she's in the OR (update 12/19)

93forestpearl · Post by **93forestpearl** » Tue Oct 24, 2006 8:31 am

The teardown and build finally started today.

Start time: 4:30 pm
End time: 10:30 pm

Damage report:

Several 10mm fender bolts broken
Couple 12mm bolts broken
One dethreaded control arm bolt
One broken 19mm socket
One massive gear oil spill, der da durhhh
One gashed finger knuckle

Progress:

I put that clutch in over a 100k ago.

I had a couple other monkeys there lending a hand. Everything went fairly smoothly, considering 13 years of Minnesota weather, and my rough treatment from 76k to 190k. I'm thinking I won't be so lucky on the rear suspension and diff/support since I've only had the struts out before. PB Blaster is my friend.

After everything is torn down, I'll take the 5MT apart to rob it of its stub axels for the 6 speed, strip the EJ22E of everthing but the shortblock minus oil pan, and the list goes on for about 12.4 miles. I'm shooting for less than eight weeks on this build. It includes:

installing new motor I built (http://www.bbs.legacycentral.org/viewto ... highlight=)

rotated mount
rebuilt (custom) lower rad suppt
relocated rad
FMIC & plumbing (behind headlights)
modified wrx exhaust
rewire for standalone (G2)
plenty of other wiring for Zeitronix, gauges, etc
complete rear driveline teardown for bushings
adding rear swaybar/boxing in mounts
reworking pretty much the whole fuel/vaccuum/pcv/everything system

This has been in the works for soo long its almost surreal.

BAC5.2 · Post by **BAC5.2** » Tue Oct 24, 2006 11:54 am

Sweet. I've been looking forward to this for a long time!

Yukonart · Post by **Yukonart** » Tue Oct 24, 2006 8:11 pm

HELLS YEAH!!!!!

Bheinen74 · Post by **Bheinen74** » Tue Oct 24, 2006 9:36 pm

that clutch disc looks good still.

Richard · Post by **Richard** » Wed Oct 25, 2006 2:50 am

That's one helluva project! Hope everything goes well. And not too many more mashed knuckles.

AWD_addict · Post by **AWD_addict** » Wed Oct 25, 2006 8:59 pm

Cool!
What kind of clutch is that?
What year is that 6MT?

Kelly · Post by **Kelly** » Thu Oct 26, 2006 3:29 am

Sweet.

Say, what kind of welder ya got there?

93forestpearl · Post by **93forestpearl** » Thu Oct 26, 2006 6:38 am

AWD_addict wrote:Cool!
What kind of clutch is that?
What year is that 6MT?

The clutch in the picture is my Exedy OEM replacement that I put in when I brought the tranny in for a rebuild at about 90k. Apparently I'm really nice to my clutch.

The 6MT is outta an '05. Its got 8k miles on it. I'll be using the OEM clutch that came with it off the bat. Next year I'll update the heads, throw in a better clutch, and possibly get a bigger snail since I'll have to get topfeed injectors anyways.

rallitektech wrote:Say, what kind of welder ya got there?

You saw Pete's little Miller, haha. It runs off 220v, but I'm not shure of the exact model. It should work alright for the bit of welding I have to do. Little welders can be a pain sometimes though.

Anyone have experience welding stainless? I've read that C25 work OK, just that the puddle doesn't move as well, and that there is more spatter. If its really lame for trying to weld stainless, I guess I'll have to get something else, like 90%He 7.5%Ar 2.5%CO2. I really don't care how pretty the welds are, just that they work and hold up.

93forestpearl · Post by **93forestpearl** » Tue Oct 31, 2006 8:22 am

I've been making some progress, just haven't had time to go up to campus and upload pics. I did today though. I took the 5mt apart for the stubs, but thats looking like time wasted. I got the hydralic pedal assembly in tonight, with the master mounted. Installed the new bushings in the steering rack and mounted the turbo cross member. Think my old rack was a little rough, hehe? I had to get one of the tie rod ends off as the boot had a tear in it (ghey).

Even more fun was getting the rear suspension apart. One of the big lateral link bolts actually came out. A bushing pin was frozen to it, but a little heat along with a pipe wrench took care of that. On the driver's side I wasn't so lucky. Yeah, I broke a $27 bolt

Tomorrow I'm headed to school to use the press and get the new bushings in. Should be *fun*. Once thats all done, I can put the rear all back together with the TLeg diff. I always feel good when at least part of the car can touch ground.

Post by **Legacy777** » Tue Oct 31, 2006 7:46 pm

Have fun with the bushings.....I had to pretty much destroy the old bushings to get them out.

At least you're putting poly bushings back in. They should be easier then those damn STi bushings.

93forestpearl · Post by **93forestpearl** » Tue Nov 14, 2006 7:15 pm

I haven't had a chance to post in a while, but I've made some progress. The motor is pretty much ready to drop in. I just need to get the rest of the suspension and driveline back together. I found out that the SuperPro bushings for the diff support bracket are NOT for a Legacy, after I cut/burned out the old ones. So I've been wrestling with a car at the JY to get another one, so I can get the the whole rear of the car back together.

Then there was the stub axle saga. I thought I could use my 5mt stubs in thte 6 speed. Not the case. 5mt stubs are the same from '90 to '04. 6 speed stubs are different as the groove on the inside of the stub is bigger for the circlip to fall in to. So I needed to order them, and come on a slow boat from Japan, or at least it seems

Anyways, I'll get that diff bracket tomorrow and put the back end together. My stubs and seals are supposed to be here thursday, and that night I'll get the motor and tranny dropped in, hopefully. Then the fun stuff starts. Lots of cutting and welding.

Oh, and a neat little thing is that the oil drain tube can be installed straight up like stock, or rotated 90 degrees to the right.

AWD_addict · Post by **AWD_addict** » Wed Nov 15, 2006 12:41 am

Nice wrap. What kind is it?

93forestpearl · Post by **93forestpearl** » Thu Nov 16, 2006 7:18 am

From Ebay for $18

BAC5.2 · Post by **BAC5.2** » Sat Nov 18, 2006 9:51 pm

Whats wrong with the diff support bushings?

legacy92ej22t · Post by **legacy92ej22t** » Sat Nov 18, 2006 10:24 pm

I'm confused. Are you building up the EJ22E for F/I or are you dropping something else in there?

BAC5.2 · Post by **BAC5.2** » Sun Nov 19, 2006 4:47 pm

Built EJ22T IIRC.

93forestpearl · Post by **93forestpearl** » Sun Nov 19, 2006 7:54 pm

BAC5.2 wrote:Whats wrong with the diff support bushings?

They were just too small for the Legacy bracket. I crawled under my buddies GD and the bracket definately has smaller bushings. Its all good. He bought those from me so I don't have them just laying around.

legacy92ej22t wrote:I'm confused. Are you building up the EJ22E for F/I or are you dropping something else in there?

Its an EJ22T. The pics of the motor build are here.

http://www.d.umn.edu/~pidd0002/Car%20Stuff/Assembly/

I've been making some headway, but everytime I make two steps forward, I take one step back. I got the rear suspension all back together and the diff up in there. Then we were hanging the tranny up in there when on the nuts on the other side of the sheetmetal broke loose from the weld. GODDAMMIT!!!!! So now I need to cut an access panel to get at it with a wrench and the welder. I guess its kinda fitting, since the one for the rear of the control arm right next to it has it's threads pretty well mangled.

Hopefuly this week I can get the car back on the ground with the motor in and a start on plumbing.

Richard · Post by **Richard** » Mon Nov 20, 2006 1:23 pm

PB Blaster usually works for all but the most stubborn bolts for me. Sometimes it helps to use a wire brush to clean the bolt/nut area so the oil can get through easier. That stuff has some wicked wicking proporties. Much better than WD 40 IMHO. Spray it on, give it a little while, and bam. No sticky nuts. Helps em go back in, too.

Post by **Legacy777** » Mon Nov 20, 2006 7:33 pm

93forestpearl wrote:
BAC5.2 wrote:Whats wrong with the diff support bushings?

They were just too small for the Legacy bracket. I crawled under my buddies GD and the bracket definately has smaller bushings. Its all good. He bought those from me so I don't have them just laying around.

I did some investigating, and yeah there isn't anything out there for our rear diff bracket. I've even approached a few vendors about making some, and unless I could get x amount of people committed to buy some, I'd have to buy them, or something like that. I've got an email or something with the numbers.

93Leg-c · Post by **93Leg-c** » Tue Nov 21, 2006 7:55 am

What kind of muffler do you have?

93forestpearl · Post by **93forestpearl** » Tue Nov 21, 2006 7:48 pm

93Leg-c wrote:What kind of muffler do you have?

I've got an ebay exhaust that I will be hacking up to fit the Legacy and my rotated mount.

This morning I cut an access panel in front of those two mounting points and got a new nut welded in there. Hopefull tonight I'll have the motor and tranny in. I'll post pics tomorrow.

206er · Post by **206er** » Wed Nov 22, 2006 3:17 am

awesome build man, great job.

got any pics of the rotated mount uppipe/downpipe?

93forestpearl · Post by **93forestpearl** » Wed Nov 22, 2006 8:53 pm

Made good progress yesterday. I cut an access panel to get at that nut on the inside. I wasn't as bad as I thought it would be. It just sucked welding it back shut, since undercoating like to catch on fire

Motor and tranny are in. I'll start the plumbing on sunday. I hope to have the radiator mounted and uppipe/downpipe done.

Youcan see the difference in teh stubs. It's nice how that kinda stuff comes on a slow boat from japan.

Oh, and that ebay h-brace was a biotch to fit. I had to seriously elongate of the holes.

We also tried one of my buddy's WRX wheels over my brakes. They fit, but barely. I don't know it that would be enough clearance.

Imprezive · Post by **Imprezive** » Wed Nov 22, 2006 9:13 pm

you should clean your engine bay before its too late!!!

Post by **Legacy777** » Thu Nov 23, 2006 5:12 am

Yeah those brakes are pretty close.....I don't know...you may be ok though.

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A forum for 89-94 BC-BF(BJ) Legacy Owners and Fans

she's in the OR (update 12/19)

she's in the OR (update 12/19)