pontoontodd

Plumbed a tee into the top line feeding the steering brake and put a bleeder on that, after bleeding that spot and the calipers a bit more it seems fine now. B replaced a front wheel bearing on his Forester which seemed to help his on/off throttle steering issue. I edited and posted two videos from our last trip to the UP, one long, one short:

Yes except I have mine plumbed the opposite from your example. It sort of works as a locker but mainly it's used as a steering brake. It's my favorite kind of steering brake. This shows how we ran the lines and how close the brake is to the center console compartment. Center console reinstalled, handle lines up perfectly with one of the coin holders. Mirror adjustment switch doesn't go all the way back in. Ran the lines under the carpet and through the stock grommet under the back seat. Connected them to the bulkhead under the seat. I tried a different bleeding procedure which ultimately didn't seem to be an improvement.

One of the two main projects I wanted to do this winter on the Impreza (other being the gas tank) is installing the cutting brake from the black Outback. I made this bracket to bolt it next to the parking brake. B replaced the ABS unit with a couple of tee fittings. The one for the fronts is our solution for those lines. B rerouted the braided stainless line we had in the black Outback from the master to the cutting brake, it was still in good shape. Bolted to the cutting brake. Bolts down using two stock fasteners on the top of the driveshaft tunnel. It backed right up to the storage compartment in the center console so I plugged the normal feed location and plumbed the line from the master to the top (former bleeder location). This lines the handle up with the coin holder in the center console (haven't cut that out yet). Handle will be bent too. I made and ran new braided stainless lines from the cutting brake to the bulkhead fitting under the back seat that feeds the stock rear brake lines. We spent quite a bit of time and brake fluid trying to bleed it. I eventually got it to the point that it was driveable and I could lock up the left rear tire but the brake pedal and cutting brake are definitely spongy. Related to this mod was adding another heater core under the one I've been using. Hoping it will give me a little more insurance against overheating. Plan is still to put the two small puller fans on the main circuit in hopes that the pusher fans don't have to run much. They seem to shred plant matter and jam it into the condenser and radiator. B and I did some mockup and made a couple brackets to bolt the second one on underneath the original. That hose linking the two is definitely not ideal but I don't think it's closed off and will probably open up under pressure. I do plan to put a barbed elbow in there to help though. Should make sure the one closer to the fan is getting coolant first too. Still gathering a few connectors for rewiring the fans and extra fuel pumps.

I think it was too long but I should check.

Last weekend we did some work on B's Forester. His carpeting has been getting wet on the driver's side so he pulled off the fender, wipers, carpeting, etc to investigate. Eventually noticed part of the floor had some small cracks in it. After a little tar removal and poking he discovered about a 2-3" square section was basically rusted to nothing. So he cleaned up the sheet metal around that and welded in a fresh piece. Meanwhile I went through his front struts. Main task was replacing the bushings in the strut bodies. This pair of struts may have been on the black Outback, regardless they have seen a lot of abuse and the bushings were badly worn. Replaced the shock oil in one and replaced a few shims that were maybe slightly cracked. Verified our notes on the valving were accurate. Replaced some other boots/seals, repacked steering bearings with grease, etc. He says it's noticeably more solid now. Yesterday we worked on my Impreza. Still seemed like the radiator and condenser were pretty dirty so I got a long nozzle air gun and tried a few different modifications, this seemed to work the best. Plugged the end (M6x1) and drilled a .15" hole in the side. Then you can get that between the radiator and condenser and blast out one or the other. We got quite a bit more debris out. Replaced the steering rack. It was leaking badly from the driver's side. This would then quickly degrade the boot which would split open. I was refilling the reservoir about once a week by the end of the summer. Fortunately M had put a rebuilt rack in his (my old) blue Impreza a couple years before we parted it out so that one is (hopefully) still pretty fresh. We pulled the skidplate and replaced the rack. In the course of swapping that out I discovered that the bottom U joint on the steering shaft is nearly locked up in one direction. After putting everything back together, you can feel the tight spots in the U joint when turning the steering wheel with the front end off the ground. So I'll have to replace that. A bit disappointed, it's only been in there a couple years, new from Subaru (and extended by me). We had a bit more time and the front end was already off the ground and wheels and tires were off so we decided to go through my front struts. Didn't take too long, verified the valving mainly, added a bit of oil, replaced a wiper, regreased the steering bearings. We intend to go through our rear struts sometime this winter too. Still working on getting material for all the 6MT low range parts so we have a couple complete assemblies (including one for B). We should really tear down the one that was in the black Outback sometime and confirm the failure mode there. I think I have all the plumbing bits I need for the extra fuel tank. Need to get some electrical bits for that and the fan rewiring. We did take a peek at the ABS sensor wires and they're not super small, maybe 20 gauge, we think two of those will be adequate to power a fuel pump.

In case you hadn't noticed we have a lot more options for vehicle modifications than Australia. These pumps are 255lph. Assuming this extra tank is 10 gallons that would take about nine minutes. Could have it going before you even start filling the main tank. Worst case you fill up the main tank, pull off to the side for ten minutes, then go back to the pump. Guess I'll find out. I think this will be the simplest way. One hose connecting the tops of the tanks for venting. One hose connecting the bottom of the secondary tank going down through one of the access panels and down to the bottom of the main tank. Have two fuel pumps side by side teed into that bottom hose one pointing each direction. One of those pumps could run the engine in a pinch. Definitely looking forward to the magically increased range.

Thanks for all the advice on this. Good to have someone else looking over my shoulder making sure to at least warn me when I'm doing something I shouldn't. Yes, we're just using these as transfer pumps. One for each direction since they all seem to have a check valve built in, the only reversible ones I can find are pretty expensive. 14ga seems overkill for 5A. I use 16ga for almost everything. Will take a closer look at the ABS wires for sure, I like the idea of just using them for power and then grounding the other terminal of the pumps. Will probably see what other wires are running back there we're no longer using too. On the topic of wiring, any suggestions on a relay/fuse good for 80+ amps? Want to put both the pusher fans on the secondary fan circuit. Figure I'll switch the big relay I add with the stock wiring/relay. Those fans pull almost 30A each (over 30A when submerged in water apparently). Planning on putting both the puller fans on the primary fan circuit, they are small and don't draw as much so I should be good there. Currently have one of each on each circuit on 30A fuses.

Good point I'll take a look at the gauge of those wires. Won't be under much pressure so according to the internet it'll draw 4-5 amps and even 22 gauge wire should be adequate. Definitely not getting any relays involved. Thanks again for the cabin air filter tip. We were discussing how full of junk the evaporator would be without it. Like the one on the black Outback was.

B and I worked on the secondary fuel tank for the Impreza. I pressure tested it and flushed it out, seems like it doesn't have any leaks even at 30psi. I got the mounting flaps carved up so it fits and matched up the bumper mount holes. We had to do a little more hammering in the spare tire well. We came up with a plan on how we want to mount the fuel pumps and run the hoses. I need to get another pump, some hoses and fittings. Going to try to get wire connectors for the ABS wires so we can use those for the fuel pumps since they're already running front to back and will never be used for ABS again. B replaced the cabin air filter and cleaned out the airbox and blower fan, they were all loaded with debris. He also traced the brake lines under the hood and we came up with a plan on eliminating the ABS module and plumbing the left/right steering brake from the black Outback.

Impreza has still been wandering a bit so I wanted to replace a couple of the lateral link bushings and CV boots. Got a bunch of Group N bushings so I'd have some on the shelf for future repairs. With the billet knuckles and dog leg trailing arms and the stainless studs in place of the long bolts it's a much easier job than it used to be, didn't take me long to get both axles out. One thing I've been wanting to address almost from the beginning of this swap is the slop in the rear diff stubs. The combination of slop in the diff splines and the splines for the female axles allows the inner CVs to move around more and have more backlash than normal. The splines for the inner CV were worn on the stubs that have been in the car for a couple years now. I peened a pair of them like the one in the bottom of this picture. I tried pressing them first to squish the splines but that did nothing. This may not last long as a means of reducing the slop but I figured it was worth a try. B swapped out a couple of the lateral link bushings and cleaned up the long studs. He also shorted a couple of the inner bolts that were rubbing on the inner CV boots. I regreased and rebooted a couple CVs and replaced one axle. Once we got it all back together one CV had basically no slop on the splines, the other one still had some but less than before. While we were under there I decided to refab the section of exhaust that hangs under the subframe. Cut out that flattened section and replaced with 2.5" x .095" 4130. Actually has clearance to the CV joint now. We also came up with an initial plan for mounting the extra fuel tank. Can't wait to get that hooked up. B unbolted the top of the radiator and pulled it back the little it can move with the radiator hoses on it, then he blasted a bunch of crap out from between the radiator and condenser with compressed air. I want to get/make some different nozzles for doing that more effectively, should probably at least check that regularly. Still hoping that getting the puller fans on the primary fan circuit and the pusher fans on the secondary fan circuit will help.

Posted videos from our trip back in June, one long, one short, maybe the best mix of mud/sand/rocks from the UP yet

Took five wheel and tire assemblies to Discount for their road hazard warranty. Only one leaked, others had big cuts in sidewalls etc. They'd ordered five new tires as replacements and then swapped them on to my wheels. When I pulled in to pick them up the manager recognized me and came out of the building and met me in the parking lot to tell me where they had them stacked. He asked about how the car did off road, how far we go, etc. Not necessarily a good sign when the tire shop manager instantly recognizes you. Drove the white Outback to the machine shop last Monday and the trans broke on the way there. Shifted hard (which it does the first few shifts when cold sometimes) then no forward or reverse propulsion. Faint grinding noise when in gear. C picked me up and gave me a ride to my house. Drove the Impreza to the scene and we hooked up the tow bar and lights. Towed it back to my house. Drove Impreza in garage, unhooked tow bar, jacked up rear of Impreza, pushed sideways, drove Impreza out, pushed Outback in. That week I disconnected everything from the trans and on Saturday B helped me swap it out. I refabbed the exhaust to get some driveshaft clearance. Used a steel cone to make the muffler rounder, replaced the most bent/crushed piece of tubing, relocated one of the hangers for more CV clearance. While I was doing that B disassembled the auto and confirmed that the input shaft broke. There were also a couple of chipped gear teeth on the center diff (?) planetary but I don't think that was a problem. I found one of them on the drain pan magnet. After driving it a bit I am still getting used to how much smoother it is. I knew the old trans was shifting hard sometimes especially when cold but I still find myself bracing for a hard upshift or downshift that is now super smooth. Perhaps smoother shifting than ever in my ownership. Sunday my wife and I went kayaking with the Impreza.

Long overdue trip report from early October. B and I decided to revisit some of the challenging portions of the trail riding with T in 2019. Friday morning before I left I shoved a couple pieces of hardware cloth between the radiator fans and grill/bumper. We met at Canyon Falls and headed north a little bit and started trail riding. Many of the trails we were on Friday were not on any of our maps and were quite overgrown. One of them stared getting soft and the Impreza started digging in to the mud. I locked the center diff and got out the folding recovery ramps and was able to get back to dry ground. We saw several different Notice of Authorizations posted for culvert and temporary bridge construction for logging operations. Some of these were about ten years old but we'd never seen them before anywhere. Impreza temp gauge started creeping up, the main fan fuse was blown so we replaced that. Not really sure why, it was fine the rest of the weekend. The hardware cloth in front of the fans did keep getting packed up with leaves and other vegetation all weekend, we cleaned them out quite a few times. Unfortunately none of the trails we explored for the first few hours went anywhere so we had to go back to the highway to go north a few more miles to some other trails. We were heading towards a hill on the topo that showed a trail going to the top so I tried to get there. Again wound up on some trails not on the maps and eventually came to a sign with a skull reading Paul Hytinen's trail of no return. That trail was basically a straight shot to the top of the hill. The first section was a fairly long and rocky climb, the only time I used low range all weekend. And yes that's an interior door panel lying next to the climb. We both made it up with no major drama and the rest of the trail was fairly mild. It was getting late so we camped in the little clearing at the top of the hill. In the morning B discovered that his RF tire had gone flat due to a small sidewall cut. He was able to double plug it. One of the first trails he had us go down was fairly narrow, rutted, and muddy but we made it through. At this point his plug was leaking so he replugged it which lasted the rest of the weekend (sort of...). Found a big tailings pile back in the woods. Found some decent campsites along a road next to a neat stream. Went to one of the stream crossings we'd turned around at on a previous trip with a less capable Subaru. Crossed it easily and continued. Went up a muddy climb that wasn't too steep but had a lot of logs that we're guessing other people put down but probably didn't help us. We both made it to the top but then I managed to go a little too far to the right and slide into a soft spot. Shortly after this I had a small stick jammed in my LF brake heat shield making an amazing amount of noise so we removed that. At that point I realized I couldn't open the RF door because the rocker was smashed up. Found an old RV way back in the woods. Went up to Mt Arvon from the west. Parking area was full of golf carts so we continued northeast. Got to another stream crossing we'd marked and turned around at with T but this time crossed easily. Eventually reached an old railroad grade that started out muddy and rutted which we had also turned around at on a previous trip. A little ways east a beaver dam was flooding a portion of the grade. This pond looks like it was probably occupied. Fortunately there was basically a beaver dam on either side of the road. We dug some drains in the dam on the downstream side and were then able to drive through. We were both briefly stuck but some jacking and logs under the tires got us back on the move. Just east of that was a four way intersection. We continued east on the grade and stopped at another beaver dam. This one was a similar deal but did not seem active, they had kind of dammed both sides so we dug ditches on the downstream side. Frog eating an earthworm, don't think I've ever seen that before. After a little draining It was starting to get a little late so we decided to go back to the intersection which had a big clearing and cook dinner. We then drove back to the beaver dam to check the drainage. Just before we got there B's Forester got stuck in a muddy rutted section and wasn't driving and making a noise that sounded like splines stripped out coming from the rear end. I was able to push the LR IB CV back in the diff and he was able to continue driving. We dug some more in the main section and fortunately kept walking to the far end and started draining a short but deep section at the end. By now it was getting close to sunset so we drove back to the big intersection to camp out. CV popped out of the diff a couple times on the way back. We jacked it up each time and were able to get it back in but it didn't seem like it had popped out far, maybe 1/4”. The next morning we started disassembling that suspension corner and got the axle out. Splines on the IB CV had stripped out, fortunately the diff gear looked fine. Put in his spare LR axle, ate breakfast, and drove back to the beaver dam to survey our work. Water levels had dropped almost a foot overnight. Found some more tadpoles and insect larvae We were both able to drive through, the hole at the far end was still deep enough to be deeper than my bumper so it's a good thing we drained a foot of water out of that. Of course just a little further was an even bigger beaver dam and this one was mostly on the downstream side of the road so we turned around and went back through the one that had been draining overnight to the intersection we'd camped at. Headed south and then continued east. Looped around to the other end of the grade and found another beaver dam quite a ways from where we'd turned around. Headed north, found some cool waterfalls. Revisited some other muddy spots we'd turned around at before and got stuck briefly and turned around again this time. A while later on another trail B got the Forester stuck in a frog filled stream crossing. Some jacking and shoveling and wood under the tires got him out. Then we got to another muddy rutted section. We walked it and poked at it with sticks and it didn't seem too bad except for the far end. Which is where I got stuck, somewhat high centered on some small trees that were fallen across the road we hadn't bothered to move. Probably with a little more momentum I would have gotten through. Took us quite a bit of high lifting, shoveling, recovery ramps, and wood stacking to get it on semi dry ground. Then B got stuck a little before where I had. We hooked up our straps and I was able to pull him up to the decent section of trail. We continued down that trail and just before we got to the major dirt road there was an RV and a giant tent set up in the trail. Fortunately there was a side trail nearby that connected to the dirt road and we continued. Our next point of interest was the beaver pond where T had flooded his Impreza in 2019. If I hadn't had it marked on my GPS we would never have noticed it. The road was built up several feet and a new culvert had been installed. The pond was still there but not much risk of flooding the road anymore. We went to a waterfall B had taken us to before, it's probably about a 50' slide and does have a little parking spot alongside the trail but no signs or anything. There's some metal chairs and pots and pans, a legit grill, and other cooking supplies stashed there but probably not enough flat ground for a couple tents so we decided not to camp there. We continued north and found a spot on a side trail to cook dinner and camp out. We headed back south, not long after that B's RF tire had another sidewall leak, this one probably worse than the first. We just swapped on the spare tire. Headed down a long somewhat rocky trail/road and rediscovered the vintage Barrington IL city bus turned camper we'd seen in 2013 and haven't seen since. Also saw an old plow truck parked alongside the road. Drove up to Big Bay and got gas at the station on the south end of town, it's well stocked with groceries and even has a decent hardware section in the back. Stopped at Thomas Rock Scenic Overlook on the way back to the trails. Excellent view, short walk. B wandered us down some narrow trails in varied forests we'd never been on. Headed back west on a slightly more northern dirt road than we'd been on. This one must have been some kind of major route long ago as there was a concrete bridge near the (current) end of it. Drove around the trails in that area, some good fall views but everything was eventually either bermed off or overgrown. By this time we needed to go back to civilization so we headed south on a major dirt road. Stopped at a boat ramp/park to air up and eat PB&Js and checked out an old truss bridge that's only open to pedestrians. We were entertained by the bicycle hanging from the top and ratchet straps underneath. Convoyed down to Green Bay, got gas, ate dinner, and split up for the rest of our drives home. Shortly after we split off I was stuck behind some old man camped out in the left lane. I finally got a gap on the right to pass him and as I was doing so I saw a cop parked in the median. Looked in my mirror to see the lights flashing and the cop pulling out on the highway. He eventually caught up to me and pulled me over. I assumed it was going to be for speeding. He walks up to the passenger window and asked if I'd been having fun off roading. Then says he pulled me over for loud exhaust. Asked if the exhaust was modified or if something had come loose off roading, I chose the latter option. He came back with just a warning ticket and said he was jealous of the fun we probably had over the weekend off roading. I would definitely like to make the Impreza quieter I just don't know how. I do have a slightly larger muffler I want to try but I doubt it will make much difference. I have a little more motivation to try it now though. Overall we had a good weekend, only major repair was the rear CV axle, good weather, almost no rain, almost no flying insects, no ticks. Saw a surprising amount of frogs. Trails were relatively dry, fall colors were neat. Should probably go up in October more often. Over 200 miles off pavement, spent the majority of our time and maybe miles on trails/roads we hadn't been on before, probably a quarter to a third of our time on roads that weren't on any of our maps. Perhaps the biggest portion of just trail riding of any UP trip I can remember. We were on some major dirt/gravel roads but it was a small portion of the time. Probably only 10-20 miles of pavement driving all weekend. Had to go out of our way to get to a gas station. We'd both dumped our jerry cans in our tanks but I was still probably within a half gallon of being empty by the time we filled up. Definitely further encouragement to get the extra ten gallon tank hooked up. Used the weavable recovery straps a few times for recovery, 5-10 times for pulling/breaking logs out of the trail. Radiator fans getting blocked by vegetation was an ongoing issue but fairly easy to deal with. Glad I put the hardware cloth in front, it may have saved the condenser from getting truly packed and folded over with debris. B didn't have that problem, we're assuming it's a pusher fan thing. I plan on putting the two small puller fans on the primary fan circuit. Those shouldn't attract as much debris and hopefully will be adequate for cooling most of the time. Then put the two big pusher fans on the second circuit, probably with a bigger relay and fuse. One morning the clutch pedal was almost to the floor but still worked. Eventually pumped up and seemed to work normally the last couple days and ever since. Mpact clutch disc seems a lot smellier than the one I had before but worked fine. It smelled like I'd been slipping it badly a bunch of times and while I was certainly working it in the woods it didn't seem to be slipping. Only used the low range once but had the center diff locked most of the weekend. Unlocked it a few times for long gravel roads. It did lock itself a couple times but then stayed unlocked all the way home and the next day of driving. Not making any more noise than usual. The next day while driving parts to heat treat in town some hispanic guys in their 20s were stopped next to me at a stop light. They signaled me to roll down my window and asked if the Impreza was fast. I just told them it had a six cylinder. Driver says me too and asked if I want to race. Sure. Light turns green and I let out the clutch at about 5000RPM and it proceeds to slip pretty badly as the car accelerates. Meanwhile their Chrysler 300 front driver is burning a tire. I had a couple car lengths on him but he stayed in my blind spot up to about 50mph when I backed off. The next weekend my wife and I went up north and stayed with some of her family. Impreza cruise seems to be working consistently, I wonder if the connection to the trans was getting loose/dirty. Has a bit of a wiggle when cornering sometimes. Eventually figured out one of the inner lateral link bushings is shot. Trans was noisy on the way back up north but has been quiet lately. Mostly in the center diff portion I think, when locking that it's definitely quieter (when it's noisy). It does have three different models of tires on it at slightly different pressures. Did lock the center diff by itself a couple times after the rebuild but hasn't in a while.

Any updates on this? Going to do any racing this summer?

Video from our trip to Arizona in April