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Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG
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Ryan_S
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PostPosted: Wed May 05, 2021 10:29 pm    Post subject: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

I am just starting to gather all the components to get my car running. The car has been sitting with a broken "pro street" type 1 transmission for past 5 and a half years, I blame myself and the launch control button for the broken type 1 trans.

I'm recording a vlog while I build. I'll be updating the youtube channel and the build page here as I can, and as parts roll in.

the "too long didn't watch" details of the build are as follows.

1969 VW Karmann Ghia, SubaruGears RWD reversed ring and pinion into TY751 subaru split case 6 speed transmission, LSD, mated to a Subaru EZ30 H6 3.0L, Megasquirt MS3 ECU. As of right now no plans for turbo as the 3.0 puts out a decent amount of power. The stock reported numbers are 240hp/220 ft lbs at the crank.

I am hoping to get some advice on a clutch. Any input would be greatly appreciated. Also if anyone has any input on the 6mt conversion and cutting/welding they did to the center diff that would be greatly appreciated.

Here's part 1.


Link


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Subaru EZ30 & 6MT build thread https://www.thesamba.com/vw/forum/viewtopic.php?p=9645526

~sold~ Old DIY 1915 EFI/Microsquirt build https://www.thesamba.com/vw/forum/viewtopic.php?t=616855


Last edited by Ryan_S on Thu May 27, 2021 12:19 am; edited 1 time in total
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PostPosted: Thu May 06, 2021 6:46 am    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

Following! Looks like fun.
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PostPosted: Thu May 06, 2021 8:09 am    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

Nice swap idea! The Subaru 6 cylinder sounds 100 times better then the subaru 4 cylinders. Truely awesome sound, smooth and throaty.

You wont need a turbo, that 240hp/220ftlbs of torque will do more then the turbo 4 cylinder subies and you wont sound like a engine limping with a dead cylinder.
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PostPosted: Thu May 06, 2021 10:01 am    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

At least you wont have to worry about losing your back seat, unless you count a flat wood board wrapped in vinyl, a "seat".
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PostPosted: Thu May 06, 2021 11:32 am    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

for clutch get a southbend stage 2 and you will have no problems. whatever you do make sure you send out your ring and pinion to get race prepped at Weddle industries. with megasquirt controlling i would throw in a turbo!! are you just going to use the stock 6 speed lsd? i am running it in a 5 speed and it is awesome!!!
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panel
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PostPosted: Thu May 06, 2021 3:02 pm    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

https://engineswapdepot.com/?p=14853


Link

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Ryan_S
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PostPosted: Thu May 06, 2021 9:38 pm    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

jpaull wrote:
Nice swap idea! The Subaru 6 cylinder sounds 100 times better then the subaru 4 cylinders. Truely awesome sound, smooth and throaty.

You wont need a turbo, that 240hp/220ftlbs of torque will do more then the turbo 4 cylinder subies and you wont sound like a engine limping with a dead cylinder.


I've heard a few different videos on youtube here and there, and the videos of the factory cars with a header and it does sound really nice. Some describe it as sounding like a Porsche flat 6.
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Last edited by Ryan_S on Thu May 27, 2021 12:19 am; edited 1 time in total
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Ryan_S
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PostPosted: Thu May 06, 2021 9:43 pm    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

gprudenciop wrote:
for clutch get a southbend stage 2 and you will have no problems. whatever you do make sure you send out your ring and pinion to get race prepped at Weddle industries. with megasquirt controlling i would throw in a turbo!! are you just going to use the stock 6 speed lsd? i am running it in a 5 speed and it is awesome!!!


Thank you for the recommendation. I should have mentioned I also am curious if a lightweight flywheel makes sense for this build. I know there are pro's and cons for ACVW, but not sure about Subaru.

Are you talking about the REM finishing Weddle will do to a R&P?

I actually haven't opened the case up to see if it has an LSD in it from the factory. I would guess it doesn't but who knows. Regardless I ordered the subarugears LSD, I know their stub axles will work.

I wouldn't mind doing a turbo at some point. I think I'll focus on getting everything running right, cooling, tuning, etc before I think about that much of a power upgrade. I will likely be doing E85 first things first though. I don't know if I could keep the trans alive with a turbo. I'll have a hard enough time as it is not dropping the clutch all the time.
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Subaru EZ30 & 6MT build thread https://www.thesamba.com/vw/forum/viewtopic.php?p=9645526

~sold~ Old DIY 1915 EFI/Microsquirt build https://www.thesamba.com/vw/forum/viewtopic.php?t=616855


Last edited by Ryan_S on Thu May 27, 2021 12:19 am; edited 1 time in total
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Ryan_S
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PostPosted: Thu May 06, 2021 9:46 pm    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

panel wrote:
https://engineswapdepot.com/?p=14853


Link


Thanks for linking the video, that guys build is insane! it's a shame he doesn't update his webpage anymore.

This is his original webpage. It has TONS of good info and pictures, but it is a clunky website to navigate. If I had a lift to pull the body off I would be very tempted to do AWD.

http://www.basilari.com/
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Subaru EZ30 & 6MT build thread https://www.thesamba.com/vw/forum/viewtopic.php?p=9645526

~sold~ Old DIY 1915 EFI/Microsquirt build https://www.thesamba.com/vw/forum/viewtopic.php?t=616855


Last edited by Ryan_S on Thu May 27, 2021 12:18 am; edited 1 time in total
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Ryan_S
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PostPosted: Fri May 07, 2021 11:40 pm    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

In this video I document some items I could have covered better, such as the difference in the reinforcement webbing on the 5 speed and 6 speed. I also look much more closely at the unfortunate broken electrical components on the JDM engine.

In addition to that I pulled my megasquirt 1915cc out. I am hoping to find a young college aged engineering student who would be interested in buying the engine for a good deal and would continue the project. I cover some more backstory in the video, but basically I want to find someone who will learn and grow their engineering passion with this engine like I did when I was in school. I'm in the Southern California area and willing to mentor a bit to get an engineer started on the project. If any of you know any suitable candidates that would benefit from and enjoy this project engine please let me know. If I can't find anyone I'll sell the engine with the option of buying it with the 1915 spec Kadron set I have.



Link


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Subaru EZ30 & 6MT build thread https://www.thesamba.com/vw/forum/viewtopic.php?p=9645526

~sold~ Old DIY 1915 EFI/Microsquirt build https://www.thesamba.com/vw/forum/viewtopic.php?t=616855


Last edited by Ryan_S on Thu May 27, 2021 12:18 am; edited 1 time in total
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Ryan_S
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PostPosted: Wed May 26, 2021 9:18 am    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

I can't get these drums off. I made a custom gear puller tool to pull the drum and sheared the bolt on it. Anyone have any ideas?

I had put blue loctite on the splines to stop the drums from shearing their splines circa ~6 years ago or so. The loctite worked, I stopped shearing drum splines. I'm probably going to cut the drums up.

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PostPosted: Thu May 27, 2021 9:24 pm    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

panel wrote:
https://engineswapdepot.com/?p=14853


Link


come on now i cant be the only one who just got a boner listening to that masterpiece Shocked Very Happy
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PostPosted: Thu May 27, 2021 9:33 pm    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

nice work! i will be following along. one day i want to build an early notchback with the same powertrain. AWD would be neat too as you mentioned. would help balance the weight out too. if you have the fab skills anything can be done.
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gears
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PostPosted: Sat May 29, 2021 7:21 am    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

The KG will get up & go with the Subie 3.0. With that extra rearward weight, I'd replace the subiegears TBD with a true (plate style) LSD for off-throttle stability.
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PostPosted: Sat May 29, 2021 8:41 am    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

Heat will break down the loctite.
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Ryan_S
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PostPosted: Tue Jun 01, 2021 3:49 pm    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

gears wrote:
I'd replace the subiegears TBD with a true (plate style) LSD for off-throttle stability.


First I've heard of this phenomena. I'll have to research some more. I have a feeling for the time being the car will keep it's subarugears LSD. Thanks for the heads up.

johnnyvw164 wrote:
Heat will break down the loctite.


In the video it shows a tiny portion of when I was using a propane torch. I suppose I could give the oxy torch a go. I may attempt more heat next go around.

Chickensoup wrote:
nice work! i will be following along. one day i want to build an early notchback with the same powertrain. AWD would be neat too as you mentioned. would help balance the weight out too. if you have the fab skills anything can be done.


Thanks! My problem right now is space and lift capability, as you can see by my small "garage" lol. I've seen a handful of builds started but never a finished product.

One neat thing about an AWD build... SubaruGears doesn't recommend going beyond 400 ft lbs or so of torque through the "Hi-power" R&P gear. Going AWD would lower the total torque going through the rear wheel R&P, distributing some of the torque through the front wheels.

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I'm still waiting on trans parts to arrive from SubaruGears/Subiworks.




.
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Ryan_S
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PostPosted: Mon Jun 21, 2021 4:25 pm    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

I spent a little more time on the project yesterday. I began taking the H6 intake apart to begin planning on what intake/ITB's I want to build.

I'm thinking about using Triumph 675 Dayton ITB's for my ITB's. These bikes are a 3 cylinder bike, so easy work for a flat 6. The H6 oval intake shape should have an equivalent diameter of about 42mm. Google searching is saying these ITB's have a throttle diameter of 44mm so a tiny bit oversized will most likely work ok.

There's a Porsche flat 6 build with these for their ITB's, although I don't like that they have unequal length intake runners. As shown in this thread these ITB's can be split into individuals. I'm planning on splitting these ITB's, I'm sure the linkage would be tricky after splitting them but we'll see.
https://www.triumph675.net/threads/dayt ... che.37461/

If anyone has a better ITB suggestion I'm open to it. I'm specifically looking for ITB's that can be readily split into singles and spaced appropriately for proper intake runner length/design.

Regarding the round ITB to oval port I'm thinking about 3D printing a manifold then lost wax casting it out of aluminum. I've always wanted a good excuse to do this.

Check out the video below for my process to create the first pass at an intake manifold flange for dimension checking.

Image may have been reduced in size. Click image to view fullscreen.



Link

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Ryan_S
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PostPosted: Mon Jul 05, 2021 10:32 am    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

Well I ended up cutting the drums up to undue the E brake lines. Even after cutting the drums the lines were not easy to get undone.

Spalding Auto Parts from Spokane WA shipped me this section of harness out of a 2006 car. This will make wiring everything up a breeze.

My SubaruGears internals have all arrived. No excuses now... I have to tear apart the transmission.


Link



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~sold~ Old DIY 1915 EFI/Microsquirt build https://www.thesamba.com/vw/forum/viewtopic.php?t=616855
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PostPosted: Tue Jul 06, 2021 12:57 pm    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

Ryan_S wrote:


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there was a guy who printed his manifolds with a high temp filament for a turbo type 4 set up. lemme find the name. may be an easier option than casting although ive been playing around with that idea as well.
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PostPosted: Tue Jul 06, 2021 1:07 pm    Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG Reply with quote

https://www.thesamba.com/vw/forum/viewtopic.php?t=...p;start=40

i think the answer is somewhere in here
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-'05 B5.5 TDI Wagon 17in sport rims ;EGR + BSM + ASV Delete, Stage-2 Tune, straight pipe
'65 Tourist Delivery Build
'66 RIP
'69 RIP
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