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.