bracket for the starter ground. Will get those ordered Monday. Went through all the engine connectors after I found a few loose, and found where one of the miscellaneous brackets that were in the trunk went and got it installed.It's a good thing I can look at the BRZ to see where things go, or how, or what bolts they use.

The used bulkhead harness I ordered was delivered as I was working today, so this evening I started on that. Got the 2nd horn working by repairing 1 wire for it;
http://www.challengepromotions.com/Wills/FRS/36.jpg




Got the oil pressure switch connector replaced;
http://www.challengepromotions.com/Wills/FRS/35.jpg

Got the alarm buzzer, corner light and turn signal harnesses repaired, just got to finish wire-looming and taping them up tomorrow;
Only connector I still need is the wiper washer pump connector;
Reference pages, to make sure everything is straight!

This is great. Please keep taking photos and documenting every step!

Good day today to tidy up a few things, hope to start welding the drivers side fender braces this week if I can borrow the welder!

Today I got the exhaust stud drilled out and replaced, reinstalled the exhaust, installed both undercover trays (fiber & Metal), got the radiator, condenser, fans all installed and cleaned up the battery and tray.

Since I'm off this week I hope to get it ready for hood, fenders and bumper cover by next weekend!

I did pick up a used, mint hood today, still hoping to find some nice used fenders so I don't have to buy new.

Impressive thread. Keep 'em coming.

Nice work/documentation.
Nice jack stands.
Keep er' uuup

Day 16


Busy, busy day today. Taking advantage of some spring vacation time.


#1 - Picked up & installed the positive battery terminal cover (you can see it in 1 of the pics below) and the 1 missing transmission to engine mounting bolt.

#2 - Obtained a wiper washer pump wiring harness and finished the left front wiring repairs!

#3 - Filled & bled cooling system, car ran for 30 minutes came right up to temp and had no issues or strange noises.

#4 - Borrowed the welder and went ham today!
First mock up and measurements:
http://www.challengepromotions.com/Wills/FRS/45.jpg


Lower bracket welded in, mocking up and measuring headlight bracket / upper core support:
http://www.challengepromotions.com/Wills/FRS/46.jpg


All welded up, primer sealer coat:
http://www.challengepromotions.com/Wills/FRS/47.jpg


Final color match top coat:
http://www.challengepromotions.com/Wills/FRS/48.jpg


http://www.challengepromotions.com/Wills/FRS/49.jpg

Install the front air box components, lower air deflector & repaired left wire harness!
Install the drivers side upper fender bracket, hood release & wiper washer lines (also primed, sealed & color matched):
Install the passenger side upper fender bracket (also primed, sealed & color matched):

Headlights in..and function test:

Quick walk-around video:
https://youtu.be/l8mJjTTJPEI


Engine start up:
https://youtu.be/SO4THomIRto


I've found that the car has a few mods...
1. Works Axleback exhaust
2. Carbon Fiber Trunk Spoiler
3. Backup sensor in rear bumper (not connected, car had a stereo system in it that was removed prior to me getting it, stock stereo has been reinstalled.)
4. Led tag lights (only 1 was working, threw them out, installed regular bulbs)

Windshield gets replaced tomorrow, and fenders and front bumper cover get ordered!

Awesome work... I love keeping up with well documented build threads like yours. Always something to learn, always something new to look forward to! Lots of reference pics too! Keep up the good work!

__________________________________________

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Day 19


Took it for a drive around the neighborhood tonight, got a few odd looks lol, but it runs and drives great. New windshield installed (not by me lol), hope to have the hood, fenders & bumper back from the paint shop by next weekend and a few small odds & ends finished up during the week. Then to the State of Florida for it's inspection...dowroa gets first dibs ;)

Day 21


Dropped off hood, fenders, front bumper & fender garnish at paint shop today.

Finally got the bracket for the starter ground and installed it. Nothing else came in today, hopefully tomorrow.

Day 23


All right, lots of parts came in today but still in somewhat of a holding pattern to the painted pieces return from the paint shop.


I *think* I have everything I need to finish the assembling once the painted parts arrive...
Emblems, fender liners, clips, bolts, turn signals, trim...I guess we'll see if I missed anything.


Painted parts are projected to be ready Friday afternoon or sometime Monday...


With the parts that arrived today I...

Installed the wiper washer tank, I had to remove the headlight to do it...but that's OK because the headlights have to come out to install the fenders.
Installed the missing wiper arm caps
Clay barred, and performed a 2 step paint correction on the trunk, rear fenders and roof:

Day 27

Paint shop didn't finish the body parts yet, doing little things as I can...

Engine cover plate came in, installed
Rest of the air box / sound generator pieces came in, engine area is pretty much complete.
Clay barred the doors

Day 29

Paint shop had the parts ready...couldn't bring them all home due to their size, LOL. Only got both fenders and garnishes in the trunk of the Legac\y today, will take the Forester tomorrow to get the hood...and maybe the bumper cover if both will fit.

Right Fender installed with garnish, fender liner & windshield trim
Left Headlight
Right Headlight
Right Garnish & Windshield trim

Inner View Left Side
Inner View Right Side
Front View
New Rear emblem came in, car previously had Toyota emblems spray painted flat black...
More to come...

Day 29


Got hood & bumper home yesterday, a little later than I normally get home. Installed the hood, put the front bumper together. I'm missing 1 bumper nut in order the get the front bumper cover installed...had to order it today.

Will get the bumper on as soon as that bumper nut arrives, and then some time next week I hope to get it over to work and recharge the A/C, do the alignment and get the new paint buffed out. Then submit the rebuild inspection paperwork to the state.

Day 37

:happyanim:

Rebuild is complete! Road tested 15 miles tonight, no issues or noises. No dash warning lights and everything (minus one the A/C temp switch lights) is working. Taking it to work tomorrow to recharge the A/C and align it...then to the paint shop to buff & polish the newly painted panels. Dropping off the Florida inspection paperwork on Friday and hope to get it inspected next Thursday! (They only do inspections on Thursdays)

https://youtu.be/sBkVWSgUIOg

Can't wait for the next one! :D

All cleaned up & pictures out in the sun:

dowroa, when are you coming down? ;)

Replaced the bulb in the A/C temperature control last night, now all the interior lights are working. State inspection is tomorrow.

This is awesome to see. Excellent work!

Also, not going to lie, I'm interested in what the "2016 Legacy 3.6R - STI Tweaked Daily" is like. Do you have a build thread anywhere?

FR-S passed inspection! Florida title in hand.

Car sold, went to Kansas!