EG in a GG by Eazy

Discussion in 'General Subaru Discussion' started by Eazy_E_Rich, Feb 1, 2015.

?

H6 > H4 ?

  1. Yes, I like that porsche sound.

    15 vote(s)
    88.2%
  2. No, I've got to have that H4 rumble.

    2 vote(s)
    11.8%
  1. Eazy_E_Rich
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    Eazy_E_Rich Well-Known Member

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    It seems to get the job done really well. I am not the owner (I'm also not a welder, my friend did all the welding on this project thus far) but it from what I can tell it's a solid welder. It adjusts nicely when working with brittle steel, which was the case with some of our recycled exhaust parts.
     
  2. Eazy_E_Rich
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    Quick Update

    Last night we triple checked all the wires in the harness. Everything looked good so we got rid of all the labels on the wires and started cleaning up the harness.
    [​IMG]
    Engine side is looking good, but we still have to clean up the ECU side.

    -Eazy
     
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  3. Eazy_E_Rich
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    [​IMG]
     
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  4. Eazy_E_Rich
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    Last night I removed the exhaust and painted it with high heat paint. Hopefully this slows down the rust process.
    [​IMG]

    Also worked on new vacuum lines for the intake. I noticed that my Vapor purge control solenoid had broken when I took it apart.
    [​IMG]

    I may not need it as I'm not planning to run the SVX charcoal canister.

    -Eazy
     
  5. Eazy_E_Rich
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    Got a bit more done on the project this evening.

    I spent quite a bit of time shaping some angle steel to be the new top rad crossbar.
    [​IMG]

    At this point I wanted to fit the radiator better so I fitted some grommets to the bottom of it.
    [​IMG]
    You can also see our rust repair weld in this next photo:
    [​IMG]
    Since my AC condenser will sit in front of the radiator I had to modify the radiator and where the headlight mounts to allow the lines to fit.
    [​IMG]
    With that taken care of I fit the fans on the radiator and tied them down.
    [​IMG]

    Here's what it looked like when I put the bumper back on:
    [​IMG]
    I spent the rest of the night finishing up the intake, fitting fuel lines and the wiring underneath. It really helped to attach the lower intake to the upper intake before you put it on. It would be pretty much impossible to put it on one at a time.

    Here's what it looked like right before I gave up for the day.
    [​IMG]

    -Eazy
     
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  6. tangledupinblu
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    This should be at the LaXCruise for us to ooogle over. Jussayin
     
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  7. Eazy_E_Rich
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    Once I had the bumper and radiator in place I decided to throw the bumper cover on and the rest of the trim pieces.

    I had to cut about 1 inch from the back of the bumper for it to fit with the AC condensor out in front.
    [​IMG]

    Also gave it a bath in the rain.
    [​IMG]
    Front end view with everything attached.
    [​IMG]

    TODO:
    • Install Harness
    • Install Wideband wires / gauge
    • Power Steering pump
    • Alternator (broke the EG one I had)
    • Mount coolant reservoir
     
    Last edited: Apr 20, 2015
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  8. Eazy_E_Rich
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    Small Update:
    I put the battery in to roll down the windows and I tested out my wiring of the 06 transmission.
    [​IMG]
    Seems to work just fine.

    Also took a quick picture of the new gauge pod:
    [​IMG]

    I got around to mounting the external coolant tank:
    [​IMG]

    Here was my first solution to an upper radiator hose:
    [​IMG]
    It's a rather weird angle. I ordered a gates 12 inch 1-1/2 --> 1-1/4 flexible reducer, but it's just too long. I might end up rolling what you see here with some added strength.

    Last night I installed hood pins:
    [​IMG]
    They look alright but with the curve of the hood right near the front, I wish they sat back a few more inches.
    [​IMG]

    Anyhow, I'll be up to some more wiring tonight. If anything exciting happens I'll snap some photos / vids.

    -Eazy
     
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  9. tangledupinblu
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    Just wait until you feel the torque of that badboy pulling you down the road!
     
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  10. Eazy_E_Rich
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    It's Alive! :)
     
  11. Eazy_E_Rich
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  12. Eazy_E_Rich
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    Had a bit of a setback with the water pump.

    Once I had the car firing up I saw coolant pouring all over the ground. After replacing a few hoses didn't fix the problem we noticed it was leaking at the water pump gasket.

    Spent yesterday and today pulling the front end apart and pulling the timing off.
    [​IMG]
    [​IMG]
    Finally getting to the water pump this is what I found.
    [​IMG]
    Looks like I must have been in a rush to put the gasket on, pretty dump on my part.
    You can see that the gasket folding like that actually made an indentation in the water pump.
    [​IMG]
    I actually had an extra water pump and gasket that I ordered by mistake, so I replaced them today.

    Here was the setup we had for testing out the wiring harness and just getting the car to fire up.
    [​IMG]
    Pretty messy, but it was effective.

    I also ordered the popular gauge pod for my wideband O2 gauge and a cheap oil pressure gauge I picked up.
    [​IMG]
    [​IMG]

    The latest is that I have put the car back together and ran the wiring harness through the firewall. I taped up the harness in the engine bay but still have some more cleanup to do in the passenger footwell.

    I did take the car around the block and the drive-train seems to work well. The O2 sensor was not connected so the car was not running the greatest but I was impressed with how smooth the clutch felt, the 2.5 clutch chattered really bad when I replaced it, but I'm guessing that was due to the wear on the input shaft of the transmission. This one felt very smooth all around.

    Here is another video from today.
     
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  13. Eazy_E_Rich
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    Picked up a super cheap air filter:
    [​IMG]
     
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  14. tangledupinblu
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    Spectre from VatoZone? If so, that's what we run on the RSVX also! Lol

    Lookin good E-Z!
     
  15. Eazy_E_Rich
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    Indeed it was a Spectre, grabed it from Amazon for like $18. I was looking for a very specific size, but the spectra website is basically a clone of the K&N one so that made it pretty easy to find what I was looking for. :thumbup:
    Thanks for the kind words. ;)
     
    Last edited: May 12, 2015
  16. derp
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    derp Well-Known Member

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    now get that rust fixed!
     
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  17. Eazy_E_Rich
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    Update:
    Car is running very well. This thing has some serious torque. With the 4.44 final drive no matter what gear you're in you can feel this thing pull.

    The main last thing before I got the car on the road was extending the alternator and power steering brackets. I used the EJ accessories which didn't exactly line up with the EG pulley offset.
    Here is a photo of the installed EJ brack on the EG33. Highlighted are the welds and spacers.
    [​IMG]

    Had a shop weld this up, it was 14mm on the dot. Pretty expensive, but I'm glad that it's done. They just added the new tabs, and I drilled the new holes.

    The same thing was done to the power steering bracket.

    I also installed a T fitting where the oil pressure sensor attached to install the sender for my oil pressure gauge and finally got all the gauges working. There was an engine ground in the bulkhead of the EJ harness that was not connceted which meant that none of the gauges were working.

    [​IMG]

    -Eazy
     
  18. tangledupinblu
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    ;)
     
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  19. Eazy_E_Rich
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    Here's a shot I took of all the gauges working:
    [​IMG]

    I also noticed the fuel pump was whining very loud last weekend, and finally it died on Tuesday.

    Stock OBS pump vs 03 WRX pump (Top):
    [​IMG]

    Thanks @Zombie for your very fair price on the used pump. With your generosity you've enabled things like this to happen:


    -Eazy
     
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  20. tangledupinblu
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    God i love that sound, it makes me want to go out and fire up the RSVX! I have an STi catback on mine. 80's Porsche sounds ftw!
     
  21. derp
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    derp Well-Known Member

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    If you want 80s Porsche sounds, go buy an 80s Porsche. :p
     
  22. Eazy_E_Rich
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    Eazy_E_Rich Well-Known Member

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    Hey all,

    Been busy with summer but I've got some more updates to share with my EG33 Outback Sport.

    Last summer I bent two of my rims.
    [​IMG]
    [​IMG]
    Finally got around to replacing them.
    [​IMG]

    I also picked up some all weather floor mats from a local 06 STI owner.
    [​IMG]

    Then I installed a trailer hitch.
    [​IMG]
    With the 4.44 ratio and the Subaru big block the car has no trouble pulling this thing.

    Next project was to replace an axle with a torn boot in the right front. Once I pulled it apart I realized my ball joints were shot and my control arms were very rusty.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    When I tried to take the ball joints off the spindle I snapped the bolts on both sides.
    [​IMG]
    When a friend and I couldn't get it out by welding a nut to it with a MIG welder I took it to a local shop in Rochester and he was able to get them both out in about 30 min with a TIG welder.
    [​IMG]
    I finally was able to hammer out the ball joints. (big screwdriver and lots of patience)
    [​IMG]
    I also replaced the tie-rod ends while I was in there.
    [​IMG]
    Here you can see the Aluminum Control arms that I picked up from Rock Auto.

    I also replaced the cracked windshield.
    [​IMG]

    Then I put on a WRX wagon wing.
    [​IMG]


    Next up:
    • Figure out oil leak from under timing cover
    • Custom AC lines (might have this done over the winter)
    • Replace steering rack (Even after rebuilding the pump the steering assist feels a bit strange, has a few dead zones)
    That's all for now.

    -Eazy
     
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  23. Nhibbs
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    How much were the aluminum control arms on rock auto?
     
  24. Eazy_E_Rich
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  25. Medic_538
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    Excellent job! Love seeing cars brought back to life.
     
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  26. Eazy_E_Rich
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    A few weeks back one of my rear wheel bearings started acting up. It has so much play that it felt like the lugs were loose. So I figured this was the perfect time for a rear drum -> disk conversion.
    [​IMG]
    (If anyone needs to fix their rear drums I've got some lightly used parts I'd part with for next to nothing.)

    So I ordered up some WRX spindles from Cali and I was pleasantly surprised with everything that came with.
    [​IMG]
    Backing plates, parking brake cables, pads and rotors were even in great shape.

    During tear-down it was clear that I was basically going to have to replace all the rear end parts. Had to cut quite a few things off.
    Also the axle would not come out of the hub. (had an extra though)
    [​IMG]

    Rockauto came through with lateral links(both sides), sway bar endlinks and bushings, pads and rear rotors.
    I picked up all the bolts required from the dealership, including the huge spindle bolts which are crazy expensive:
    [​IMG]

    Also in this conversion you need the Brake Pressure control valve from a car with disks along with the e-brake cable that ties the two rear cables together. I followed this tutorial and found it relevant to my 2002 with rear drums and an 02 WRX.

    http://www.rs25.com/forums/f105/t144728-diy-drum-disc-brake-conversion.html


    Here's a few shots of the results.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    I also threw some new cam seals in while I had the car out of service:[​IMG]
    I also figured I would throw the ebay crank pulley on because... why not.
    [​IMG]

    Quick plug for the a new local brew pub in Rochester:
    [​IMG]
    Took me over a month do get this done, and I went through quite a few growlers in the process.

    -Eazy
     
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  27. EricS
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    EricS Nooberator

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    Good stuff EZ! How does it drive? :)
     
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  28. Eazy_E_Rich
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    Drives Great!

    The suspension is all in check, my driveway is quite steep and it used to clunk when I pulled in, no sign of that now. Rides like a new car!

    Engine pulls hard, surprises me every time I get on it.

    With the 4.44 final drive it's not economical to drive much over 75, but I'm not much for speeding anyhow. (runs 3000 RPM at 70 MPH)

    Thanks for the kind words @EricS
     
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  29. Eazy_E_Rich
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    So I pulled my trailer for about 20 miles this weekend and I noticed that my car was getting pretty warm. The needle even topped out in the red going up a hill.

    I've got a suspicion that the 1992 Saab 900 Turbo Radiator might not be large enough for this engine. I'm curious to hear what @Chux used for a Radiator in his various swaps.

    I think I might go with an aftermarket Griffin, it's about 1.5 inches thicker than the Saab one I'm running now.
    http://www.summitracing.com/parts/gri-2-26185-h

    -Eazy
     
  30. Eazy_E_Rich
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    Picked up some STI seats locally on CL.
    [​IMG]
    They are good for hauling beverages:
    [​IMG]
    -Eazy
     
  31. Eazy_E_Rich
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    I'm getting the EG33 Impreza ready to head out to California this March.

    I picked up a spare full EG33 with everything included from a local junk yard.
    [​IMG]
    This gave me the option to build re-build the engine and while still keeping it running.
    So I tore it down slowly over the last 2 months and had the heads done.
    [​IMG]
    [​IMG]
    Internals were in suprisingly good shape for having around 200K on them. I bet this thing still ran great.
    [​IMG]
    [​IMG]
    We cracked the block open this weekend
    [​IMG]
    [​IMG]

    I also picked up a Griffin Radiator to replace the Saab 900 turbo radiator. I think the Saab is big enough but I really wanted more cooling capacity.
    [​IMG]
    Began mocking it up so I would know what my Hoses would look like.
    [​IMG]

    I also picked up a MegaSquirt III ECU with the MS3X expansion board. I also grabbed the JimStim and JimStimX boards for bench testing and also to practice soldering.
    [​IMG]

    I had a cold start issue also, below 40F it was super lean. Ended up replacing the coolant temp sensor and now all is well.
    We rigged up some switches and an LED which now gives me access to the diagnostic trouble codes via counting the pulses from the LED. This will come in handy until the MS3 is ready, then I should be back to OBD2.

    I hope to have the newly rebuilt engine in by Mid-February and this spring I'll work to get the ECU finished.
    A friend and I are planning to build some long tube headers also so stay tuned for that.

    -Eazy
     
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  32. Eazy_E_Rich
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    Went into the machine shop this weekend to clean up the internals and check everything out.
    [​IMG]
    [​IMG]
    EG33 Crank, We measured all the bearings and pistons.
    [​IMG]

    The block halves were pretty dirty so they spent some time in the wash.
    [​IMG]

    Bead blasted the top and ringlands of the pistons:
    [​IMG]
    [​IMG]

    Awesome work by Dave at Metro Engine Services, by far the most knowledgeable engine machinist I've worked with and a really nice guy. (Also he has a Closed deck EJ22T block he would like to get rid of if anyone needs one)

    Crank and pistons checked out good. Next up is new crank and rod bearings and piston rings. Looks like I might have to order 2 sets of EJ22T bearings for this thing since not many places sell EG33 bearings.

    -Eazy
     
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  33. tangledupinblu
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    Dave is the shizznit!
     
  34. Chux
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    Chux Well-Known Member

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    Wait....what? Megasquirt can output to OBDII now?
     
  35. Eazy_E_Rich
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    I guess I assumed it could. Looking at the documentation I don't see that anywhere.
    At least I should have better diagnostics than I have now with my blinking LED.
     
  36. Eazy_E_Rich
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    @Chux do you have opinion on head gaskets? I've seen the OEM replacements which are cheap but I am wondering if Cometic gaskets are worth the extra cost.
     
  37. EricS
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    EricS Nooberator

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    So awesome. When do the twin turbos go in?

    What were you thinking you'd need the OBD output for?
     
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  38. Eazy_E_Rich
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    No boost at this point, going to see what I get from long tube headers and a tune.

    I don't need OBD but I would like diagnostic output realtime, such as can be had from a bluetooth OBD2 adapter and a smart phone.

    Currently I am looking at using an Arduino and some LCD displays to get a few simple metrics. (MPG, Vacuum, Coolant temp digital value, ect.)
     
  39. EricS
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    But you could do a twin fog-mount TD04 for super cheap!!! Since each one is only feeding 1.65l, they don't run out of steam at RPM like they do on the WRX. And the EG33 headers can be swapped L/R to get the outlets front facing with no mods required. You've got the MS3 to be able to run SD... With even very mild 5-10psi of boost I think you'd be very happy with the results :)
     
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  40. Eazy_E_Rich
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    I like the idea. Pretty limited time with the current build, supposed to be on thesmokingtire in early March. I think a turbo build will be my long term goal once I get the ECU up and running.
    Since I have an extra EG33 laying around I may specifically build that one for boost, slightly lower compression and then drop it in my 2000 2.5RS.
     
  41. Chux
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    Chux Well-Known Member

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    Megasquirt is pretty versatile, so I wouldn't be surprised if someone has at least tried to get that to work, but I don't think I've seen any standalone communicate with the OBDII port on any level.

    You definitely will have better diagnostic capability than a blinking LED, you'll have better than most OBDII readers, too. I'm hoping to megasquirt my Celica fairly soonish in anticipation of boost. It's pretty crazy what's possibly with MS. I think I've seen a dozen different approaches to making some sort of dedicated "glass cockpit" instrumentation setup. There's even a simple program for PalmOS that can display almost anything from the MS, not the highest-tech platform, but I have 3 compatible devices in the basement, I'd just have to buy a 12v cable for one, and I'd be set.

    OEM, unless you're going with a fairly crazy build. Personally, I think head studs, and some sort of cylinder sleeve reinforcement (semi-closed deck) are much more helpful than the gaskets themselves.
     
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  42. EricS
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    EricS Nooberator

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    Congrats on TST, that's awesome!
    For the fog-mount TD04s, you can run two cheap WRX/STI ICs front-mount flipped vertically for next to nothing :)

    For diagnostics/dash, have you seen the Android app that interfaces with MS? http://tunerstudio.com/index.php/shadowdashmsmenu
     
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  43. Eazy_E_Rich
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  44. euro
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    euro Well-Known Member

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    subscribed. This is awesome.
     
  45. Eazy_E_Rich
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    Update: New Radiator, Report from out west.

    Been pretty busy over the last few months.

    I fitted and installed my new Griffin Radiator
    [​IMG]

    It fits pretty good, but I could use a larger cooling fan.
    [​IMG]

    Picked up a WRX Momo steering wheel thanks to a fair deal from @tangledupinblu
    [​IMG]

    Next a friend and I packed up the car and headed out west for a road trip.
    [​IMG]

    Pretty much Iowa and Nebraska suck.
    [​IMG]

    [​IMG]

    Things start getting more interesting in Colorado
    [​IMG]

    [​IMG]

    Nothing like H6 WOT 3rd gear pulls over the continental divide! Thanks for the idea Top Gear.
    [​IMG]

    Awesome Mexican food once you start coming down from the elevation of the Rockies.
    [​IMG]

    [​IMG]

    Stopped to see some sights in Utah
    [​IMG]

    I am amazed at how the EG33 does in the mountains. Especially with the 4.44 final drive we didn't even have to downshift to climb the mountains at 70 MPH.
    [​IMG]

    Quick stop in Las Vegas, who needs sleep right.
    [​IMG]

    Once we pulled into LA we swapped on the summer wheels and tires.
    [​IMG]

    [​IMG]
    Some nice gentleman thoroughly washed the car for $18. It was pretty funny to see it get washed next to AMG Mercs and plenty more > $50k cars.
    [​IMG]

    All ready for the big review.
    [​IMG]

    Heading to the shoot in the Malibu hills. Man these roads are sick.
    [​IMG]

    Arrived on scene.
    [​IMG]
     
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