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1992 VR4 #71/1000

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Paint (part 1 - body panels)

I was really hoping to get all the body panels painted before the New Year, but this is as far as I'll get before the holiday travels. I got the hood sanded down for primer:
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Then I got all the body panels laid out in the temporary paint booth. Aside from the hood and one of the fenders, each one requires some special preparation attention:
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Also, I got FUBAR back on wheels. The 4-bolt rear end is officially in, so I guess that means the 5-lug conversion is complete too:
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I'm going to be moving across the country pretty soon and getting FUBAR and all it's parts onto one trailer is going to require some work, so expect a bunch of updates in early January that make FUBAR look like a car again.
 
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Intermission - Cross Country Move

I wasn't able to get everything painted before the move and, as a result, progress will suffer for a few months while a get the new garage set up with some of the big tools I sold that will require replacement. However, I got a few small things done and I suppose this exodus from Indiana is part of the FUBAR story.

Out of necessity, I had to install the front and rear windshields. I started by prepping the adhesion surfaces:
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I got some good quality 3M window adhesive and followed other prep instructions. One pointer that isn't completely obvious from the instructions is that the best shape for the nozzle is as shown. It's a shame that I had to buy a second tube to cover an additional foot of glass, but that's how it goes, I guess:
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Finally, I cleaned up the glass, did a test fit, made sure the cups were already installed prior to adhesive application, and did a sort of test run from work area to car:
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Last, but not least, there was the matter of stuffing everything into FUBAR that was required to get it on the trailer. I started by installing the engine and transmission for safe keeping. They'll have to be pulled again, but damn if they don't look good in there:
gbHUhhzuA2OVeyaQBNXuM8vAy8uQMjrnnnKeOc2Vxs1tDgvVfO-JLSM2DjnIopjkvfr_MZbmrp9qVz0W_PQ=w1000-no-tmp.jpg


Then I got FUBAR about as completely stuffed full of parts as one could possibly accomplish; only possible with doors removed:
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Then everything except for the bumpers and lights were added, including weather stripping and some additional tape in anticipation of a little rain along the way:
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Finally, after an hour of wrestling with a Harbor Freight puller wench, FUBAR was ready to go:
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Next update will probably be in a few months. I'm getting married, starting a new job, getting some money back in the bank, and then I'll be able to get the garage set up and start on FUBAR again.
 
Well, after moving across the country, getting married, starting a new job, and getting a little bit of money back in the bank, FUBAR started looking pathetic enough to get some attention. Settling right at home here in Atlanta, FUBAR's first act of territorial marking was taking a dump all over the garage floor. More coming soon :)
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This post will wrap up the intermission section. I'm an extremely particular person, and this extends to my workspace, so I've been spending my project time over the last month or two getting the garage set up just how I want it.

The work started by giving myself some visibility because the lighting in the new garage was terrible. Now's it's like high noon at midnight:
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Next was tool migration. I have no idea how I did it for so long, but somehow I used to store all the tools now in the box on the right in the tiny little guy on the left. I put a coating of truck bed liner on top so I could toss tools on it without scratching it up. Thanks Harbor Freight:
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After that I had to get everything off the floor so I built some shelves in tandem with setting up my air compressor (note the race slicks for my bike, Roadrash... trackday in August at Barber Motorsports park!!! Bike on the right belongs to my wife... I'm a lucky guy!):
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Built a workbench because I don't like working on the floor. The decks are coated with truck bed liner:
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I built some more storage shelves and got the air hose, power chord, and drop light all centrally located from the cieling(ish):
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Set up a welding corner where everything is nice and out of the way when not in use:
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Finished off by getting the rest of the crap of the floor with some pegboard. Pegboard is awesome. I like pegboard:
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Finally finally finally, now that I can stand to be in the garage, FUBAR awaits:
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What gun(s) did you use to spray the primer and paint? Did you have any heat or ventilation in your little paint booth there?

I used an HVLP gravity feed gun from Harbor Freight. The booth was ventilated with fans on either end of the booth. The entire garage is/was heated... guessing mid 70s.
 
Intermission 2 - Another Cross Country Move

It's been well over a year since my last update on this build. Life happens. Career ambitions, time invested in motorcycle racing, poor personal project facilities, the list goes on... but FUBAR has not even been on the radar lately.

Anyway, got another cross country move finished, this time to Denver, CO, and after what will probably be the last time I'll be able to convince my wife not to roll FUBAR into the street with a "FREE" sign on the windshield, I was able to bring the old Galant along one more time. As has been the case for the last couple years, this car is at the bottom of the priority list, but the project isn't dead yet. I'm very hopeful I'll be able to do something meaningful on this car in 2020.

Here's the latest relocation pic and some wishful thinking about getting back to work after the New Year:

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I'm trying to build some momentum on the build again here. FUBAR has been all emptied out, which has twice now been quite a chore. Before:
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After:
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FUBAR's contents in temporary storage:
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I've also started shuffling things around in the garage and making the "must have" repairs to have a useable workspace. That's in process right now, so more photos to come once there's a finished product to show off.
 
Dude please don't give up! You're so much further from when you pulled it out the snow, don't forget all the work you have already sunk into it. I would love to see this project finished!!

Seriously appreciate the encouragement. Support from my fellow DSMers is what's kept the project alive for this long.
 
This project continues to transpire in waves. I wanted to wait to update the thread until after my first vehicle-related update but that's probably another month or so out so I'm gonna throw in some intermediate garage updates.

The garage, as it sat, was a complete mess and also needed significant repair work to the walls. The pictures shown really don't do justice to the extent of the work done. I probably spent a solid 40-50 hours on this. Anyway, here's the baseline status:
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I started with the patchwork on the walls. Lots and lots of sheetrock compound used here:
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Eventually, I plan on going with some nice paint and giving the "dream garage" treatment, but right now the priority is getting to work on FUBAR, so I sealed everything up with some primer to call it good for now:
-Pw04FdsByvHZYnJ7DHypCFDqBT0sAOq7TMbpAWt8-p-DzK59rryZ3w1IA-XgEXXykbcrFdi9kmHJGCi0p3b1VYQ=s979-no.jpg

Now I'm in the process of getting everything organized so that I can actually use my tools. The very first thing after that will be another paint booth for the 3rd time in 3 years.
 
I'm finally about to return to work on FUBAR, which is very exciting, indeed. Leading up to this point has involved quite a bit of final garage prep. Because I'm me, that work snowballed into a bunch of sub-projects.

The first step was freeing up space and organizing all of FUBAR's parts a bit better in the crawl space with some storage shelves made from re-purposed wood:
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Next I moved on to the "Power Pillar" which was iterated on a few times prior to being good enough to work with:
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After that, I made a big lighting upgrade because dimly lit workspaces are terrible to work in:
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Then I went a little nuts with pegboard because I have a thing for organization, and pegboard is great for that:
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After dinging the wall a few times with FUBAR's door, I threw up some birchwood to protect it:
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Finally, I added some wall art with some of my favorite rally cars above the workbench:
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The last thing to transpire before finally returning to work on FUBAR was completing race prep on the Ducati, which could have been its own build thread:
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Unfortunately, COVID has killed the motorcycle racing season but, on the bright side, I won't be waiting until winter to resume work on FUBAR.

To date, FUBAR has now endured: 3 moves, a career change, 3 other vehicle projects, an engagement, a marriage, and now the arrival of my first child. More to come on actual FUBAR work soon.
 
Brake System Engineering

I finally did some ACTUAL work on FUBAR again, for the first time in a long time. Granted, the majority of this work is engineering and Bill of Materials work, but it still counts because it has put a $1000 worth of part on my purchase list about 10 days from now.

I've had more than a few close calls rolling the car around with no brakes and decided that now's as good a time as any to do something about that. I started by pulling out all the old brake parts to take stock of what I have in hand. Junk lines, toasted and siezed calipers, corroded carriers, fried pads, a bunch of mounting brackets, and a seriously tired-looking brake booster:
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After some very general observation, I knew the only safe route for this critically important system was NEW stuff. On the one hand, that can be quite an expense, on the other, it's liberating because I get to choose things that support my needs. At about that time, I put on my engineering hat. I have an old brake design calculator I created in my racecar engineering days that's comprehensive, and it works. Along with a bunch of inertial and effective mass calculations, here's a good visual of the forces considered:
1--qRhh7fR-AUY4wAKQFY7v9Dv6-PjRNG37FXP3sJJqLucPsCxJWNcz4sJ4P50gVSqmbpsfkz0TzTyvh4jQ=w1000-no-tmp.jpg


I'll spare you the dirty details, but after some measurement of various vehicle systems, and consideration of some vehicle dynamics, I finally came up with a few viable options to meet the needs of a loaded Galant VR4 running 315 Hoosier A7 race slicks in an autox setting:
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Ultimately, I decided to go with the Outlander upgrade with a heavy bias toward the front achieved with larger rotors and higher friction pads in front than in rear. This choice should allow me to keep my required pedal forces at a reasonable level, and gets closer than any other option to achieving the front bias required to avoid locking up the rears with each heavy brake application. Also, since this is autox, I neglected brake fade consideration because I have yet to have that problem with other very fast and heavy vehicles on stock+ systems. The duty cycle just isn't really long enough to fade brakes in autox if you have decent pads/rotors/and fluid. Now, all this is good and well, but doesn't mean much if I can't find the right parts to do all this. So I finished up with some research on where and how to get what's needed to build this system and created a bill of materials here:
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So, I've done my homework, I know exactly what I need to buy. Holiday season is fast approaching, which involves other expenses, so I'm waiting until my next credit billing cycle to start purchasing, and will be ordering parts for FUBAR in mid November. Stay tuned to watch me start hacking into the brake system.
 

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Brake System Construction

I finally got some new parts in the mail and did some work on the car. After playing some games having things shipped to a friend in Texas, then here, because Colorado and Rock Auto are currently in a fight with one another, I was able to get all the calipers, carriers, and rotors I needed for the car:
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Bolting everything up was easy enough and, for the time being, the hardware sits on the car as shown:
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But, because this is FUBAR, nothing is ever that simple...
 
The factory lines were completely shot, as were the old aftermarket lines on the car:
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For the flex lines (and pads for that matter), I have stuff in the mail right now from JNZ (damn good company to do business with thus far). However, to "connect the dots", so to speak, I have to get both ends of the system in place, which means starting at the pedals and working out toward the calipers. At this point in the project, I'm sick to death of the wire wheel and brake cleaner approach and decided to make my life infinitely easier with a parts washer upgrade and a serious blast cabinet.

For the parts washer, I started with harbor freight bones, then added a Bosh 044 knockoff pump driven by a laptop converter to handle proper solvent without melting (like the last pump did), added a 2 stage filtration system, welded up the hole where the fishtank pump normally sits, added in a t-valve to toggle between a faucet and a brush setup, and put a closed cell gasket on the door in the event I want to let something soak for awhile:
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For the blast cabinet, once again, I started with the harbor freight bones, but I took my time to seal everything up properly, added a special gasket to the door, upgraded the hopper door gasket, gave myself an additional air chuck and nozzle for blowing things off before pulling them out, and picked up a vacuum off Craigslist to build a proper dust filtration system. I also added a breather vent with a scotchbrite pad in the back to relieve the pressure that builds up because it's now sealed so well and moved the whole mess out to the shed to keep the garage clean and tidy:
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With some proper refurbishment tools put together, it was back to work on the pedal assembly...
 
As with everything on this damn car, the first step tend to be cleanup, rust removal, or both. The pedal assembly was certainly no exception. Assessed the filth on the workbench:
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Tore everything down:
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Did some sand blasting in the new cabinet while thanking myself profusely for making that purchase and setting it up because it was an ENORMOUS time saver:
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Got everything thoroughly cleaned up and dried off:
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Did some priming and painting and then waited 7 painful days for everything to get a full cure:
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Finally, today, I was able to put it all back together:
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Next, it'll be a very similar process for the brake booster so that I can bolt up my new master and start running the lines. More to come soon (I hope).
 
Once again, can't stress how much of a time saver the blast cabinet and parts washer are. If you're on the fence, just go get some... they're awesome.

For the brake booster, from the outside it was looking pretty terrible. It's obvious that the brake fluid sat on that outer surface for quite some time either from a leak or from someone filling the master with sloppy hands and failing to wipe things clean. After washing things off and taking them apart, the functional bits inside were actually all in remarkably good condition so I left well enough alone there, blasted off the rust, whire-wheeled the half with the diaphragm to keep it out of the blast cabinet and free of contamination. Finally, I masked where I needed to and applied some primer and 3 coats of enamel. Now for the long 7 day wait for a full cure before I put everything back together and on the car. I'm hoping the flex lines will be here by then so I can start routing the hard lines:
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