coolhandluke 2013 BRZ Rebuild - HPDE

[coolhandluke]

Introducing rebuild #15 by Dave-ROR and Opie, my new track car, a 2013 BRZ Limited with 64k:





First wash:



Odometer:




Opie quickly got to work replacing front core support:
















Replacement hood & fenders:



Initial fitment prior to paint:






BOM for front end rebuild:
* Used hood
* Used fender
* New fender
* New 2017 front bumper & grille
* New 2017 fog lights
* New 2017 L/R fog light surrounds
* New 2017 headlights
* New windshield
* New left headlight bracket PN 57707CA012
* New right headlight bracket PN 57707CA002
* New T-brace PN 53029CA0219P
* New left support PN 53029CA809P
* New right support PN 53029CA709P
* New Rock Auto front corner light set

forman inspecting:



Back from paint



Fog light surrounds installed:


Fog lights installed:


Front end - final assembly









New windshield




Engine Swap - BOM
* 2015 engine with ~50k
* 2015 coilpacks
* 2015 engine wiring harness
* New spark plugs
* New serpentine belt

Engine out:



Donor engine out:



~50k donor engine ready:





Oil cooler & Radiator install:



BOM:
* We Don't Lift Racing, Perrin Oil Cooler Kit PN# PSP-OIL-113
* We Don't Lift Racing, CSF Aluminum Radiator PN# CSF7050

Take away, I would recommend the oil cooler kit from Jackson Racing over Perrin. The mount points for the oil cooler are a better design.











Interior:

This car will be driven on the street so it was important to source replacement airbags. Opie went above and beyond with cleaning and reinstalling the interior.

Removing interior & cleaning:












Next up, brakes & suspension installation by Dave-ROR.

[coolhandluke]

Brakes BOM:
* Essex Brakes Sprint competition BBK: https://www.essexparts.com/essex-des...0299brzfrsgt86
** Essex Brakes, AP Racing CP8350 four piston calipers
**Essex Brakes, 299x32mm, 60 vane AP Racing disc
** Essex Brakes Front pads, Ferodo DS1.11
** Essex Brakes Front pads, DS2500
** Essex Brakes Rear pads, DS2500
** Essex Brakes Spielger SS Brake Lines
** Essex Brakes fluid, AP Racing Radi-CAL R2
*APR Studs, PN 100-7716

This BBK is custom designed by Essex for any GT86 and tested for the track. My prior track car, a 98 ITR, had a BBK, and it was important to maintain high quality braking capabilities and heat resistance during extended track days for both 200tw & rcomps.

I also liked how this BBK was designed to work with existing OEM brake master cylinder and ABS. This kit also shaves 20lbs of unsprung weight.


Credit to Dave-ROR for this section of work.

APR studs:



Removing OEM studs:



I was delighted to here this process is much easier on the GT86. Honda platforms require also replacing the wheel bearings for extended stud installs.


Essex Brakes BBK, SS lines, and studs, etc:






Wheels and BBK:

[coolhandluke]

Projects - Next up:
1: 2022 front AL hubs
2: OS Giken clutch LSD + Diff bolts + bearings + Motul fluids
3: 2017+ or aftermarket HU for CarPlay
4: Essex Racing BBK upgrade

[Dave-ROR]

After a title issue from hell (f$ck you Copart!) this car actually has a title and is legal! Might be on track at Sebring soon.. or in Cali.. depends on @coolhandluke laziness level.

[coolhandluke]

Originally Posted by coolhandluke

Projects - Next up:
Projects - Next up:
1: 2022 front AL hubs
2: OS Giken clutch LSD + Diff bolts + bearings + Motul fluids
3: 2017+ or aftermarket HU for CarPlay
4: Essex Racing BBK upgrade

Project updates:
2: OS Giken SLD - @Opie helped secure new OEM diff bearings. This was a ~3mo backorder but both have arrived.

Track updates:
*Booked Sebring event with Chin Motorsports in December with @Dave-ROR & @Opie

[coolhandluke]

Project Updates - #1 2022 front aluminum hubs:

After researching on Essex Racing's site, I've learned the '22 AL hubs require more work than a simple caliper bracket:
https://www.essexparts.com/toyobaru-...s-gen1-vs-gen2

If you add the Gen.2 BRZ aluminum knuckles to your car, our original Gen. 1 299mm or 325mm systems will not fit! You will need our revised CP8350/299mm Kit #13.01.10153 or CP8350/325mm Kit #13.01.10147....

If you had our original CP8350/299mm Sprint Kit #13.01.10005 or our now discontinued CP8350/325mm Endurance Kit #13.01.10006, it will NOT fit on your new 2022 BRZ. Our advice would be to sell your old kit complete on the used market.

This has lead to me considering selling the AL hubs and leaving the car as is or go forward with a new BBK that matches the '22 hubs. It doesn't hurt that Essex Racing starting a Black Friday sale today and they released new GR86/Gen2 '22 kits last week.

[coolhandluke]

PSA - Essex Racing's Black Friday sale continues:
https://www.essexparts.com/aftermarket-products

Project Updates - #1 2022 front aluminum hubs

I have leveraged a sale above to replace my existing Essex Competition Sprint BBK for the Gen 1 hubs to a Gen II hub BBK, so project #4 is officially on the list. I will be posting this lightly used BBK for sale once I complete the upgrade from the Competition Sprint kit:https://www.essexparts.com/essex-des...0299brzfrsgt86

@Dave-ROR and I will update as we confirm wheel clearance. This kit will clear Gen II OEM 18'' wheels but unsure on my existing Enkei RPF1 in 17x9 +35 wheels. I'll post updates as I'm able to to install.

[Racecomp Engineering]

Please document your hub conversion.

I know there's good info from a Japanese source but more would be appreciated.

- Andrew

[coolhandluke]

Originally Posted by Racecomp Engineering

Please document your hub conversion.

I know there's good info from a Japanese source but more would be appreciated.

- Andrew

I will as I'm still learning the mechanics of Gen I/II hubs myself, as I come from two decades in the Honda world. I hope to start testing next weekend.

[Racecomp Engineering]

Originally Posted by coolhandluke

I will as I'm still learning the mechanics of Gen I/II hubs myself, as I come from two decades in the Honda world. I hope to start testing next weekend.

This is the link I was referring to earlier...might help.

https://minkara.carview.co.jp/smart/...4954/note.aspx

- Andrew

[coolhandluke]

Originally Posted by Racecomp Engineering

This is the link I was referring to earlier...might help.

https://minkara.carview.co.jp/smart/...4954/note.aspx

- Andrew

Oh nice find.


Project updates, @Dave-ROR & @Opie educated me today and helped with BBK vs. wheel clearance.

Project 1 Update: 2022+ Aluminum hubs, parts required:
- Front Hub assembly (includes studs) PN: Subaru 28373CC000 2x (same PN per side)
- Front Hub - Axle Hub Mounting Bolt PN: Subaru 28376SJ000 8x (4x per side)


Project 4 Update: Essex 355mm BBK
-Enkei RPF1 17x9 +35's do not clear
-I've reached out to @Apex racing parts with the Essex Wheel Clearance Template since they sponsor the forums.

Updates from Essex Racing on wheel clearance:

Originally Posted by Essex

CONFIRMED WHEELS THAT FIT WITHOUT A SPACER:
-OEM 18" 2022 BRZ
-APEX Arc-8 17x9, ET 35 (very close fit, make sure you have 2mm clearance)
-APEX EC-7R 18X9.5 +40mm

CONFIRMED WHEELS THAT REQUIRE A SPACER AND WILL NOT FIT WITHOUT ONE:
-APEX EC-7R (17x9, ET35) - very close but will require a few mm

[coolhandluke]

Project #4 updates thanks to @Apex on the new @Essex 355mm BBK:

Wheels that clear:

CONFIRMED WHEELS THAT FIT WITHOUT A SPACER:
-OEM 18" 2022 BRZ
-APEX Arc-8 17x9, ET 35 (very close fit, make sure you have 2mm clearance)
-APEX EC-7R 18X9.5 +40mm
-APEX VS-5RS 17x9 +35mm

[JRitt]

Originally Posted by coolhandluke

Project #4 updates thanks to @Apex on the new @Essex 355mm BBK:

Wheels that clear:

CONFIRMED WHEELS THAT FIT WITHOUT A SPACER:
-APEX VS-5RS 17x9 +35mm

Thanks for that addition...our site has been updated.

[Dave-ROR]

No one ever posted a brake/wheel update.. I'm sure ryan is working on it but for proof that the VS-5RS 17x9 +35 wheels from @APEX Race Parts fit the humongous brakes from Essex / @JRitt ....



IIRC my EC-7Rs in 17x9 +35 technically fit also.. but if they did it was way too close to actually run... but a spacer should, in theory, make it work.