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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

#26 LeoneTurbo

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Posted 18 August 2011 - 07:37 AM

Well I started off end of last summer, thought that a bit of welding and painting would be done before the end of the year :clap:

But since this is my first restoration I was a bit wrong... I got the body back half way August this year so I just started work on it. I planned a lot in advance though like making sure I got all the parts I wanted to renew (as far as new stuff was still available).

I'm now working on getting the brake- and fuel lines done. I want to get rid of the hill-holder and I also need a bigger return line for the EJ-conversion. I'm using the original return line as evap.

Besides that I'm replacing all the suspension bushings. I have blasted and coated all the parts except the front cross member as it was still in good nick. The parts with bushings I couldn't get out or installed myself (I haven't got a press) I took to the local dealer and hope to get them back tomorrow. Then I can also get cracking on installing the Cross Bred Performance kit on the rear brakes for 5-lug conversion.

Then there still is the EJ 5MT I need to get installed (making new mounts) and modify drive shaft and gear shift mechanism. Fortunately I already have a set of modified front axles for the late EJ-hubs I'm using.

#27 LeoneTurbo

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Posted 19 August 2011 - 06:03 AM

Some more progress today:

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Routing engine wiring loom in the engine bay

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Location of ECU in passenger footwell, youngest son watching with interest

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Installing the front 5-lug hubs

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Adjustable, custom made top mount installed

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Hoisting the EJ 5MT transmission into place, need to figure out how I want to fab a mount for it though...

#28 LeoneTurbo

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Posted 06 September 2011 - 05:12 AM

Slow progress but it's rolling now:

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The ride height at the back is too low, I will have to adjust it one or two notches on the torsion beam. Mind you, it's got a 90L LPG (liquified petroleum gas) fuel tank in the back, and no engine and interior yet.

Edited by LeoneTurbo, 06 September 2011 - 05:14 AM.


#29 1982gl4

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Posted 06 September 2011 - 07:38 AM

Wow looking great. I hope my current wagon project can come out looking this good. Keep up the good work!

#30 two85s

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Posted 06 September 2011 - 10:24 PM

Looking so good! I'd like to see how and where you put the LPG tank in. I have seen it done in a GMC 1976 pick up, but never have I in a Subaru. That will run very clean. Will it affect the horse power up or down, I wonder? Your car is really coming together nicely. Thanks for updating, Aaron

#31 soobenthusiast

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Posted 06 September 2011 - 10:49 PM

I believe there is a guy locally running propane or natural gas in an EJ car. I've never seen his setup, so I'm also quite interested to see how it's done. How does one convert a fuel injected car to lpg?

#32 two85s

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Posted 06 September 2011 - 11:01 PM

Soobenthusiast, the GMC truck has a gas tank also and you could switch from gas to LPG with the flip of a switch. My dad still owns the truck but he only runs propane, passes smog every two years no problems. Aaron

#33 LeoneTurbo

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Posted 07 September 2011 - 07:10 AM

I have the system in my Legacy Wagon now with a small tank in the spare wheel well. I wanted a bigger tank in my EA81 Wagon for greater range so it will be in the luggage compartment. It's stripped down on a metal frame bolted to the chassis.

From the gas tank there is a hard copper fuel line to the evaporator in the engine bay. The gas enters the evaporator, which is connected to the coolant system of the engine, in fluid state and is heated so it becomes in gaseous state. It then passes through and inline gas filter and goes to the LPG injectors. They are connected to the intake manifold via small hoses.

The ECU of the LPG system cuts the petrol injectors and calculates the LPG injection time based on the injector input signal from the petrol ECU.

#34 LeoneTurbo

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Posted 07 September 2011 - 07:18 AM

Engine output is about 10% less on LPG (however there are system which inject fluid LPG into the intake manifold which lower the temperature of the intake charge when the LPG evaporates which actually increases horsepower) and fuel consumption is about 20-30% higher (in litres).

I usually get 8 km per litre of LPG (about 23-24 MPG) in my Legacy and with only a nett volume of 46L the range is about 370 km (my daily commute is 340 km).

I hope to get better LPG mileage in my EA81 Wagon as the engine will run a higher compression ratio (LPG has higher octane level so no fears for knock) with ported heads and a less restrictive exhaust system without cats. Oh and less aggressive cams.

#35 two85s

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Posted 07 September 2011 - 08:19 PM

Very interesting Thanks! let's see a photo when you can? That's a healthy daily commute :eek:. Have a good one! Aaron

#36 LeoneTurbo

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Posted 08 September 2011 - 07:09 AM

Some pics of the tank and wiring in the EA81 Wagon. The engine bay pictures are of my Legacy Wagon.

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#37 LeoneTurbo

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Posted 17 September 2011 - 04:14 AM

Today I collected my refurbished seats...

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#38 92_rugby_subie

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Posted 20 September 2011 - 03:18 PM

:eek: :eek: :eek: :eek: :eek: :eek: :eek:

Nice seat :D

#39 Loyale 2.7 Turbo

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Posted 20 September 2011 - 05:26 PM

Nice Looking seat! 


Edited by Loyale 2.7 Turbo, 27 June 2013 - 11:52 PM.


#40 NICALM

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Posted 30 September 2011 - 10:22 PM

That is one GREAT Looking Roo. Im partial to this gen wagon and you seemed to have found quite a gem! keep up the amazing work and ill keep following your posts:grin:

#41 LeoneTurbo

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Posted 01 October 2011 - 12:10 AM

Some progress...

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I want to get the car up and running by the end of this month, but there's quite a list of things to do:

- make crossmember for transmission
- modify/fit gear linkage
- make front exhaust pipe
- have a stainless steel fuel tank made
- install dash
- install front axle shafts
- rebuild one front brake caliper (one's already done)
- install/modify hand brake

That's about it :grin:

#42 LeoneTurbo

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Posted 09 October 2011 - 07:43 AM

OK another update. Last week I rebuilt the brake caliper and installed both on the car. I also modified the shift linkage and the transmission cross member they just have to be welded.

I wanted to install the front drive shafts but found out I got the wrong EJ outer cups to fit the EA cage (25 splines fit the transmission but not the cage) so I ended up sending a pair of BE/BH Legacy shafts to be shortened (yup, cut and weld), expect them this week.

As I got a box with nice parts from GeneralDisorder I continued with the dash (I got the pig tails for the older style cluster - which I like better than the later ones). Yesterday I spent the whole day to figure out how to wire in the new old cluster but it's done now and I also made the adapter loom between the ECU and the cluster (for CEL, speed sensor and tacho signal).

This is what the car looks like now:

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#43 1982gl4

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Posted 09 October 2011 - 10:14 AM

About the color I'm going for with mine just a bit darker. It looks very nice. I really like that cluster a lot as well, ours never had the silver trim around it, I may have to look into doing that! Glad to see somebody else fixing one of these up, most people just drive them into the ground.

#44 LeoneTurbo

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Posted 31 October 2011 - 08:26 AM

Today I collected my SS tank and installed a 2WD Legacy tank and gauge unit (had to bend the arm for the gauge a bit to clear the tank wall):
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Remove the hand brake cable holder plate from a Legacy handbrake and welded it onto the EA81 handbrake:
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Had the SS exhaust pipe welded in place after I did the measuring and cutting over the weekend:
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Stil have to weld it up to the last bit of the front pipe (with the bracket to the gearbox) and install the O2-sensor bung.

So some major hurdles have been taken. I hope to have the car mechanically 'ready' in 2-3 weeks now.

#45 LeoneTurbo

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Posted 07 November 2011 - 07:40 AM

This weekend I filled the rear diff, transmission, engine and cooling system with the required fluids and installed the intake stuff.

Some more pictures:

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I still have to get a go at that transmission mount and I have to get a spacer made for my front struts. The spring hat is now in contact with the top mount so when I turn the steering wheel it grinds a bit.

More to come...

#46 LeoneTurbo

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Posted 19 December 2011 - 10:49 AM

I decided to halt this project until spring. I'm not happy with the way some things have turned out (mainly transmission mount, exhaust routing) and the crap weather... I will repair my Legacy (rear whel bearings and rear brake lines) and run it for another year.

#47 Idasho

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Posted 19 December 2011 - 07:28 PM

Woah! Care to shed some more info on the fuel tank?

Is it a custom jobber? Does it use OE hardware to mount?

Car is looking excellent btw! :banana:

#48 Loyale 2.7 Turbo

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Posted 27 June 2013 - 11:48 PM

Any Updates on this Awesome Project?

 

Kind Regards.



#49 LeoneTurbo

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Posted 06 August 2013 - 06:50 AM

dash.jpg

 

Re-installed the das now with digital cluster (which actually works - or so told my buddy who gave it to me).

 

Now it's time to concentrate on the driveline again...






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