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Team WorldTour Samba Member
Joined: September 02, 2010 Posts: 2426 Location: Der Vaterland
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Posted: Sun May 22, 2011 9:10 am Post subject: |
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So, it's finally going to happen! On 27 May, I will be starting the conversion!
Today I pulled out the interior so I could get to the rust that is bleeding through the exterior paint.
This is the outside now-
Just to better illustrate the issue....
And from the inside....
Anyone care to help out would be greatly appreciated... _________________ 1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat! |
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levi Samba Member
Joined: February 11, 2005 Posts: 5522 Location: Las Vegas
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Posted: Sun May 22, 2011 8:15 pm Post subject: |
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Good!
I've been looking forward to this, since as far as I know, no one has chronicled the process yet. _________________ One of these days I'm gonna settle down,
but till I do I won't be hangin round.
Going down that long lonesome highway,
gonna see life my way
https://youtu.be/cSrL0BXsO40 |
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Team WorldTour Samba Member
Joined: September 02, 2010 Posts: 2426 Location: Der Vaterland
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Posted: Thu May 26, 2011 1:32 pm Post subject: |
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On the night before I start my conversion project, a steady stream of nightmare senarios are parading through my head. I try to steel myself against them by reminding myself that I have studied the RJES disk that came with my bellhousing; that I have studied everything Eric has given my so far.
But still the nagging is there. My girlfriend doesn't understand why I have spend the equivalent of a years-worth of her pay on this project. She doesn't see the point when the van ran good and we enjoyed it so much.
Now I'm afraid. The what-ifs have set in.
WHAT IF- everything goes wrong?
WHAT IF- I don't finish in time?
WHAT IF- I've forgotten something?
WHAT IF- WHAT IF?!?!!!?
I look at my van right now, and I can't help but wonder- 'I thought $19,000 worth of stuff would take up more space'. hmp! _________________ 1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat! |
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Spinal Tap Samba Member
Joined: August 01, 2008 Posts: 413 Location: Chicago IL
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Posted: Thu May 26, 2011 1:43 pm Post subject: |
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It'll be OK. Get started. Break it down into small, manageable chunks of work. Apologize to your GF now for all the time you'll be spending with the Van an not with her.
It'll be alright.
If you weren't so far out west, I'd off my amateurish rust remediation and welding experience. _________________ '85 Westy
'74 MG-B
RCB wrote: |
Its called tact...and tact is the ability to tell someone to go to hell in such a manner that they anticipate the trip. |
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Team WorldTour Samba Member
Joined: September 02, 2010 Posts: 2426 Location: Der Vaterland
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Posted: Thu May 26, 2011 1:46 pm Post subject: |
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Spinal Tap wrote: |
If you weren't so far out west, I'd off my amateurish rust remediation and welding experience. |
I'm actually in Germany..... _________________ 1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat! |
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Spinal Tap Samba Member
Joined: August 01, 2008 Posts: 413 Location: Chicago IL
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Posted: Thu May 26, 2011 1:54 pm Post subject: |
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Domo wrote: |
I'm actually in Germany..... |
You should have said...I was in the UK the other day, which is probably closer than Chicago is to the Pacific...
Good luck! _________________ '85 Westy
'74 MG-B
RCB wrote: |
Its called tact...and tact is the ability to tell someone to go to hell in such a manner that they anticipate the trip. |
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Zeitgeist 13 Samba Member
Joined: March 05, 2009 Posts: 12103 Location: Port Manteau
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Posted: Thu May 26, 2011 4:02 pm Post subject: |
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Holy cow, $19k?!?!?!? Titanium and platinum better be your preferred fasteners for that kinda cash _________________ Casey--
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik? |
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insyncro Banned
Joined: March 07, 2002 Posts: 15086 Location: New York
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Posted: Thu May 26, 2011 4:20 pm Post subject: |
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Every man needs to know his limitations.
A project like this will present many limiting factors along the way.
How you deal with them is the tricky part.
Keep pluggin'. |
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Team WorldTour Samba Member
Joined: September 02, 2010 Posts: 2426 Location: Der Vaterland
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Posted: Thu May 26, 2011 9:41 pm Post subject: |
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Zeitgeist 13 wrote: |
Holy cow, $19k?!?!?!? Titanium and platinum better be your preferred fasteners for that kinda cash |
$1200- vehicle cost
$3000- parts and shop time to make it roadworthy
$1000- 1.9L engine rebuild (parts and shop time)
$3000- Subi motor
$3000- Eric's parts
$2000- RJES parts
$2500- GoWesty parts
$2000- Van Cafe parts
$1000- rims and tires
(all prices rounded for simplicity)
Looking at the van and seeing $19,000 in parts is seeing EVERYTHING, not just the conversion parts. _________________ 1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!
Last edited by Team WorldTour on Sat May 28, 2011 2:07 pm; edited 2 times in total |
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Team WorldTour Samba Member
Joined: September 02, 2010 Posts: 2426 Location: Der Vaterland
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Posted: Fri May 27, 2011 3:00 pm Post subject: Day 0ne of the engine swap... |
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So, the way this is going to work out is like this: I work a full day, then drive to the barn and work on the van untill dark.
That gives me 3 hours on days I work. I have the barn for two weeks.
So, today I got all the parts unloaded, the Subi motor unloaded,
the coolant drained from the VW motor, all the electrical unplugged, and the drivers side axle out.
The passenger side axle would be out too, but those bolts come pre-stripped. I hope I can drop it down with the axle still in..... _________________ 1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!
Last edited by Team WorldTour on Sat May 28, 2011 2:21 pm; edited 1 time in total |
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Team WorldTour Samba Member
Joined: September 02, 2010 Posts: 2426 Location: Der Vaterland
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Posted: Sat May 28, 2011 2:19 pm Post subject: Day Two... |
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So today I got the second axle out. I broke the EZ-OUT on one bolt, and got the rest with vise-grips and a pipe wrench.
I got the engine on the ground today.
Then my camera died.
In addition to this, I got the transmission off the engine, ready for tomorrow. I have the next three days off, so I expect to get alot of things done. On Monday, I have to go to the Subi dealer and pick up my bolts that finally came in. _________________ 1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat! |
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Team WorldTour Samba Member
Joined: September 02, 2010 Posts: 2426 Location: Der Vaterland
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Posted: Mon May 30, 2011 3:04 am Post subject: Day Three |
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So today I got alot done. I took the tranny to another shop and steam cleaned it.
I got the old engine wireing harness out,
and made the swap to the RJES bellhousing.
Richard- This is the clearance issue I told you about on the phone:
As you can see, the bolt and the fork do not play well together!
I solved the issue by grinding about 2mm off the back of both sides.
Now everything fits and moves as it was meant to!
_________________ 1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat! |
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insyncro Banned
Joined: March 07, 2002 Posts: 15086 Location: New York
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Posted: Tue May 31, 2011 6:59 am Post subject: |
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You don't have to grind a thing if you use a cap head bolt available at any hardware store. |
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RJES Samba Member
Joined: April 23, 2008 Posts: 17 Location: Staffordshire, UK
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Posted: Tue May 31, 2011 8:19 am Post subject: |
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The next batch of the arms for the clutch release shafts are already designed for increased clearance. Also, there is a new option of a 100% new clutch shaft now, for both the pull and push to release clutches. As of a few weeks ago these all come zinc plated and passivated now too.
Regards,
Richard Jones,
www.rjes.com |
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Team WorldTour Samba Member
Joined: September 02, 2010 Posts: 2426 Location: Der Vaterland
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Posted: Tue May 31, 2011 1:52 pm Post subject: Day Five... |
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Yesterday I didn't get much actual work done on Domo. I spent most of my day at Busdoktor.de's yard. Ordered the replacement sill for the rusted out drivers side center. I also ordered a metal fuel line bit. You all know the plastic piece on the firewall that likes to break? This guy makes metal ones. Billited, I think...
The other half of yesterday was spent at the Subaru dealer, trying to figure out what clutch Richard recommended. I had Richard on the phone, and the dealer looking up part numbers that Richard was feeding us. Finally, we ordered three different types in the hope that one of them was correct! The dealer was POSITIVE that they all are 'push' clutches.
Anyway, today I got the engine wiring harnesses swapped out.
Thank you once again for that Eric! You saved me 600Euro! (Thats the going price for these things here! 500 for the big one on the engine, and 100 for the small one on the intake!) I just can't figure out why the auto wrecker would just randomly cut off two plugs, one from each. I said it before, and I will say it again; Don't EVER trust a Russian auto wrecker!!!!
I also got the computer mounted on the firewall.
I put it were the rear heater would sit. I plugged in the main wiring harness, punched a hole in the firewall and ran the wires through.
I started running the new P/S lines and also started trying to figure out the cooling system.
I am still trying to find the correct 'pull release' clutch that Richard recommends, but even the Subaru dealer is having a hard time figuring it out.
Tomorrow a coworker is coming by after work to help run the check engine wiring to the dash and running the throttle cable. I'm still stumped as to how to get it IN the housing.... _________________ 1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!
Last edited by Team WorldTour on Mon Jun 06, 2011 12:04 pm; edited 2 times in total |
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Team WorldTour Samba Member
Joined: September 02, 2010 Posts: 2426 Location: Der Vaterland
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Posted: Wed Jun 01, 2011 11:38 am Post subject: Day Six... |
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Did most of the coolant piping today, couldn't figure out the small black hose though.
I emailed Eric for another set of notes. The first set of notes he sent me are sitting on a crashed harddrive right now....
My co-worker came out after work today. We got into the dash wiring before we realized we didn't have any extra wire.
Then we ran the new throttle cable in the van. After opening the package and reading the instructions, I now feel like an idiot after yesterdays post....
It got dark pretty quick today, summer came and went real quick. It was last Monday. Real nice day, can't wait till next year.... _________________ 1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!
Last edited by Team WorldTour on Sun Jun 05, 2011 3:54 am; edited 1 time in total |
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Team WorldTour Samba Member
Joined: September 02, 2010 Posts: 2426 Location: Der Vaterland
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Posted: Sat Jun 04, 2011 3:41 pm Post subject: Day Eight... |
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So, my co-worker came out again today. We really tore into the wiring.
We got the check engine light and the VSS wired in. I got the throttle cable laid in,
and the cooling hoses all finished.
I am still waiting on a clutch to arrive from the States, but when it does, I think that I will be able to mount the engine and start it up.
Where is that clutch....? _________________ 1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat!
Last edited by Team WorldTour on Sun Jun 05, 2011 3:53 am; edited 1 time in total |
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insyncro Banned
Joined: March 07, 2002 Posts: 15086 Location: New York
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Posted: Sat Jun 04, 2011 3:49 pm Post subject: |
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Sweet.
Can't wait to see it running and driving.
dylan |
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Team WorldTour Samba Member
Joined: September 02, 2010 Posts: 2426 Location: Der Vaterland
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Posted: Sat Jun 04, 2011 3:54 pm Post subject: |
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...me neither.... _________________ 1990 Feldjäger Syncro AAZ
Click to view image
H6 Subaru Engine Swap Thread
WV2ZZZ25ZFH094138(x)/ WV2YB0257LH057308(x)/ WV2ZZZ25ZLG113270/
"Where am I going? And what am I doing in this handbasket?" -Nicodemus Jordan
When All Else Fails: Lather, Rinse, Repeat! |
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levi Samba Member
Joined: February 11, 2005 Posts: 5522 Location: Las Vegas
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Posted: Sat Jun 04, 2011 4:51 pm Post subject: |
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No pics of any of this ?
I was really hoping we were going to have the first documented process.... _________________ One of these days I'm gonna settle down,
but till I do I won't be hangin round.
Going down that long lonesome highway,
gonna see life my way
https://youtu.be/cSrL0BXsO40 |
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