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Annie-other Subaru Swap - Build Thread
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deathman68
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PostPosted: Thu Nov 12, 2020 3:41 am    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

I believe you’re correct JSMskater. I’m doing some additional digging on how the Subaru alternators work, it’s clear that they need to “sense” voltage in order to charge properly. The Vanagon guys have some good additional info:

https://www.thesamba.com/vw/forum/viewtopic.php?p=8819938
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Build Thread: 1973 Riviera+Subaru 2.5+5 Speed
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scirocco_crazy
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PostPosted: Thu Nov 12, 2020 6:56 am    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

I am getting my donor vehicle tomorrow and will check. It is an 08 so it might match to what you are doing. Will let you know soon
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Current Build 1976 VW Bus Subaru with EZ36 https://www.thesamba.com/vw/forum/viewtopic.php?p=9443081#9443081
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deathman68
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PostPosted: Sat Nov 21, 2020 5:28 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

Anyone who says they can do the harness in 16 hours either doesn’t care what it looks like or is a seasoned pro. Props to the latter. I have closer to 40 hours into it which includes the three days it took me to figure out I pulled a bonehead move and fried my ECU...couldn’t figure out why my a/c and fan relays weren’t working properly when the fuel pump and main relay were just fine. Mental note: always unplug the ECU when soldering even at 2am.

So here are some pics of the progress:

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

The dog was exasperated from removing all the wires that weren’t needed:
Image may have been reduced in size. Click image to view fullscreen.

Starting to take shape:
Image may have been reduced in size. Click image to view fullscreen.

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


Plugged it all back in and hot wired the fuel pump...success!

Link


Next up I will be pulling the engine and trans to start the refresh. Just waiting on Subarugears confirmed Black Friday sale!
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deathman68
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PostPosted: Thu Dec 03, 2020 12:56 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

Total Spend to date: $7589.29 Shocked

Well that escalated quickly. Things got expensive recently since I took advantage of Subarugears Black Friday sale to pick up the needed parts to mount the engine/trans and I also sprung for quality electrical parts along the way. Picked up OEM quality parts like the water pump and idlers along with Six Star MLS head gaskets, new plug wires, plugs, etc etc. I may have gone a little overboard with Speedhut's sale as well since I picked up a set of custom gauges which isn't really necessary for this conversion, but it's going to look cool, so why not? AND I picked up a shortened oil pan from Outfront...while I wait for Christmas to come early (ie for parts to show up), I've dove head first into the "while I'm at it" rabbit hole.

I thought I would share my latest side project: modifying the wiper switch to be able to use a motorized washer pump instead of the current pressurized system. Total cost: $1.95 + shipping. I'm sure I'm probably reinventing the wheel with something that has been documented elsewhere, but here is some additional info:

Step 1: Order a tactile microswitch and then pull the mechanical pump activation switch from the wiper switch and yank the little plunger actuator out of it
Image may have been reduced in size. Click image to view fullscreen.


Step 2: Using the tool of your choice, lop off a section of the mechanical activation switch. Make it close to flush with the base circle.
Image may have been reduced in size. Click image to view fullscreen.


Step 3: Grab your microswitch and place it in the hole created by Step 2 so the stock plunger is in contact with the microswitch plunger. Use a gob of hot glue to tack the microswitch where you want it.
Image may have been reduced in size. Click image to view fullscreen.


Step 4: Check Continuity and reposition if necessary.

Step 5: Mix up some JB Weld after thoroughly cleaning the plastic area to remove any grease/grime etc.

Step 6: Place JB weld in a few different spots, but don't overdo it in the event you need to replace the switch at any point in time. Let cure for the recommended time.

Step 7: Check continuity. Reinstall in the wiper switch, solder your new 16awg wires to it to trigger your new relay, and enjoy your new motorized washer pump (that part was omitted for obvious reasons).
Image may have been reduced in size. Click image to view fullscreen.

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1973 Riviera “Annie”
Build Thread: 1973 Riviera+Subaru 2.5+5 Speed
EJ25+5 Speed Conversion Part/Cost Tracker


Last edited by deathman68 on Thu Dec 03, 2020 5:36 pm; edited 2 times in total
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JSMskater
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PostPosted: Thu Dec 03, 2020 3:26 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

very nice keep it up Cool

i didn't count how many hours i put into the first or my 2nd harness, but the 2nd one came out a lot cleaner and once you get the hang of it they go a lot faster.
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skills@eurocarsplus
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PostPosted: Thu Dec 03, 2020 9:41 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

deathman68 wrote:
Anyone who says they can do the harness in 16 hours either doesn’t care what it looks like or is a seasoned pro. Props to the latter. I have closer to 40 hours into it which includes the three days....


thats why i send a box of spaghetti to jeff robenolt with 600 bux and he sends this back

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

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gprudenciop wrote:

my reason for switching to subaru is my german car was turning chinese so i said fuck it and went japanese.......
[email protected] wrote:
most VW enthusiasts are stuck in 80's price land.

Jake Raby wrote:
Thanks for the correction. I used to be a nice guy, then I ruined it by exposing myself to the public.

Brian wrote:
Also the fact that people are agreeing with Skills, it's a turn of events for samba history
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deathman68
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PostPosted: Fri Dec 04, 2020 9:55 am    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

Quote:
thats why i send a box of spaghetti to jeff robenolt with 600 bux and he sends this back


Yeah that's why I said I think anyone doing the conversion should do this just ONCE, then gladly fork over the money to have someone make it art for future conversions.

Skills, the intake and valve covers in the pic you posted look amazing. Are they powder coated or painted? I was considering powder coating the intake manifold but have heard mixed reviews about possible warpage powder coating the valve covers which seems strange to me at only 400F.
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skills@eurocarsplus
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PostPosted: Fri Dec 04, 2020 7:40 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

polished. every fucking miserable inch...all polished

and yea, i use to feel like i had to be the hero and do every single inch of stuff...not worth it to me anymore.

i have built a few transmissions, i have converted a few harnesses...no more, i got a guy for that...

the problem is...when you do a project of this magnitude it just isn't worth the time or space to have shit scattered out in a million pieces when you have so much other stuff to do...

when i built my deluxe i had my buddy shoot it. i did all the crap work like paint the chassis/interior...the rest...fukkit he has a booth.

i try to tell people...pick up a couple hours of OT at work...do what you're good at and pay someone to do what they are good at. no need to be a slave to this shit and zap all the fun out of it

wiring, no matter how big or small is a HUGE time suck to do it right. even with jeff's harness i will have 2-3 hours in laying it out and another couple hours tying it in.

if i did a harness and had 40 hours in it...it would be a 4k harness
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gprudenciop wrote:

my reason for switching to subaru is my german car was turning chinese so i said fuck it and went japanese.......
[email protected] wrote:
most VW enthusiasts are stuck in 80's price land.

Jake Raby wrote:
Thanks for the correction. I used to be a nice guy, then I ruined it by exposing myself to the public.

Brian wrote:
Also the fact that people are agreeing with Skills, it's a turn of events for samba history
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old DKP driver
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PostPosted: Fri Dec 04, 2020 10:27 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

Skills, you may have to the S.F. Bay Area this next spring/summer as you could
Have 2. Jobs for your experience/expertise including a Vanagon that I purchased
Today.
Happy Holidays to you and yours🙂
Chris
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Merling
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PostPosted: Fri Dec 04, 2020 11:45 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

deathman68 wrote:
Speedhut's sale as well since I picked up a set of custom gauges


Any chance you'll share the "custom" setup? Been thinking about different gauges on mine but not a lot of info on the subject out there.
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deathman68
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PostPosted: Sat Dec 05, 2020 3:24 am    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

Quote:
Any chance you'll share the "custom" setup?


Sure thing. They are the 4” dual gauge kit from speedhut. If you go to their website you can filter by kits and then customize to your tastes. The options are endless. I went with the hot start GPS gauges so no fiddling with calibrating for different size tires etc to get an accurate speed reading, though I’m wondering what will happen when I go through a tunnel. I’ll have my BlueDriver app running from the OBDII as backup so I’m not too worried.

Here’s the setup I went with in the end. Disregard the wonky size/position of the VW logos I added since this is before their art dept corrected per my instructions:
Image may have been reduced in size. Click image to view fullscreen.

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


Once the gauges get here and I get them mocked up, I’ll include some more pics of how they look in the bus. Just need to recondition the dash first.
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PostPosted: Sat Dec 05, 2020 3:35 am    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

Wonderful to see wiring craftsmanship of this caliber.

Top shelf work.
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skills@eurocarsplus
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PostPosted: Sat Dec 05, 2020 9:12 am    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

old DKP driver wrote:
Skills, you may have to the S.F. Bay Area this next spring/summer as you could
Have 2. Jobs for your experience/expertise including a Vanagon that I purchased
Today.
Happy Holidays to you and yours🙂
Chris


that's what they make transport companies for Very Happy

it would be very hard for me to leave here for any length of time. someone has to man the gates of hell and keep the nightmare alive
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gprudenciop wrote:

my reason for switching to subaru is my german car was turning chinese so i said fuck it and went japanese.......
[email protected] wrote:
most VW enthusiasts are stuck in 80's price land.

Jake Raby wrote:
Thanks for the correction. I used to be a nice guy, then I ruined it by exposing myself to the public.

Brian wrote:
Also the fact that people are agreeing with Skills, it's a turn of events for samba history
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deathman68
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PostPosted: Sun Dec 06, 2020 2:49 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

Progress continues. Got the engine and transmission yanked. Just in time too...my parts just cleared Miami customs from Australia
Image may have been reduced in size. Click image to view fullscreen.


Engine on the stand and ready to be torn into
Image may have been reduced in size. Click image to view fullscreen.


No pics of the trans...I was DONE after shearing several bolt heads on the mounts and busting my knuckles. Northern car with too much corrosion. In the end, I man handled it to snap the mounts and get it outta there.

Bring on the reverse cut gears!
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badstuw
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PostPosted: Sun Dec 06, 2020 5:51 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

Hey, awesome work so far. I just got done pulling my harness this weekend, engines already pulled. You mentioned A/C and cruise control. I plan to implement both of these in my build. Cruise control is pretty easy, the column switch (and the dash switch, necessary?), the cable module, and the controller (I'm pretty sure that's it).

But A/C is the only thing I'm trying to make sure I keep all of the necessary components to leave in the harness. I have a DPD under-dash unit and the goal is to have an A/C switch, like the normal subaru console button, which should activate the relay and the clutch of the compressor, along with the fans which should be ecu controlled. Is there anything specific you needed to save off the main dash harness or the fuse/relay box from the driver side? I've saved everything so far.
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deathman68
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PostPosted: Sun Dec 06, 2020 6:18 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

Cruise as you’ve gathered is pretty straight forward. The hardest part will be deciding where you want to mount the module and deciding if you want to maintain the functionality of the brake/clutch switches. In my case, I’m adding the wires to the main loom and running the wires from the Engine comp to the dash of the bus. I will mount the main switch in the dash and the sub switch on the column.

Re: AC, there’s nothing special you really need to carry over from the main harness. You can wire your ac switch to your ecu lead so it adjusts engine rpm accordingly when you switch on the A/c. Aside from that just make sure you use a good relay and fuse the power to the compressor.
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deathman68
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PostPosted: Mon Dec 07, 2020 12:11 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

Ho ho ho Cool

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PostPosted: Tue Dec 15, 2020 6:56 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

Progress continues. Got the engine torn down to the short block. Heads are currently at the machine shop getting a full refresh. I learned that at minimum the head gaskets had been done previously (MLS Six Star which I take as a good sign) and possibly even the cylinders honed/pistons since they were fairly clean with prominent cross hatching and showed “like-new” compression results. Nevertheless I used my trusty B12 Chemtool to soak the pistons/cylinders to remove what little carbon build up there was and to preempt any coking of the oil rings since the provenance of the engine is unknown. Nasty pic below:
Image may have been reduced in size. Click image to view fullscreen.


I then proceeded to clean thoroughly and lube the bores with oil. Next up I will use my old school technique of sandpaper on glass plate to achieve the RA 50 finish on the block mating surfaces prior to bolting the heads on.

I ordered about a hundred replacement fasteners/brackets to replace all the corroded ones. Should have the heads bolted back up and the block cleaned and reassembled by early Jan.

In the meantime I get to daydream about driving with my newly delivered custom gauges from speedhut. They feel really solid, but only testing will tell
Image may have been reduced in size. Click image to view fullscreen.

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skills@eurocarsplus
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PostPosted: Wed Dec 16, 2020 5:10 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

i can tell by the carbon on the piston tops that engine burnt oil
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gprudenciop wrote:

my reason for switching to subaru is my german car was turning chinese so i said fuck it and went japanese.......
[email protected] wrote:
most VW enthusiasts are stuck in 80's price land.

Jake Raby wrote:
Thanks for the correction. I used to be a nice guy, then I ruined it by exposing myself to the public.

Brian wrote:
Also the fact that people are agreeing with Skills, it's a turn of events for samba history
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deathman68
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PostPosted: Wed Dec 16, 2020 5:21 pm    Post subject: Re: Annie-other Subaru Swap - Build Thread Reply with quote

Good call Skills. Always impressed by your knowledge. Precisely why I pulled the pistons to check for coking of the oil rings and having the heads done with new valve stem seals etc. Hoping this will resolve any oil burning issues while I work out cooling kinks and save for a new short block once I’ve got everything set up.
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EJ25+5 Speed Conversion Part/Cost Tracker
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