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The Justy is back


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19 replies to this topic

#1 RallyJusty

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Posted 01 January 2004 - 11:10 PM

Actually it never left. it just took a summer vacation while I worked.

----The following is a long post----

OK--- The car has taken a serious turn to the insane. I had finished the whole drive train swap from 3 cylinder (turbo'd) with the ECVT, to an EA82 drive train from an 89 turbo sedan (can't remember the model). Front to back '89 drive train with a shortened driveline to fit the justy's original wheelbase, at the sedans stock width, 8 inches wider than the justy's.

Discovered that an evil neighbor, that had complained about how ugly the car is, had filled the engine with water. They were thorough enough that water eventually found it's way into the turbo. It was parked inside a secure garage we shared under our building.

TODAY--- I took the 1.8l engine out of my 1993 impreza to put into the beast. The tranny in the justy is the dual range with the vacuum engaged transfer case. I want to keep that tranny, but...

The flywheel housing is larger on the impreza engine than the EA82. the 2 lower bolts on the engine and the bolt holes in the tranny, and the tranny input shaft all line up, and the splines of the tranny and the impreza clutch all slide together nicely.

HOWEVER, the rest of the tranny case and the impreza engine
flywheel housing are not the same, and the impreza flywheel is larger than the EA82 flywheel. The flywheels don't swap (crankshaft bolt pattern is slightly larger on the impreza). The starter becomes a real buggar, and I am not sure about clutch clearance.

Has anyone done this swap? I did a search of posts on all open forums, written several different ways, and saw nothing that answered this particular dilema.

The impreza engine modernizes the drivetrain nicely, while the older tranny gives me some fun options to try out.

I am greatful for any advise, or even smarty-pants remarks if they make me laugh.


Troy

#2 Mike W

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Posted 01 January 2004 - 11:38 PM

Did we ever get to see pictures of this thing? If not, we need to and you'll probably get some possitive feedback to compensate for what you're $%^&* neighbor did. Anyway, this may not be much help but there's some info on the Offorad Subaru Club of Queensland website about putting an EJ22 engine into a ea82 style car. Supposedly he used the EJ gearbox and put the EA82 style guts into it. Here's the link: http://www.subaclub....k/NewEngine.htm
For more info you might try asking on the BYB message board.

#3 TheSubaruJunkie

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Posted 01 January 2004 - 11:49 PM

Did they get Justy's in Australia? if not, they might not be of any help at all.

If you need a place to put pictures, contact me and i can set you up with a login for the Image Gallery.

-Brian

#4 GeneralDisorder

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Posted 01 January 2004 - 11:51 PM

Screw the engine swap - Kill the neighbor - sounds like more fun to me.....

That's really sad - great to hear that he didn't accomplish anything tho - since your still working on it.

I think if it were me, I would park a couple more ugly cars down there just to mess with the guy. I'm just vindictive that way I guess.

GD

#5 bushbasher

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Posted 02 January 2004 - 02:15 AM

sounds like time for some sugar in the neighbors tank.

#6 JonOfScio

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Posted 02 January 2004 - 03:18 AM

screw sugar, put a ton of napthalene in his tank and make his engine fry to hell.

#7 calebz

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Posted 02 January 2004 - 03:25 AM

Originally posted by TheSubaruJunkie
Did they get Justy's in Australia? if not, they might not be of any help at all.

If you need a place to put pictures, contact me and i can set you up with a login for the Image Gallery.

-Brian



Brian.. its an Ej motor and an EA tranny.. just a justy body.. I'm sure that the OZ boys are familiar with the EA and EJ stuff.

Perhaps kennedy engineering could hook you up with something.. the do the adapter plates for VWs

#8 Ma-fia

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Posted 02 January 2004 - 04:02 AM

Originally posted by JonOfScio
screw sugar, put a ton of napthalene in his tank and make his engine fry to hell.



I can't even express how my shaky little hands are itching to do that to one personage!... I don't even know what's stopping me.

Water in the engine! Things like this make me mad.

#9 RallyJusty

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Posted 02 January 2004 - 11:39 AM

I appreciate the response to what my neighbor did. The sad fact is that I had moved to our new place (with my own 3 car garage!) before I discovered it. Good news, garage. Bad news, dirty trick.

Reguardless, I have the impreza engine, and I plan on making it work if I can. I do have the Impreza tranny, but it isn't as much fun.

Pictures are coming. For real this time. I am creating a web page for the project, and I have already set up a web cam in my garage, but the pictures are coming out so crappy that I asked my wife for a little digital camera to keep in the garage just for the project. I can go ahead and post what I got, but it may not be too clear. Give me a couple of days to finish the web page, and it should be going by Monday.

I have also taken out the struts up front, and I am building a double A-arm suspension. The engine needs to be in it's final location to finish that project.

Troy

#10 TomRhere

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Posted 02 January 2004 - 01:47 PM

Dirty trick by old neighbor = :madder:

New 3 car garage = :grin:

Double wishbone front suspension =:headbang:
I would like more info on that one.

#11 RallyJusty

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Posted 03 January 2004 - 02:45 PM

Success with the whole flywheel issue. The bolt holes for mounting the flywheel to the crank are the same in number and size, but slightly further out radially. The flywheel fit perfect on the centering bushing on the crank flange . I will machine each hole on the flywheel ,at the same width, going out radially to meet with the Impreza mounting hole locations.

The next bit of creativity will be making a 16mm spacer to accomdate the difference in flywheel thickness and engine bellhousing differences. That same spacer will give secure mounting locations and protection for the area of the flywheel housing exposed by the smaller EA transmission.

The engine and tranny for my design were always going to be directly mounted on rails that run parrallel down the long axis of the engine/tranny, to a tie point behind the driver in the roll cage. That design should allow me to take the torsional stress off of the spacer, making the spacer easier to design and build. In fact the whole suspension and drivetrain are tied to the roll cage, giving me a very sturdy little car.


All in all I think today should prove very exciting in the Justy shop.

Just couldn't wait to share

Troy

#12 hatch4x4

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Posted 03 January 2004 - 03:56 PM

First thing... this is amazing. I have always wanted to see a EJ swap into a Justy. I have been planning to do it to my Justy in a year or so, after taking some more metal work and machining classes.

What kind of clearance issues have you run into engine and tranny wise. Did you have to modify any of the original frame under the hood? How about fitting the transmission under the body? I always figured one would have to cut out part of the floor for the tranny to fit. How about steering? I always pictured using an EJ crossmember and using the steering box on that. Man you make me want to take a trip to Colorado now. I hear the snowboarding's pretty good there... hmmm ;)

Lastly, I know everybody has been asking, but we're all dying for pictures. How about I send you a disposable camera for you to fill up and send back to me :D :D I'd scan and post them for you. Good luck man,

-- Jeff

#13 incognito

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Posted 03 January 2004 - 10:07 PM

Naw po-po's can test for arsenic... they can place it right back to the point of purchase.

Go with sugar.

#14 electryc_monk

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Posted 03 January 2004 - 10:57 PM

There is one particular thread I am apart of on one of the www.ausubaru.com forums(the new name for the byb's) (in the conversions folder!

BTW its only supoosedly 10mm thick so you can run a EA82 flywheel with elongated (dremmel is the word they use) holes on the center crank bolts.


I am personally awaiting a forwarded email with the documents for this "adapter plate" as its gonna be a bit still for some reason.......

#15 RallyJusty

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Posted 04 January 2004 - 12:32 PM

Last night I finished mounting the EA82 flywheel onto the impreza engine. I used an end mill bit in my drill press and elongated the holes. I only had a 3/8" bit, which is smaller than the original hole, so I had to work each hole a few times to get the elongation and hole size I needed.

The process I used was to elongate one hole, press the fly wheel on and bolt through that 1 hole to the crank. Then I used a sharpie to mark the pattern I would need to use to correctly elongate the remaining holes. Since half the hole on the crank was visible through the holes on the flywheel, it was easy to do the marking. The elongation cut was slightly more that 1/2 the original hole diameter. As a result the pattern wasn't directly out , but rather a semi spiral effect. This is because the same number of holes were used on the crank, and equally spaced, but at a slightly larger radius.

The work took me a few hours to do, but the result was very tight.

Today I will begin the process of building the spacer.

Also I did a quick bit of writing on a web page that I will use to document the progress, post current photos, and give a bit of history for the project. I still think I should have that up and going by tomorrow.

Troy

#16 RallyJusty

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Posted 04 January 2004 - 12:48 PM

By the way, thanks for the hook-up on that ausubaru site! That is exactly what I am doing, and it appears that they do it quite a bit. In fact they had a pic of the adapter plate. Let me know when you get the data, although I don't think I am patient enough to wait.

THANKS!

Troy

#17 Mike W

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Posted 04 January 2004 - 02:06 PM

Nice job of forging ahead with the project and doing the previously undone. As for making the adapter plate, do you have access to a mill or are you just roughing it with a bandsaw or something? Thanks!

#18 RallyJusty

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Posted 04 January 2004 - 03:53 PM

Mike,

I do have access to a mill, But I am working on a design that will give torsional strength, the spacer, and a solid connection, without milling an adapter.

The tranny and engine will be mounted directly to common rails. The two lower bolts coming out of the EJ flywheel housing line up with the two lower bolt holes on the EA tranny.
My current thinking is making the bracket common to both the engine and tranny, by being mounted to the rails as a solid mounting point for both. Rather than milling a seperate spacer, just for the engine/tranny connection, the mount may then be part of the new double A-arm front suspension I am building. I can pass the engine side lower bolts throught the bracket/spacer into the tranny's lower bolt holes, and have the bracket traverse around the tranny, supplying hard tie points and the spacer required for the offset upper tranny bolts. Then just build a nice shroud out of sheet metal to keep debris out of the flywheel housing.

The solution may help resolve some hard point issures I am working out for the suspension. I want the whole thing to drop as a unit for ease in repairing the front suspension, engine, and tranny.

Everytime I write more about my project on this site, I think more people are going to assume I'm nuts.

Troy

#19 electryc_monk

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Posted 06 January 2004 - 11:10 AM

Originally posted by RallyJusty
...(cut)...
Everytime I write more about my project on this site, I think more people are going to assume I'm nuts.

Troy



Hey Troy err I mean Pot, Hi, I'm Kettle. :D

#20 subeepl

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Posted 06 January 2004 - 12:25 PM

a very creative nut, like most of us;)
With my son we want to make a 4x4 Hill buggy out of "Domingo" this year :rolleyes:




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