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Guest Message by DevFuse
 

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84 4WD Wagon new daily driver with future EJ swap


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48 replies to this topic

#1 LeoneTurbo

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Posted 25 June 2010 - 03:32 AM

Two weeks ago I bought this 1984 EA81 Wagon 4WD. It is in decent shape, but I want to replace the outer sills with custom made ones out of thicker, better quality steel. Besides that, it needs some welding on the rear wheel arches and a new paint job as my wife doesn't like the Moss Green.

It has a few nice factory options like power steering, electric mirrors and a 3.889 rear plate LSD!

I will register the car next week and once I got the plates and pass the road worthiness test I will start work on it. Things to do:

- body work (see above)
- EJ engine swap and install LPG (Liquified Petroleum Gas) fuel system
- EJ AWD D/R 3.900 5-speed gearbox swap
- EJ series front hubs/brakes and rear Cross Bred 5-lug disk brake kit
- install dash with extended instrument cluster
- find beige Forester seats
- finish chrome bumper swap

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Edited by LeoneTurbo, 29 June 2010 - 07:14 AM.


#2 ShawnW

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Posted 25 June 2010 - 08:57 AM

Cool car. I personally love that color.

That rear differential is awesome. I have never seen a Subaru of this era with that gear ratio let alone an LSD unit.

#3 baccaruda

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Posted 25 June 2010 - 09:45 AM

3.889? Is that metric or something? :grin:

#4 LeoneTurbo

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Posted 26 June 2010 - 01:47 AM

That's what I wondered too :)

I'm sure it will work just fine with my 3.900 EJ-box as the ratio is only 0.3% off.

I was amazed it had that plate diff, I didn't even notice it until I was driving behind it on the way home from picking it up, there was a shiny sticker on the diff...

:banana:

I bought a bunch of new spares from an ex-dealer and they also gave me the original showroom colour cards so that makes it easier to pick a colour. We're now debating either Extra Black (code 74) or Reef Blue (code 46) for the paint job.

Edited by LeoneTurbo, 26 June 2010 - 01:50 AM.


#5 LeoneTurbo

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Posted 28 June 2010 - 06:21 AM

Awaiting presentation of the car for registrattion, I modified the instrument cluster I'm planning to install:

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I removed the speed sensor signal thing from the unit Jim (ruparts) kindly sent me, and installed it on the European speedo. I need the speed signal for the JDM engine ECU I'm going to use.

New updates and pics will follow.

Edited by LeoneTurbo, 29 June 2010 - 07:14 AM.
Link to pics updated


#6 LeoneTurbo

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Posted 29 June 2010 - 07:15 AM

The finished cluster with 180 km/h speedo with speedsensor and tachometer with ECS lamp:

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#7 LeoneTurbo

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Posted 13 July 2010 - 02:24 PM

First relevant upgrade done: master cylinder of a 1993 Legacy:

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Still have to bleed the brakes and modify the sensor/connector for the brake fluid light.

Now all I have to do to pass the annual road worthiness test is swap the exhaust manifold as it's got a few holes. Oh and the clutch is almost gone but that will have to wait for the EJ swap.

#8 LeoneTurbo

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Posted 05 August 2010 - 12:41 PM

New update... The brakes are fine now, right front CV has been swapped but the 'new' one also clonks :grin:

I picked up a free set of coil over Bilsteins (off a 2003 WRX) which had a broken spring. They are the PS9 version which means they are adjustable. The dampers themselves seem to be fine still. I'm calculating spings which fit the weight of the car better and make them not so harsh... Obviously, I will only be using the front struts. I expect my second hand adjustable top mount to arrive in the next few days so I can modify it to fit the standard 2-bolt pattern on the body.

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Another update is a contemporary steering wheel... The boss I bought new in Japan, the steering wheel off Ebay Germany. I already started sanding it as it was slightly worn but that is a hell of a job - so that will take a while. I want to stain the wheel slightly darker brown/mahony before applying new layers of clear coat.

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#9 Gloyale

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Posted 05 August 2010 - 12:54 PM

nice car.

My favorite color for that body.

Shame you are painting it.

#10 GeneralDisorder

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Posted 05 August 2010 - 01:23 PM

Looking really nice BTW. That's a really neat EA81 with some special features it looks like.

Curious - is the source for those steering wheel adaptors still around? We in the states might like some if you can get them or point us in the right direction?

GD

#11 variant13

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Posted 05 August 2010 - 01:44 PM

I'm so sorry I've been out of touch! I just spent two weeks in Flanders, it would have been a hoot to meet up with you and check out the Rad Roo!

J

PS - probably my favourite factory colour, too!

#12 LeoneTurbo

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Posted 05 August 2010 - 02:11 PM

Looking really nice BTW. That's a really neat EA81 with some special features it looks like.

Curious - is the source for those steering wheel adaptors still around? We in the states might like some if you can get them or point us in the right direction?

GD

I bought it from Yahoo Japan Auctions, I get parts via Japan Auction Centre. They are readily available new.

#13 LeoneTurbo

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Posted 27 August 2010 - 01:30 AM

So I recently purchased the following parts for this 'project':

- EA81T air filter housing
- EA81T front cross member
- EA81T fuel tank
- EA81 a/c evap unit

I also started working on the engine for this car, and the plans have changed a bit since I first started this topic. From a n/a EJ20 SOHC to this:

- EJ20 open deck crank case with oil squirters from a JDM STI Version 1
- EJ16 short throw crank and long rods (rod/stroke ratio is 2.05)
- 48mm ACL Race rod bearings
- EJ20 n/a pistons with new rings

The shortblock is assembled and ready for the heads:

- EJ22T USDM heads with Delta 220 cams
- STI Version 3/4 metal cylinder heads (11044AA463)

Calculated compression ratio is 8.4, which is (almost) perfect for the small(ish) TF035 turbocharger I will be using on the engine (available on AUDM and EUDM Forester S-Turbo or 2.0XT EJ205 engine, developed 177 hp and 175 lb-ft on really low boost). Engine management is nothing fancy: a JDM ECU from a 1998 WRX Wagon. With a TD04 it developed 250 PS and 225 lb-fit on a 2L, so my 1748cc engine (bore 92, stroke 65.8 mm) will give about 190 PS.

Edited by LeoneTurbo, 27 August 2010 - 01:58 AM.


#14 Allouez

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Posted 28 August 2010 - 12:54 PM

Great-looking car. I love the color too, but it should be fun painting it.

#15 LeoneTurbo

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Posted 04 September 2010 - 11:31 AM

OK so I stripped the car for welding and painting, found three nasty rust spots:

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Last pic shows how the car looked when I drive it to the workshop. Quite noisy without carpet and any weatherstrips!

Keep you posted.

#16 Firespray401

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Posted 05 July 2011 - 12:30 PM

Bumpity. What's the latest on this gem? :banana:

#17 LeoneTurbo

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Posted 23 July 2011 - 04:57 AM

This:

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#18 92_rugby_subie

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Posted 23 July 2011 - 05:19 AM

Wow! Nice clean choice in color!

Looks like you covered the rust areas very well!

Cant wait to see more progress, will subscribe!

#19 GeneralDisorder

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Posted 23 July 2011 - 07:24 AM

I bought it from Yahoo Japan Auctions, I get parts via Japan Auction Centre. They are readily available new.


Interesting indeed - think you could point me to an auction for one of these? Is that a Momo pattern?

GD

#20 LeoneTurbo

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Posted 23 July 2011 - 09:14 AM

I'm actually not using that steering boss so you can have it if you like, 10 US$ plus shipping.

#21 soobiefreak85

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Posted 23 July 2011 - 04:40 PM

Beautiful!!! I love the color!! Can' wait to see it put together post lots of pics please. Great job on everything!

Wes

#22 LeoneTurbo

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Posted 24 July 2011 - 02:14 AM

Thanks for all the comments.

A quick write-up on all the specs that have changed:

Engine
EJ18 with high compression pistons, ported cylinder heads and post-2006 equal length exhaust manifold and 2" exhaust system (short stroke turbo engine ditched due to cost of the entire setup). I expect 125 hp @ 5500 rpm and 125 lb-fit @ 4500 rpm.

Tranmission
Single range AWD EJ 5MT with 3.9 final drive and long ratios for smooth and frugal highway cruising (60 mph is 2400 rpm). I hope to get between 30 and 33 mpg depending on how fast I travel (usually around 85 mph).

Interior
Ditched the wooden wheel for an original 4-spoke wheel which will be re-trimmed in black leather. I pruchased a set of WRX front seats which will be trimmed in beige vinyl and so will be the original rear seat.

#23 LeoneTurbo

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Posted 16 August 2011 - 12:36 AM

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Arriving home...

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Arriving home...

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Assembling the door and window mechanisms (note the new grommets)...

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After half a day of work (and a lot of muscle ache, weatherstrips are a pain to install even when some are new).

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Luckily I got help installing the grommets from my two sons...

#24 Loyale 2.7 Turbo

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Posted 16 August 2011 - 02:29 PM

Wonderful Job, I Really Like what you are Doing to that Subie, it Looks Really Nice that I Can't Wait to see the Final Look!

 

The 3.889 Rear LSD Differential Ratio is done by nine pinion gears and thirtyfive ring gears, (9/35) isn't it?

 

Could you post more photos of that Differential?

Kind Regards.


Edited by Loyale 2.7 Turbo, 14 June 2013 - 08:02 PM.


#25 two85s

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Posted 17 August 2011 - 01:55 AM

Wow, looks great and you really seem to know what you're doing. How long have you been planning this build? Please keep posting pictures. It's inspirational. :clap: Kind regards, Aaron




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