Blue Porscheru Conversion, Subaru 2.5 SOHC NA with Suby Tranny Options

[R_u_dd]

Blue Porscheru Conversion

I started this project back in May of 2014 and wanted to share the journey with my friends and family.
There's something appealing to people about taking a left-for-dead vehicle and bringing it back to life.
I hope this build thread is a bit different than the others. It's a Subaru conversion which is not as common.

I am/was a newbie. This is my first car restoration, if you can call it that.
My welds are not pretty, but I've improved and learned throughout this process.
This is a great car for a first restoration. It's light, simple, and very cool- mid engine with a targa top.

This is the plan- We are starting with a 1971 tangerine 914 with light to moderate rust, nothing too serious.
The original engine was a 1.7. Like so many other 914's it ran but has been sitting for a long time.
The engine seems too far gone to try to rebuild it= lots of rust and corrosion.

Powerplant: 2003 Subaru Impreza TS 2.5 SOHC, Natuaral- No Turbo, Why? Plenty of Power for me and no turbo lag. See Engine Choices thread.
Transmission: Subaru 5MT 2003 Impreza TS
ECU from: 2003 Subaru Impreza TS
Electronics: Wiring Harness simplified by Small Car Performance
Axles: 944 axles and CV's with Subaru inside CV- 4 lug for now.
914 suspension.
No fender flares
Voltage Blue Metallic: (Honda color), Painted Sail Panels.

Before Pictures

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1486250894.1.jpg)

The Future Look- Concepts

The 914 visualizer, a very cool app.

Current Look:

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.imgur.com-17072-1607919164.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.imgur.com-17072-1607919164.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.imgur.com-17072-1607919165.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1459666779.1.jpg)



Contents

Axles
Blasting Glass Bead Videos
Battery Tray Area
Battery and Tray
Budget Scenarios
Brakes
Bumper - Valence
Clutch
Electronics
Engine Discussion
Engine Mount
Engine Work
Floor Pans and Engman Kit
Fuel Pump
Fuel Tank (Cleaning with Electrolysis)
Paint Prep and Metal Work
Paint Prep Continued
Radiator
Seats and Interior
Seats Re-upholstery Links
Transmission
Transmission Mount
Videos

This thread is for entertainment purposes only. I am not a certified mechanic.
There are many that have pioneered the suby conversion before me, but this
is my story.

Hope you enjoy this thread!

Chris

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1486249676.1.jpg)

[R_u_dd]

Floor Pans

One of the first tasks was to replace the floor pans. I tried to save the old ones, but they were just too far gone. Some of the parts were usable, like the pedal cluster support and the jack stand supports. Those were removed and welded to the new floor pans. This was all done on my back underneath floor jacks, not recommended. If you want to dive right in and build your car without building a rotisserie, you are saving time now but will work much harder and lose time in the end...

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.1.jpg)

The left side- worst part

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.2.jpg)

The cabin. Tried cutting out portions, but the cancer kept showing up in pinholes everywhere. Sound familiar?

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.3.jpg)

View from below:

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.4.jpg)

I sprayed the floor pans with epoxy paint. They were purchased in front and back halves because I had trouble finding a single piece and I thought it would be easier to install- not having a rotisserie. Not a bad move looking back, but more welding.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.5.jpg)

Saved some old parts and strengthened with extra metal.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.6.jpg)

Looking back, these welds are so embarrassing. Not hot enough. I have learned a lot since.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.7.jpg)

This piece keeps you from punching through the floor with your foot

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.8.jpg)

Ugly welds, I know. I thought about an ugly weld thread contest. Who makes the ugliest welds. Getting better though.

Epoxy primer, etching primer, and seem sealer oh my! Incidently, I had to grind this back off, redrill the holes and weld it back because I was off just enough that the pedal cluster did not line up correctly. Recommend welding this on after the floor pans are welded to the car. Measure thrice, cut once.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.9.jpg)

Rear panel in and Engman Kit with new metal braces sleeved over the old ones. Hope the seats still fit.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.10.jpg)

It helps to have small helpers.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.11.jpg)

And he does good work:

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.12.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1455413294.1.jpg)

The firewall behind the seat was a chore with the gummy glue adhering the sound barrier. Bead blasting is the way to go- cheap, great results, fast...

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.13.jpg)

A few extra brackets to tie the Engman kit to the floor pan for added strength. Already much better welds although I did not need to weld the entire length of those brackets. It's better to leave open spots for flexing. Otherwise, the metal can crack.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.14.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1455411952.1.jpg)

Jumping ahead a few months, the finished floor pans with car torn down for painting after bead blasting and first coat of epoxy primer, but we'll get to that.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1437945676.15.jpeg)