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Subaru Conversion Build and partial how-to
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notchboy
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PostPosted: Wed Sep 11, 2013 10:34 am    Post subject: Reply with quote

Awesome work brother!

Im happy to know someone that will help me with my conversion when and if that day comes.

Keep up the work and hurry up! This shits taking like what 3 years now? More?
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Sloride
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PostPosted: Wed Sep 11, 2013 1:37 pm    Post subject: Reply with quote

Keep at it and keep posting pictures.

It seemed like it took me an eternity to do the conversion in my bus but since then I have been driving and loving it.

What are your plans for the rad?
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JSMskater
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PostPosted: Wed Sep 11, 2013 2:29 pm    Post subject: Reply with quote

notchboy wrote:
Awesome work brother!

Im happy to know someone that will help me with my conversion when and if that day comes.

Keep up the work and hurry up! This shits taking like what 3 years now? More?


naw not that long... maybe 2 years? shit. Maybe it is coming up on 3 years now...

mostly its been sitting cause I was finishing out my degree. Now I'm out of school and still unemployed so, lots of time for the bus! Plus I have to move at the end of the month, so the car has to at least be driveable by then...
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PostPosted: Wed Sep 11, 2013 3:52 pm    Post subject: Reply with quote

another update Cool

got my fuel return elbow back!

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I need to shorten the ends so it'll fit right, but it's got the bend and the fuel return nipple for the EFI so I'm happy. Cool


someone asked about rads:

here is the steel I'm making into a mounting bracket/ bypass air dam for the rads. There will be a twin/mirror on the other side.

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the rad, 1 of 2 (the other will be mounted similarly on the other side) it's a single pass scirocco/ VW mk1 radiator. I wanted to do all aluminum dual pass, but the thickness and weight wasn't going to work in the confined space.

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stock subie fan
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I have to rig up a mounting system for these. or maybe find some mk1 vw fan shrouds.
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PostPosted: Wed Sep 11, 2013 6:14 pm    Post subject: Reply with quote

Very inspiring!

Sorry if I missed it - have you decided on what starter to use with the KEP adapter?
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Lionhart94010
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PostPosted: Wed Sep 11, 2013 6:40 pm    Post subject: Reply with quote

With a twin rad on the other side it looks like you will have plenty of cooling :0)

Someday I may want to have a Subie option, I saw a couple on YouTube they seem to accelerated extremely well
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PostPosted: Wed Sep 11, 2013 11:06 pm    Post subject: Reply with quote

Fodder wrote:
Very inspiring!

Sorry if I missed it - have you decided on what starter to use with the KEP adapter?


right now the stock one is in there, and I was going to try using it before I went out and bought a heavy duty one. Some people have gotten away with using the stocker.
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Nepenthe88
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PostPosted: Thu Sep 12, 2013 7:57 am    Post subject: Reply with quote

JSMskater wrote:
stock subie fan
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Yes! This!!
This is definitely the way to go about doing a Subee transplant in a bay. It's a clean elegant solution and one that's proven to work in the hot HOT Aussie summers. You rock. The only reason I plumbed my bus different was cause the PO hacked giant holes in each back side. Booo!! And trust me when I say those stock subee fans are PLENTY strong enough to pull air thru the stock fresh air vents. So long as no air can escape around the radiators you shouldn't have a cooling issue. Here's a quick video of the air-flow being generated by one stock subee fan on my bus:

Link

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PostPosted: Thu Sep 12, 2013 8:23 am    Post subject: Reply with quote

Nepenthe88 wrote:

Yes! This!!
This is definitely the way to go about doing a Subee transplant in a bay. It's a clean elegant solution and one that's proven to work in the hot HOT Aussie summers. You rock. The only reason I plumbed my bus different was cause the PO hacked giant holes in each back side. Booo!! And trust me when I say those stock subee fans are PLENTY strong enough to pull air thru the stock fresh air vents. So long as no air can escape around the radiators you shouldn't have a cooling issue. Here's a quick video of the air-flow being generated by one stock subee fan on my bus:

Link


awesome video! I have no doubt it will work -- lots of others have done it successfully. I wish I had access to a CFD program so I could build a computer model but alas, I don't have 5k to drop on engineering software for personal use. Laughing

btw, I owe a lot of my conversion to some of your postings/musings via the wiring -- you'll notice I borrowed your fuse block/relay board design. keeps everything neat, and I have an orange LED light for my CEL. I might actually have a few questions for you about the wiring once I'm all done putting it back in -- namely I have 3 wires I'm rather clueless as to where they go/what they are, and they're not mentioned in that big long EJ22 conversion thread on STF.
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Nepenthe88
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PostPosted: Thu Sep 12, 2013 9:05 am    Post subject: Reply with quote

JSMskater wrote:
btw, I owe a lot of my conversion to some of your postings/musings via the wiring -- you'll notice I borrowed your fuse block/relay board design. keeps everything neat, and I have an orange LED light for my CEL. I might actually have a few questions for you about the wiring once I'm all done putting it back in -- namely I have 3 wires I'm rather clueless as to where they go/what they are, and they're not mentioned in that big long EJ22 conversion thread on STF.


Oh, hey thanks! If you go to the "EJ22 in the flatback bug" thread link in my sig (which you've obviously already been to) I should have posted links to all the documents I used to do my wiring harness. Theoretically, the answer should be in there somewhere Very Happy Either way, PM me or post whatever questions you have and i"ll do my best to answer them! I'll be watching.

Also... I'm gonna pull the engine that's currently in my bus (works off a three plug engine harness) and swap it for the engine I was working on in the Flatback thread (2 plug engine harness) in a few days/weeks. That said, I'll have a working three plug harness I have no use for pretty soon. If someone else is afraid of doing the wire harness work and wants it, PM me. I'm sure we can work something out. Granted, it's not the tidiest bit of electrical engineering as it was done by the guy who started my subee swap, but it works (I've been driving with it). Thanks for the Hijack Very Happy
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PostPosted: Mon Sep 16, 2013 12:34 pm    Post subject: Reply with quote

Twisted Evil progress

the rad fan modified -- had to cut off the stock tabs and weld on longer ones. I plan to eventually shroud the exposed parts of the rad on the right, top, and bottom with ABS plastic I can form with my heat gun.

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pardon my heinous welds -- I'm out of practice and the steel I was using for the tabs/extensions was considerably thicker than the fan shroud steel, so I had problems with blow-through and getting the right setting on the welder.

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this is when it was just tacked in
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fully mounted Cool its still a little ugly, but with some paint and grinding it'll look damn near professional.

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as you can see, it blocks air from escaping except through the rad. this is the key. There will be sealing foam around the edges to prevent air from leaking past where it meets the body.

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profile to get an idea for thickness
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mocked in the car, not attached. I will be using riv-nuts where the stock insulation rivets used to be, with a tab welded onto the rad bracket so I can pass a bolt through to mount it. There will also be a tab on the bottom where it meets the body.

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it's at an angle here so it wouldn't fall over, but you get the idea.
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this gap will be filled with some abs plastic and/or foam seal.
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another overall shot

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what I plan to do for the intake manifold clearance problem...

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I'm having the "U" pipe made up as I type... Cool


moving on to the fuel pump and lines today! more to come!
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PostPosted: Mon Sep 16, 2013 12:58 pm    Post subject: Reply with quote

JSMskater wrote:
another update Cool

got my fuel return elbow back!

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This is a great idea! It would also work nicely for someone who wants to turn a carburetted bay into an FI one instead of replacing the tank. Early bays already have a metal line so the mod would be simple. Nice job!
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PostPosted: Mon Sep 16, 2013 12:59 pm    Post subject: Reply with quote

wow. that engine is CLEAN, and nicely uncluttered without all the rigamarole and wires attached. Must be nice to work on like that!
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PostPosted: Mon Sep 16, 2013 2:54 pm    Post subject: Reply with quote

Sourced your u-pipe locally I assume? Exact specs would be nice for future converters who don't want to reverse the intake manifold. Thx.

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PostPosted: Mon Sep 16, 2013 7:42 pm    Post subject: Reply with quote

man... THIS IS AWESOME! Im sitting down and watching this thread! Keep it up man, your the man!
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PostPosted: Thu Sep 19, 2013 8:35 am    Post subject: Reply with quote

update!

so day before yesterday, I tried to install my fuel tank filler neck elbow replacement. I discovered that the alignment isn't perfect, but close enough to work without issues. Just wish I could kink the tip a tad. Anyways, I fought for 4 hours trying to get this thing in, and failed. I discovered what the problem was:

some bozo, probably the same bozo who cut the hole in my rear deck to get access to the gas gauge sender, replaced the filler neck hose with one that is 2" diameter. the pipe is 2.25". While at the time the rubber might have been soft enough to stretch, the hacked out straight sections I was using were NOT. So it wasn't sliding on the hard tubes in any appreciable way other than banging on it with a ring and a mallet.


SO I went to NAPA after discovering with my calipers the erroneous hose diameter, and got the correct 2.25" filler neck hose....

I was done in 20 min. Rolling Eyes Laughing Brick wall

with new hoses:
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old on left, new on the right.
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installed.
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you'll notice theres a slight kink- I ended up using my manly muscles to push these into a better alignment after I took the photos, but even so the misalignment isn't terrible. Not enough to cause leaks, and I used extra long hose length so it would seat perpendicular to the surface of the pipes, the "bend" in it is taken up by the flex in the rubber. we're good to go Cool
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sorry the photo is blurry, it was dark by the time I got to finishing this:
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that, is a rivnut or rivet nut. Basically a rivet that has a threaded inner hole. I was able to re-use the existing insulation holes with these rivnuts, so I can re-install insulation and the radiator brackets with removable screws. I plan to use a few more, since they're rather small/wimpy screws. I could go larger on the rivnuts, but they get harder to install with a hand riveter the bigger you go and I'm almost out of funds for new tools. Laughing
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vwnutt6969
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PostPosted: Thu Sep 19, 2013 11:17 am    Post subject: Reply with quote

Awesome job!
I'm getting my ducks in order to do the same to my 71 westy.
Only issue I'm having is, who makes the engine mount for this swap?
I have searched and searched and read but it seems to be the one thing no one talks about.
Could you post a photo of the mustache bar adapted to the EJ22?
Thanks!
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PostPosted: Sun Sep 22, 2013 9:10 pm    Post subject: Reply with quote

phew. another update!!

radiator frame drivers side, final fitting before I weld it all up legit.

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you can see here how it mounts -- tabs, with bolt head screws into the rivnuts. it is a TIGHT squeeze in there to get em in, but it is not difficult and can be done quickly. holds it tight too. the bottom has a bracket that follows the curve of the body, and is supported by a pair of studs.

this is how you mount the rad:

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already attached to the frame/bracket with screws/washers from the other side, you swing this into place and it's supported from underneath by the studs and lower curved bracket. this way, you can easily install the upper bolts while still having some wiggle to get them in straight and without binding.

largest gap, this will be filled with a panel of plastic or foam seal.
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upper bolts
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the clearance in the back near the firewall -- pics tomorrow of it all fitting together but trust me it all fits!

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with the rad mounted. this one is larger than the other, and the subaru had these asymetrical size fans. why? I don't know. But I'm repurposing what I have for now, but down the line I'll get the smaller from a junk yard and mount that instead for a cleaner look and better fit.
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(dont mind the missing screw in the corner, I was just mocking it up)

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annnd now the other side Twisted Evil

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same process for installation as the other side. mount rad to frame/bracket, swing into place, and bolt up. I haven't made the tabs for the top yet in these shots, but I'll do em up tomorrow.

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fan for that side isn't done yet, but this is what it'll look like, but with the modified tabs and some extensions to the other side like the first rad fan.

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(1st fan for reference:)
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believe it or not (since it's still stained as hell) I scrubbed for over an hour with a blue pan sponge to get the engine bay clean. I think I may shoot it in black undercoat or something down the line. I didn't bother with the areas that will be hidden, just the engine bay aft of the firewall.

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so, this part is ridiculously expensive (250!) but it did take time to make and I needed it fast so I can't really b*tch too much. this was the first attempt by the shop I contracted to make the throttle reverser:

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and it was obviously a tad too tall.

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so....
we fixed it. Cool

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with the engine lid shut (don't mind the disintegrating plastic)

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sooo I'm exhausted but I have to keep pounding away at this. tomorrow I should have the engine hanger bar sorted out, and maybe get around to plumbing up the cooling and fuel systems. BTW the intake pipe is fully welded cleaned up and finished now, just haven't shot any pictures.

more to come!
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notchboy
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PostPosted: Mon Sep 23, 2013 8:06 am    Post subject: Reply with quote

Nice, clean install. Cool
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PostPosted: Mon Sep 23, 2013 2:25 pm    Post subject: Reply with quote

Yeah! Keep this going! Inspired over here!
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