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]

Radiator

Some background and research:

Radiator Thread

Vent Holes

What Aluminum Radiator are you running?

Scirocco Style Radiator

Information on Cooling Systems

Will the Scirocco radiator really work

It seems there are a lot of ways to put a radiator in the front trunk. Very few people have successfully put the radiator anywhere else. I hate to lose the trunk, but possibly I can limit the damage by putting a smaller radiator between the front lights. This requires a radiator of 11" x 31" or less. Jeep Cherokee makes a radiator that is a double pass and that size. The double pass, I am assuming affectively doubles your cooling surface area.

Since my engine is a non-turbo 2.5, it's not a v8 or a turbo, and won't require nearly the same cooling capacity. The original radiator for my car is 13.38" x 27" X 0.63" or approximately 361 square inches of cooling area. Notice that it is very thin. The Scirocco style is 11" x 20" X 1.5" or affectively 440 square inches of cooling area since it is double the thickness. When I got the radiator in the mail it seems very small, which is what I wanted, but now I am second guessing myself as to whether this will really cool the engine. What do people think in this regard. Advice needed. It seems that people are running these Scirocco radiators, so they must work.

Here's some pictures of my progress so far. You can see just how small this radiator is.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1443360005.1.jpg)

This is a real simple bracket made of angle steel with two holes for the pegs on the radiator.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1443360005.2.jpg)

Another piece of angle steel (about 18-20 gauge) brackets the top of the radiator. I am intentionally not securing the radiator tightly. It needs to move in the mount because of the flex in the front of the car. If you bolt it in tight, the radiator can crack.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1443360005.3.jpg)

Picture from the back. Lot's of room in there. Hopefully not too much...

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1443360005.4.jpg)


Working on the shroud. Kind of a PITA, but getting there...

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1455402913.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1502074992.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1455402914.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1455402914.4.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1455402914.5.jpg)

This is how I decided to handle the vents.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1455402914.6.jpg)

I am planning on covering the vents with something like this to retain strength.
This is one made at 914sgonewild.com

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1455402914.7.jpg)

Here it is the final cutout covers. Can you still see the triangles?

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1467095619.1.jpeg)

And, a shot of both:

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1467095619.2.jpeg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1486251982.1.jpeg)

Protected radiator hoses. These are conduit pipes split down the middle.

I finished off the radiator with an overflow tank and in-line fill.

(IMG:http://www.914world.com/bbs2/uploads_offsite/vgy.me-17072-1502074992.2.jpg)