Chausx's '98 BD Legacy - Her donor busted a bolt 4-13-14

[Chausx]

I'll finally post my Legacy onto the forum.

I'm in a deep relationship with my '98 Legacy. She's a beautiful 4 door sedan with a few simple mods at the moment. She still retains the stock phase1 ej25 with a 2.2l intake tube and cheap after market cone filter.
https://sl-i.net/FORUM/images/imported/2011/04/SubaruLegacyProject001-1.jpg
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Current Mods\Additions as of: 4\24\11
-Spectre cone filter
-Pioneer Deck
-Pioneer Speakers
-JL Audio 10" sub
-JIC coilovers

Upcoming Mod list:

-Suspension:
--JIC Coilovers (Complete)
--Noltec Camber Plates front\rear

-Engine:
--EG33 Swap
https://sl-i.net/FORUM/images/imported/2011/04/SubaruLegacyProject020-1.jpg
https://sl-i.net/FORUM/images/imported/2011/04/SubaruLegacyProject021-1.jpg
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--Rebuild Stuff
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--Megasquirt & Tuning Stuff
https://sl-i.net/FORUM/images/imported/2011/04/SubaruLegacyProject041-1.jpg
https://sl-i.net/FORUM/images/imported/2011/04/SubaruLegacyProject033-1.jpg

--Drivetrain
https://sl-i.net/FORUM/images/imported/2011/04/SubaruLegacyProject040-1.jpg
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--Exhaust
https://sl-i.net/FORUM/images/imported/2011/04/SubaruLegacyProject038-1.jpg
https://sl-i.net/FORUM/images/imported/2011/04/SubaruLegacyProject039-1.jpg

--Exterior
https://sl-i.net/FORUM/images/imported/2011/04/SubaruLegacyProject037-1.jpg
JDM Headlights also coming in.

[Chausx]

Now that I've shown you what I have lying around the house right now I'll get down to the skinny of this project. My phase1 EJ25 is nicely leaking oil everywhere and after a refresh and no luck involved I decided to look into another engine. I decided on building the 3.3 out of a SVX and began my hunt for the engine. I went looking for about 6 months with no luck finding one lying around. I decided to join one of my friends on his search for a 1UZFE for his RX-7 project. We found his and decided to go further south to another junkyard and look around. Well luck have it we come across a SVX with everything intact. I go and ask the lady how much for the engine and she tells me $150 + $80 core. So long story short, I got an EG33 for almost nothing.

I'll be posting more information of the progress of my 3.3 as I move along. The full project tear down won't actually begin until the beginning of May as finals are coming up next week. But after that I'll start posting more about the swap.

As of right now the swap will involve a rebuild of the engine. Along with that I'll be porting the heads and exhaust manifolds(stock ones), building a shortened airbox(like the one you see on EFI Logics just not as pretty.), adding a lightweight flywheel w\ Group N STI mounts, custom exhaust with the Magnaflow muffler as my collector and the Dynomax VT muffler as my rear pipe. The engine will be controlled with a megasquirt 3! Because of the length difference in the 3.3 and from previous swappers experiences I've decided to get ahead of the game and look into hood pins and I decided on the Aerocatch versions for this project. Of course nothing is absolutely set into stone but as of now this is what I'm going with.


My Legacy - Current as of 4\24\11
-LED gauge light mod|JIC coilovers

https://sl-i.net/FORUM/images/imported/2011/04/SubaruLegacyProject009-1.jpg
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[anothernord]

Awesome! Great choice on going with the Megasquirt; lots of people love it. Hopefully you can get it tuned well enough daily-driver-duty. Keep us updated!

[Chausx]

I do love megasquirt. I've been running it on my CA18DET powered 240sx for the past 4 years now. Now its time to build my N\A project.

[httrdd]

Yea I am going to look into an effective way of tuning down the road with my turbo build on my swap. Looks like it is going to be a nice project and looks like you are attacking it the right way with a rebuild. If you want to use that stock hood latch take a look at the radiator and placement that I used(members ride thread in sig). Good luck with it I will keep tuning in.

[Chausx]

Yay my Noltec Camber plates came in!

https://sl-i.net/FORUM/images/imported/2011/04/20110426173023-1.jpg

For $200 BNIB for both sets that's a steal of a deal!

[Chausx]

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Ok here is my latest update on this. Pulled out both side camshafts on this, valve covers, oil pan, heads, lifters(placed into box there), I'm stripped down to the final block section. Need to remove the circlips and go make a ghetto wrist pin removal tool. After this I plan on a major scrub down and then I'll start doing the measurements and rebuild phase. From a visual inspection the factory crosshatch is still on the cylinder walls. There is a normal amount of carbon buildup which is good to see. The oil was a little bit sludgy from sitting and being weathered on. The oil pan has a little surface rust so I'll need to strip the paint and redo that also.

Items of choice that have or will be stopping at my door step:
'05 STI Fuel Pump(Arrived)
Aeromotive FPR(Arrived)
Aeromotive Spring Kit(Arrived)
JDM Headlights brought to me by Flea4me (thanks again!)
-6an Stainless Steel Hose
Fuel Rail Adapter

[httrdd]

Man if you have the dough get your cams ground. That would make a nasty 3.3. Any other mode to the engine while it is apart? There is an huge Svx meet in PA May 20th that I am going to to see all the FI builds. I plan a complete tear down of a spare block and rebuild for some high boost.

[Chausx]

I was looking into getting a set of ECUtune cams, but I'm not going to go too crazy into. I may do a grind on the cam at a later date. I'm now working on a little budget then when I started.

[grayguy]

Will delta do regrinds on these? How much would that run?

[Chausx]

Will delta do regrinds on these? How much would that run?

Good question. If I only had the answer to that. Which I don't to be honest.

Ok well the Legacy is up on jack stands at the moment with the start of some major work ahead of me.

Progress so far as of 5/11/11(pictures to come):

Ok well I decided on my JDM headlights to black out the reflector panel inside of the headlight. Which it took a couple of hours but it is now done. Yesterday I decided to clean up both headlights. I used the 3M lens renewal kit and the blue magic headlight lens sealer. If you follow the instructions down to the letter on the kit it'll work wonders. I'm not really sure about the lens sealer but we'll see in time. Today I decided to put them on my car which was an interesting experience. They both went in with a few minor issues but nothing I couldn't handle. I decided to wire the extra daytime running light (194 bulb) in also. I didn't like the look of the normal so I picked up some LED amber bulbs to put into place of the clear 194 bulbs.

Then I decided to put the Noltec camber plates on. The fronts went on pretty easy and no modification was required to get them to fit properly. The rears on the other hand are another story. The way the rears go with the JIC coilovers aren't easily mountable like the fronts. I'll need to use the spring rubber mount on the top to make it work, but I'll need to shave down about 1\8 of an inch all around to make it fit on the Noltec coilovers(I'll get pictures to better describe later). Since they are adjustable in the rear I decided to modify the cover so it can be adjusted without removing the rear seating area. So I scribed where I needed to cut on the cover and trimmed away. I haven't finished the rears yet, but they should be finished by tomorrow. Pictures to come tomorrow of progress.

[Chausx]

Some more updated pics:

https://sl-i.net/FORUM/images/imported/2011/05/20110513210136-1.jpg
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[Chausx]

Ok here is the lastest update I have for everyone:
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It's been a little bit but here's a small update. So I took the block halves and the head to get cleaned. I decked the block halves .020 over. Which was just a little under perfect for clearance. I spent a few days cleaning up the casting flash within the port and trying to smooth out the transitions. I moved onto lapping the valves and making sure those were all nice and pretty.

I decided to use 2 sets of EJ22 main and crank bearings which were perfect and clearanced out easily within spec. threw the 2 halves together check piston to head clearance. Take it apart again to throw the other rods back in super lube everything with Lucas assembly lube. Throw the pistons in after cleaning them with some effort lining up the rods and the pistons together. Got the heads on them and decided to paint it black with the valve covers. I had to stop because the gasket set coming from Subaru doesn't have the cylinder head half moon seals on the back so I had to order those in. I just received those today at my work which is nice. The new water pump and oil pump are into place. The NGK spark plugs you see are a special 3 prong surface firing spark plug for something to try with this build.

This is a small update of what I've been doing lately. More to come as I go along.

[Chausx]

https://sl-i.net/FORUM/images/imported/2011/07/SubaruLegacyYay287-1.jpg
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Here are the picture as of late. The engine was placed into the bay and connected to the transmission. It took about 45 mins of juggling and shoving and such to get it to go but its there now. The engine bay is black the block is black. The dash is out and the HVAC will be out by tomorrow so I can start wiring. Sorry this is really not detailed but its late. More details later.

[anothernord]

Very cool project. The H6 swap is the next big thing.

[httrdd]

Still at it I see. You should of had the cams ground while it was apart. ;) you will enjoy the instant torque!

[grayguy]

Makes me sad I got screwed out of my SVX... :( :( I'm going 2.2e turbo now until I come across another 3.3

[Chausx]

Very cool project. The H6 swap is the next big thing.

It has become the next big thing and what a large engine it is. It took so long to get the engine into place and so much wiggling. But its all worth it in the run.


Still at it I see. You should of had the cams ground while it was apart. ;) you will enjoy the instant torque!

Yeah I'm still burning away at it. I'll be happy to see instant torque once I get the damn wiring harness together. Thats my main project at the moment is making my plan for my megasquirt and what wires to keep and what wires to use for other things.


Makes me sad I got screwed out of my SVX... :( :( I'm going 2.2e turbo now until I come across another 3.3

What a said way to go. It's a project thats worth the time and effort if you want to do it. But to be honest I don't think I'll do another 3.3 swap like I'm doing again. But most likely I lie about doing it and if someone needed some help I would probably help them with it.

[grayguy]

Having done both swaps, NA-to-turbo, and 2.2-to-3.3, I am pretty sure the 3.3 swap is far easier, faster, and more simple than building a turbo setup. I'm fairly sure I could do either in a weekend if I wanted to tho so maybe it's a wash.

[Chausx]

Having done both swaps, NA-to-turbo, and 2.2-to-3.3, I am pretty sure the 3.3 swap is far easier, faster, and more simple than building a turbo setup. I'm fairly sure I could do either in a weekend if I wanted to tho so maybe it's a wash.

Lol I wish I could do mine in a weekend. I've spent alot of time thinking and pondering and purchasing to get as far as I've gotten and I'm still a few weeks off from completion.

[grayguy]

Yeah, there was a fair bit of that when we did StatGSR's 3.3 swap, but having done one now I think a second one would be pretty simple. The only shitty part is the wiring, and that can all be done before hand.

[Airgne]

make sure you fix your photos next time. if the are jacked up again i will just delete them.

[Chausx]

Ok its been about a month since I've updated anything. And here it finally is. I've had a whole bunch of grief with trying to get everything figured out. But I can finally say it runs!

Here is the youtube link: http://youtu.be/4mYVMXf7i5c

Here are the pics as of late. These are in not in order.

https://sl-i.net/FORUM/images/imported/2011/08/408fb3d6-1.jpg
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[Huffer]

Well done!!!

[httrdd]

Is that a coil pack rail? Inerestong idea. Also looks like the radiator I use/recomended.

[Chausx]

Well done!!!

Thank you!
Is that a coil pack rail? Inerestong idea. Also looks like the radiator I use/recomended.

Yes I had a large problem with the stock EG33 igniter not liking dwell at more then 1 ms and a small grounding issue with it. So I jumped onto some coils from a 5.3l GM pickup. I used Accel 8.8mm wires with MSD GM boots. The design of the coil pack came from an Audi build: http://forums.audiworld.com/showthread.php?t=2177224

With some easy engineering and a few holes drilled I got that mounted. It was totally worth the effort as air flows directly to that area from the duct. I've also made some custom powersteering lines and such to help with some of the issues I had before with the old ones. Once I get the harness and such buttoned up. I'll take final pics before I get the exhaust done. I did use that radiator design you recommended for me as I was running low on time and needed something sure fire. So I have to thank you httrdd for that wonderful suggestion.

[Sleepinsuby]

How do you like the ms on the eg? Iv been debating running ms on my rwd eg swapped legacy ss. I would do another merge but I'm realy debating supercharger down the road and ms would make it so much easyer.

[httrdd]

Ms is good, but a lot of the Svx guys us hydra. I will be using ms myself.

[Sleepinsuby]

Hydra is so expensive. I like the options ms gives you. I'm curently still wiring up my ej22t hybrid on the ms3x. I don't think much will be different on the eg from the ej. ( except 2 more cylinders) the reason I'd like ms to would be to use a eaton m90 on the eg as the supercharger. It's a gm set up factory you could use the throttle body and just make custom upper manifold and get rid of the emissions flap in the upper manifold.

[Airgne]

go over the rules one more time, might get locked.

[mshriver]

I just read over the rules again and am very confused about that last comment^ Care to elaborate?


By the way, Very Nice Legacy!

[Chausx]

Ok so it has been several months since my last post up. I'm also confused about why my thread got locked. Maybe because of the comments not exactly relating to my thread.

But the skinny on my legacy:
She is running very well.... That is all. At the moment (3\2\12) she's been running with my MS3X tune and small modifications on 88 octane gas and really liking it. The only issues I'm having is getting it to rev past 5.5k so I'm missing my top end and I haven't had the chance to put any major changes down because of school.

I'll actually been working on my Project 240sx for this summer so nothing too major will be done to the Legacy other then tuning to get her back up to a 7k redline. In the next couple of days I'll post pics of the mostly finished project and how she sounds with her exhaust and all.

Here are some pics when fall came around:

https://sl-i.net/FORUM/images/imported/2012/03/EG33LegacyRuns0051-1.jpghttps://sl-i.net/FORUM/images/imported/2012/03/287910_574067583029_122802861_31918523_1-1.jpghttps://sl-i.net/FORUM/images/imported/2012/03/322327_574067433329_122802861_31918522_1-1.jpghttps://sl-i.net/FORUM/images/imported/2012/03/325760_574067158879_122802861_31918520_6-1.jpg

[Huffer]

^^ What EM are you running?

[httrdd]

What maf are you runningg? Stock svx maf worked for me.

[Chausx]

^^ What EM are you running?

I'm using Megasquirt 3 for my engine management with a MS3X expansion card.


What maf are you runningg? Stock svx maf worked for me.

I'm not using a MAF. I'm using the MAP sensor that comes with MS3. I've been debating to play with a MAF with MS3X but I haven't really put much effort into looking at the benefits\pitfalls of using one.

UPDATE:

So I've learned how to finally get her to rev up to 8k. Seems like my cam signal had alot of noise in the line. So I had to place a 2.2k resistor from + to - then a 18k resistor in the + side of the line. this cleaned up my signal and 8k red line was achieved. Sorry I've been distracted with school lately so I haven't placed much time into documenting my info. I'll get a full detailed video and image gallery sometime when school slows down.

[httrdd]

I still have that intake when you are ready!

[omgshitsjrdn]

I'll trade you leggys LOL

[Chausx]

So its been a little bit since the last time I actually posted anything about my project. Since 2011, I've been running my EG33 powered BD reliably as my DD car for the past 3 years now. If any of you recall, I've been running a Megasquirt 3 and have been happy with her. I also decided to do a few random things like:

-Switched her from a map\speed density to a MAF design. I used a Ford Mustang MAF and couldn't be happier.
-The suspension has been fiddled with and it went to '04 STI shocks and struts w\ stock top mounts up front.
-Shoes I went with a set of ROTA Grids 17x7.5 +48 offset.
-I threw in WRX seats in front for more bolstering.

But then, I ran into an issue. As of January 2014, emissions went into play and my Leggy wouldn't pass emissions at all. So my simple solution was to find a donor car with everything and do a swap back. as of 3/25/2014 I found the Legacy I wanted. A nice winged wagon with some mileage and some engine issues for $700. So now, i'm looking to go back to stock. Sad to have to undo my work, but i'm on the road to find an 03-05 Forester XT for my new off road build. I need my Leggy till I can pay for a Foz.

Below is a few pictures of what I will always remember her as and the donor legacy I decided to pick up. I'll have more photos as I start to swap her back.

https://sl-i.net/FORUM/images/imported/2014/04/PhotoGrid_1396977928070_zpsa6truhuy-1.jpg (http://s253.photobucket.com/user/Chausx/media/PhotoGrid_1396977928070_zpsa6truhuy.jpg.html)
https://sl-i.net/FORUM/images/imported/2014/04/PhotoGrid_1396978039879_zpsveu2yo3g-1.jpg (http://s253.photobucket.com/user/Chausx/media/PhotoGrid_1396978039879_zpsveu2yo3g.jpg.html)
https://sl-i.net/FORUM/images/imported/2014/04/PhotoGrid_1396965560875_zps8317ec28-1.jpg[/url]

[oskar_subaru]

Holy hell i feel for you guys with those emission rules, over here they make the rules tighter and tighter every year but they don´t apply to older cars, i think it´s ridiculously stupid that they can all of a sudden say that you can´t drive your car anymore :smt021

[Wagonista]

Well that is saddening. I had dreams of EG33 swapping my Outback. Utah is great for some things, but their emissions laws are not so great.

[Chausx]

Holy hell i feel for you guys with those emission rules, over here they make the rules tighter and tighter every year but they don´t apply to older cars, i think it´s ridiculously stupid that they can all of a sudden say that you can´t drive your car anymore :smt021

Well, atleast I think they are being kind of lenient for people that are having some emissions issues so they can sort it out. So I don't think they are saying you just can't drive it, but you'll just pay a fee and then be given a year to sort it out. Which is nice of them. But I don't think my Leggy applies.


Well that is saddening. I had dreams of EG33 swapping my Outback. Utah is great for some things, but their emissions laws are not so great.

It is saddening that I have to put her back to stock, but that'll help me with resale value some. Well if you are in the market I have mine. :grin: I'm amazed that the Cache Valley area has lasted as long as it has without emissions. I do love Utah and that's why a Foz XT lifted build will be what I want to do next.

[Chausx]

Well I had the chance to play with the 2.5 in the other Legacy today. I yanked the engine out and took off the timing cover to have luckily found my issue with her without getting knees deep in her. As you can see in the pictures, the timing tensioner pulley broke at the bolt. Amazingly the cams were only slightly off time because of the loose belt but not bad at all. I've decided to take the engine to a machine shop to extract that bolt. I would rather not deal with any repercussions if I made a mistake extracting it. Other then that issue, it looks like I'll be hunting the junk yard for a new crank gear. The crank position sensor teeth were slightly ground down\damaged which could be another reason for her not starting up.

https://sl-i.net/FORUM/images/imported/2014/04/IMAG0678_zpsusqx6w4u-1.jpg (http://s253.photobucket.com/user/Chausx/media/Legacy%20Project/IMAG0678_zpsusqx6w4u.jpg.html)
https://sl-i.net/FORUM/images/imported/2014/04/IMAG0676_zpspvhph6fy-1.jpg (http://s253.photobucket.com/user/Chausx/media/Legacy%20Project/IMAG0676_zpspvhph6fy.jpg.html)
https://sl-i.net/FORUM/images/imported/2014/04/IMAG0679_zps2prgepca-1.jpg (http://s253.photobucket.com/user/Chausx/media/Legacy%20Project/IMAG0679_zps2prgepca.jpg.html)
https://sl-i.net/FORUM/images/imported/2014/04/IMAG0680_zpsdatu8xa7-1.jpg (http://s253.photobucket.com/user/Chausx/media/Legacy%20Project/IMAG0680_zpsdatu8xa7.jpg.html)
https://sl-i.net/FORUM/images/imported/2014/04/IMAG0681_zpshoco6dih-1.jpg (http://s253.photobucket.com/user/Chausx/media/Legacy%20Project/IMAG0681_zpshoco6dih.jpg.html)