Subaru EJ25 progress thread - 2020 Modifications, Turbo, Engine Cleanup, Interior Upgrades Options

[malaga_red75]

Hi,
updates:
The car has been to the body shop and back in a record 2 weeks for the hell hole repair work (it always helps when your mom went to high school with the body shop owner).
While it was in the body shop and while I was home on thanksgiving break, I did some work on the subaru engine. I took off the wiring harness and the power steering pump and the A/C pump. I also removed the intake and the alternator. I put on the KEP adapter plate and flywheel/clutch assembly. I mated up the tranny and just snugged down the nuts cause I am going to send the tranny out soon for a rebuild....Dr. Evil?


Anyways....My question is this:
When the tranny and engine are mated up, the clutch fork has way too much 'slop' before the clutch begins to engage. I then realized that this might be caused by the thickness of the adapter plate pushing the transmission out further than it used to be. So, do I have to compensate for the width of the adapter plate? Thanks in advance.


-Peter

[TonyAKAVW]

I got my expansion tank from a local place (which has a web site) www.importedcarparts.com. Anyway, its the expansion tank from many late model Audi and VW cars. Its nothing special, just cheap. I think it was $15 or so.

-Tony

[malaga_red75]

Thanks Tony!

Anyone have an answer for compensating for the width of the adaptor plate?

[TonyAKAVW]

The custom flywheel should compensate for this. I had no problems when putting my clutch in. I already had the adapter plate, so I ordered a flywheel and clutch kit from Kennedy and had no fit problems etc. That was perhaps the smoothest part of the conversion actually. Make sure you have all new parts in there including the bushing for the fork, etc.

-Tony

[malaga_red75]

Thanks Tony, I will not be at home for another two weeks...school....but when I get a chance I will replace the fork bushings...etc. and re-check my install.

Until then...studying for finals....I wonder sometimes why I am a CE major and not ME...seems more appropriate for my hobbies... (IMG:style_emoticons/default/dry.gif)

[malaga_red75]

Hey guys,
Sorry I haven't posted in a while, I have been on my vacation and...well been vacating. haha!

Anyways, I have some things to post about the car so here we go-

-I tackled the radiator shroud and finished it. This was the biggest ???? for me and I am glad that I was able to do it. It was my first time working with sheet metal, so it isn't pretty but I think it will do the job.

-My uncle came over yesterday and today and welded in my floorpan, seat brackets, and tacked in place my engine mount for the subaru engine. He is now going to take the seat mount to his work and use the bigger 220 (we only had a 110) to weld it together. He did an amazing job and I don't know where I would be without his help thus far.


Next---

well, I am heading back to school in a few days and wont be able to work on the car for about a month but here is what will be next eventually.

-now that interior is done, paint with por-15
-paint front trunk with por-15
-run radiator lines (on the way from renegade) and install expansion tank
-hook up electrical and put the intake and alternator back on and then install the engine


that's the line-up for now. let me know what you think and oh yea....PICTURES!!! (and i have a clip of my uncle laying down a weld, but I'm not sure how to get that on here...youtube and then post link??)


First...test fitting and making panels



more.

[malaga_red75]

Painted and finished


Seat bracket...spot welds drilled out...conveniently making holes for plug welds

[malaga_red75]

Welded in



Tacking in place



Welding

[malaga_red75]

last....finished



-Peter

[jimkelly]

man - u should have been a plastic surgeon - that floor pan/ seat bracket weld job looks great! jim

[malaga_red75]

man - u should have been a plastic surgeon - that floor pan/ seat bracket weld job looks great! jim

I wish I could claim it to be my doings....but it was my uncle. He was a welder in the navy and is still his profession. He raced in SCCA historic races with his Ford Cortina. Actually that whole side of the family was into cars. My grandpa owned a Ferrari/Packard dealership near Hillsborough, CA. Also, Phill Hill raced for him and was a family friend for many years (to my mother and her siblings). Spencer is the last name for anyone who wants to know.

-Peter

[TonyAKAVW]

Looking great! Your sheetmetal work looks fine! Nicely done.

[cymaster007]

Nice job! Im in the process of putting the JDM EJ20 into my 1970 914, I used an old BMW radiator my father had laying around down i San Diego, and still need to clean up how the mounts look. How much did you spend on the kennedy adapter plate?

[malaga_red75]

Nice job! Im in the process of putting the JDM EJ20 into my 1970 914, I used an old BMW radiator my father had laying around down i San Diego, and still need to clean up how the mounts look. How much did you spend on the kennedy adapter plate?

The KEP adapter plate/flywheel/pilot bearing and all necessary parts is about 500 shipped. I got a few other things that bumped up my cost.

www.kennedyeng.com


Looks good...I do have one concern with your radiator setup though (and others may agree) the radiator may be to close to the gas tank wall and have problems with getting the hot air out of the engine compartment assuming you are venting through the fenders.

going through the hood might be an ideal situation for your setup

not too sure... anyone else??

_peter

[jd74914]

Nice job! Im in the process of putting the JDM EJ20 into my 1970 914, I used an old BMW radiator my father had laying around down i San Diego, and still need to clean up how the mounts look.

Looks good...I do have one concern with your radiator setup though (and others may agree) the radiator may be to close to the gas tank wall and have problems with getting the hot air out of the engine compartment assuming you are venting through the fenders.

going through the hood might be an ideal situation for your setup

I'd be concerned with both the lack of ducting and lack of exhaust area. Air will always try to go the path of least resistance which means that without good ducting it will flow right out your exhaust holes. As a rule of thumb you want much more exhaust area than intake area and I don't see how you can attain that with that radiator placement. In any case, those are just my opinions.

Peter,
The car is coming along nicely.

[charliew]

007 all that setup will do is recirculate the hot air. There will not be enough area behind the rad. for the hot air to get away from the radiator. Sorry but you need a redo on that setup.

[malaga_red75]

Peter,
The car is coming along nicely.
[/quote]


Thanks jd!!! I am now at school, so the car sits and will wait for me to return to hopefully fire her up. its getting close.

My uncle finished welding my engine mount bar so now the engine can be put in the car and will stay there. radiator lines are on the way, harness is ready to be put back on the car....oh boy.

I have one question about the fuel pump.

I have done some research and it sounds like a 5.0 mustang pump will work fine?

-do i need to get special fuel lines to accomodate size changes between 914 stock lines to pump to subaru lines??

Thanks in advance.

-Peter

ps. anyone go/went to Chico State?

[dlo914]

Great progress! Once i'm done with school n finances are steady imma start up a 914-subie project. Hopefully, i can find help with the electricals.

[malaga_red75]

Great progress! Once i'm done with school n finances are steady imma start up a 914-subie project. Hopefully, i can find help with the electricals.

That was my second biggest concern (fabbing the radiator shroud was by far the most challenging). I took the easy and consequently more expensive route and had these guys take care of my wiring harness.

www.enginewiring.com
-my harness took a while to be completed becuase they had to order some more relays for me but very nice guy, really nice to talk to and he definately knows his stuff. now i have it back and it looks like a stock wiring harness for a 2.5 subaru 914!!

-Peter


anyone on the fuel pump?

[dlo914]

how much did it cost? b/c i think a friend of mine is thinking of starting a 914 project with the ej25. As far as cost so far how much have you spent? Engine, Harness, radiator and doo-dads. I think we might have found a roller for $500 out near riverside...MAN i wish i had kept that shell Tony gave me for free! CRAP!