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)

[mgp4591]

Do you have the cast engine bracket or the other style? I've seldom seen the cast style weld up strong enough to the brackets to be safe enough for my tastes- not pointing fingers or anything, just curious as to what others are doing for the Subie mounting situation... Thanks! (IMG:style_emoticons/default/popcorn[1].gif)

[R_u_dd]

Do you have the cast engine bracket or the other style? I've seldom seen the cast style weld up strong enough to the brackets to be safe enough for my tastes- not pointing fingers or anything, just curious as to what others are doing for the Subie mounting situation... Thanks! (IMG:style_emoticons/default/popcorn[1].gif)

Looks like it's welded steel to me. The cast mount is used in the later models with the pass-through hole for the shift rod on the side shifter transmission.

The plan is to follow the design of Amenson in his PorSti Build as shown in post #2.

He drills through and bolts onto the bracket rather than welding directly to it. My goal is to try to mount the engine forward as much as possible to center the engine in the engine bay and avoid cutting the trunk. Since there is no turbo, I should have enough clearance to avoid cutting the trunk even if it has to be mounted further back than I would like. The axles will need to be aligned at a slight angle for proper lubrication of the CV joints. It will be a critical step to mount the engine correctly. It is also important to get the transmission level to keep 4th and 5th gear oiled properly.

[mgp4591]

Do you have the cast engine bracket or the other style? I've seldom seen the cast style weld up strong enough to the brackets to be safe enough for my tastes- not pointing fingers or anything, just curious as to what others are doing for the Subie mounting situation... Thanks! (IMG:style_emoticons/default/popcorn[1].gif)

The plan is to follow the design of Amenson in his PorSti Build as shown in post #2.

He drills through and bolts onto the bracket rather than welding directly to it. My goal is to try to mount the engine forward as much as possible to center the engine in the engine bay and avoid cutting the trunk. Since there is no turbo, I should have enough clearance to avoid cutting the trunk even if it has to be mounted further back than I would like. The axles will need to be aligned at a slight angle for proper lubrication of the CV joints. It will be a critical step to mount the engine correctly. It is also important to get the transmission level to keep 4th and 5th gear oiled properly.

I thought I'd studied that thread over and over- somehow I missed that bit right there! That's exactly what I was looking for, and the other comments give me confidence to use that for my EG33 swap- thanks for the help!

[914forme]

I thought I'd studied that thread over and over- somehow I missed that bit right there! That's exactly what I was looking for, and the other comments give me confidence to use that for my EG33 swap- thanks for the help!

I had one issue with small car mount on my swap. Oil filter clearance. Got the darn thing all welded up, and could not get the filter on the mount. Its a little tight. I will be running a Accusump so my plan is to run remote oil filters, and a cooler, with the Accusump. I should just dryjsump this thing, but then I would be into it for way more than a 911 swap.

(IMG:style_emoticons/default/poke.gif) If you read my thread, I think you will get an idea of how far the engine can go forward with the small car mount. I have almost no trunk floor cutting. Except for the clutch slave, and well that hole could have been a lot smaller. (IMG:style_emoticons/default/dry.gif) (IMG:style_emoticons/default/headbang.gif) realized I never took pics of the mount its self and the issue I was having. Could have sworn I did (IMG:style_emoticons/default/headbang.gif)

[DBCooper]

(IMG:style_emoticons/default/poke.gif) If you read my thread, I think you will get an idea of how far the engine can go forward with the small car mount. I have almost no trunk floor cutting. Except for the clutch slave, and well that hole could have been a lot smaller. (IMG:style_emoticons/default/dry.gif) (IMG:style_emoticons/default/headbang.gif) realized I never took pics of the mount its self and the issue I was having. Could have sworn I did (IMG:style_emoticons/default/headbang.gif)

I also got the Smallcar mount but ended up not able to use it. It's really well-made and and compact, works well for non-turbo cars, but isn't compatible with a turbo setup where the exhaust from the left side has to cross over to the right across the front of the engine. That's right where the Smallcar mount goes. It's possible, I suppose, but would mean you'd have to relocate the turbo and do a lot of custom plumbing.

I've never seen anyone put it on their list, but one of the nice things about the non-turbo engines is that you'll end up with an equal-length exhaust, which gets rid of the typical Subaru exhaust burble. With an equal-length exhaust they sound really good when they get into the upper RPM range. My son joked about driving his 914/WRX to work and for weeks a WRX owner kept trying to spot the other turbo Subaru he was sure he was hearing come into the parking lot, never thinking it was the 914. Was startled when he finally figured it out.

By the way, with an Accusump you won't need it, but the Killerbee windage tray works pretty well to prevent oil starvation, and not too expensive.

[mgp4591]

(IMG:style_emoticons/default/poke.gif) If you read my thread, I think you will get an idea of how far the engine can go forward with the small car mount. I have almost no trunk floor cutting. Except for the clutch slave, and well that hole could have been a lot smaller. (IMG:style_emoticons/default/dry.gif) (IMG:style_emoticons/default/headbang.gif) realized I never took pics of the mount its self and the issue I was having. Could have sworn I did (IMG:style_emoticons/default/headbang.gif)

I also got the Smallcar mount but ended up not able to use it. It's really well-made and and compact, works well for non-turbo cars, but isn't compatible with a turbo setup where the exhaust from the left side has to cross over to the right across the front of the engine. That's right where the Smallcar mount goes. It's possible, I suppose, but would mean you'd have to relocate the turbo and do a lot of custom plumbing.

I've never seen anyone put it on their list, but one of the nice things about the non-turbo engines is that you'll end up with an equal-length exhaust, which gets rid of the typical Subaru exhaust burble. With an equal-length exhaust they sound really good when they get into the upper RPM range. My son joked about driving his 914/WRX to work and for weeks a WRX owner kept trying to spot the other turbo Subaru he was sure he was hearing come into the parking lot, never thinking it was the 914. Was startled when he finally figured it out.

By the way, with an Accusump you won't need it, but the Killerbee windage tray works pretty well to prevent oil starvation, and not too expensive.

Did you sell your Smallcar engine mount after you decided not to use it or is it for sale? Long shot but I figured it's worth a try... (IMG:style_emoticons/default/idea.gif)

[DBCooper]

Did you sell your Smallcar engine mount after you decided not to use it or is it for sale? Long shot but I figured it's worth a try... (IMG:style_emoticons/default/idea.gif)

I'm pretty sure they're in a bin somewhere. I've moved twice since then and during that last move hurt my back, back's still not good so still have bins stacked everywhere. How patient are you?

[mgp4591]

Did you sell your Smallcar engine mount after you decided not to use it or is it for sale? Long shot but I figured it's worth a try... (IMG:style_emoticons/default/idea.gif)

I'm pretty sure they're in a bin somewhere. I've moved twice since then and during that last move hurt my back, back's still not good so still have bins stacked everywhere. How patient are you?

Turns our I'm pretty patient- your answer came in while I was still in the hospital so it got buried for two months until I was back and dug through stuff. If you've still got your mount I'd be interested in buying it if you think that it would a fit the EG33...