Budget 1991 Turbo Legacy Build

Discussion in 'Photo & Video Gallery' started by Quinn, Jul 27, 2017.

  1. Quinn
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    Quinn Active Member

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    I purchased the car off of a member on here on July 14th 2016, with intent on just fixing the engine issues and replacing the transmission to make it a solid daily, But then I found out how easy it is to DOHC swap these cars using EJ20G parts because the wiring is very similar, so with that in mind, the build got more expensive.

    Original FS thread: https://mnsubaru.com/threads/91-rio-red-legacy-lsi-2-2-turbo-500.51498/#post-842292
    Picture from the day I picked it up.
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    Had to disconnect the driveshaft to get it onto the tow dolly. Fun job when you forget to bring a jack along.
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    Home safe!
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    Started getting the engine out of the car that day, Got it completely out the next day.
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    At that point I didnt really do much with the car, few weeks later i picked up this 1999 Outback for as a transmission donor, car had a snapped cam gear.
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    I scored some STI aluminum lateral links with fresh solid bushings and Whiteline 27mm front and rear swaybars with kartboy endlinks. Also got a different rear subframe because the stock 4.11 rear diff cover would not mount to the stock subframe. (Had to do alot of hammering to get that swaybar to clear the spare tire well)
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    With help from a buddy we got the transmission hung in there and the engine in as well. Originally I had gotten some EJ25D cylinder heads for it, but I found some EJ20R "Twin Turbo" heads on craigslist locally, (better cams, bigger ports) So those went on as well.
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    Was lucky to get my hands on a set of JDM Metal EJ20G cam gears, so those went on along with an 11mm STI oil pump and the TD05h 16g turbo I plan to use, mocked up on there. FB_IMG_1501160396660.jpg Got the car all timed, radiator in, Got a Version 3 STI Type RA Ej20g intake manifold to use as well.
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    Hard to tell in this picture but I got some STI Lower control arms in, and some KYB struts with Eibach lowering springs (not the final suspension setup)

    Will add more soon. 7/27
     
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  2. Chux
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    Chux Well-Known Member

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    Very interesting. Don't forget to swap the longer axles in to match your wider suspension parts.


    What are you doing for engine management?
     
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  3. Krazylegz1485
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    Krazylegz1485 Well-Known Member

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    I approve this message.

    Nice work! Sweet project, too.
     
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  4. jubella2
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    jubella2 GC8 FTW

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    Super sweet! I love how compatible subaru parts are.
     
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  5. retreif
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    retreif Well-Known Member

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    That's a lot of apples.
     
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  6. Quinn
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    Quinn Active Member

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    Im using the Outback axles, are they longer because of the lift? Otherwise what axles would you recommend?

    For engine management im using a 20g ecu with a chip. Still using the 550 cc STI injectors.
     
    Last edited: Mar 20, 2018
  7. Quinn
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    Quinn Active Member

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    My dad does old Chevy things. those boxes are all filled with old chevy parts mainly 1958-1970.
     
  8. Quinn
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    Quinn Active Member

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    Gonna dump a few more misc pictures FB_IMG_1501160491406.jpg FB_IMG_1501160453765.jpg FB_IMG_1501179139898.jpg FB_IMG_1501179089487.jpg
    Bonus: The car on Jackstands is what the current suspension is from, Plus my DD in the background
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    Attached Files:

  9. Quinn
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    Quinn Active Member

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    Here are those videos I promised you.
     
  10. Chux
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    Chux Well-Known Member

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    I'm assuming the STi control arms are from a GD...which has a wider track width than either of your donor cars.
     
  11. Quinn
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    Quinn Active Member

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    Im aware of that, they are from a GD. I was told that because the car was going to be lower, they would even out.
     
  12. Chux
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    Chux Well-Known Member

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    100 Acre Wood Rally 2012. Christy Carlson's car broke an axle shaft pulling out of tech inspection. She had relatively recently put a JDM clutch-type LSD from a GC and matching axles into her GD. Only a couple rally's on it (and she's not a very aggressive driver). We helped her repair it...

    Circlips jammed into the diff, RR inner DOJ cup cracked a little bit, LR DOJ cup split open AND LR shaft snapped off at the joint. After an alarming amount of pounding, the RR axle came out of the diff, really mangled the circlip on the way out. Couldn't get the LR out of the diff, so we welded the crack, then welded a mild steel strip around the cup, and picked up a reman axle at a local parts store in the morning, disassembled it, and reassembled it in the old cup.

    [​IMG]2017-07-27_03-14-02 by Numbchux, on Flickr


    Yes, Rally use. Yes, rally ride height. But this was a LOT of carnage, and this stuff wasn't installed on that car very long. I wouldn't
     
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  13. Leonnosyt
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    Leonnosyt Member

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    nice build
    love that there is still some first gen stuff around here. will you be utilizing the 5th injector in the ver 3 intake manifold? if so how are you triggering it?
     
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  14. Quinn
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    Quinn Active Member

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    Right away, no I will not be using it. Jake (mentioned above) has an idea on how to make it work. He is currently finishing up his V2 RA Closed Deck 20G swap in his 2.5rs. So he has the same intake.
     
  15. Quinn
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    Quinn Active Member

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    Put the wheels on and finished up the interior. (dont mind the parts car or the messy garage ...) 20495730_2020573327956434_377451277_o.jpg
     
  16. Krazylegz1485
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    Krazylegz1485 Well-Known Member

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    Frickin pallet racking in the garage?! Lucky...
     
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  17. Quinn
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    Quinn Active Member

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    More V3 Goodies, Seats from a 555 edition car (1 of 555 sets) and a v3/22b STI steering wheel (not in the greatest shape) Carpet doesnt fit too well, i think the legacy has a larger interior than the GD wrx, so the carpet is "meh", Bugeye WRX rear seat fits decently.
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  18. Quinn
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    Quinn Active Member

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    Now that I have time, I will try and think of the entire "Mod list"

    Exterior (nothing major)
    -Replaced the broken tail lights
    -Replaced broken marker light
    -Painted Grille
    -Buffed the headlights
    -Installed the missing quarter/rear window trim
    -Sourced the full set of factory mud flaps/mud gaurds (not installed)

    Suspension
    -KYB GR2 struts with Eibach Lowering springs (plan to change this)
    -27 mm front and rear Whiteline swaybars
    -Kartboy swaybar end links front and rear
    -GD STI aluminum lower control arms (solid bushings)
    -GD STI aluminum rear lateral links (solid bushings)
    -Whiteline anti-lift kit
    -Ebay rear strut tower bar
    -JDM GC8 STI carbon fiber front strut tower bar

    Driveline
    -03 Impreza 2.5RS 4.11 5 speed transmission
    -Window-Welded transmission mount
    -99 Outback open rear differential (I have a 4.11 LSD to install)
    -08 (i think) Forester rear subframe (window welded diff bushings)

    Engine/Clutch
    -Stock EJ22T shortblock
    -JDM EJ20R Cylinder heads
    -JDM EJ20G metal cam gears
    -JDM/EDM EJ20G Type RA 5th injector intake manifold
    -TD05h 16g turbo (90 degree inlet like the stock VF11)
    -Stock headers and up pipe
    -Ebay Catless Turboback exhaust
    -XTD Stage 4 un-sprung 6 puck clutch
    -GD Coil on Plug conversion
    -STI 550cc yellow injectors
    -Usual gasket/o-ring/seal replacements

    Wheels/Tires
    1999 Impreza 2.5RS 16 inch 5 spoke wheels
    Dunlop Direzza DZ102's in 205/55/R16

    Interior
    -V3 STI World Rally Manufacturers Championship front seats (1/555)
    -Bugeye WRX rear seat
    -Bugeye WRX grey carpet
    -V3/22B steering wheel
    -Replaced original radio with an identical one (With working AUX port from the factory)

    Brakes
    -Stock
    (trying to find a good deal on 4 pot/2 pots)


    Im probably missing some things, will continue to update
     
  19. Quinn
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    Quinn Active Member

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    Picture of the mess outside my house 20472755_2022612881085812_1272689065_o.jpg
     
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  20. tangledupinblu
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    tangledupinblu Event Coordinator Staff Member

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    Is the blue one on the left an L?
     
  21. Quinn
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    Quinn Active Member

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    Nope. 99 RS
     
  22. Quinn
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    Quinn Active Member

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    Finally solved my turbo oil drain issue, the 20R heads apparently use a different oil drain, therefore it would come close to lining up with where it needed to be, found the right one, and got the turbo on for the last time.
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  23. Quinn
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    Quinn Active Member

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    Small update, wiring is just about finished up, waiting on a silicone intercooler y pipe in the mail, after that, it should run.
    Decided to put together and install my Prodrive STI Bilstein struts and Prodrive P1 red springs that ive had laying around for the last 2 years or so, Same setup used on the 22B, i believe it was also an optional upgrade for the P1. got the fronts done last night, rears get done today.
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    Bonus potato engine bay pic.
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  24. Quinn
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    Quinn Active Member

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    Got it going today.

     
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  25. tangledupinblu
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    tangledupinblu Event Coordinator Staff Member

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    Cold start flames ftw!
     
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  26. Quinn
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    Quinn Active Member

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    It was already nice and warm haha!
     
  27. joebush44
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    joebush44 Well-Known Member

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    [​IMG]
     
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  28. Quinn
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    Quinn Active Member

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    Here is a good one of the rotational idle

     
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  29. Quinn
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    Quinn Active Member

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    Back in the garage, to fix a few things and clean up some wiring. Main issues were a pretty substantial vacuum leak caused by what I would assume was a bent fuel rail of all things, and the coolant temp sensor wires not being extended properly due to the ej251 coolant crossover pipe i needed to use, and where the sensor is located.
    [​IMG]
    [​IMG]
     
  30. Quinn
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    Quinn Active Member

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    Got it "done" just in time to still make it up to proving grounds, 300 miles and it didnt miss a beat
     
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  31. Quinn
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    Quinn Active Member

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    Ordered some glass headlights and factory side skirts from Australia, expecting them in the mail soon
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  32. Quinn
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    Quinn Active Member

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    Got the skirts and headlights! Still looking for a rear lip.
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  33. Quinn
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    Quinn Active Member

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  34. Quinn
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    Quinn Active Member

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    Little update, Not too much has changed, The first transmission i put in had a horrible howl to it and i believe the input shaft began moving in and out causing the clutch to slip. I swapped the transmission with one i got from the junk yard, same really horrible howl on decel, So going to put in transmission number 3 with a brand new clutch and hope i dont need to take it right back out again.

    Picked up some parts for it too
    Ghetto FMIC kit
    Parallel fuel rails and lines
    4 Pot WRX front brakes (rears coming soon)
    Kartboy short shifter

    Probably some other things im forgetting

    Ill try and keep this a bit more updated :)

    26685279_2344347705578993_5141885194037591656_o.jpg
     
  35. silver03
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    silver03 Well-Known Member

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    Going thru this thread again is like watching a favorite movie again...it's still very enjoyable. thanks for the update.
     
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  36. Quinn
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    Quinn Active Member

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    Im happy to hear that! Ill keep them coming! Ive found motivation to be out in the cold working on it so expect some more in the near future!
     
  37. Quinn
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    Quinn Active Member

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  38. derp
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    derp Well-Known Member

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    I still have my 5 speed from my legacy gt... Worked perfectly and I have the rear diff to go with it.
     
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  39. Quinn
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    Quinn Active Member

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    Price on that stuff? Mileage?
     
  40. derp
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    derp Well-Known Member

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    Around 145k on it. I wanted $750 iirc but with no bites, 600 bucks for all of it?
     
  41. Quinn
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    Quinn Active Member

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    Thats a little spendy for me, Ill probably stick to the $98 dollar upull transmissions for now haha
     
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  42. Quinn
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    Quinn Active Member

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    28061049_2411146708899092_2192106731656191025_o.jpg
    Finally got the new clutch in, new transmission in, the rear 22b Bilstein suspension is finally installed along with a rear strut tower bar, Welded the transmission mount solid, kartboy short shifter installed and ive started chipping away at all the sound deadening in the trunk/rear seat area.

    Currently repainting the 4pot front brake calipers, still need to locate brake pads for the 2pot rears, along with some adapter brackets but other than that I have everything else, then those will all be installed with braided brake lines.

    I obtained parallel fuel rails and lines for the STI 550cc injectors (just need to figure out how that all gets installed)

    Found a period correct "The Prodigy" CD in an old factory radio, so that rides around with me now.

    Purchased bulbs and harnesses for the jdm/edm/audm glass headlights, those will go on shortly. (stock headlight light output is appalling)

    I have a front mount intercooler kit that im debating trying to install, I do not really want to cut the car up too much, If I find a cheap factory EJ20G "slanty" intercooler I would prefer to run that at the moment. My JDM carbon fiber STI strut tower bar will not clear the current 06-07 WRX intercooler it has now, in fact it currently rubs the hood. So I need to find a better solution for an intercooler.

    Its also still on wastegate pressure, need to find a manual boost controller.

    Its coming along, Hopefully ready for drags in the spring.
     
    Last edited: Feb 21, 2018
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  43. Quinn
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    Quinn Active Member

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    28811148_2436704423009987_1707647281_o.jpg
    Finally got the glass headlights installed!
     
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  44. Quinn
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    Quinn Active Member

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    Picked up an air to water intercooler with icebox for the car, I decided to go that route because I do not really want to cut the car up for a FMIC. So that will go on soon as well
     
  45. Krazylegz1485
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    Krazylegz1485 Well-Known Member

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    Word association...
    [​IMG]
     
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