S60R Rebuild

This is what i've been working on lately. Some of you might have seen my thread on SS, but i'm going to copy it over and continue it here.
 
Never rebuilt a car before but decided to fix this S60R I bought at auction. At first it seemed like a simple fix..  lets just say i've learnt a lot from this one.
 
I picked up a cheap crashed 05 S60R 6MT in May at auction. As far as I could tell, the damage is limited to the right rear quarter, wheel, door, and upper control arm. The passenger curtain airbag also deployed and the dash is displaying the airbag urget message.
 
I have already replaced the airbag and have a replacement upper control arm. I figured that if I could swap the control arm, the car would be driveable and would allow me to finally decide whether or not i'm going to continue with the body work or just part the thing. Currently i'm leaning toward fixing it and just driving the piss out of it. I love the color combo (magic blue on atacama) and am interested to have a P2 to tinker with.
 
Initially I didn't realize that the rear subframe would need to be dropped, but the job doesn't look too bad.. I say that now.
 
Does anyone have any tips before I dive in?
Drop the cat-back
Disconnect driveshaft/electrical connector(s)
Rear brakes/ebrakes/cables
ABS sensors/lines
Disconnect lower shocks
Evap lines
Drop subframe
 
and couple pics.

 

 

 
 
 
Well, things went very smoothly despite not having a lift. A few small quirky things that weren't noted in the instructions I printed out, like where the active chassis connector is located and that you need to lower the gas tank to snake it out. You can certainly see the engineering improvements over the p80 chassis cars though. I couldn't belive how easy it was to get the exhaust off/on.
 

 

 

 
Out with the old

 

 

 
New arm in and subframe reinstalled.

 
Back on her feet.

 
I only got to drive up to the end of the road, but so far so good. No funny noises or vibrations. I did notice some rubbing on the front tires on hard turns. Car came with Pirelli snow tires 235/40R18. I just picked these up for a decent price and will throw some summer tires on. Just waiting for my bro in law to bring them out from Calgary.
 

 
Body work is next, but i'm having a buddy do that. I found a rear pass door and rocker panel in 467 Magic blue.
 
 
 
 
 
But of an update..
 
I gutted the interior, scrubbed and hosed off all the carpets and conditioned all the leather.
 

 
The front of the car had a protective coating put on some time ago, which was starting to look like dog stuff. With a heat gun and some patience, I was able to get it all peeled off. It seemed to have done it's job because the headlights and front bumper etc. look great.
 

 
Got my door and rear quarter from an 07 S60 2.5T which also has the painted door trim etc.. paint code 467. The door handle was chrome and the glass not tinted, so I swapped those parts over from my old door. The R speaker is obviously far better so I swapped that over too.
 

 

 
Then it was off to the body shop..
 

 
I dropped it off on the Thursday and it was done by Monday.
 

 
Next I had to take the interior down to the shop, get it all installed and then reset the airbag light and any other codes that popped up from being driven to and from the paint shop half stripped out. Since it was a write off, it has to have a frame inspection, alignment and then provincial inspection before I can register it in BC and insure it. The only way it can be driven from shop to shop is with a "repair man" plate.
 
Ever seen a P2 atacama interior in a laser blue 2000 V70R?
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Voila..
 

 
Got new all seasons for the spare set of pegs..
 

 
And now for the bad news....
 
I get all done with the car, send it to the frame shop and go get the new all season tires mounted so I can swap the wheels over when I get the car back. I just get home, crack a beer and think to myself how great tomorrow will be when the car is insured, new wheels on, give it a good wash.. and then phone rings.. it's the frame shop and there are some major issues. Rear subframe is bent and probably some of the rear passenger side suspension. He did try and pull the subframe forward on the right side, but with it being aluminum, it wouldn't come to within spec.
 
After the initial shock, several more beers and a restless nights sleep, I figured I was too deep to cut my losses. I was able to source a used rear subframe, left and right rear suspension, hubs, shocks, springs etc.. from an 07 S60R with 62k miles that was hit in the front. $525 Which isn't too bad, and my rear shocks are leaking anyway, so i'm hoping that these should be in better shape since they have half the k.
 
The parts should be here next week, and then the work begins again. Since i've dropped the rear subframe once, it should be much quicker this time around.
 
How she currently sits in my driveway...
 

 

 
 
 
The replacement subframe, suspension and spindles etc.. arrived so the work begins again.

 
Had the old one out in no time.

 
Front bushing on the passenger side. You can see how ovaled it is and there are even intentations in the bushing sleeve from the bolt threads when it got hit. This pushed the front arm of the subframe back, causing the rear wheel to be cocked out slightly. I don't know why I didn't pay closer attention to this when I had it out the first time. Lesson learned.
 

 
Replacement subframe

 
Pulled apart the old assembly to get the rear diff and axles out. Then lowered the replacement subframe into position to install. Much easier to work at waist height than on the floor.
 

 
As it stands, I have the suspension and diff/axles/hubs all swapped to the new subframe and it's bolted back to the car. Just have to left each side with a jack to the "normal position" and then torque it all down before I can install the ebrake cables, rear brakes, exhaust and reconnect the driveshaft.
 
The plan is to have it towed back to the frame shop on Monday and be driving it by mid next week.
 
Also have a new aux belt tensioner on the way since it's almost shot and sounds terrible.