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]

Axles

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1447544911.1.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1447544911.2.jpg)

Subaru on top and 914 on the bottom. The Subaru is a 29 spline and the 914/bug axle is a 33 spline.

My axles will need to be shortened because the engine is set forward slightly from the designs of other cradles such as Ian's. I set the engine farther forward to avoid cutting the trunk and flipping the manifold (for now). Note that there is 4 inches of offset from the transmission to the wheel hubs.

There should be some bend in the axles and CV's for proper lubrication of the CV's, but how much is too much? According to the Blind Chicken, the maximum angle for the Type 1 CV (bug CV measures the same as the 914) is 12 Degrees. For this reason, I may have to go with the 944 CV's (22 degrees offset capability), on the 914 axles and do a 5 lug conversion while I am at it.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1447544911.3.jpg)

Sawtooth shortened his axles to 18" from 20.25". When I called Dutchman, they suggested doing a mock up by cutting the Subaru axle off and using angle iron to splint the axles together, which would work fine if I had an extra axle to cut up. Anyone? I am going to have to mock up some temporary axles to make sure the CV's will handle the offset and to get the right measurements before I cut the axles down to size.

Otherwise, I am concerned about getting the measurements right for the axle length. One positive (with Dutchman) is that you don't need to send all the measurements if you have a sample Subaru axle end to use as an example of what you want, so the only real measurement you need is the axle length- with no other modifications (ie. 911/944 CV's). I would like to keep it simple and use the 914 axles and CV's if possible.

This is similar to what I plan to do here:

Subaru inner CV- 914 axle- 914 outer CV- 4 lug wheels (for now)

Update: The plan is to use 914 stub axles, Renegade conversion plate, 944 CV and axle, resplined on the inside for the Subaru CV to the 5MT transmission. The following discussion is me trying to learn what to do.

Axle Info and Threads:

Axle Info 101 from Blind Chicken

"Things I think I know about CV's and Axles"

Dutchman Axles

Corkus- Axle questions for a Subaru Tranny, Another Subaru conversion...

Axles Shortened in Subi Swap?

Angle of Articulation Bus Axles 944 vs 914


5 Lug Axle Conversion:

Sir Andy- Convert to real 5-lug using 944 CVs

Eric Shea- Easy 5-Lug Conversion - 911 Running Gear, For High Power Applications...

I went out and took some measurements with the 914 axles. It looks like I am close to 22 degrees which is the max for a 944 CV. (Update- At 12 degrees) Hmmm. This is a critical decision here. The 914 CV is supposed to max out at 12 degrees. So, I may have to find some 944 CV's but that is fine since it allows me to switch to a 5 lug wheel.

Take a look at these pictures. I am curious and need opinions here on this angle. The wheel and CV seem to turn without much friction, but apparently I am past the angle that these CV's can handle. If this angle is too steep (even if I go with the 944 CV), I have to stop here and redesign my cradle and likely cut the trunk.

What do you think?

More pix-

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1447544912.4.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1447544912.5.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1447544912.6.jpg)

The 944 axles and conversion plates have arrived. I purchased the plates from Renegade Hybrids. They are about a half inch thick and bolt into the 914 stub hub on one side and the 944 cv on the other. This gives a much stronger CV threshold and a larger angle of travel, now up to 22 degrees. This should prevent me from having to redo the engine cradle and flip the manifold.

(IMG:http://www.914world.com/bbs2/uploads_offsite/i1301.photobucket.com-17072-1471580651.1.jpg)