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-   -   My New Project: Building a S401 (https://legacygt.com/forums/showthread.php?t=164248)

sixspeedlegacy 06-22-2011 08:42 AM

Quote:

Originally Posted by BrandonJ 2001 GT Limited (Post 3439339)
There's a guy over on my Indiana Impreza forum that merges harnesses fairly cheap from what I've heard @ $300. I'm with you though, I'll pay a bit more if the parts are quality and it means less time.

I can understand the GF killing you. My wife will have my balls in a Crown Royal bag, or she'll own half of JoAnn Fabrics by the time I'm done...lol

So I assume you currently own a full JoAnn Fabrics at the moment?:lol:

Yea to be honest, the easiest way to do it and how I would normally do it is just get a Sti bulkhad harness(or a car with the appropriate ECU plugs) and just re-pin the plugs right at the ecu and add the few wires needed for AVCS, DBW and the fuel pump controller and leave the rest all factory. On my car though the harness is hacked up from when I had one of those add on NA modules and then later I had my Autronic wired in so I'd rather replace it anyways.

That said $300 for a merge is cheap from what I have seen. I do my own labor but I know some do pay others so it's a cost to consider.

Ben

sixspeedlegacy 06-22-2011 08:40 PM

Did a rendering in SolidWorks tonight. I will have to print it out and see if it works before I get it made but this should be a much cleaner and more precise way of doing it. :) I'll likely send it in to get a quote on the cost tomorrow as well. I'm just hoping they can do it in a thin enough material that is plastic.

http://i756.photobucket.com/albums/x...wdimension.jpg

http://i756.photobucket.com/albums/x...yrendering.jpg

Ben

BrandonJ 2001 GT Limited 06-23-2011 07:23 AM

Quote:

Originally Posted by sixspeedlegacy (Post 3439473)
So I assume you currently own a full JoAnn Fabrics at the moment?:lol:

lol...no, but I'll end up buying one to butter her up to let me buy what I want...:lol:

I wouldnt see why someone couldnt make that out of a plastic sheet fairly inexpensive.

MRLancaster 06-23-2011 12:20 PM

Im deffinatly keeping up with this build!!! :munch:

sixspeedlegacy 06-30-2011 08:55 PM

Quick update:

I read about another BE swap using straight spec B axles so I was curious if I could press the ABS trigger wheel on the spec B axle somehow. So I called and spoke with ECS about Ryan's rear axle setup. He is just running Spec B rear axles with no ABS. I plan to retain ABS so I'll have to create a GT/Spec B hybrid axle. It kind of pisses me off to use a 40k mile stub on a brand new axle but at this point I'm not buying new axles haha.

I also was able to get the drive by wire relay i need for the DBW pedal from someone on NASIOC so hopefully i should have that next week. :)

I will try and get some stuff accomplished tomorrow when I head home. I got a leak down tester from Harbor Freight, let's hope it works. Had a 20% off coupon so that was sweet.

I was sent the remaining parts from the company I bought the drivetrain from. They ended up sending me a new coolant crossover tube and a new exhaust manifold! I didn't expect that but that was sweet. Definitely great customer service. Now I just need the motor to check out alright and I'll be pumped!

I created myself a "to do" list for this weekend. Let's hope I can get it all done.

Should have some good progress pics coming this weekend.

Ben

BrandonJ 2001 GT Limited 07-01-2011 07:11 AM

Looking forward to the update pics. Good luck over the weekend.

LosAngelesLGT 07-01-2011 08:27 AM

Thanks for the update Ben! Enjoying the build and pics. Staying tuned for more updates... Hoping this is a big weekend for you.

SurlyOldManMN 07-01-2011 08:43 AM

I will probably need a break from ruthlessly flogging Pinoys this weekend. The offer for sausage-fingered assistance is still on the table. :woowoo:

sixspeedlegacy 07-02-2011 12:01 AM

Haha, thanks Pete.

Tonight was pretty much a bust. After having my first eye exam ever that rendered me half blind for about 4 hours I then went out to start work. Then we had a storm roll through and it knocked power out for 2.5 hours.

I did manage to swap the R180 flange with the R160 flange so I can use the auto legacy driveshaft I have. :) It was pretty easy to take off, thanks again to my electric impact gun. Torquing it to the 134 lb/ft spec is another matter. I did discover that a 1/4" thick screwdriver is not the proper tool to hold the flange stationary and will shear... I wish I had access to Subaru special tools. I still need to finish torquing it to spec tomorrow.

Tomorrow should be much more productive.

Ben

joelwatts 07-02-2011 08:51 AM

^if that would have been a snap on screwdriver we Prolly would have been reading, "today sucked. Had to go to the hospital".

TexasLegacy2.5GT 07-02-2011 06:43 PM

Sixspeed,

This build has my attention. I like your vision of what you are planning it to look like. Making the car look as sleek as possible is very cool. Just started looking at donor STI's for myself at the auto auctions here in Tx:
http://i231.photobucket.com/albums/e...5WRXback-1.jpg
http://i231.photobucket.com/albums/e...2005WRXSTI.jpg
http://i231.photobucket.com/albums/e...TIengine-1.jpg

The CoPart and IAA auctions get these guys in all the time.
Just for the record when I first came aboard I had a dork like Matt2NOT always trying to put negative jargon all the time bragging about how good he was seeking validation "I was the 1st to do this, I was the first to do that". Really? This guy keeps saying "butt hurt" too. Kinda makes you wonder.....Haha!! Best thing to just ignore our little bourgeois friend and not waste time on him. There are more positive folks on here that want to help you along the way.

Cheers my friend! Carry on, carry on.

SBT 07-04-2011 11:19 AM

TL2.5GT - you've got access to vehicles that most of us can only "hope" for. Good luck with your build. I'm sure as diligent as you've been about your sourcing project that this will come to a successful build for you.

SSL - Keep it coming Ben. Have always been impressed with both your initiative and your mad modding skills.

sixspeedlegacy 07-04-2011 04:22 PM

I got some decent stuff accomplished the past two days. It's all small stuff and I didn't get all done with everything I wanted to but that's how it goes.

I swapped the companion flange from the R180 to a R160 so I can use the legacy driveshaft. So far the best buy of probably all my tools has been the Chicago electric electric impact gun from harbor freight. For $40 it has worked great, no issues and even if it busted I can get another one.
http://i756.photobucket.com/albums/x...p/DSC00386.jpg
With R160 flange on it.
http://i756.photobucket.com/albums/x...p/DSC00388.jpg
A casualty of the project. For reference the nut needs 134 lb/ft of torque and I didn't have a specialty tool. I had to come up with another way to brace it torque it down.
http://i756.photobucket.com/albums/x...p/DSC00387.jpg

Here is the frustrating part because the whole point of working this weekend was a leak down test. I bought a harbor freight one for $32 with a 20% off coupon. The problem is the gauges just aren't precise and accurate enough. Depending on where you set the gauge before the reading it could be different by 10% which is pretty much worthless. I'll be taking this back and buying a better one. I tried to get one from Napa and of course they didn't have one at either store when I needed it.
http://i756.photobucket.com/albums/x...p/DSC00390.jpg
I tried to be as consistent as possible when setting it before the reading.
http://i756.photobucket.com/albums/x...p/DSC00392.jpg
this is Cylinder 1. This is showing nearly 40% leakage. I believe I wasn't at TDC, but either way I did it again and it read around 20%, still too high. All the cylinders were from 15%-21%, too high in general but I'm assuming I don't have 4 bad cylinders. I couldn't hear any audible leaks or feel any air coming from any of the possible locations.
http://i756.photobucket.com/albums/x...p/DSC00393.jpg

sixspeedlegacy 07-04-2011 04:23 PM

This is a concern, I saw this after I pulled the paper they had stuffed into the turbo. It is a piece of glass. I flipped the motor over on the stand and didn't see anything else come out but I'll spray air in there to make sure there is nothing in there.
http://i756.photobucket.com/albums/x...p/DSC00410.jpg
swapped the turbo intake to fix the torn rubber portion. This was quite annoying and I really hope I never have to do it again. In the process I did tear the intake manifold gasket, so I'll get some new ones. I need to order other gaskets as well so I'm just going to do it all at once, next time.
http://i756.photobucket.com/albums/x...p/DSC00413.jpg
The source of future fun. :) the stock turbo has zero shaft play so that is a positive.
http://i756.photobucket.com/albums/x...p/DSC00415.jpg

coolant crossover tube so now there is no plugged bung on it.:)
http://i756.photobucket.com/albums/x...p/DSC00417.jpg
Swapped the bung tapped side of the manifold for a stock one. It looks like the oilpan has taken a little damage from the bottom, not bad but there is a bit of a dent. I am partially concerned it could have impacted the pick up tube so I may have to pull it off for inspection which is really annoying.
http://i756.photobucket.com/albums/x...p/DSC00418.jpg

sixspeedlegacy 07-04-2011 04:24 PM

This was the resulting gap after tightening it down, there is no way this could have been pulled together with the stock bolts? I may have to loosen the other side and then put it together.
http://i756.photobucket.com/albums/x...p/DSC00426.jpg
I will be able to use just a regular 3" 2 bolt flange and gasket for when I build the rest of the exhaust so that was a positive. I will not have the donut gasket in there but I will have a flex section.
http://i756.photobucket.com/albums/x...p/DSC00425.jpg
Yep, cutting up a rare cluster prodrive gauge cluster, do not try this at home, unless you are doing what I am doing haha.
http://i756.photobucket.com/albums/x...p/DSC00428.jpg
Legacy cluster frame cut out for the Sti cluster to slip in.
http://i756.photobucket.com/albums/x...p/DSC00429.jpg
Looking factory. :D
http://i756.photobucket.com/albums/x...p/DSC00430.jpg
http://i756.photobucket.com/albums/x...p/DSC00431.jpg
I am gonna have to trim the top tab off as it gets in the way of the harness plug as does the rest of the top so pretty much all the tabs on the top will get cut off. It should still snap together fine with the rest and be secure.
http://i756.photobucket.com/albums/x...p/DSC00433.jpg
Still needs more adjustment for final positioning before I secure it all down but its a good start.
http://i756.photobucket.com/albums/x...p/DSC00434.jpg

That's it for now, won't be really any progress for about 2 weeks. I wanted to get my speakers and door panels installed but the first day threw everything off.

Ben


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