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Full Version: jim kelly's 1975 914 suby build (a bolt on affair)
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jimkelly
i have a 1975 914 roller and a a few ej22 engines and a couple of suby 5 spd transaxles
https://www.diyautotune.com/shop/megasquirt...ed/microsquirt/
microsquirt with 8" harness $370
GM clt sensor 3/8 npt $17
GM iat sensor 3/8 npt $22
GM map sensor $75
3/8 npt tap $10
18x1.5 tap $12
18x1.5 bung for aem o2 sensor $4
AEM 30-4110 $165
Set of 6 Pcs Spark Plug Ignition Wire Lead For 2.8L VW Passat $30
VW bug Beetle golf oem 2.0 ignition coil pack assembly 032905106b $20
Subaru WRX OEM Crankshaft Timing Sprocket pn-13021AA141 $30
celica radiator 2 row - $170 (see post #2 and my v8 thread)
exhaust header - $100 ebay (see post #152)
stainless fuel lines - $99 tangerine - 8mm supply and 8mm return
stopper drive pinion - made myself
http://www.914world.com/bbs2/index.php?showtopic=104513
stock 914 axles machined on one end - $150 Dutchman
tires - 185x50x15 - $300+-[/b]
engine cradle and trans hangars - mepstein $550 (see post #32)
mr2 shifter - $35 ebay
shift knob ebay $12 (see post #170)
front bumper grills - $35 dflesburg
stock style fuses - ebay $13
set of speed bleeders - $30 pelican
brake peddle switch - $24 pelican
ebrake handle assy with cable and equalizer - $56 bdstone914
lug bolts to roll car around my garage - free mark epstein
set of nice complete late model doors - $150 (thanks lorin, series9, rat rod charlie)
center section of fuse box - free mark epstein
a front steel bumper - free mark epstein
late model tach with single directional indicator - cabinetmaker $40 shipped : )
two pair front amber lens bought from 914rubber for both my cars.
///////////////////////////////////////////////////////////////////////////////////////////
looking forward to...
good fuel mileage
modern fuel injection
modern 5spd transaxle - useable 1st gear for taking off from dead stop & in traffic
light weight car
big space in engine bay
running some low profile 15 inch tires on 5.5" wheels - maybe 185x50x15

//////////////////////////////////////////////////////////////////////////////////////////
reference materials and links...
http://www.shoptalkforums.com/viewtopic.php?t=136053
http://www.surrealmirage.com/subaru/swap/electrical.html
http://legacycentral.org/
http://www.northursalia.com/modifications/...lschematics.pdf
http://www.main.experiencetherave.com/subaru_manual_scans/

vanagon related links...
http://subaruvanagon.com/conversion_services_Wiring.htm
https://smallcar.com/vanagon/subaru-vanagon...cation-kit.html
http://www.kennedyenginc.com/Pages/SubaruVanagonGen.aspx
http://www.rockymountainwesty.com/v/vspfil...nstructions.pdf
http://www.weidefamily.net/vanagon/HTML/05/main.html
http://www.ultimatesubaru.org/forum/topic/...iring-diagrams/
http://www.numbchuxconversions.com/Files/Harness%20info.pdf
http://consumerguide.com/used/1990-94-subaru-legacy/


pulling ej22 harness from subaru (Tim Seward) per tim 90 and 91 harnesses are same


be sure to watch all (busaru) segments


Subaru engine test stand (Jeff Robenolt)
jimkelly
this ebay radiator was mentioned by a member. the price is right, so it may be what i will use?

update 19dec2015: I recently put one in my v8 car using a&p mech's mounting style and it is working fine.
jimkelly
some sensor fake output info... from tonyakavw and scott914...

Okay, so I THINK I WILL NEED TO fake/simulate the following sensors depending on which Subaru donaor car I buy..

Fuel level sender (0.12 to 4.95 volts)
Fuel Temp sender (2.5 to 3.8 volts)
Fuel Tank Pressure sender (2.3 to 2.7 volts)
Rear O2 sensor signal (0 - 0.9 volts)
Neutral position sensor (+12 in neutral, 0 when in gear)
Rear O2 heater sensor signal (0-1.0 volts)
Power Steering oil pressure sender (open/close)

There may be one more, I'm still finalizing the wiring...

Most of these wil use small 10-turn potentiometers to set the desired signal voltage, but I may end up using real metal-film resistors in the end, as they are a bit more reliable.

-Tony

Regardnig the sensor simulator, I won't be simulating the front O2 sensor. That is used by the ECU to run the enigne, whereas the second sensor is there just to verify the cat is working. Since I'm not going to be running a cat, I have to simulate the second sensor.

that looks like you are mising a few plugs, but i cant see it all very well. dont tape it up too much you will probably have to open it up once to fix something.

all the plugs i can think of are :

brain
2 o2 plugs
3 for engine connection
fuel pump relay
main realy
ignitor
obd connector
purge and pressure switching solinoids ( 2 plugs )
connection to relay board

then loose wires are :
power
ground
speed sensor
temp sensor if you go stock

then you need wires from the alt
r_towle
Wait, what?
Don't you have a v8?
Smallblockbug
Im pretty sure this is his other car. But yes he has a v8 car to.
jimkelly
i have a wife, 2 boys, and two 914s. that is about it BUT that is all i need smile.gif

have we ever concluded whether or not this subaru spool ( pn - 498427100 )is a part that will work in our conversions?

$134
https://subaru.service-solutions.com/Detail.aspx?id=86

vs $229
http://www.bremarauto.com/products/subaru-...conversion-kit/

vs $200
http://www.subarugears.com/Pricing/Pricing.html
Stacks914
I am sorry did you mention fuel mileage??? LOL jk man looking good!!
jimkelly
YES, yes i did. it will be my daily driver once complete.
mepstein
QUOTE(jimkelly @ Sep 30 2015, 09:01 AM) *

YES, yes i did. it will be my daily driver once complete.

Same here driving.gif
76-914
When does the build start? Not a fan of acquisition threads, so much. Onward thru the Fog! beerchug.gif
mepstein
QUOTE(76-914 @ Sep 30 2015, 11:21 AM) *

When does the build start? Not a fan of acquisition threads, so much. Onward thru the Fog! beerchug.gif

There's a lot of stuff to acquire before the build.
76-914
QUOTE(mepstein @ Sep 30 2015, 08:39 AM) *

QUOTE(76-914 @ Sep 30 2015, 11:21 AM) *

When does the build start? Not a fan of acquisition threads, so much. Onward thru the Fog! beerchug.gif

There's a lot of stuff to acquire before the build.

If you want to complete the build in one week, yes. Or someone that is paying a 3rd party, as in your case. JMHO
mepstein
QUOTE(76-914 @ Sep 30 2015, 06:00 PM) *

QUOTE(mepstein @ Sep 30 2015, 08:39 AM) *

QUOTE(76-914 @ Sep 30 2015, 11:21 AM) *

When does the build start? Not a fan of acquisition threads, so much. Onward thru the Fog! beerchug.gif

There's a lot of stuff to acquire before the build.

If you want to complete the build in one week, yes. Or someone that is paying a 3rd party, as in your case. JMHO

I'm going to get some help from my shop on the Suby build but I'm the one building the car. The Porsche build is getting done by scotty b. If I had the money, I would have both cars built 3rd party. I will say that for me, a non mechanic, just getting the parts together is a struggle, not a bad one and the people on this site are great and I'm having fun but for me, a lot of this stuff is pretty confusing.
jimkelly
i'll try to blend ACQUISITION with ACTUAL BUILD photos and text.

my car needs some welding, but the rest will mostly be bolt in. nothing too fancy, that is for sure. super low dollar build. planning on frankenstein axles or have dutchman machine some.

http://www.dutchmanaxles.com/
jimkelly
$35 ebay

actual unit as received
A&P Mech
All those pieces and parts look familiar. smile.gif What motor are you planning on using?
mgp4591
QUOTE(jimkelly @ Sep 30 2015, 06:53 PM) *

i'll try to blend ACQUISITION with ACTUAL BUILD photos and text.

my car needs some welding, but the rest will mostly be bolt in. nothing too fancy, that is for sure. super low dollar build. planning on frankenstein axles or have dutchman machine some.

http://www.dutchmanaxles.com/

Do you know of anyone here or elsewhere using these axles or any idea of the cost?
jimkelly
Dutchman has been recommended by bigkat_83 who is amazing resourceful and a phenominal fabricator.

as I understand it, not all conversions can use the same axle length but I have to recheck but I think bigkat had Dutchman machine stock 914 axles to work with his suby conversion. I think the cost is about $150 for the machining on one end. one end would retain the 914 cv spline, the other end would get a suby spline machined in, I believe.

you (and I) need to read every suby thread, I have several listed in my signature.
76-914
QUOTE(jimkelly @ Oct 2 2015, 07:52 AM) *

Dutchman has been recommended by bigkat_83 who is amazing resourceful and a phenominal fabricator.

as I understand it, not all conversions can use the same axle length but I have to recheck but I think bigkat had Dutchman machine stock 914 axles to work with his suby conversion. I think the cost is about $150 for the machining on one end. one end would retain the 914 cv spline, the other end would get a suby spline machined in, I believe.

you (and I) need to read every suby thread, I have several listed in my signature.

Yep, it's all covered.
mgp4591
Sweet idea for the axles- I may just send my SVX axles and have the other end reworked for heavy duty Porsche cv joint ends. Which cvs are the strongest that match up with our rear hubs once they've been modified for 5 lug?
jimkelly
sawtooths axles

>> has anyone used this dimension with a coldwater cradle ??
jimkelly
why I MUST HAVE a Subaru engine and trans biggrin.gif



and

76-914
QUOTE(jimkelly @ Oct 3 2015, 05:12 AM) *

sawtooths axles

>> has anyone used this dimension with a coldwater cradle ??

Your getting way ahead of yourself. You'll need to measure those once your drive train is in. These cars vary dimensionally. Don't be surprised if there is a 2-10mm difference between sides. You will want these cut as long as possible. They should just barely squeeze in to place with very little room to spare. BTW, when do you plan to start working on the conversion?
jimkelly
your conversion was epic - others can see it here.
http://www.914world.com/bbs2/index.php?sho...hl=subaru++tool

mine will be primarily a bolt in affair. mine will only be of some interest to those that have my very limited skill set. sorry sad.gif

thanks though regarding your comments related to axles. shades.gif

I am trying to find anyone who is using a coldwater cradle and a 914 cv at wheel and suby cv at trans. cause we should all be in same boat.

jim

QUOTE(76-914 @ Oct 3 2015, 07:20 AM) *

QUOTE(jimkelly @ Oct 3 2015, 05:12 AM) *

sawtooths axles

>> has anyone used this dimension with a coldwater cradle ??

Your getting way ahead of yourself. You'll need to measure those once your drive train is in. These cars vary dimensionally. Don't be surprised if there is a 2-10mm difference between sides. You will want these cut as long as possible. They should just barely squeeze in to place with very little room to spare. BTW, when do you plan to start working on the conversion?
Chris H.
QUOTE(jimkelly @ Oct 3 2015, 07:15 AM) *

why I MUST HAVE a Subaru engine and trans biggrin.gif



That red one looks familiar...but then again there are a lot of red ones... idea.gif



Ross is using the setup you describe Jim (rnellums), or something similar. He is 5 lug I think.
jimkelly
OD of splined end of stock 914 axle is 1.066.

what i am confused about in sawtooth's machining drawing is that the end with all the measurements looks like the 914 end that should have remained untouched i thought. is the CV ID of a suby larger or smaller than the CV ID of a 914 stock cv. i assume smaller otherwise how else could a stock 914 axles be machined to accept a suby cv ????
mepstein
Jim - if you or someone will tell me how to remove the Suby axles from cv's, you can have my axles for free.
jimkelly
once upon a time, i had a legacy parts car and removed an axle for poscharu, not sure they are all the same but there may be a pin thru the cv and thru the stub axle on the trans side. on the wheel side i think there is a big nut holding it to that side, not sure.



be sure the drain all fluid from trans before disconnecting it from engine, when you get to that point.
mgp4591
QUOTE(mepstein @ Oct 7 2015, 03:59 PM) *

Jim - if you or someone will tell me how to remove the Suby axles from cv's, you can have my axles for free.

The inners come free when you cut the inner boot completely off, locate the large inner snap ring that's just inside the lip. Then the inner tripod should pull right out of the cup end. So far as the outer joint goes, once again pull the outer boot completely off and taking a REALLY large mallett (so no metal breaks off and injures someone), smack the hell out of the cv joint, away from the shaft. After a whack or two, it should come right off. Done it hundreds of times, it's not too hard.
jimkelly
mepstein
Thanks guys.


I'll probably cheat and have one of my mechs do it. They're young. I can own them with a cheeseburger.
jimkelly
decided to drive the pickup truck to mark's shop and get me a sweet engine cradle and trans hangars biggrin.gif thanks mark
jimkelly
finally got my 1975 back onto some wheels and tires, so I can roll it around. passenger side brakes were locked up, finally pushed it real hard a few times and now it rolls again. went to remount my fuse panel and noticed it had a cracked ear, so I need to replace it. reinstalled the rusty peddle cluster too. might bleed the brakes tomorrow. basically it is a roller that needs doors and a drivetrain.

giving the interior its first coat of rustoleum, from a can I had laying around. popped in both rear lenses, not in the best of shape. reinstalling headlights, they will be permanently up. off to ace to get some allen screws, somehow I lost 4 of them blink.gif got the screws and got both headlights in, now to figure out how to fix them up solidly.

this car has some rust, need to weld in 3 patch panels, and longs ain't so pretty either.
jimkelly
how could i best protect these pin holed longs without welding new metal in ??

i'm thinking phospho, then rise, a primer, then a skin of bondo, then rustoleum.

or maybe just rustoleum primer, skim of bondo, then a coat of rustoleum paint.
jimkelly
my buddy - rat rod charlie - is on his way to daytona for bike week with his harley and his trailer. while he is down there, he is going to visit series9 for me and pick up a pair of late model ARIZONA doors from ablesnead whose car is at joe's shop biggrin.gif
76-914
QUOTE(jimkelly @ Oct 7 2015, 11:56 AM) *

OD of splined end of stock 914 axle is 1.066.

what i am confused about in sawtooth's machining drawing is that the end with all the measurements looks like the 914 end that should have remained untouched i thought. is the CV ID of a suby larger or smaller than the CV ID of a 914 stock cv. i assume smaller otherwise how else could a stock 914 axles be machined to accept a suby cv ????

Read right past this the first time but yes, you are correct. Plenty of meat.
jimkelly
got me some doors coming via series9's shop.
Andyrew
QUOTE(jimkelly @ Oct 12 2015, 10:07 AM) *

how could i best protect these pin holed longs without welding new metal in ??

i'm thinking phospho, then rise, a primer, then a skin of bondo, then rustoleum.

or maybe just rustoleum primer, skim of bondo, then a coat of rustoleum paint.



What happens when you stab it with a screwdriver? If it goes through I would replace it...Mine looked like that and I patched it.. You have a fairly easy job there. Sure it'll set you back maybe 2 weeks but its the right thing to do... If you dont have a welder you can rent them fairly cheap.
jimkelly
my head light question thread at this link... pics below.

http://www.914world.com/bbs2/index.php?showtopic=267076
jimkelly
decided that I will just put a delrin spacer here to keep headlights in UP position, permanently.

the idea is less demand on electrical system and less weight. and I always drive with headlights on anyway.

rcvd my ebay fuses and a knob for my V8 car.
jimkelly
new doors coming home today. guess i'll put white doors back on white car and my black car will get the NEW TO ME red doors. i know i saved some triangle door glass, hope i saved the caps that hold them in place? gonna stop by mepstein's shop to pick up a front bumper and a fuse box. slow progress is still progress popcorn[1].gif
flmont
Jim,..how do U intend to run the water lines under car or thru the longs,..?? Frank
jimkelly
under - it is tried and true - but thru longs gives more ground clearance I suppose.
rightpedal
Jim I laugh every time I see the "pickup" in action. I'm so getting you ratchet straps for Christmas. (to increase the load dimension capability)

Wait now i want to make the red one onto a porcamino!!!!

Sorry the deep end comes quickly for those of us in the shallow end of the gene pool.

Just wanted to say I like that you use your car.

Steve

porcamino....it has a ring to it
jimkelly
white doors are back on my 1975 and red doors are now on my 1972. having an issue with the caps for the triangle windows though.
914forme
And to think I just man handle doors in place, put them on my legs, with my wheelie stool, and then make up new words for all the frustration I cause myself.
jimkelly
thank god I had the hoist... no way could I have installed 4 doors without it... would have had to ask the wife for help/muscle smile.gif

got the caps on, seems all years are the same.

I have some sort of radiator leak, its slow. will investigate this further.

bushings to keep headlights permanently up are in.
jimkelly
yesterday I picked up a fuse box section and a front bumper from mark Epstein (thanks mark!). my center fuse box section had a broken ear, so I replaced it today (one wire at a time). I put white fuses in all for now, but will replace with higher amp fuses as required asap. so far I can see I have, headlights low and high beams, marker lights, brake lights, wipers. I think I have a faulty horn relay?

I do not have my dash gauges in and am wondering if this could be stopping my directionals and hazards from functioning?
mepstein
Save your old fuse panel in case you or someone else needs to harvest more metal clips in the future.


I do admire the way you make progress on your car.

Another edit - looking at your list, I have a couple more parts. I think the battery that came in the California car is almost new. Your welcome to it. I'm going to try one of the new super small, super light lithium batteries.
jimkelly
mark - that is awesome - I am so glad I got a kid that goes to school up in your area which requires me to pass by your shop every few weeks smile.gif

I think I am short a few door hinge screws and a horn, gonna add these to my list.
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