First Update in a While

So it has been quite a while since I've updated our progress. That definitely doesn't mean we haven't had things going on. Since the last update we have:
-replaced a broken shift cable to the tune of $185
-poured solid urethane motor mounts
-finished the bushing installation
-replaced the broken passenger headlight motor
-discovered we had a bent front wheel
The car is getting a roll bar this week in preparation for VIR North on May 16 and 17th!

Things to do before that weekend are:
-flush brake fluid and buy good pads to swap in at VIR
-get an alignment and tech inspection
-still need to make sure we do not have an active oil leak (the engine area is just real dirty, and I'm not convinced its just old road grime)
-get the bent wheel swapped out (straight used wheel is sitting in my garage)

Prothane Bushings - Rear Installation

What should have been a relatively simple install turned into quite an ordeal. I started with the rear suspension only, taking off the control arms and strut rods to put in the new bushings. That was easy enough, and I got one of the new strut rod bushings back in. However, getting the other two old bushings out was not so easy. I tried all the tricks I found online and could not get them to even budge. So I took it to a machine shop and just had them pressed out - more expensive than it should've been, but you can't win them all right? Then getting the pieces back on the car was more complicated than anticipated as well, until Jeremy pointed out we could loosen one of the strut rod bolts to get the flex we needed to line up the last bolt. Next time it will be lightning fast! The real fun was yet to start, as when we were torquing down all the bolts, the two bolts holding the ball joint to the hub decided to strip the threads on the hub. I swear the torque wrench couldn't have been more than a quarter turn away from clicking to 83 ft lbs and we would've been done. Instead the bolt just started spinning, oh joy. After much debating and some discussion with our Dad, I went to look at taps to rethread the bolt holes. Metric taps are nearly impossible to find, unless you buy a whole $50 to $60 set. I also didn't really want to jump all the way to a 14mm bolt from the 12mm that was OEM. Too much material to take out of the hole. A 1/2" hole is 12.7 mm, so I decided to give that a shot. I found a 1/2" tap and handle at Lowes for under $20, and bought new bolts and washers to match the new threads. Wound up costing me $16 with a coupon. To get the tap and handle enough clearance to work, I had to take the ball joint back off the car, and swing the hub out away from the LCA. The threading went good actually, slow since you have to clean out the hole and tap every couple turns though. Then I went to reattach the ball joint to the hub, using the new bolts and threads. It was amazingly smooth (i guess new threads and bolts would do that for you) and it did torque down to the required 83 ft lbs. I test drove the car around a bit and everything is fine. I did also find a small tear in the inner axle boot, which I patched with bike tire sealant - it seems to be holding so far, but I will definitely check this often.