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]

Paint Prep Continued...

The metal work and preparations for final paining are at the point where I could call Scott, my painter, back into the game. We started doing some final paint prep before we go to paint. The whole process is new to me and it's great to learn from a veteran. These are the steps that we are taking:

Metal work to remove rust.
Bead blasting with glass beads. Similar to sand blasting, but the beads are much smaller.
Primed with Epoxy Primer
Primed within one week with high build primer
Primed with Urethane Primer over the top
Rust encapsulator in key locations, like over the battery tray area.

Most of this was done several months ago. I then worked on some final metal work like the radiator mount, front valence, rear jack point.

Now we are ready for final prep work which included block sanding with 80 and 180 grit. We used foot long blocks made of a flexible rubber, with velcro on the sides. Scott also uses a metal file to knock off the high points. Scott marks the low spots with a circle and the high spots with an "X". The low spots are then filled with glazing compound, a very thin filler, and sanded with 180 grit. He also used an air sander.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1456678354.1.jpg)

One of the steps we took was to roll the fenders to give them a better shape. We only moved the fenders a quarter inch, but rolled the lips and got rid of the funky inward curve of the shape when looking overtop the fenders. It is amazing what a subtle change like this can do to the aesthetics and functionality.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1456678354.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1456678354.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1456678355.4.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1456678355.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1456678355.6.jpg)

This is what the primed car looks like. This is "two laps around" the vehicle, or two coats of Urethane primer separated by 10 minutes of drying.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1456678355.7.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1456678356.8.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1456678356.9.jpg)

Next up, sanding with 400 and 600 grit, some final prep and then Painting!!!