Rallywagon

Come on down....could you bring a few low rust '84 wagon bodies with you? I'm in Asheville, NC about 2 hours northwest of Columbia....got several good offroad areas in western NC. LOTS of Subarus in these mountains, but ALL of them rusted by the road salt. I am always jealous of you NW guys. I have been looking (on and off again) for a new 83/84 wagon body for years. I have 2 good drivetrains ('87 Hatch and '84 wagon) and a gnarly tire setup. Welcome to the South.

I run 205/75 R14's. They are a very tight, but acceptable fit. They only scrub when I lock the steering out to either side, but the turning radius is virtually unchanged. I purposely chose rims with a large negative offset like the stock wheels (45mm). But you'll notice in my signature that I have converted my hubs to 4x100mm, so I use '95 Mazda Protege' wheels.

I have solid lifters, not hydraulics in my '84 engine. Anyone else know of a source for rocker arms? Thanks.

After 2 new axles and exhaust repair, I have my 'ru on the road again with 248k miles. The only significant drivetrain problems are a slow leak either from a cracked head or head gasket and a worn valve rocker arm. Stop leak in the coolant keeps me in decent shape on the leak, but the worn rocker arm knocks a fair amount. Does anyone know a source for rocker arms? Thanks.

Thanks for the tips! I was afraid it was gonna be impossible... I had heard Subaru metal was very thin and difficult.

Anyone have specific experience in welding on the early 80's models? - wire recommendations, -voltages, - preparation tips for repairing rust outs. Thanks.

Morgan, Your videos are very similar to the tough sections of the trails I am doing now with my '84...I just need lower gearing to push my 205/75R14 MT's. I just hate to continue putting a lot of effort into the mechanicals of my '84 when the body is close to literally cracking in half from rust. (And all the '80-'84 wagons around here are that rusted.) If I put a dual range tranny and a lift on the Impreza, do you think it could ever hang with the older models? Unfortunately, I have read that the EJ18 has peak torque at a much higher RPM. But wouldn't it be great to have that smooth, solid, quiet Impreza unibody as a platform to build on? What we all really need is a way to put 4.44 diffs in the old EA dual range 5 speed and then beefier axles to take the abuse. Thanks for the feedback.

The Impreza has a spent center diff and some dents...that is why I am considering how I could off road it. It also needs some good, new front axles. I have e-mailed cvaxles.com for a quote of their best. Any other recommendations for axles...I don't want to fool with any more cheap rebuilds that last only a year at best? Thanks for the thoughts so far.

What do you guys think...I have the opportunity to get a pretty good '93 Impreza for less than $1000? My '84 has been a blast but it is so rusted it is beyond saving, I think. The '93 has no rust, and of course, no locking center differential. - Could I put in a dual range tranny from an EA? (I have a good 4-spd dual range.) - Anyone have gear ratios and final drive for the '93 Impreza? - Gearing is super important here...lots of rocks, narrow trails and climbs. I'd appreciate some meaty comments. (Sorry for the cross post, but I got no specific responses in the retro fit forum.)

Unfortunately, the last D/R's in the US were about 1989 models. Do you know if the D/R Impreza trannies on your side of the pond locked the rear diff while in low range...or was it always the use of the viscous center diff?

Haven't done it yet...want input. (Searched the forums and couldn't find this exact swap idea.) I have a chance to get a '93 AWD 5MT Impreza wagon with a wasted center diff. It has an excellent EJ18 in it. I already own 2 EA81 cars with 4 speed D/R trannies, but the bodies are completely rusted.... What are your thoughts on putting an EA81 dual range tranny into a '93 Impreza (I could find an EA82 5 spd dual range too, if that would be better) - differential gear ratio of a '93 Impreza 5MT AWD with EJ18? I could swap in an old rear diff if needed? - how would the older tranny fit into the Impreza body? I would want a lift on the Impreza too. - gear ratios of older tranny compared with the '93 AWD 5MT? Higher the ratios the better..the goal is slow offroading. - other pluses or minuses or roadblocks? Thanks for any thoughts!

Thanks for the comments...does the Rust Bullet leave behind a tough layer with some strength like POR-15?

Thanks guys. Glen can you give me the specific name of the Dupont product...they have a million at the autobody supply. Scott

Did any of the dual range wagons come with MPFI? Thanks.

I have used a discontinued brand of rust converter with limited results, but I have heard good things about the AW Chesterton product. Anyone have a strong recommendation for or against any particular rust converters? Thanks.

What years used the throttle body injection and what used multipoint? Advantages, disadvantages, opinions? I need good gas mileage for commuting, but I also do some offroading. Thanks.

Great pictures, Carl. That really looks promising at Brown Mountain. I assumed it was all narrow trails since most of the ORV area is advertised for motorrcycles. Looks perfect for the Sube though. Thanks.

Bump. Anyone else have input? Thanks.

Anyone have real knowledge of swapping a later model EA81 and dual range tranny into a '79 wagon? Also, do the '77-79 wagons rust as easily and severely as the '80-84's? Thanks for any input. I am still trying to decide how to put my great EA-81 dual range drivetrain into a body that will be around for years. I love the performance on and off road of my slightly modified '84, and I have a great '87 EA81 hatch drivetrain...but I need a good 4-door body in the Southeast to put it all together!...forgive my whining. Scott

What was the last year of the dual range trannies (3.90 diff. gearing) sold in the US? Also, anybody ever taken a FWD '81 or so GL and put the 4WD running gear under it?....any major issues...I assume that gas tank has to be swapped...what else? (I may have found a rust free FWD near me.) THANKS!

Welcome, Lucky...from the other end of the state. I'm in Asheville. There's a handful of us on the board here in NC. Let us know if you are heading to Asheville...we'll show you some trails for your car if you like to get off the beaten path. Since you are a Sube enthusiast in my neck of the woods, (compared to all these pacific-northwesterners), I'd like to ask a favor. I am always on the lookout for an '83 or '84 wagon with no rust. I have an '84 with great interior and mechanicals and some mods, but the rust is killing me. If you find any, even 2WD, out your way with no rust, please let me know. Thanks and welcome, again.

Thanks for the comments!

Please let me know how this works and post pics if you can. I have been noodling around the same idea. I want a wide "radiator" that fits under my hood line but is not as tall as stock. Then I could cut into my front end and create a better approach angle for off roading. Thanks.

Rick, Looks like an awesome project!....Can you help me out with 3 questions... 1. Does the Castrol Super Clean cut the tar like junk used under the carpets? 2. What type of welding are you doing on your auto sheet metal projects, and can you give any hints...TIG, MIG, pulsing? 3. What kind of welding rod seems to work well with Japanese auto sheet metal (Subaru if you have gotten that far) in your experience? Thanks very much! Here on the east coast we have to battle body rust, and I am about ready to start cutting and welding!

Yep....I had to do the drill and tap thing. And I used plenty of anti-seize putting things back together, so hopefully, it won't happen again.