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]

Engine Mount

The inspiration for the engine mount design comes from Amenson's Thread. I am using the Smallcar engine mount which is designed to mount a Subaru engine into a Vanagan. I am also using their oil pan which is designed together with the mount. This is a nice oil pan, aluminum, increases oil capacity to 5 Qt and yet is shorter in profile. It also provides a jack point or flat place to set your engine on the ground or a work bench.

The front part of the mount has to be cut off in order to move the engine forward in the engine bay. I flipped my Porsche engine bracket upside down to lower the engine about an inch.

I am using the Subaru Transmission which is different then Amenson's thread. He has a side shifting Porsche transmission which is really desirable. With that setup he has to put the engine in the right place to also utilize the transmission mounts and thus four mounting points for the setup. My bracket is for my 1971 with a tail shifter where the shift rods go around the bar rather than through the engine bracket bar. Which allows me to flip the bar.

Since I will be using the Subaru transmission it is important to get the transmission bracket the right height so the transmission is level to properly lube the fourth and fifth gear. Trying to get the engine in the right place to:

-avoid cutting the trunk,
-level the transmission,
-give enough clearance in front of the engine, and behind,
-align the axles properly (they need some angle, but not too much.
-measure for custom fit axles. It's a lot easier to use the Porsche tranny).


(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1443289264.1.jpg)

In this picture, the Porsche bracket bar is not flipped yet and you can just see the curl of the Smallcar mount touching it. The engine is still too far back. The final mount will be 2" more forward and 1" lower.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1443289264.2.jpg)

Lower side view showing the Porsche bracket and better view of the Smallcar mount. The engine is not level in this shot, or in its final position. Still assessing the position. That curved tube is for the dipstick. Once the mount is welded together, the oil pan comes with it when it is removed. You will see this in later pictures.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1443289264.3.jpg)

Welded angle iron across the mount first while the mount is still on the engine, to insure that there's no movement. Now to finish the mount, I had to remove the mount and oil pan from the engine. At this point the oil pan stays with the mount.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1443289264.4.jpg)

Notice the waterpump tube to the left. The bracket bar will need to clear that by 1/4" to get the hose on. Also, the bracket bar needs to clear the oil filter with enough room to change the filter. This required some careful fitting.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1443289264.5.jpg)

Fitting the bracket bar onto the engine mount. The waterpump tube on the left does not have the clearance yet by the blue tape. The oil filter is on the opposite side barely visible and needs as much space as possible.


(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1443289265.6.jpg)

Here, the mount has been removed with the oil pan. I cut the front of the mount off and welded a piece of flat steel on the front which will provide a lip for the bracket bar. I welded another piece of angle iron for the back lip, greater strength across the bottom, and to give the bar more clearance from the water pump tube.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1443289265.7.jpg)

The holes were rosette welded and new holes were drilled for the bracket. I considered welding the bracket bar to the mount, but keeping them separate is a better design as long as it is strong enough. Having the lip on each side should keep it from moving.


(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1443289265.8.jpg)

I welded the nuts onto the backside of the mount because they will not be accessible to the socket wrench once the mount is back on the engine. Cool design, hah? Hopefully everything fits in the right place, because I don't want to do this all over again!


Next up, fit the transmission on the engine and measure for the transmission bracket...