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Royal Loyale


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12 replies to this topic

#1 Crazyeights

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Posted 13 April 2014 - 01:46 AM

I have always liked Wagons. I picked up this 1992 Loyale in June of 2013.

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A 5 lug swap was planned as well as rear disc brake conversion. I also looked into adding a rear sway bar from an XT coupe. Anyway, I know everyone likes to look at pictures and I have a small head-start already.

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Once the suspension, brakes, and tires are taken care of, I'll most likely finish up with an EJ swap. I have some pieces gathered already.  This is a spare time project with a limited budget so this thread might not get regular updates. It is a nice daily driver at the moment though, with working A/C :)

 

Many of you have inspired this build. Nico, Rick (The General Himself), Gloyale, Bratsrus1(Jerry), Tex, Turbone, TheLoyale, Jezek, Monstaru, Bratman18 and EVERY other one of you!!! Thanks...

 

Hope you enjoy!


Edited by Crazyeights, 13 April 2014 - 10:56 AM.


#2 Crazyeights

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Posted 13 April 2014 - 10:29 AM

After reading everything I could find about the 5 lug conversion process (most of it all from here) I started gathering parts. I ended up doing the brake upgrade at the same time. I wanted a spare front cross-member to modify for XT6 front lower control arms. I figured I might as well start with a Turbo cross-member to keep my engine upgrade options open down the road (remember the talk about the EJ swap) :grin:

Attached File  T-Crossmember dirty.jpg   182.84K   54 downloads Attached File  T-Crossmember cleaned front view.jpg   228.07K   71 downloads Attached File  T-Crossmember cleaned rear view.jpg   235.86K   81 downloads

Two cuts had to be made on each side in the pocket area to provide enough clearance so that the XT6 LCA's won't rub. The metal was peeled up slightly (about 1/4 inch) and re-welded. I liked this option better than tacking on washers, although that would have worked too.

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It works and looks pretty good too.

Attached File  XT6 LCA Installed first side.jpg   131.99K   86 downloadsAttached File  XT6 LCA Installed second side.jpg   129.72K   79 downloads Attached File  T-Crossmember installed left side.jpg   114.63K   68 downloads Attached File  T-Crossmember installed right side.jpg   162.29K   76 downloads Attached File  T-Crossmember installed finished.jpg   145.74K   61 downloads

 

More to follow...

 

 

 

 



 


Edited by Crazyeights, 13 April 2014 - 11:01 AM.


#3 TheLoyale

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Posted 13 April 2014 - 12:22 PM

I'm following this one! Nice progress so far. What are those 4 bolts for right in front of the fuel tank?



#4 Crazyeights

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Posted 13 April 2014 - 11:50 PM

I'm following this one! Nice progress so far. What are those 4 bolts for right in front of the fuel tank?

I think it might have been from an old trailer hitch. That makes me smile too. First gear up the pass in the snow at five grand doing 14 mph pulling a trailer. Yeah, we have all worn that hat at least once :ph34r: 90 HP on it's best day and lucky if the head gaskets last past the first timing belt interval.

 

Oh well just stay runnin' for a few more months... The radiator was plugged solid when I bought the car. I didn't really realize it and TBH I didn't care either. Until it blew the entire end tank off of the passenger side on my lunch break :clap: WHAT A MESS! Now it has a shiny new brass one a few months early. The old EA82 chugs on at almost 30 mpg....


Edited by Crazyeights, 14 April 2014 - 02:13 AM.


#5 Crazyeights

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Posted 01 June 2014 - 01:46 AM

Time for a quick update. The 5 lug swap is complete. The modified EA82T ("Turbo") front engine cross-member with XT6 front lower control arms is installed. The brake system upgrades/modifications are finished for now too. I put in new lower ball joints as well. I cleaned up some Legacy 14" steel rims so that I could retain the same tires short term. They are 185/70-R14's. I have several thousand miles on this configuration now and it feels great.

 

Attached File  5 Lug Swap finished left side.jpg   201.15K   41 downloads Attached File  5 Lug Swap finished left side -2.jpg   175.89K   47 downloads Attached File  5 Lug Swap finished right side.jpg   196.86K   46 downloads

 

A quick look at the interior;

 

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So far so good! Details to follow soon with some more pictures.


Edited by Crazyeights, 12 October 2014 - 12:35 PM.


#6 Crazyeights

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Posted 01 June 2014 - 12:50 PM

Here is a picture of the donor car that the front suspension parts came from.

 

Attached File  Strut and Knuckle donor.jpg   34.94K   14 downloads

 

The front brakes consist of Loyale calipers on EJ knuckles, rotors, pads, and caliper brackets.  It works by using one of the Loyale caliper pins on the EJ bracket. A big "Thank You" to the member that figured this out first in another post. I like this for now because you can retain the front E-Brake. I ended up using EA81 outer tie rod ends so that the toe could be adjusted properly.

 

Attached File  LF EJ Brake swap.jpg   100.85K   18 downloads Attached File  LF EJ Brake swap - 2.jpg   115.66K   20 downloads Attached File  RF EJ Brake swap.jpg   107.69K   19 downloads


Edited by Crazyeights, 12 October 2014 - 12:34 PM.


#7 Crazyeights

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Posted 01 June 2014 - 01:07 PM

I wanted both sets of inner DOJ cups (23 spline EA82 and 25 spline EA82T/EJ22) on hand to fit the Impreza front axles I am using. That should help keep the future engine and trans swap "down-time" to a minimum. That takes care of the front for now.

 

Attached File  DOJ Inverted.jpg   28.02K   14 downloads Attached File  DOJ Inverted - 2.jpg   27.15K   15 downloads Attached File  EJ - EA Front Axle.jpg   135.65K   12 downloads

 

More to come soon ...


Edited by Crazyeights, 12 October 2014 - 12:39 PM.


#8 Crazyeights

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Posted 12 October 2014 - 10:50 AM

Progress has been made :zzz:
I gave up (for now) trying to find a way to mate the EA82 rear axles in the Loyale to the inner DOJ's on the 2001 Legacy GT VLSD rear I was going to use.

 

I picked up an open 4.11 rear end out of an earlier Legacy with stubs and cleaned it up. The rear end ratio has to match the EJ 5 speed trans that is about to go in. So, with missing link installed, all I needed to do is wait for a slow day and "pull the trigger" on the EJ swap.
Attached File  IMG_2676.JPG   146.55K   19 downloads


Edited by Crazyeights, 12 October 2014 - 07:55 PM.


#9 Crazyeights

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Posted 12 October 2014 - 10:55 AM

Next, time to pull out the old tired EA82 and trans to make room for the new EJ22 and it's 5 speed EJ companion.

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Motors and stuff everywhere

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What a mess!

Stay Tuned...


Edited by Crazyeights, 12 October 2014 - 07:56 PM.


#10 Crazyeights

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Posted 12 October 2014 - 10:58 AM

I actually put this N/A EJ22E engine in with EJ22T manifolds and water pump installed to make sure they would all clear the frame and they do! 

Attached File  IMG_2661-2.jpg   158K   21 downloads

 

The EJ22T in my garage slated for this project may still find it's way under the hood someday.

Attached File  DSCN0813 - Closed Deck.jpg   155.72K   17 downloads Ya, I really DO have one :grin:

 

But for now, Under the 'neath!

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I had the XT6 cross member parts to make the trans bolt in properly and that worked out great. Now with all of the major pieces installed I could take some final measurements for the rear drive-shaft. I had read that the center section had to be shortened by 55mm to make it fit properly. I wanted to double check this dimension before sending my only drive shaft out to be cut down. Drivelines Northwest in downtown Seattle gets the "props" for doing some fine work, quickly, and at the right price too!

Attached File  IMG_2656 -DNW EJ Shaft.jpg   122.95K   13 downloads

 

Thank you!


Edited by Crazyeights, 12 October 2014 - 05:10 PM.


#11 Crazyeights

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Posted 12 October 2014 - 11:09 AM

It Lives!

 

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It sure is a lot more fun to drive now!


Edited by Crazyeights, 12 October 2014 - 11:44 AM.


#12 Crazyeights

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Posted 12 October 2014 - 03:35 PM

I am still working on the interior.

Attached File  IMG_2703 - 1.jpg   153.03K   19 downloads

The shifter work was made a LOT easier thanks to SubaruTex's thread leading the way here;

http://www.ultimates...j-swapped-cars/

The Legacy shifter mod worked great with only a couple of minor changes. I wanted the rear shifter mount to be able to float fore and aft on a rubber bushing like the factory used. Due to the difference in trans tunnel design between the EA82 and the Legacy there isn't ANY extra room in there to use the stock Legacy shifter mount like I had wanted to. I also didn't want to cut the factory Loyale shifter opening in the floor without a solid plan in place first. I made this up quickly out of the parts bucket. This way the car stays running and I wasn't wasting shop time fabbing something up with the car in the air.

Attached File  EJ Shifter - 1.jpg   121K   24 downloads Attached File  EJ Shifter - 2.jpg   141.07K   17 downloads Attached File  EJ Shifter - 3.jpg   118.36K   18 downloads

It is safe, solid, and functional so it is good enough for now. I also added a 5 mil plastic vapor barrier under the insulation but over the metal to keep moisture from getting to the back side of the carpet.

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I found a combination of plastic that fits as a shifter surround and I'm pretty pleased with it.

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I was trying to make it look like the factory could have made it.

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The trip computer installation should be complete soon including the dash display. At first the clock and outside temp will work. The other functions may have to wait until later. The dealer was still able to get the new mini light bulbs to make the dash LCD display function again.  I even have the outside temp sensor to mount in the grill :)

 

So far no fault codes after almost a week. I am really liking this conversion a lot!  No more trouble going up hills or getting up to freeway speed. I just about ready to mount the ECU and finish tidying up the interior.


Edited by Crazyeights, 13 October 2014 - 11:45 AM.


#13 nick1208

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Posted 14 October 2014 - 03:43 PM

:popcorn: 






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