My suby 2.5 conversion

streetbuggy8804 · Posted: Sat Feb 11, 2012 5:40 pm Post subject:

Got some goodies.

Rear facing Thermostat housing.
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Got these Fromm the junk yard. They were already cut off where the cat or merged part would be. Works well for my needs. To to chop and re weld.
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GTBRADLEY · Posted: Sat Feb 11, 2012 7:15 pm Post subject:

Any updates Shawn? Or did we switch over to the other Subi build?
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1973 Surfer GT Boat
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that is family owned since new

Baja68 · Posted: Wed Feb 15, 2012 6:52 am Post subject:

Nah I am still working on the body and I have a budget on how much I am letting my self spend a month so its going slow.

I did finish small things on the motor finished making my pcv system and finished the return fuel line system into the tank.

And I got the accel cable tied in and working.

I really would like to finish the paint and body so I can put the car back together for test drives so I can test my rear radiator system.

I also need to get the body on so I can weld up the exhaust in the correct position.

So I am still gathering parts and fixing 40 year old body issues Smile

I have not given up and I will not! Twisted Evil

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diffdude · Posted: Wed Feb 15, 2012 12:17 pm Post subject:

I have a Wrx exhaust manifold if you need the exhaust to sit higher than the manifolds you got . I tryed it on mine but it still sat to low for my liking so I had to make my own.

Baja68 · Posted: Mon Feb 20, 2012 6:51 am Post subject:

So over the weekend I was looking things over and I noticed when operating the gas pedal it was not opening 100% when I had the pedal all the way depressed. It was only going about 75% open at the throtle plate.

So I found I had to modify the gas pedal stops it works now Smile

I am glad I found this out before I test drove it and thought it would not go fast enough Smile

Just one more thing to add to the conversion list.

Getting alot closer on the body soon as it's done I can move on to test drives and testing the cooling system.
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streetbuggy8804 · Posted: Mon Feb 20, 2012 8:31 am Post subject:

I'm still dealing with the throttle issue. Can you post some pics?

Baja68 · Posted: Mon Feb 20, 2012 12:32 pm Post subject:

Sure I will get some tonight after work and put them up for ya.
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Baja68 · Posted: Tue Feb 21, 2012 4:04 pm Post subject:

Ok Street here the pics of what I did with the throtle cable.

I had the factory line that was cut so I tied my cable to that cable using a barrel nut I had to drill the barrel nut hole out to be big enough for both cable to slide through.

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Three places on the pedal had stoppers that had to be cut off.
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streetbuggy8804 · Posted: Tue Feb 21, 2012 6:28 pm Post subject:

Dang. That is a good and simple fix. Unfortunately mine throttle body is not the same. Back to the drawing board for me.

Baja68 · Posted: Sat Mar 31, 2012 2:47 pm Post subject:

just an update for yall I found my front end had play in the tube bearings and bushings so complete rebuild on the the beam is what I decided on.

I finished the beam and ball joints and decided to order weld in ajusters instead of the 1 bolt type it already had they should be here next week.

I finished the fuel filter I decided to go with the subaru filter and clamp from a 2002 forester it worked out good.

The body is ready for paint I bought a new paint gun off the snap on truck and will be shooting in over the course of next month.\

Got a factory radiator and fans need to finish the body so I can do the exhaust and then its just put it all together and drive it Twisted Evil

here is a pic of my filter set up -- you can also see where I ran the return line through the tunnel same as the main fuel line.

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Street hows yours coming ??
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Baja68 · Posted: Mon Apr 30, 2012 9:47 am Post subject:

Here are a few pics of what I plan for for the radiator I have a used radiator in it factory radiator.

I just zip tied it in for test drive if cooling is suffeciant I will weld in a mounting system to the rear bumper.

Just need to finish the paint and do the exhaust and the car is done come on paint work Mad

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streetbuggy8804 · Posted: Mon Apr 30, 2012 10:39 am Post subject:

Are you planning on using a surge and or overflow tank?

Baja68 · Posted: Tue May 01, 2012 8:44 am Post subject:

Ya I will use the factory over flow tank it fits right in on the passanger side of the radiator.

I have not bought one yet on the list Very Happy

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Baja68 · Posted: Fri May 25, 2012 7:48 am Post subject:

Since I am using the factory harness and ecm I have to run my own temp sensor to my VDO temp guage. Since the factory temp sensor in the coolant cross over and hooks straight to the ECM for the EFI.

I figured I would put up the part and part source I used for any one else wanting a solution that was cheap and good fit.

I used an adapter from EBAY
http://www.ebay.com/itm/150804670918?_trksid=p3984...mp;vxp=mtr

and the VDO sensor from Jegs
http://www.jegs.com/i/VDO/918/323-057/10002/-1

The adapter I had to drill the back side hole larger the sensor was to tight fit after the threads but that was a real quick and easy modification.

The adapter and sensor went into the coolant plug here ( I chose the back of the #2 cylinder side this is the side known to run hotter its by the starter)
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Baja68 · Posted: Thu Jun 21, 2012 8:37 am Post subject:

Ok I am back at it with my rebuild

I spent a few days putting everything into a box I built for the rear seat area.

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put my tail lights on and my alternator on.

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Added fuel return line to the fuel tank and a vent line to vent pressure out.

I also made some front support brakets from the front beam to the front of the buggy.

So I went to put coolant into my free donar radiator and it leaked like crazy so I have now ordered a radiator.

I am starting to rethink my exhaust originaly I was going to do duel exhaust but I am starting to wonder if this my be a bad idea since the factory Y-pipe header I have on it now merges the 2 sides to one like a VW merge exhaust. I had a talk with the techs and they brought up the meged pipe will help with scavaging and balancing the exhaust to give you a wider power range.

So I am still up in the air on the exhaust I flipped the header to face the trans under the car wich looks cool but I loose some ground clearance this way.

So coming right along I will take some more pics of the braces and the exhaust tonight and put them up soon.

started it with the key last night sounds AWESOME ! but its an open header Smile

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Subarugears · Posted: Fri Jun 22, 2012 2:56 am Post subject:

You have probably worked this out and thought of it....but....if you are using the factory shrouds and fans, they will suck air through the radiator and forward over the engine and trans. Is that your intention?

If you want to draw the air out the back you will need to reverse polarity on the fan motors however they will not work as well as push fans. The shrouds and fans should be on the rear of the radiator if your intention is to get the hot air exiting out the back, running the wiring and polarity as standard.
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Baja68 · Posted: Fri Jun 22, 2012 5:50 am Post subject:

Good question yes this is an area of great debate.

I plan on using the fans in there factory set up wich will be pulling air in towards the engine.

2 things here to consider the fan shrouds are designed to draw air from the whole face of the radiator by the shroud it looks to be design to creat a type of vacume in the shroud to pull air across the whole face. Also I belive the air that goes under the car will be kicked up after it passes the bottom of the radiator.

When I tested the air flow through this set up by running the fans both directions the fans don't push hardly any air I belive due to the shrouds.

If this turns out to not function as I intend I plan to buy aftermarket pull fans to hook to the oter side of the radiator.
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Baja68 · Posted: Fri Jun 22, 2012 6:04 am Post subject:

As I was saying about the brackets and the exhaust here is some pics of the front brackets I made and pics of the exhaust header flipped to face the front.

I am thinking about taking the exhaust off the header and splitting it then runnig it to the back on each side of the motor.

My only concern with this exhaust idea is I loose ground clearance couple of inches I am not sure if I want to loose any ground clearance. Still thinking about it.

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Baja68 · Posted: Fri Jun 29, 2012 2:02 pm Post subject:

ok found the problem with my fans I had wired the fans up

so that the trigger from the ecm would supply 12v to the relay.

Come to find out after reviewing the wiring diagram that the ecm applies ground to the trigger wire not power.

DOH!!!

well problem solved YAY!
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Baja68 · Posted: Mon Jul 02, 2012 8:00 am Post subject:

Cars coming along fine

The rear radiator works just fine as far as at idle it does not over heat fans cycle properly.
Temp guage goes to 205 the fans come on the guage goes to 180 fans go off.

I am working on exhaust and A/F - O2 Sensors at this time but my mufflers were damaged in shipping so I get to wait 7-10 days to resove this issue
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Here are some pics of location consideration I was doing I am thinking face them straight out the back not facing up and point them out a little to keep the heat off the radiator here are some pics of the muffler sitting on a trash can to get an idea.

I bought red carbon fiber mufflers so they would stand out more and match the car color.

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So whats left

-do exhaust and sensors
-inspection - registration - insurance
-install hood
-install seats
-install head lights and blinkers frt
-install seat belts
-alignment

-drive it to dial in suspension
-drive it to test rear radiator at high way speed for proper cooling.

If all goes to plan with the rear radiator cooling properly have to pull rear bumper and weld in supports for radiator and repaint it.
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My suby 2.5 conversion
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