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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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 Posted: Tue Jul 06, 2021 4:25 pm Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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Thanks for linking the thread! I think my only hope is 3D printed lost wax casting right now if I decide to do printed manifolds. That PPS might work but that's some expensive stuff! I just got ITB's ordered and a vacation is coming up so I'll have to wait on design/fab.
Right now my plan is to try some test pieces with sheet metal like the video below. The hope is that I can achieve 1/10th of this guys quality, this guy is a master.
I'm also going to test making bench vice die's to see if I can push annealed copper water tube into an oval shape on one end. Check out the Stuff Made Here videos at the bottom. I'm not sure how to do the math for the spring back of an oval shape though 
For both cases the plan is to use 3D printed tooling.
Link
Link
Link
_________________
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 |
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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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| Posted: Wed Jul 07, 2021 6:50 pm Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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I made my first bench vice pressed 3D printed tester manifold in copper tube. The goal was preserve the round tube on one end and have a smooth transition to a given oval size at the bottom. The results came out really good!
Check out the video for the full build process
Link
_________________
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 |
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Chickensoup
Samba Member
Joined: January 06, 2018
Posts: 5368
Location: Good Hope, GA
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| Posted: Thu Jul 08, 2021 9:01 am Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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thats soo cool! didnt have time to watch the entire video, but it seems like it worked!
_________________
-'85 c10 5.3 LS, 222 cam, long tubes, x pipe, 3 inch spin tech's
-'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
Hosea 4:6 "My people are destroyed for lack of knowledge" |
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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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| Posted: Thu Jul 08, 2021 5:16 pm Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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| Chickensoup wrote: |
| thats soo cool! didnt have time to watch the entire video, but it seems like it worked! |
No worries man! I know my videos end up long but I really do try and cram in as much useful info as I can so others can replicate if they want to pursue a similar path. My goal is to teach others.
I'm really happy with how the copper turned out. I attempted pressing the other unannealed part and it didn't go very well, it started digging into the plastic tool. annealing is very important for this. When I bump up in size for the actual ITB's I'll be sure to hammer the tube while the copper is still on the printed part. Hammering work hardens the copper relatively quickly.
_________________
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 |
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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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| Posted: Fri Aug 06, 2021 11:32 pm Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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Sorry for the project delays, life's been busy. I stared tearing into the Subaru split case 6mt today. I have to say the mechanism to shift the 6mt is really impressive. It's really odd that it's a cable shift mechanism that acts on what appears to be a traditional rod shift once it's torn down. I have to wonder if it's possible to just use a more traditional rod shift instead of a cable shift. Regardless I have a cable shifter + cables assembly out of a 2014 car.
I'm trying to plan how to plug the end of the transmission. There's a lot less material that can be cut away compared to the 5 speed. I knew from the get go there wouldn't be nearly as much to cut but I didn't anticipate it would be so much more material that needed to remain in place.
Plugging the nose of the trans will be a big challenge.
I spent some more time thinking about the plugging process after I finished recording. I'm thinking it's necessary to plug the hole where the gear flings oil, then plug the oil return hole. I think that plus the Subaplug will be adequate. I'll shoot a quick email to SubaruGears to see what they say.
Check out the video below if you want to see the way the shifter mechanism works. It's very impressive
Link
_________________
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 |
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oprn
Samba Member
Joined: November 13, 2016
Posts: 12683
Location: Western Canada
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| Posted: Sat Aug 07, 2021 4:22 am Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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Is it true these engines have a poor record on head gaskets? If so is there a fix? My neighbor has one in a car with this issue and if there is a decent fix I may consider buying the engine from him for a project.
Thanks!
_________________
We had the stone age, the bronze age, the industrial age and now we are in the age of mass deception and mind control for corporate profit. (The mass media age) |
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sled
Samba Member
Joined: February 16, 2005
Posts: 6179
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| Posted: Sat Aug 07, 2021 8:37 am Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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just want to say I'm following eagerly, don't stop posting!
I've had secret (or not so secret) perversions of putting an ez30"R" and five speed into my '58 bus...or in mid-engine layout in my mid 60's race car project.
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drive your split. |
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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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| Posted: Sat Aug 07, 2021 9:09 am Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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| oprn wrote: |
Is it true these engines have a poor record on head gaskets? If so is there a fix? My neighbor has one in a car with this issue and if there is a decent fix I may consider buying the engine from him for a project.
Thanks! |
I've heard both sides say they get high mileage with zero problems and others say head gaskets are the only problems they've seen when they have to work on the cars(the latter from a shop I trust). From everything I've heard these are very rock solid engines. If you watch the "top 3 failures" video below head gaskets aren't mentioned... Hard to say.
Due to my situation and where I live I wouldn't buy an engine with a problem. I live in close enough proximity to the JDM importers to where it would probably be easier and/or more cost effective to just go grab another JDM engine for ~$1200.
| sled wrote: |
just want to say I'm following eagerly, don't stop posting!
I've had secret (or not so secret) perversions of putting an ez30"R" and five speed into my '58 bus...or in mid-engine layout in my mid 60's race car project. |
Do the mid engine 6 cylinder and 6 speed split case(or STI trans?)!
It should be trivial to simply lock out the output shafts and make a 2WD. However, the pinion shaft won't be the strongest due to the oiling holes and bearings still being present which remove material. You would want to see if SubaruGears has a "hi power" pinion shaft that's not a reversed gear. That would be a really easy job of just a pinion shaft and lockout mechanism. Watch the last video if you want to see what I'm getting at regarding the lockout mechanism if you aren't familiar, specifically look for the portion after I pull out the center diff.
The split case 6 speed with cable shift will be SO MUCH easier to get a rock solid shift linkage compared to the rod shift transmissions.
Link
_________________
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 |
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Dauz
Samba Member
Joined: January 05, 2010
Posts: 1790
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| Posted: Sat Aug 07, 2021 9:54 am Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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Say NO to H2O
I'm kidding, I'm down with all boxer configurations |
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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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| Posted: Tue Aug 10, 2021 5:45 am Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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Anyone have experience with aftermarket frame horns in a street car?
I'm considering some frame horns for this build. It would probably be less work for the end result I want. Lower center of gravity and further towards the front. If anyone has build threads or pictures that would be greatly appreciated.
More importantly, has anyone done aftermarket frame horns with the body still in place?
I started running through fit checking, vid below. If I want to adjust things to a nice position it looks like a lot of cut/weld.
Link
_________________
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 |
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Chickensoup
Samba Member
Joined: January 06, 2018
Posts: 5368
Location: Good Hope, GA
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| Posted: Tue Aug 10, 2021 3:20 pm Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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| Dauz wrote: |
Say NO to H2O
I'm kidding, I'm down with all boxer configurations |
I don't want to die today. Or tomorrow 
_________________
-'85 c10 5.3 LS, 222 cam, long tubes, x pipe, 3 inch spin tech's
-'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
Hosea 4:6 "My people are destroyed for lack of knowledge" |
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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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| Posted: Sun Aug 15, 2021 9:46 am Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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I got a double done whammy yesterday I got the cases split and walked through the full disassembly. I documented quite a few tricks and things to make the uninstall easier. The job wasn't that difficult. I also talk a bit more about 3D printed press tooling, I'm working on that a little bit in the margins. For those following in my footsteps I highly recommend you watch the two videos for special instructions I figured out on the way.
Link
Link
_________________
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 |
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Chickensoup
Samba Member
Joined: January 06, 2018
Posts: 5368
Location: Good Hope, GA
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| Posted: Sun Aug 15, 2021 10:40 am Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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Nice work! And thanks for taking the time to make these videos. I think one day here soon when the Subaru swap thing gets even Larger, a whole lotta people are going to find these videos helpful.
_________________
-'85 c10 5.3 LS, 222 cam, long tubes, x pipe, 3 inch spin tech's
-'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
Hosea 4:6 "My people are destroyed for lack of knowledge" |
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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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| Posted: Sun Aug 15, 2021 9:30 pm Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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| Chickensoup wrote: |
| Nice work! And thanks for taking the time to make these videos. I think one day here soon when the Subaru swap thing gets even Larger, a whole lotta people are going to find these videos helpful. |
Thanks!
I'm hoping it's useful for others. I think the next generation isn't as forum focused so perhaps getting this build on the youtube platform will help with future builders. That and I can't tell you how many times I find old builds that have image hosts that are gone so you don't get to see the pics.
I'm hoping I can do a good enough job of demystifying the 6mt and I really hope it's not too big a job for others. The 6mt from everything I'm seeing and hearing really does appear to be a much better transmission. I bet the 5mt with PPG gears probably outperforms the 6mt but that's getting into serious money territory.
_________________
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 |
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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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| Posted: Wed Aug 18, 2021 6:19 pm Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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I worked on perfecting my copper intake manifold pressing technique. This copper tube is a 1.5" coupler. I had to make this a multi stage press operation. The first operation increases the diameter of the full tube, the second operation presses the copper tube into the oval shape. I did a much better job on the multipart self disassembling press tool this time around. I still need to make some adjustments, the first operation needs a more aggressive/wider taper to open the tube diameter to be a bit wider. This press was much more difficult on the secondary operation since the tool was being engaged on the full surface area from leading edge to trailing edge since it was also trying to open the tube up to the final diameter rather than the first press video where the final diameter was already set within the factory tube itself.
Overall I'm still very impressed with the repeatability and dimensional accuracy. I have some tricks up my sleeve planned for making the intake manifold flanges with budget minded equipment.
My video on the operation goes way in depth on the process, for those who want to follow in my footsteps.
Link
_________________
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 |
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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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| Posted: Sun Aug 22, 2021 10:32 pm Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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I'm working on a proof of concept with my small copper tester tube. I'm testing 3D printed milling jigs for the router. The intent is to have multiple plates that slide into the jig bolted to the plate to account for the different operations that need to be done to the aluminum.
The oval was ~.5mm too narrow on the widest dimension and ~.20mm to narrow on the narrowest dimension, better to be more narrow as you can always remove more material later. Overall I'm very impressed. I have a lot of changes to make for the final size jigs. I will be greatly increasing the size of the jig components to allow for a much more consistent router contact to the top surface of the plastic. The next aluminum base will be much thicker and will have a stepped surface to give a better chance of the brazing rod to do it's job sealing the two metals. I don't know when I'll crank out the manifolds, hopefully soon. I need to get supplies.
_________________
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 |
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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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| Posted: Thu Aug 26, 2021 10:59 pm Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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Testing out the copper to aluminum brazing/solder rod I bought on the small tester piece of 3D printer tool pressed copper tube into the 3D printer milling jig cut aluminum plate...
I'm getting much closer to putting together the 3D printed tooling to mill and press the full set of intake parts. Then it'll just be a matter of brazing it up. I used about 1/3 of the rod on the 1" copper tester tube oval side. I'll probably have to order more brazing wire.
This is some really high quality stuff. I haven't brazed anything in about 6-7 years and this stuff flowed incredibly well.
I highly recommend this stuff for this specific application.
https://lucasmilhaupt.com/EN/Products/AL822.htm
_________________
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 |
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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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| Posted: Thu Sep 09, 2021 10:30 pm Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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Alright I made progress working on the internals of the 6MT. The 6MT pinion shaft nut is a real pain to deal with. I also have a race in the diff housing that isn't stiff, it has a light spin. SubaruGears thinks it's fine. Let me know if you have an opinion on it I could really use some input, I'm not a bearing/differential expert.
Link
_________________
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 |
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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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| Posted: Wed Sep 22, 2021 1:36 am Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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My milling jigs for the intake manifold base plate is done. They utilize removable inserts for the different drilling/milling operations.
I'm hoping to start the milling process tomorrow. I'm waiting on trans internal parts from Subaru before I continue the trans internals.
_________________
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 |
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Ryan_S
Samba Member
Joined: June 17, 2012
Posts: 74
Location: Stranded on some road
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| Posted: Wed Sep 29, 2021 3:01 am Post subject: Re: Subaru Conversion: EZ30 + 6mt + Megasquirt into 1969 KG |
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I have finalized my analog CNC process for my intake flanges. The process is mature enough to where I can share it, this took a heavy amount of testing and iteration to get right. Check out the process in the video below. Once everything is all set up and you know what to do it's really relatively painless. I'm sure it takes WAY more time than an actual CNC would take, but this is something most people can accomplish from home.
The pocket below was milled using a handheld router and a drill press aided by my 3D printed milling jigs.
I edited two videos together, one being the cliff notes version and the other being a VERY long in depth teaching video that goes over everything you need to know to replicate this at home.
This video will finish uploading/processing sometime around sunrise.
Link
_________________
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 |
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