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Project GC8: Taking Care Of Business With ST Suspensions

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Project GC8: Taking Care Of Business With ST Suspensions – Speedhunters



Project GC8: Taking Care Of Business With ST Suspensions

Welcome to another instalment of Fixing Broken Old Japanese Cars On My Driveway.

On today’s episode, we’ll be swapping out a set of old Cusco coilovers for a set of brand-new ST Suspensions XTA items. And because there’s a list of things to do as long as my arm, I’ll be tackling each one individually until Project GC8 – my 1999 Subaru Impreza WRX Type RA 555 Limited – is where I want it to be. Even if that means doing them in a non-traditional order.

I’ve been a Speedhunters contributor for nearly a year now, and in addition to hunting down all the raddest cars (and meeting some fantastic people along the way), it’s also exposed me to some of the coolest products, upgrades and tech available on the market. Which is dangerous when you’re embarking on your own project.

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One of those is ST Suspensions, whose parent company happens to be KW Automotive. And we’re all familiar with the incredible work KW does when it comes to making cars handle infinitely better, be that for road use or motorsport.

How does ST Suspensions fit into this? Well, ST Suspensions are like an entry-level point into KW. They still boast quality and handling improvements, but at a more affordable price for a wide selection of vehicles. Plus, when you’re ready to delve into the world of high-performance or track solutions, you can easily make the jump to KW.

You might remember from a previous update that I took the Impreza on a five-hour road trip up to Nagano recently, so the idea of a 2-way motorsport-specific kit might be slightly wasted on my daily. One thing did stand out from this trip however: the old Cusco coilovers fitted by a previous owner performed as well as they looked. Terrible.

The rebound adjusters were either seized or spinning freely, meaning there was no way to tell what setting they were on. If I had to guess, I’d say the fronts were set for time attack and the rears to try and mimic a Toyota Century. The whole car felt completely different at each corner.

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Thankfully, ST Suspensions had the perfect solution in the form of their XTA coilover kit. This is one of their top-of-the-range solutions which boasts ride height adjustment and rebound as well as camber-adjustable top mounts. But what made this kit particularly special was the customization ST currently offers on all their coilover kits.

Not only could I choose a custom spring colour, but also a neat little message which would be printed on each spring. Have a little scroll down to see what I went for; it seemed fitting given this particular car and the questions I’m usually asked about it.

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Yup, that’s cherry blossom pink – the iconic STI colour. And a little text to remind myself that this project is very much being built and not bought.

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Why choose ST over KW in this instance? Well, the ST XTA coilover uses the damper technology and components as found in KW coilover kits. They’ve even built in the same factory. But there’s two main differences – the materials being used and the price, with one of those directly affecting the other. KW units use a full stainless steel strut, whereas ST ones use galvanized zinc-coated steel to bring the price down – perfect for a project like this.

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With all my parts and tools ready, I set aside a day to remove the old Cuscos and install the new ST XTA units. I have limited experience fitting coilovers, but failure to prepare equals prepare to fail.

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Needless to say, as I unbolted the old coilovers something strange happened. All the bolts came loose… with no rounding. No threading, seizing, nothing. Each coilover emerged from its housing with no bloodied fists, and I held each up into the sun like Simba in that scene from The Lion King.

There’s a good reason for this. Firstly, it’s a clean Japanese car. Secondly, it’s never seen a salted road. The engine may be in need of love, but the rest of the car has been looked after meticulously and not subjected to a life of grime, salt or mud. The last Subaru I changed coilovers on was my Forester STI – a Japanese import that’d spent a year in the UK. You guessed it, that process was the polar opposite to this one.

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With the old units out, I gave the hubs a quick clean (as well as the top mounting points) ready to offer up the ST XTA units. The fit is perfect; no need to cut or adjust anything even to get the camber-adjustable top mounts in. I nearly fainted, although that might have also been the 30+°C weather.

The only downside was the clearance for the Cusco strut brace, but it’s a small price to pay for otherwise perfect fitment both at the top and into the hub too.

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It kept getting better, too. With the ST units firmly in place, I could connect the brake lines and ABS sensor in the provided tabs. No messing, no need for cable ties – just perfect integration with the OEM clips. You’ll have to excuse my surprise here, but that’s what a lifetime of car tuning does to you. A simple, easy fitting process shouldn’t be a surprise, but it’s a welcome change, especially when embarking on the install yourself.

The rears? Exactly the same story. The STI top hats I purchased fit perfectly too, slotting snugly around the damper piston with a satisfying click, the springs firmly held in place with a billet aluminium centering piece. Everything went together as if it were OEM.

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To get a basic height, I took measurements off the old units and set the ST XTAs to what I thought would give a similar height. Compared to the heavy, seized spring perch of the Cusco ones, the ST springs move freely meaning ride height can be adjusted in seconds.

As an added bonus, the ST XTA spring perches are made of a friction-optimised polyamide composite material with a stainless steel insert. Sounds jazzy, right? Essentially, that prevents any corrosion occurring between the spring and the strut body. Technology passed down from the halo KW range.

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Once I set the front and back heights, I took a step back to see how the car sat. The fronts were a bit low and the rear far too high. No issues however, simply jack it back up, wind the springs down and continue until happy.

It’s difficult to see in the photos, but the rear wheels have positive camber due to the ST XTA lower hub mounting tabs (which are more in line with the OEM shape) versus the old Cusco units which increased camber. It’ll need proper alignment and setting anyway, so this will get resolved later on.

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I’ll get on to that once I’ve got the rest of the mechanics and bushings up to scratch. Remember that list I was telling you about earlier on? Yup, it’s a big one. And I’ve just added a wheel alignment to it, but it’ll be absolutely worth it in the end.

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Even with my limited tools and experience, it’s been a properly rewarding process fitting my Impreza with this XTA coilover kit. What I anticipated to be a pig of a job turned out to be super easy, and it won’t be long until the fun really begins.

I say that, because on the next episode of Fixing Broken Old Japanese Cars On My Driveway I’ll be pulling out the EJ boxer engine, breaking it open and (attempting) to replace the internals. On my kitchen table.

The anxiety is already kicking in, but until then it’s time to go put some more miles on Project GC8.

Toby Thyer
Instagram _tobinsta_
tobythyer.co.uk

The SH Garage on Speedhunters

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SH Garage: Pushing The Limits Of Project GC8

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SH Garage: Pushing The Limits Of Project GC8 – Speedhunters



SH Garage: Pushing The Limits Of Project GC8

The Purchase

There are two ways in life: the quick way and the long way. If we use food as an analogy to unfold this deeply profound philosophy, the quick way is Uber Eats and TV dinners, while the long way is slaving over a hot stove while following a Michelin-star chef’s recipe and feeling a real sense of achievement when belts are loosened at 9:00pm.

Almost everything in life is better when we take the time to savour the moment and really put in the hard yards. It allows us time to make plans, contemplate outcomes and work out how to get there. It also helps to eliminate any chance of things going wrong, although, Sod’s law dictates that something will always go wrong. Bracing for the inevitable, the best we can do is take it slow and do it properly the first time.

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As they say, if something’s worth doing, it’s worth doing right. These profound words of wisdom also ring true when it comes to building cars. And when it comes to modifying or repairing our pride and joy, the stakes are a little higher.

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I’ve learnt my lesson in the past, rushing things with my project cars and ultimately making them worse. This one will be different, or at least that’s the plan.

As is often the case with rare old cars, my GC8 was at the other end of the country, which meant I bought it sight unseen after a late-night, Asahi-fuelled Yahoo! Auctions Japan bidding battle. Win!

To be fair, the car was very true to its photos and listing blurb. Mostly. The body is straight and paint the is excellent, but unfortunately some specifics were omitted from the mechanical description. The ad stated: “engine runs fine with no problems, but 3rd gear sometimes pops out.”

The latter part of that statement I could deal with, because a 6-speed swap from a newer GD series STI was on the cards regardless. But the first half of that statement did not really tell the full truth. While the engine did indeed run fine, boosting nicely and not leaking oil from every orifice, there’s a subtle rattling sound coming from deep within.

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I’m generally a pretty trusting guy, and even more so in Japan where I stupidly think that people are 100% trustworthy and honest. Because of this I didn’t really listen carefully to the engine when I collected the car, and with a photoshoot to get to I simply drove my auction win away into the sunset.

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After the shoot I stopped to take some pics of the new car, and in the quiet of the night it was soon obvious that the engine did in fact have a problem. By the time I emailed the seller, I was told “I didn’t hear anything, why didn’t you say something?”

Honestly, I’m actually at peace with the whole thing and looking forward to replacing the engine’s innards soon. Considering how much I won it for at auction, I’m pretty happy anyway.

The Trip

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Before I start pulling the WRX apart and replacing everything, I wanted to see what the weak points of the car are. A visual inspection would have probably been enough, but where’s the fun in that?

When I headed to Nagano Prefecture for an event recently, I had two choices: take the toll roads and get there in two hours, or take the scenic route and get there in five. Obviously, I decided to go the long way and make a kind of touring holiday out of it. It would be a good opportunity to just enjoy the car before it goes in for surgery. After all, taking things slow is my new zen, remember?

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Pushing the plucky little Impreza through the twisting mountain roads, it was easy to imagine how McRae and Burns must have felt on WRC tarmac stages. The sparse interior allows a direct connection to the outside world; the rush of the wind, growl of the motor and gentle pssshhh of the turbo blow-off valve make every corner a delight.

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And boy, there were a lot of corners.

Taking the scenic route means leaving Kanagawa Prefecture, going past Mt. Tanzawa and heading into the highlands of Yamanashi Prefecture. From there it’s a couple of hours driving through the Minami Alps past Mt. Kita (Japan’s second largest mountain after Mt. Fuji) and Mt. Aka until finally arriving in Nagano Prefecture where Nagano City has an altitude of 371.4m.

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Even though I had an evening photoshoot to get to, I could not resist stopping at what seemed like every mountain pass to take photos of either the car, the road or the view. It’s a trip that I won’t forget any time soon. A soak at one of Nagano’s local onsen was a welcome respite from the day’s drive.

The Test

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This isn’t the first road trip I’ve had in Project GC8. Some of you may remember I that I drove it home from Tokushima, a 12-hour trip, if not you can check out that story here. What I didn’t tell you was that, because of the aforementioned engine issue, I babied it, keeping revs under 4,000rpm for most of the way.

That’s why this trip was so much fun. I just stopped worrying about things and just enjoyed the drive. Knowing that I’d be replacing most of the engine, I wound down the windows and removed the exhaust silencer which drowned out the mild-but-ominous ticking from under the hood. I wanted to see how the suspension components had held up after years of track use. I was never going to really lean on it, because I didn’t want to be stuck on a mountain with a conrod lodged in my radiator, but I could at least hit boost every now and again and focus on the handling.

Admittedly, to really test the limits of an Impreza, it really needs to be driven on a track, but with very few cars on the road, I was able to attack the tight corners of these mountain roads with enough vigour to get an idea of how things are holding together. Surprisingly, the tired and worn Dunlop Direzza tires did a pretty decent job keeping grip.

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Less surprising was the lack of body roll through these corners. The Cusco half cage and strut tower braces make the chassis and body very tight indeed with little-to-no flex. Steering is direct and basically the GC8 will just go anywhere you point it. However, left-hand turns induce an irritating squeal from the steering pump and right-hand turns invokes a lovely whir from the front drive shaft, or somewhere in that vicinity.  

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Once I started pushing the car through some serious corners it became obvious that each side of the car was handling differently; the left side hard and the right side soft. When you’re driving a car renowned for its balance and low center of gravity, having mismatched coilovers is like Usain Bolt running with a trainer on his left foot and a stiletto on his right.

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The Verdict

Overall, despite the elephant in the room (or in the cylinder block), the little Impreza is in good structural and cosmetic condition and is an absolute joy to drive. It’s a very direct, visceral and sensory-tickling experience which will only improve with some attention to its worn parts.  

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As I’ve said before, these cars were never built from the factory as rally cars or track weapons. Basically, they were sold – especially in the case of the Type RA – as a base car for works teams, privateers and hobbyists to build into race cars as they deemed fit. Subaru were not, and still are not, a big company compared to the likes of Nissan and Toyota, so manufacturing costs had to be kept low in some places to make any profit. Considering that 99% of this car is stock, I think it’s held up pretty well.

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Half of the modifications it does have are inside the cabin. There’s a Sparco bucket for the driver, HKS boost meter and a Lamco triple gauge set, a Momo wheel and of course an ETC reader who reminds you to insert your card every time you turn the key.

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Being a Subaru, this one, like most, has lived a colourful life, and it’s been setup for light track work and spirited road driving. It came with some extra goodies, those I’ve mentioned already plus a Cusco rear diff brace and master cylinder stopper, as well as Endless brake lines and pads.

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The weak points are definitely all the bits made of rubber. After 22 years and 170,000km it’s safe to say all the suspension bushings need replacing with OEM STI items. The engine, gearbox and rear diff mounts could all probably do with being upgraded to poly bushings too. Further inspection found a ripped open steering rack boot.

The Next Step

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So, what’s next? Well, like a newlywed couple planning their honeymoon weekend away in Tahiti, I’m busy planning the purchase of all the new internal parts for the EJ boxer engine. It’s all very exciting, although I’ve never got as far as a honeymoon so I can’t compare.

The Cusco coilovers have to go because they have either not been looked after or have just given up the ghost of their own accord. Thankfully, one of Speedhunters’ fantastic Official Suppliers has stepped in to help in this department, and I look forward to bringing you that story in due course.

Toby Thyer
Instagram _tobinsta_
tobythyer.co.uk

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Editorial Director:
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Commercial Director: Ben Chandler
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Contributing Editor:
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Contributors: Will Beaumont, Keiron Berndt, Jordan Butters, Ron Celestine, Mario Christou, Cian Donnellan, Matthew Everingham, Blake Jones, Stefan Kotze, Vladimir Ljadov, Paddy McGrath, Rick Muda, Sara Ryan, Trevor Yale Ryan, Dave Thomas, Toby Thyer, Simon Woolley, Naveed Yousufzai