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View Full Version : rkrenicki's 1992 Subaru Sambar SDX - 2018-06-16 - Let there be light!



rkrenicki
12-27-2016, 03:12 PM
A couple of people know about this already, but I am excited to say that I am currently in the process of importing a vehicle from Japan. EDIT: It is officially on the boat swimming its way across the Pacific as I type this, so here is the big announcement!

1992 Subaru Sambar SDX Supercharged.

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Dyno Pull!

https://www.youtube.com/watch?v=1YnfPZIDxhY



Gauge Cluster from a Sambar Diaz w/Tachometer
Défi Advance BF Gauges: 1.2Bar Boost, Oil Pressure, Oil Temp, Water Temp
Sony XAV-AX5000 6.9" CarPlay/AndroidAuto Head Unit
Polk DXi461 4x6 Speakers
Kenwood KSC-SW11 Compact Powered Subwoofer mounted behind drivers seat.
Morimoto Sealed7 1.0 LED Headlights
Subaru OEM Option Fog Lights
LED 1156 and 1157 Turn Signal and Brake Light Bulbs
24" LED Light Bar from eBay
Mitsuba Alpha II Compact Horns
Subaru Vivio RX-R Leather Steering Wheel
Subaru Carpet from Sambar Diaz
Subaru OEM Option Rain Visors
35% Window Tint on rear window
240mm Broadway Mirror
Powdercoated OEM 12" Steel Wheels w/Nankang CX668 155/80R12 tires
FatMat Rattle Trap Sound Deadener
Akabou Red Valve Cover




Complete engine rebuild
All coolant hoses
Exedy Clutch
Front struts, strut mounts, strut bearings.
Ball joints, swaybar endlinks.
Rear shocks.
Replaced both front axles.
Paint touchups/Powder Coat bed sides and wheels




Bedliner
Side window tint
Power Locks
OEM Power Window mechanisms

nepbug
12-28-2016, 10:55 AM
I love the little Kei cars, I wish they were street legal here. I really need to look into it again, I wonder if it is over 25 years old if I can register it and drive one anyways.

Kei class supercharged sounds fun! Wasn't there a supercharged Sambar at some point?

foohfooh
12-28-2016, 08:23 PM
It's a members ride II thread hmm

98legwag
12-28-2016, 08:36 PM
It's a members ride II thread hmm

That just means its not a Legacy.

rkrenicki
12-28-2016, 08:43 PM
It's a members ride II thread hmmThat just means its not a Legacy.

Yep, there is no such thing as a Kei Legacy ;)

peugoby
12-29-2016, 12:57 PM
I'm hoping for an Autozam AZ-1
https://sl-i.net/FORUM/images/imported/2016/12/1993_Mazda_Autozam_AZ1_For_Sale_Side_Thr-1.jpg

Dead91silvia
01-05-2017, 10:42 AM
I think I know now... ;)

rkrenicki
01-11-2017, 08:20 PM
I just received word that it is scheduled to be loaded on the boat on January 30th. I should have paperwork sometime around then.

rkrenicki
01-13-2017, 09:33 AM
I love the little Kei cars, I wish they were street legal here. I really need to look into it again, I wonder if it is over 25 years old if I can register it and drive one anyways.

Unless there is a specific law in your state, any Kei vehicle over 25 years old is street legal. As far as I know, there are only state laws that pertain to Kei Trucks sold as "off-road use" and not Kei Cars, or trucks imported as passenger vehicles.

Connecticut has no state law, so Kei vehicles (Trucks or Cars) are just vehicles with no restrictions. Colorado is the same way in that respect. They would just have to meet whatever requirements your state has for 25+ year vehicles.

Connecticut has no real restrictions for 25+ year old cars. I only have to do a VIN verification, and pay for registration. No emissions, no safety inspection, nothing. Of course, I will still have to jump through the hoops of a non-ISO VIN.. but that should not be too difficult.

nepbug
01-13-2017, 04:11 PM
Unless there is a specific law in your state, any Kei vehicle over 25 years old is street legal. As far as I know, there are only state laws that pertain to Kei Trucks sold as "off-road use" and not Kei Cars, or trucks imported as passenger vehicles.

Connecticut has no state law, so Kei vehicles (Trucks or Cars) they are just vehicles with no restrictions. Colorado is the same way in that respect. They would just have to meet whatever requirements your state has for 25+ year vehicles.

Connecticut has no real restrictions for 25+ year old cars. I only have to do a VIN verification, and pay for registration. No emissions, no safety inspection, nothing. Of course, I will still have to jump through the hoops of a non-ISO VIN.. but that should not be too difficult.

Hmm, I'll be researching then. It sounds like it depends on how it was imported more than anything.

rkrenicki
01-13-2017, 05:40 PM
Hmm, I'll be researching then. It sounds like it depends on how it was imported more than anything.

I am going to bring this to PM, as to not clutter up this thread. Once I am done with the process, I will be writing up a "DIY" thread with everything that has to happen. I have made a lot of phone calls and research over the last two weeks, and I have learned a lot that I want to share.

Muse
01-13-2017, 06:05 PM
I eagerly await this vehicle. That way I can test drive it and decide if I'm jumping through the same hoops for my own.

rkrenicki
01-19-2017, 03:29 PM
The time for this vehicle to depart Japan is rapidly approaching. I bought a couple of pieces for it, but I am waiting for it is ship before I really start ordering too much.

98legwag
01-31-2017, 09:23 AM
Is the car on the ship yet?

Edit- I should probably read things.

nepbug
01-31-2017, 02:16 PM
Alright, so how long then until you actually have it in possession and will be able to assess what to do first?

rkrenicki
01-31-2017, 03:43 PM
There was a slight delay in the ship leaving Japan so it left about a day late. Assuming there are no more delays along the way, it should be here early March. Unfortunately, there are a number of stops in the US before it gets to my port (New York), then I will have to deal with US customs which could take a day or two.

amusa
02-01-2017, 05:47 AM
Who is doing the paper work? Notarizing, translating, etc.

I'm planning to import. Don't know if it's easier or cheaper to do it myself or go straight to a broker like Japanese Classics or some sort so I don't have to deal with the paperwork and U.S. custom.

rkrenicki
02-01-2017, 09:05 AM
Who is doing the paper work? Notarizing, translating, etc.

I'm planning to import. Don't know if it's easier or cheaper to do it myself or go straight to a broker like Japanese Classics or some sort so I don't have to deal with the paperwork and U.S. custom.

I am not using a vehicle broker nor a customs broker for this particular import. I will be writing up a "DIY" thread after the truck is here with the details of the import process and my experiences. If you want me to go over it with you sooner, drop me a PM or find me on the facebook group and send me a message.

amusa
02-02-2017, 06:01 AM
I am not using a vehicle broker nor a customs broker for this particular import. I will be writing up a "DIY" thread after the truck is here with the details of the import process and my experiences. If you want me to go over it with you sooner, drop me a PM or find me on the facebook group and send me a message.

Still got time. When ever you are ready just post up. I need to finish up with (1) car before I can get my hands on another project. The wife want's a 240Z, 260Z or 280Z. I'm thinking Fairlady with a RB26DETT swap.

Dead91silvia
02-02-2017, 11:18 AM
I'm getting close to getting one myself. This is cool stuff! :)

rkrenicki
02-02-2017, 03:57 PM
I'm thinking Fairlady with a RB26DETT swap.

Unfortunately, that would not be eligible for import. The EPA clearance is dependant on the vehicle (and more specifically, the engine), being in original unmodified condition. any vehicle with an engine swap is automatically ineligible.

rkrenicki
02-05-2017, 11:29 AM
The truck is going to cross the international date line in a few hours, and I just received an email from my normal Japanese buying proxy that my box-of-parts will be shipping tonight.

Since I do not know the service history of the truck, I ordered a bit of everything... Exedy Clutch kit, Timing Belt kit, Water Pump, 2 sets of Brake Pads, a spare set of brake calipers (Found a set for $15, and figured it was good to have some handy), Thermostat, Spark Plug set, and Wiring Manual. I also special ordered some oil filters from my dealer (They are the same as the Subaru Justy), picked up some spark plugs, and ordered a new set of Alternator and Supercharger belts and air filter here in the states.

amusa
02-05-2017, 12:03 PM
Unfortunately, that would not be eligible for import. The EPA clearance is dependant on the vehicle (and more specifically, the engine), being in original unmodified condition. any vehicle with an engine swap is automatically ineligible.

I'm going to do the swap here.

rkrenicki
02-20-2017, 04:08 PM
The truck is still not here yet, but some of the parts have started to show up. I managed to source some Alternator and Supercharger belts, air filters, a fuel filter, and LHD headlights here in the states from various different sources. The oil filter is the same as the Subaru Justy in North America and the Subaru Domingo in Europe, so it is available worldwide. I decided to go with OEM, as they are high quality Tokyo Roki filters. Oddly enough, they even say "Kei" in the part description on them.

https://sl-i.net/FORUM/images/imported/2017/02/79C871AF8D3547CA9883709E664F449F-1.jpg

I also sourced a set of wheels and tires, as the original tires are not DOT compliant, and 155SR12 tires are not available here without importing them. After some research, I found that 1989-1999 Nissan Sentra and Nissan 200SX (B14/Lucino) wheels have the appropriate bolt pattern and hub size. I sourced a set of 14" wheels from an 200SX and some 165/60R14 tires. This is not a widely available size here in the States either, but I did find a brand new set of Hankook Kinergy Eco K425 for a decent price. These tires only seem to be marketed for the UK and Australian market, but they are marked US, UK, Aus DOT approved.

https://sl-i.net/FORUM/images/imported/2017/02/966FE017EAE146F6A1506542E162AE1A-1.jpg

These tires have little flowers on them. heh.

rkrenicki
02-21-2017, 05:37 PM
The boat just passed through the Panama Canal today. I managed to get a screenshot from their webcam as it went though.

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nepbug
02-21-2017, 05:46 PM
That's pretty cool!

98legwag
02-21-2017, 06:24 PM
That is a big boat. I wonder how many cars are on it.

Muse
02-21-2017, 07:35 PM
There's only one on it that matters.

rkrenicki
02-21-2017, 07:36 PM
That is a big boat. I wonder how many cars are on it.

Thousands. They have anywhere from 6-10 floors, with a max floor height of about 5.2m. They can carry any kind of vehicle, as small as motorcycles or as large as train cars. I do not have the size of this specific boat, but this company has boats that range in size from 4300 to 8500 CEUs (Car Equivalent Units). Fun fact, the CEU is based on the size of a 1966 Toyota Corolla RT43.

Another thing to note.. This particular ship has a draft of 10m when loaded.. so there is another 33(ish) feet of boat under the water line.

For those interested, There are a bunch of informational brochures on their website here: http://www.hoeghautoliners.com/news-and-media/brochures

Muse
02-21-2017, 07:38 PM
Sooo... it could haul, say, a dekotora Mazda Titan? Not that I have any plans for getting one.. >.>

rkrenicki
02-21-2017, 07:52 PM
Sooo... it could haul, say, a dekotora Mazda Titan? Not that I have any plans for getting one.. >.>

With ease. heh

Matty2Hotty
02-22-2017, 11:29 PM
That's funny I'm looking to get a 92 Sambar supercharged camper van but the build date is July/1992. Have to wait a few more months it looks like. You will have to pm me any tricks if I should just do it myself or broker on it.

rkrenicki
02-25-2017, 08:59 AM
Small wheels are small.
https://sl-i.net/FORUM/images/imported/2017/02/B0DB1E3545D540F592B957BDEEBF0CF7-1.jpg

Muse
02-25-2017, 03:35 PM
... can we put the Sambar wheels on the Del Sol, just to see how goofy it looks?

rkrenicki
02-25-2017, 06:30 PM
I think they actually would fit. The hub bore is a little big on these, but the lug pattern is the same. They are 165/60R15 where it looks like the Del Sol is 185/60R14. You could be even more of a low-rider. I do not know about the offset for honda.

amusa
03-06-2017, 05:51 AM
update?

rkrenicki
03-06-2017, 06:42 AM
It is still on the boat. It should land in port in a couple of days, and if everything goes to plan, I should have it next week.

rkrenicki
03-08-2017, 09:16 AM
My box-o-parts showed up from Japan today.
https://sl-i.net/FORUM/images/imported/2017/03/5FC0CA40FFCA4FD8A5A5D29D6C90685D-1.jpg
https://sl-i.net/FORUM/images/imported/2017/03/FBAE52B0B204482CA49487AD683F724B-1.jpg
https://sl-i.net/FORUM/images/imported/2017/03/861596547ABE47A98B8C3F2CC1F0F2A1-1.jpg
https://sl-i.net/FORUM/images/imported/2017/03/D319E6F4756D4450A3ACF7A3DACB441D-1.jpg
Boy, I am sure glad that I picked up the "Hight Quality" brake pads. It would be bad if I got anything of lower quality. Otherwise, I could have sworn that I ordered the timing kit that had the crank and cam seals.. but I guess I did not.


In other news, the truck is now officially on the ground in New York. I will be presenting the paperwork to customs on Friday, and with any luck, I will be picking up the truck on Monday.

dodik
03-08-2017, 11:34 AM
Congrats on the truck making the journey, looks like fun little project.

On a side note its probably only couple miles from me right now.

rkrenicki
03-08-2017, 01:07 PM
On a side note its probably only couple miles from me right now.

It is indeed, right over in Newark, across the highway from the airport.

rkrenicki
03-10-2017, 08:38 PM
The truck has been officially cleared by customs. If I had the trailer today, the Sambar would be in my driveway right now.. Oh well, it will officially be home on Monday.

Matty2Hotty
03-11-2017, 04:21 PM
What? You mean you couldn't just drive it home? lol :argue:

rkrenicki
03-11-2017, 05:50 PM
Well, it wasn't registered... and I wouldn't have been able to drive both cars back home. The port is over 2 hours away from my home.. and two states away as well..

That said, I went to the DMV and picked up temporary tags for the truck today. I am still going to trailer it home, but I am able to drive it legally as soon as it is here instead of waiting until Tuesday when the DMV opens again.

The Non-ISO VIN threw them for a loop, as I expected.. and I had to explain a bit of the export certificate.. but after a little bit, I have a proper registration document with the correct 9 digit VIN. They still need to physically verify the VIN before I can get a permanent registration, but I will have that done on the way back home on Monday.

dodik
03-13-2017, 02:21 PM
you better be picking it up today, otherwise with all this snow it will get pushed back for a few days at least.

rkrenicki
03-13-2017, 08:42 PM
Today is the day that the little Sambar came home.

These are a couple of pictures from picking it up at the port.

https://sl-i.net/FORUM/images/imported/2017/03/6552F8DE991648699E6BA1702A40D2BE-1.jpg

https://sl-i.net/FORUM/images/imported/2017/03/11B0B17E6D6D4D8C8B2754724DEA092D-1.jpg

If I fits, I sits. Actually, the interior is quite roomy considering how big the truck is.
https://sl-i.net/FORUM/images/imported/2017/03/B8DC66E90DAA4BA59A61F109B51F4012-1.jpg

I managed to fit it inside of a 6x12 Uhaul trailer, including the gate, while there was only about 1" on each side of the truck for that.
https://sl-i.net/FORUM/images/imported/2017/03/53C423B03186445AB71AAEF160BE4380-1.jpghttps://sl-i.net/FORUM/images/imported/2017/03/24872F0D57B644FD8D2E5CBF46E86CC0-1.jpg

I brought it by my dealer immediately after, and it was a big hit.. everybody at the dealership came out to see it.
https://sl-i.net/FORUM/images/imported/2017/03/C526933B75C24660B344BB37736BAA64-1.jpg

And then back home, where it will stay nice and warm inside my garage for the upcoming snowstorm.
https://sl-i.net/FORUM/images/imported/2017/03/799B56E442DF4DC8AF8ECE328995536E-1.jpg
https://sl-i.net/FORUM/images/imported/2017/03/B6F21EB632984652A44A24E3D5382AF3-1.jpg

Mod #1: 240mm Broadway Mirror
https://sl-i.net/FORUM/images/imported/2017/03/543995C32811435684F124160F32A733-1.jpg

Mod #2: Nissan 200SX wheels
https://sl-i.net/FORUM/images/imported/2017/03/DCB677D3924E4C43A911317B46778753-1.jpg

I also changed out the headlights with some LHD H6023 bulbs and I found that somehow the Japanese road flare seems to have snuck into the country..
https://sl-i.net/FORUM/images/imported/2017/03/0449FE39ACDA482993A45E2D9D60CDF1-1.jpg

Muse
03-13-2017, 08:49 PM
I thought they were gonna lift you up on their shoulders at the dealership. This thing was a hit. I'm just sad that I'm too tall to drive it comfortably.
https://sl-i.net/FORUM/images/imported/2017/03/20170313_115539_zpsc746fb2m-1.jpg (http://s1286.photobucket.com/user/SubaMuse/media/20170313_115539_zpsc746fb2m.jpg.html)

https://sl-i.net/FORUM/images/imported/2017/03/20170313_132948_zpswalgrqnp-1.jpg (http://s1286.photobucket.com/user/SubaMuse/media/20170313_132948_zpswalgrqnp.jpg.html)

Dead91silvia
03-14-2017, 02:02 AM
This little thing is awesome! Love it!

thenines'
03-14-2017, 11:55 AM
that trailer really shows how small that truck is! I'd change out the shift boot/knob-the only ugly thing in (it seams) in late '80's/early '90's subaru's.

rkrenicki
03-14-2017, 01:17 PM
(it seams) in late '80's/early '90's subaru's.

But.. it IS an early 90s Subaru ;) Reminds me of the shifter that was in my 82 Toyota Tercel that I had when I was younger.

rkrenicki
03-14-2017, 01:24 PM
I managed to get a headunit installed today. The fit is a little tight, depth wise.. I was thinking about getting a bluetooth unit, so I might as well get a CD-less unit since I do not use them anyways.
https://sl-i.net/FORUM/images/imported/2017/03/0977D99FDCC24BEEB0B42F441D640E1C-1.jpg

Turns out that it only has one speaker installed on the driver side. There is a spot for speakers on both sides, but no wires. I will have to run some over to the passenger side which will be easy. The speakers that I picked up are a little too wide to fit in the dash, so I will need to break out the dremel and trim them down. I will probably do that later this afternoon.

peugoby
03-14-2017, 04:20 PM
Looks like a riot! Congrats. What a fun car to have at your disposal. I want to see it in the bed of some jacked up F-350/the like. What are some specs on the motor (besides being supercharged)?

rkrenicki
03-14-2017, 07:43 PM
Well, I used my father-in-laws Chevy Silverado 2500HD to pick it up, so I have that handy. I parked next to it with the front bumpers parallel.
https://sl-i.net/FORUM/images/imported/2017/03/IMG_4729-1.jpg

And then Mirror-to-mirror. The cabs are just about parallel with each other here too. The Silverados bed is about 2 feet longer.
https://sl-i.net/FORUM/images/imported/2017/03/IMG_4730-1.jpg

The engine is a Subaru "Clover 4" EN07Y engine. 659cc, 4 cylinder, Supercharged. It is mounted in the rear, under the bed. In this picture, the front of the truck is on the right. The supercharger directly to the right of the alternator, and it VERY small.. just about the same size as the alternator itself.
https://sl-i.net/FORUM/images/imported/2017/03/2DBF9FB7E6EF484CB253423FC57B8BCB-1.jpg

Matty2Hotty
03-15-2017, 12:28 AM
Need a CAI setup and change the pulley might add some more boost or atleast maybe hear it whine lol

rkrenicki
03-15-2017, 10:05 AM
There seems to be a Vacuum leak somewhere, as the engine bogs down when the supercharger kicks in. I ordered some new vacuum hose, so I will just go through and replace them all.

Otherwise, I accidentally left the light on in the cab last night.. But the truck still started right up, so the battery is in good shape!

Dead91silvia
03-15-2017, 11:12 AM
HAHA! That supercharger is freaking small!

thenines'
03-15-2017, 06:00 PM
Can the bed fit a little capacino?

rkrenicki
03-15-2017, 06:31 PM
Can the bed fit a little capacino?

No, this truck is exactly the same length and width at the Cappuccino, so the bed would be about four feet short.

Muse
03-15-2017, 07:14 PM
Need a CAI setup and change the pulley might add some more boost or atleast maybe hear it whine lol

Oh, you can definitely hear it whine already.

rkrenicki
03-16-2017, 09:25 PM
There seems to be a Vacuum leak somewhere, as the engine bogs down when the supercharger kicks in. I ordered some new vacuum hose, so I will just go through and replace them all.

Another possibility for this issue was the MAP sensor. I found that there were a few different sensors for these trucks, so I went to find it and get the numbers off of it. While I had it open, I decided to change the plugs, plug wires, oil, and oil filter.

Well, it appears that either the plugs or the plug wires were my problem. The truck drives great now, and is quite happy to be tooling around at 100km/h, where before it was a struggle to get above 80. This is a great outcome, as the MAP sensor is $180-220 to replace. I did find that the valve cover gasket and the camshaft seals are leaking a little bit of oil. I have some of the seals already, but I ordered a valve cover gasket and front crank seal for when I do the timing belt.

I managed to complete my registration today, so I have actual plates on it right now. I also ordered my custom plate, and it will be here in a month or so.

I ended up driving the truck around all day today, and it was quite enjoyable.

rkrenicki
03-27-2017, 12:49 PM
It only took me 2 weeks because of a number of family issues that came up.. but I finally managed to get my two primary vehicles side by side. I decided to park the front bumpers in parallel to really show the size difference here.

https://sl-i.net/FORUM/images/imported/2017/03/A73141D16ADE4BFB9AEBA4C2022F654D-1.jpg
https://sl-i.net/FORUM/images/imported/2017/03/60BFE4633521437FB850FFEBE669A50C-1.jpg

There was some sludge in the windshield washer tank.. I think that the previous owner used straight water and it developed some algae or something in there and that plugged up the sprayers. The sprayers are tucked up behind the dashboard, so it necessitated the removal of the dash. I also had some issue with the heater, which I figured I would attack at the same time. I was really surprised how easy it was to remove the dash.. Remove the cluster, unscrew the brake reservoir, 6 bolts, one connector and it was out.

https://sl-i.net/FORUM/images/imported/2017/03/51225676564__06B5B24D63D14976AE38B346700-1.jpg

After purging the sprayer lines and cleaning out the nozzles, I took a look at the heat. The grease on the sliders and cables had dried out, so I re-lubed them all with some lithium grease spray. That fixed all but the air direction selector.. Apparently, one of the rods had skipped out of its track. When I tried to push it back in, I managed to snap the vent selector door. I sort of glued it back together for now, but I do have an entire replacement air box already on the way..

It was whipped all back together, and I am now just awaiting a replacement radio which has bluetooth in it.
https://sl-i.net/FORUM/images/imported/2017/03/1A7A4E0E192B4E6B8BB56156191E6CFD-1.jpg

98legwag
03-27-2017, 02:24 PM
So that means the Blitzen clone is not one of your primary vehicles?

rkrenicki
04-09-2017, 06:56 PM
Yesterday, I did some major cleaning of the interior, replace the heater box, and installed a bunch of FatMat (a DynaMat clone). I used an entire big roll of paper towels and a whole bottle of windex cleaning out all of the "JDM dirt" before laying down all of the FatMat. I did under the seats and halfway up the back, as well as behind the airboxes along the "firewall" so far. I will also install it in the doors, the remainder of the back, and probably along the roof. It has significantly quieted the truck down already, I cannot wait to finish the job.

Under driver seat:
https://sl-i.net/FORUM/images/imported/2017/04/61A0806801A44CCAAE7DF3D55F6FE107-1.jpg

Behind driver seat, also with Subaru Underseat Subwoofer from a Forester. I havent wired it up yet, but that will be soon.
https://sl-i.net/FORUM/images/imported/2017/04/B8D62DAE5A0541908889469853691832-1.jpg

Under passenger seat:
https://sl-i.net/FORUM/images/imported/2017/04/38FB7AAA157B4185A012C903FF508316-1.jpg

The fatmat extends all of the way across behind the airbox.
https://sl-i.net/FORUM/images/imported/2017/04/AAD0965BDC0D4EE9A9775AE73A889549-1.jpg

And up behind the wiper mechanism on both sides:
https://sl-i.net/FORUM/images/imported/2017/04/28B5745FD0264C8D9A1AEE204A312B8F-1.jpg


Today, I went to the UConn Spring Car Show. A massive show of all makes and models. I saw a good number of interesting cars, but the best thing was stumbling across another Kei Truck! This one was a Honda Acty. I managed to move my Sambar over to take a couple of pictures next to it.
https://sl-i.net/FORUM/images/imported/2017/04/F0F3BEFF07A74E7384FBF6B204A2B192-1.jpg
https://sl-i.net/FORUM/images/imported/2017/04/4513563FBBC04E46883A97102F94EA97-1.jpg

Muse
04-11-2017, 10:17 PM
You really convinced me of the worth of that sound deadening material. The Sambar is so much quieter inside now.

subyroo
04-15-2017, 07:00 AM
Yesterday, I did some major cleaning of the interior, replace the heater box, and installed a bunch of FatMat (a DynaMat clone). I used an entire big roll of paper towels and a whole bottle of windex cleaning out all of the "JDM dirt" before laying down all of the FatMat. I did under the seats and halfway up the back, as well as behind the airboxes along the "firewall" so far. I will also install it in the doors, the remainder of the back, and probably along the roof. It has significantly quieted the truck down already, I cannot wait to finish the job.

Don't make it that quiet that you can't hear what is happening underneath you. :lol: :lol: :lol:

rkrenicki
04-15-2017, 08:02 AM
Unfortunately, I have run into a bit of an issue with the engine. The other day, I replaced the crank and cam oil seals, timing belt, water pump, and valve cover gasket. The engine is running great, except now the oil pressure light comes on when the engine fully warms up.

I am trying to track down the issue now, but it appears that the oil pump is directly behind the crank oil seal which I had some issues getting to seat properly. I think I may end up having to replace the oil pump, which is proving more difficult to track down than I originally expected.

rkrenicki
04-15-2017, 08:45 AM
I plumbed in a mechanical oil pressure gauge, and it never drops below 20 PSI, even idling at full temp.... so I am thinking that the 25 year old oil pressure switch may be the issue here.

Luckily, it is the same switch as a Justy, just with a slightly different connector. I ordered a replacement on rockauto (a whopping $2!) and I will replace it. That said, I think I might get a proper oil pressure gauge and permanently mount it. The gauge I picked up yesterday is mechanical and has a 6 foot long hose. Since the engine is in the back of the truck.. that wont work for me long-term.. I have it currently zip-tied to the tailgate, 2-SEXY style.

98legwag
04-15-2017, 04:45 PM
Now you need a massive front mount for full on 2-sexy style.

rkrenicki
04-17-2017, 02:21 PM
I think I finally have the oil leaks figured out, I added some oil-resistant RTV to the valve cover gasket, and it does not seem to be leaking there anymore. It also looks like the two oil seals behind the timing belt are holding now as well. My new oil pressure switch will be here later today, so hopefully that will fix my oil light.

I have a couple of pictures from the process that I hadn't posted.

Valve cover cleaned, logo shined up, and reseated:
https://sl-i.net/FORUM/images/imported/2017/04/3E4C54087A7649B18ACC57A0ED50C5D2-1.jpg

First, the rear shocks are toast. This is fully compressed and it does not self-rebound. I ordered some brand new replacements today.
https://sl-i.net/FORUM/images/imported/2017/04/669EBF646EFE487785407607CA8B4C17-1.jpg

Shiny new water pump, timing belt, and timing belt pulley.
https://sl-i.net/FORUM/images/imported/2017/04/7FD1CF8EEBC74BE38F2807A085D756B5-1.jpg

While I had it all open.. here is the Supercharger. It is about the same size as the alternator, but a tad big longer.
https://sl-i.net/FORUM/images/imported/2017/04/CA74C5B9883E430FA3E5CE02B5553300-1.jpg

Muse
04-17-2017, 05:07 PM
https://sl-i.net/FORUM/images/imported/2017/04/robs20LOTR20supercharger_zpsi2rrkd98png-1.jpg

Somac
04-17-2017, 05:48 PM
This thing is so neat! I kind of figured but never really knew Subaru had a kei truck prior to this thread. Seeing a supercharged I4 in it just adds to the oddities. Very cool!

rkrenicki
04-17-2017, 10:37 PM
I had my order from RockAuto and another box from Japan show up today. I replaced the oil pressure sensor, and it works great now with no more light.

I did have my Sambar Dias (van version) cluster show up. After some odometer adjustment, I repinned the truck and installed it. The tachometer requires me running a wire back to the engine, which I have not done yet, but everything else is working great.
https://sl-i.net/FORUM/images/imported/2017/04/FF41BFB1D65A45E4BC8DE073851D4A7D-1.jpg

I also installed the wiper stalk from a Sambar Dias, which has an intermittent mode. I did not realize just how much I used that function until I owned a vehicle that did not have it. That.. and headlights that automatically turn off when you remove the key. I need to modify the truck to do that as well.

I also changed out the fuel filter, and the gas that came out of it was quite brown. It is probably the original filter.

rkrenicki
04-18-2017, 06:52 PM
My co-worker brought his Mini Cooper to work today. The truck is about a foot shorter than it. :)
https://sl-i.net/FORUM/images/imported/2017/04/A970716C065F4E0DBD638638B0852200-1.jpg

I also discovered the answer to the question... How fast is my little engine actually spinning at highway speeds... That would be 5500RPM or so.
https://sl-i.net/FORUM/images/imported/2017/04/B6BDF11CA4BB4E6D81F1303E34426D73-1.jpg

Muse
04-20-2017, 05:26 PM
Let me know when you do the auto-off lights. I really need that on the Sol. It's a good thing I have a 5 speed in it or I would have stranded myself twice now.

rkrenicki
04-24-2017, 02:32 PM
I tried to get a picture of all three of the Subaru's together the other day, but having one dark car.. it was proving a little difficult to get them all to come out nicely. This is the best one from that day after some adjustments to get them all visible.
https://sl-i.net/FORUM/images/imported/2017/04/6699eaa65d5849deada412780295cf0f-1.jpg

In the meantime, my new rear shocks and front rotors showed up today. Looks like they sent me KYB KSA1134 shocks, and Tokico TY021KB rotors. The shocks went on today, but I have not yet driven it around but given how notchy the passenger side was.. and how completely blown the driver side was.. It should be a vast improvement. The rotors will get replaced later in the week.

rkrenicki
04-26-2017, 05:43 PM
So.. good news: I made and installed a harness for the "underseat" (behind-seat?) subwoofer, and a sub in that location seems to be able to do what I want quite nicely.

Bad news: The sub that I bought is bad. It sounds like the amp is working okay, but the speaker itself seems to be blown. I am not sure if I am going to replace the whole thing or just the speaker inside of it... Either way, it is a pain since I used a bunch of 3M tape to mount it, and it is going to be a serious pain to take it off. I probably should have tested it before I mounted it so "permanently"

Otherwise, the brake pads and rotors went on last night and everything is riding quite nicely with them and the shocks from the other day. The back end no longer skips around on some of the medium size bumps in the road. All that is left at this point from a maintenance perspective is the clutch.

98legwag
04-26-2017, 09:58 PM
The speaker inside is really odd. Not like a normal speaker. Here is a picture of one of my old ones that gave up the ghost.

http://i1098.photobucket.com/albums/g378/98legwag/FOTE98D1_zpshjge4tsv.jpg

rkrenicki
04-30-2017, 06:59 PM
Yea, I knew that, but I still might be able to source a replacement. I also tried ordering another underseat sub, and that one was blown as well... I might need to look at some sort of alternative here..

Otherwise, I took advantage of the nice weather this weekend and I tackled some of the exterior of the truck. I had some bubbled up rust spots on the roof that I ground down and repainted, and I also repainted the bumper back to the original black.
https://sl-i.net/FORUM/images/imported/2017/04/501029C651CB4CA19A72D6128A8CF96A-1.jpg

I am going to polish out the turn signals and brake lights and then tackle the rust spots on the bed, probably sometime during the week. Once the sides come back from powder coating, then I will get some bed liner, and it should be all done!

Somac
05-01-2017, 11:47 PM
Looking good!

What is the end goal for the truck? Mostly stock with a few OEM+ upgrades? Seems like it'll turn heads no matter what's done to it.

rkrenicki
05-02-2017, 08:21 PM
What is the end goal for the truck? Mostly stock with a few OEM+ upgrades? Seems like it'll turn heads no matter what's done to it.

Yep, I bought it to use it for what it is, a truck. Keeping it largely stock with just a few minor comfort upgrades here and there.

Otherwise, I took the bed off yesterday to attack the rust between the bed and the cab. Er.. I mean I removed it for weight reduction.
https://sl-i.net/FORUM/images/imported/2017/05/AD897B8726214C559D8FF6429CFA7574-1.jpg

Here is the whole driveline.
https://sl-i.net/FORUM/images/imported/2017/05/07F792469E224B99AF66A7E680A79BB7-1.jpg

This is some of the rust here. Looks like a few dents occurred during its time in Japan, and water sat in the seam. I stripped it down with a Paint/Rust stripping wheel, and I am going to use some POR-15 to treat it before I paint and Bed-line it.
https://sl-i.net/FORUM/images/imported/2017/05/697DEE24E5AE4A3D9128536735CFE6A3-1.jpg

rkrenicki
05-13-2017, 01:12 PM
Three coats of POR-15, some primer and paint later.. the truck is back together.

POR-15 applied:
https://sl-i.net/FORUM/images/imported/2017/05/85F115EA579145F388090A71B06757C7-1.jpg

Painted:
https://sl-i.net/FORUM/images/imported/2017/05/88E20F0608A745DC9F824FB2F6AE4D8D-1.jpg

I did the same on the bed, but I need to finish it off before I have the truck bed-lined. In the meantime Yamazaki came up for a few days and we took care of a couple of projects on both the Cappuccino and the Sambar. I will let him post about the stuff done on his car, but here is the stuff we did for mine:

Power window retrofit. I need to grease the mechanism for the passenger side, as it struggles to go up.. but overall, I am super happy with this:
https://sl-i.net/FORUM/images/imported/2017/05/EAF9E9D0A82C407E9A34B6CC50A951A2-1.jpg

Yamazaki spent some time with a buffer and polished out a lot of the oxidized paint. Here is a half-and-half shot where the right side is shiny, and the other is still dull.
https://sl-i.net/FORUM/images/imported/2017/05/999DF7EA3207430D8FD87DFAF664DAC0-1.jpg

We also installed a new "underseat" subwoofer behind the drivers seat. After dealing with two different blown Subaru subs, I found a suitable new unit by Kenwood. A KSC-SW11.
https://sl-i.net/FORUM/images/imported/2017/05/301CEDBB9872408B99EFBD51811829DB-1.jpg


Just before he left, I took out the drone and took some pictures of the two Kei cars side by side.

https://sl-i.net/FORUM/images/imported/2017/05/DJI_0036-1.jpg
https://sl-i.net/FORUM/images/imported/2017/05/DJI_0034-1.jpg

The Sambar and Cappuccino are the same length and width.. but the Cappuccino comes up to just about the bottom of my windscreen.. :)

dodik
05-15-2017, 10:07 AM
isnt it wonderful how so much car can be crammed into such a small package.

Matty2Hotty
05-15-2017, 09:26 PM
You mean someone can actually fit inside the Capp with the hardtop on? :laughing6:

Dead91silvia
05-16-2017, 01:10 PM
She's coming along nicely! Love the shots next to the Capp.:)

rkrenicki
05-27-2017, 10:33 PM
I picked up some new paint to re-do the bed. It came as a recommendation from another Kei-truck owner who said that it stood up to the abuse on his truck bed very well. He stripped his Acty down to bare metal, primed and top coated with Seymour MRO High-solids paint. I picked up 2 cans of primer and 2 cans of white for $36 and figured that was cheap enough to try that out before resorting to shelling out $600+ for bed liner. I took care of the engine hatch today, and I think it came out pretty good.
https://sl-i.net/FORUM/images/imported/2017/05/F1E5F30D24484EFBA7AA324C63368727-1.jpg

In between coats, I decided to finish polishing out the rest of the truck. I stripped everything off and got to work.
https://sl-i.net/FORUM/images/imported/2017/05/0951115E46A1425DBA113DE77281A274-1.jpg

Since I ended up with an extra model decal, I decided to put it on the front hood since newer models have some sort of badge there.
https://sl-i.net/FORUM/images/imported/2017/05/8F1B4380DBA34082AA5BBD2678164721-1.jpg

After this, I waxed the whole cab exterior. I am sure that this truck had never seen soap, nevermind wax before. The paint needed some serious TLC, but it is pretty good now!
https://sl-i.net/FORUM/images/imported/2017/05/F680A2F2517D4D8A94726D7312AEBEF7-1.jpg

I still need to figure out how to deal with the faded dash, and the discolored passenger seat, but the interior is looking pretty good now as well.
https://sl-i.net/FORUM/images/imported/2017/05/098DFBFC83014EBB9AAAA273C73A29FF-1.jpg
https://sl-i.net/FORUM/images/imported/2017/05/66C81C65A151478CA74CFB5FDB941A2A-1.jpg
https://sl-i.net/FORUM/images/imported/2017/05/45D0B0CE6AE54AAFA3A1EA9D26A14A6C-1.jpg

Somac
05-31-2017, 11:12 AM
Subaru must have been awfully optimistic when they put a 140km/h speedometer in the van. :tongue:

Unfortunate how the under-seat metal is made because that means you can't swap in any other Subaru seat from the looks of it. It's so odd how much the passenger seat is faded compared to the driver seat but I guess it makes sense since someone is occupying the driver seat.

rkrenicki
05-31-2017, 02:14 PM
Subaru must have been awfully optimistic when they put a 140km/h speedometer in the van. :tongue:

Not that optimistic.. I have made it to about 130km/h in the truck before (as Grimmrican can attest)... The van is only a little bit heavier, and has the same engine.

The drivers seat was replaced just before it made its way to me, it appears to be a new or at least a very well cleaned seat. The passenger seat is original. The seat mounts are quite different, but even if they weren't.. there is not a whole lot of extra room between the seat and steering wheel for a larger seat and myself. Yamazaki bought up some seat covers that, while quite comfy.. made it challenging to get in and out of the truck with the side bolsters. The covers would shift out of position while sliding myself in and out, and eventually the strain caused them to tear on one of the seams.

Otherwise, in preparation for the trip down to MD for the Mid-Atlantic Meet, I decided to repaint the bed. After I pulled the bed off, I took a good long look at the drivetrain and decided to replace my clutch instead. Stripping off the intake and exhaust, i found that both of the rubber intake joiners to the supercharger were cracked, so I have some replacement silicone joiners on the way.
https://sl-i.net/FORUM/images/imported/2017/05/E1B567274A3C40E7872094A0736849D6-1.jpg

I also found that the muffler has a bit of a crack. I am not sure what I am going to do with it yet, but the local Meinake said that they would not weld it.
https://sl-i.net/FORUM/images/imported/2017/05/751DD76ABBA64D35A3003E97A73FD14C-1.jpg

I have had this engine hoist for over a year.. and I finally had a chance to use it. Since this was my first clutch job, I ended up making a few mistakes and pulled the engine three different times over the last three days..
https://sl-i.net/FORUM/images/imported/2017/05/3F09A9A022C6412F817C419C5902BDD9-1.jpg

After everything was all said and done, I replaced the crank oil seal, clutch disk, pressure plate, and throw out bearing. The original clutch disk and plate was recently replaced, but the throw out bearing was VERY noisy. I guess I will keep the old "Drivejoy" branded Exedy clutch as a spare.
https://sl-i.net/FORUM/images/imported/2017/05/fff11e7211454ff8adc0995f6b89a51e-1.jpg

Grimmrican
06-03-2017, 10:36 AM
Oh here we go! You should still color the VC.

Also the truck for sure has plenty power, it's very fast and nothing I expected out of it.

rkrenicki
06-03-2017, 07:00 PM
While I had everything apart, I started up the engine with no exhaust hooked up. It sounds pretty mean with essentially nothing on head, and I really like the bubble sound that it makes, but it was not very happy to stay running like that for sure.

http://youtu.be/m0gTQ0ZuSG0

I ended up using some high temperature Quiksteel on the muffler. The first batch was quite runny and it ended up falling into the muffler in one spot.. so I had to buy another little tub of it and patched up the whole bit. It is not pretty, but it seems to be working quite well. The truck is quite a bit quieter now.. I just figured they were all that loud, but they are not.
https://sl-i.net/FORUM/images/imported/2017/06/11ED04D2DA074095A4714C3C9D01C733-1.jpg

The sides should be back from the powdercoater soon, so I tackled the paint on the bed itself. My daughter and I stripped it down to bare metal in the spots where there was any rust, and scuffed up the rest of it.
https://sl-i.net/FORUM/images/imported/2017/06/FC7E0E432A1D48999C88C5B7B76D5008-1.jpg

Two coats of high-solids primer, and three coats of high-solids gloss white later..
https://sl-i.net/FORUM/images/imported/2017/06/E7565F73A61C4639900FC32FA976567F-1.jpg

I will let it cure for the next two days before reattaching the bed. Once that is done, I can refill the coolant and actually move the truck just in time for the MD meet!

While I was waiting for the primer to dry, I ended up trying to hook up my Subaru Select Monitor to the truck. I have the "up to 1997, all models" cart but I was not sure if it would work on this. I made what is essentially a SSM1-to-OBD adapter cable and plugged in the SSM2. Lo and behold!
https://sl-i.net/FORUM/images/imported/2017/06/5C19ABAA0E3C4C96B9699D0C342BA960-1.jpg

Calls it out by model name and year! I can read all of the data, and there are no codes to be read now that the exhaust is reattached.
https://sl-i.net/FORUM/images/imported/2017/06/828CCB4F6BA14F9B9CA77CE9FEC7844B-1.jpg

I just have to fabricate and install a new head liner, and possibly repaint the valve cover prior to heading down to MD. We will see how much time I end up having.

rkrenicki
06-07-2017, 10:02 AM
6 weeks later, I finally have the bed sides back from the powdercoater. After applying the new decals and replacing some new hardware.. the truck is now ready for this weekend.

https://sl-i.net/FORUM/images/imported/2017/06/9E8D91115B5942639A96CF5C645C5251-1.jpg

https://sl-i.net/FORUM/images/imported/2017/06/0A3F94D5542B400983F7172661AD5869-1.jpg

https://sl-i.net/FORUM/images/imported/2017/06/E2A25B2E32AE4B7AA5AAA80BB4AE0B1D-1.jpg

https://sl-i.net/FORUM/images/imported/2017/06/E51BB472A774497CB94E11C19AFA09BB-1.jpg

I do still have some LED tail lights, LED spot lights, and the gauge pod to install, but none one of those will likely end up on the truck prior to the weekend.

rkrenicki
06-13-2017, 09:20 AM
So, after an eventful trip down to Maryland for the SL-i meet and Boxerfest.. The little engine decided that it had enough of highway speeds when I was halfway home, and it sounds like it probably spun a bearing. 8 Hours and several hundred dollars worth of towing later.. The little Sambar did make it back to my garage.

https://sl-i.net/FORUM/images/imported/2017/06/F20721EED8224DAEA5EC720943845A8B-1.jpg

Depending on the heat, I should have the engine pulled tonight or tomorrow to really assess the damage, and come up with a game plan.

dodik
06-14-2017, 01:39 PM
ouch, hopefully it still has some life left in it. im guessing you are going to overhaul it?

rkrenicki
06-14-2017, 02:08 PM
Depending on the extent of the damage, yes.

rkrenicki
06-14-2017, 10:25 PM
Got it on a stand, pulled the crankshaft caps.. and found that cylinder 2 rod bearing was toast.
https://sl-i.net/FORUM/images/imported/2017/06/6646744DDA144C0B82E0E8A27EC835B8-1.jpg

https://sl-i.net/FORUM/images/imported/2017/06/4B88C688E56142289E27705C4E63B3E0-1.jpg

Tomorrow, I will pull the crankshaft and get it over to a machine shop. Once it is machined, I will order the proper bearings and a replacement rod and cap.

dodik
06-15-2017, 10:47 AM
didn't it have low oil light on? maybe there was more to it then swapping sensor?

tizzle
06-15-2017, 05:02 PM
How many miles/km's did it have when it let go? I was about to pull the trigger on one, but got worried that near 100,000km was too many miles for $3750. I hear G&R Imports has good prices on parts and replacement engines.

rkrenicki
06-15-2017, 06:37 PM
It has somewhere around 52,000 or 53,000kms on it.. (I pushed the chassis outside, and I do not feel like going out to look exactly). The issue here was that it was not well maintained.. the last oil change before I received it was about 4 years prior.. even though it had only driven about 1000kms. I also was traveling about 70-75mph with the engine spinning at 6000rpm.

I have been in communication with G&R and Twin Rivers here in the states, as well as Yokohama Motors and JapanParts.com to source various parts. The only quote I received back was for a replacement crankshaft with bearings at $850 (!!!) plus a $300 core (and core is graded as well) from Twin Rivers. I guess $150-200 for machining and $170 for bearing kits is a much more palatable option.

Today the crank is out. I have it wrapped up in bubblewrap to prevent more damage, and I will bring it to the machine shop tomorrow.
https://sl-i.net/FORUM/images/imported/2017/06/2017061520173350-1.jpg

I took the head off as well today. Cylinder walls look good, no gouges or visible cracks. The head gasket was also fully intact.
https://sl-i.net/FORUM/images/imported/2017/06/2017061520175954-1.jpg

The head looks okay as well. No valve damage or anything of that sort. I will have it cleaned and pressure tested. I will also have the block cleaned. I measured the head, it is 28cm from one end to the other.. just over 11 inches!
https://sl-i.net/FORUM/images/imported/2017/06/2017061520180356-1.jpg

rkrenicki
06-23-2017, 05:41 PM
After looking at the pieces a little more, it appears that the #2 piston made contact with the head. I am not sure if it just broke the seal of the headgasket or if it cracked the head, but that does explain why the cooling system pressurized and pushed out a bunch of coolant. As such, I no longer trust the head or the piston. I bought today a new head, piston, and a brandy new crankshaft.. as I found one for not too much more than I can have my old one machined for.

This engine rebuild is beginning to get quite expensive.. but I should not have any more issues for a very long time.

rkrenicki
07-05-2017, 09:11 AM
Well, this has turned into a ground up engine rebuild. Not all of my parts have arrived, but the last few should be here by the end of the week.

Rebuilt and ported Head, new piston (just #2), new rod (just #2), new rings, new crankshaft, new oil pump, all new gaskets and seals, new thermostat (while it was all apart), new pilot bearing (to go with the clutch I did last month).

Once the last few packages show up, the pictures will start flowing again. Speaking of pictures.. I just corrected all of my MR pictures from the Photobucket debacle. I need to come up with a good solution for new pictures going forward.

Somac
07-05-2017, 12:40 PM
Oof, that's an unfortunate to-do list of items, especially when it was out of the blue.

Was it difficult actually finding the pistons and rods for this motor? I'm assuming since you're only replacing one that you got an OEM one. I'm surprised you're still able to!

rkrenicki
07-05-2017, 01:23 PM
Was it difficult actually finding the pistons and rods for this motor? I'm assuming since you're only replacing one that you got an OEM one. I'm surprised you're still able to!

This engine was in continuous production from 1990 to 2012, so parts are fairly straightforward to find. Many parts never changed for the entire run, but quite a few have been updated along the way. The non-supercharged version was used in the Vivio in Europe as well and many parts were for both the NA and SC versions. Not a single part was "difficult" to track down, it really just came down to what vendor could get each part for the lowest cost. I ended up ordering everything from JapanParts.com, Yokohama Motors, and from PartSouq.com. Some really common parts like o-rings and some fasteners I ordered from my local Subaru dealer, Secor Subaru.

After everything is said and done, not counting tools, cleaners, sealants, and the towing charges... This engine has cost me more to repair than the total cost of the truck by the time it got to my driveway, but given the excellent original price.. It will still be less than the cost to buy one already here.

Also, it will be an essentially new engine.. I should have no more issues for a long while as far as the engine is concerned.

rkrenicki
07-07-2017, 11:29 PM
Progress!

While I was awaiting the arrival of parts, I decided to change the oil in the Supercharger. I may mess around with the pully size later on, but I need to focus on just getting the engine working at the moment.
https://sl-i.net/FORUM/images/imported/2017/07/20170704132445-1.jpg

I also decided to clean up the pistons with some Berryman Chemdip cleaner. I let them each soak for about 90 minutes, and then scrubbed them down. This is a before/after.
https://sl-i.net/FORUM/images/imported/2017/07/20170705195126-1.jpg

Here are all three cleaned pistons, as well as the new piston that showed up today. There are also brand new rings installed.
https://sl-i.net/FORUM/images/imported/2017/07/20170707165830-1.jpg

I rehoned the cylinders with a 320grit Flexible Ball Hone. They were not bad to start, but I figure to deglaze them and allow the new rings to properly seat.
https://sl-i.net/FORUM/images/imported/2017/07/20170707170746-1.jpg

All 4 pistons reinstalled.
https://sl-i.net/FORUM/images/imported/2017/07/20170707171803-1.jpg

Brand new crankshaft.
https://sl-i.net/FORUM/images/imported/2017/07/20170707172042-1.jpg

Crank installed top view.
https://sl-i.net/FORUM/images/imported/2017/07/20170707182251-1.jpg

Crank installed bottom view with all cleaned up bearing caps and new bearings.
https://sl-i.net/FORUM/images/imported/2017/07/20170707182319-1.jpg

New OEM head gasket.
https://sl-i.net/FORUM/images/imported/2017/07/20170707183624-1.jpg

Flowtested rebuilt head reattached.
https://sl-i.net/FORUM/images/imported/2017/07/20170707185119-1.jpg

Unfortunately, I am stalled at this point as my new oil pump has not yet arrived. It might be here tomorrow.. monday at the latest. Once that arrives, I can fully reassemble the engine.

Did I need to replace as much as I did? No, but since it is fully disassembled, I might as well replace all of these to gain back some power and prevent potential issues.

rkrenicki
07-11-2017, 04:19 AM
The oil pump finally showed up today, so assembly resumed.. until I realized that the oil filter stud is not included with the new pump, and I cannot seem to remove it from the old one. So.. yet another part ordered from Japan, and it will not be here until after I am back from vacation next week. :/

Water pump, Oil pump, Timing belt, Injector assembly, exhaust manifold, and engine wiring harness installed.
https://sl-i.net/FORUM/images/imported/2017/07/20170710162625-1.jpg

Engine "Strengthening Plate" and oil pickup installed.
https://sl-i.net/FORUM/images/imported/2017/07/20170710170414-1.jpg

Oil Sump installed.
https://sl-i.net/FORUM/images/imported/2017/07/20170710172008-1.jpg

Timing Cover installed.
https://sl-i.net/FORUM/images/imported/2017/07/20170710172015-1.jpg

All valve lash set.. and the engine spins nicely and in time.
https://sl-i.net/FORUM/images/imported/2017/07/20170710172049-1.jpg

rkrenicki
07-24-2017, 10:32 PM
The engine is reassembled and remounted! I have other pictures, but I need to sort them out later.. In the meantime, here is a video of the second start!


https://www.youtube.com/watch?v=9ihih9wrrVQ

rkrenicki
07-25-2017, 09:24 PM
The truck is officially back on the road, took it for a drive of about 50kms today to seat the rings and test for leaks. I have a couple of pictures after the valve lash adjustment, that I will pick a couple and post tomorrow.

rkrenicki
08-05-2017, 02:47 PM
I have been working on completing the engine break in for the last few weeks, so I have neglected to post up the rest of the pictures.

The engine has been running very very well since it was rebuilt. I still need to re-adjust the valve lashing now that it has been driven 500kms or so as the valve train is being a little chattery. I also need to pick up a Tee for the crankcase breathers, which I will explain a little later on. Today I changed the distributer rotor and cap as they just showed up this morning, as well as the drivers mirror which was very loose and moving around on me while driving.

But first.. Here are the last few rebuild pictures:

Coming back from vacation, these were waiting for me: The oil filter stud is obvious, but the valve cover was an OEM option. The red version was no more expensive than a non-colored cover, and it was cheaper than having my existing cover powdercoated.
2440

I also picked up a magnetic oil drain plug. It uses a M16 thread just like the newer FA and FB series engines. The hex is WAY bigger than the original (19mm vs 14mm), but it works quite well.
2441

Here is the engine reassembled, clutch installed, ready for going back into the chassis.
2442

First break-in oil change at 50kms. Lots of stuff on the magnetic plug, and the oil was dark grey with a pearlescent look and a couple of white metal flakes.
2443
2444

rkrenicki
08-05-2017, 02:59 PM
Total list of replaced engine parts:

#2 Piston
#2 Rod
Crankshaft
All rings
Main Bearings
Rod Bearings
All Gaskets and Orings
Oil Pump assembly
Head
Valve Cover (not required)
Distributor Cap/Rotor
Water pump (previous work)
All belts, including timing (previous work)
Spark Plugs
Supercharger Silicone Joiners (previous work)
Clutch, Pressure Plate, Throw out bearing, Pilot bearing (previous work except for pilot bearing)

I changed the oil at 50km, 150km, and 400kms. The 1st change was photoed in the last post. 150km was still a little dark, but much fewer metal bits in suspension. 400km was nearly perfect oil, just slightly darker than when it went in. I am going to do another change at 650kms, and do a compression test at that point.

rkrenicki
08-10-2017, 06:45 PM
Compression test results: #1 - 108psi, #2 - 112psi, #3 - 113psi, #4 - 115psi

I also re-adjusted the valve tappet clearance, and the engine is significantly quieter now. It was a little chattery before, but this is much better.

That said, I have also developed another exhaust leak somewhere.. I have a feeling I am going to have to have some sort of custom exhaust system fabbed up.

rkrenicki
08-29-2017, 09:28 PM
I have been driving this around for the last month and about 1200kms.. and I noticed that it started to very quietly knock like it was before it spun a bearing. I had only replaced one of the four rods, so I decided to pull it back apart and replace the other 3 rods and re-replace the rod bearings.

In doing this, I discovered that one of the rod caps was slightly loose! Either the studs stretched or I neglected to tighten that one down. Luckily, I caught this before the brand new crank was damaged. I do know that I neglected to mark the rod caps, and I wasnt sure on their order.. turns out they were all wrong after I found the marks during this second teardown. That may have contributed to the loose #3 rod.

One of the new rods was damaged before installation, so I am awaiting the replacement to show up before I can finish reassembly of the engine, but when this is all done.. every single moving part in the engine (except for 3 of the piston crowns themselves) would have been replaced.

thenines'
08-30-2017, 03:28 PM
So-it will be done in time for the R.I. meet? (Sorry-I had to say that-still waiting for a date!)

rkrenicki
08-30-2017, 07:04 PM
Yes, it will be at the RI meet for sure. The last rod just shipped, and I hopefully will have it by the weekend. The reassembly should only take a day or so once I have that last rod.

rkrenicki
08-31-2017, 09:08 AM
Due to Eid Al Adha, my rod is stuck in the UAE until Monday, so I will not see it until Wednesday now. Oh well, I guess it will be back together by NEXT weekend.

rkrenicki
09-02-2017, 09:46 PM
Scratch that, somehow it made it to me on Friday, so I reassembled the bottom end last night. I waited until today to do the rest as I wanted to give the RTV on the oil pan time to set up.

During the reassembly, I ended up breaking the tab off of the temperature sensor. Luckily, it is the same sensor that is used on the 1st and 2nd gen Legacy, so a quick trip to the parts store and now it is quite happy. I am still bleeding out the coolant system, but I did take it for a quick spin around the block. The engine is nice and quiet and happy, but I need to do some adjustments on timing and the belts (The supercharger seems to be straining, and the alternator pulley is squealing)

rkrenicki
09-13-2017, 09:35 PM
Oh boy, I have a lot of updates to post.

First, before the parts showed up for my second "mini rebuild", I installed a few LED lights. The first one was a significant upgrade for my reverse light. There is only one reverse light on this truck because of where the muffler is located. It is a small wimpy incandescent bulb which was hard to see before I tinted the rear window, and impossible to see afterwards.

I picked up a pair of these surface-mount LED spot lights, broke out the angle grinder and got to work. This shot shows how much larger the new lamp is from the old one.
2460

Here is the new lamp installed
2463

And here it is in operation. Unfortunately I ordered the spot beam instead of the flood beam, but it really illuminates directly behind me!
2464


I also finally installed the 4x4 LED flood lights to the back rack. They are installed, but not yet wired up. I have had these lights since before the truck showed up, and I drilled the holes in the rack prior to it being powdercoated. It just took me this long to put them on for some reason.
2465

rkrenicki
09-13-2017, 09:52 PM
The second "mini rebuild" was a piece of cake.

I am getting too good at pulling this engine, I believe I can do it in about an hour now.
2466

I now have 4 brand new rods, all with matching caps that are facing the correct direction, properly torqued, and a second set of rod bearings.
2468

Yet another new head gasket
2469

All reassembled and back in.
2470

The observant among you might see that the two vent hoses are connected now. I decided that since I had to wait for parts to arrive from Japan anyways, I might as well order the correct Akabou valve cover. Here are the two side by side.
2467

rkrenicki
09-13-2017, 10:02 PM
I have been driving the truck every day since the build, and it is very happy. I did have a rattle that resonated at around 2000rpm, which ended up being a loose timing belt cover.. and a bit of a drone that seems to be the supercharger belt tensioner. I have a replacement tensioner on the way from Japan now.

While driving around, I am often asked "What kind of Nissan is that?" because of the Sentra wheels. Just today, I was asked that question 4 times in traffic... so I decided to grind off the Nissan logos from the center caps.

What I started with
2471

After a minute or so with the stripping wheel and my drill
2472

Final result (until I paint the wheels that is)
2473

rkrenicki
09-13-2017, 10:05 PM
I also decided to get my gauge pod installed. I am not really convinced on the placement here, so I double sided taped this down until I can come up with a more permanent solution. This will do for now and I will readdress this after the RI meet. First step was to trim the gauge pod to somewhat match the curve of the dash.
2476

The curve is pretty good, but I cannot get it to sit flush on the sides. This is what bugs me the most about this setup.
2477

This is the end result for the moment. I do not have the vacuum hose run yet nor the wiring connected to the truck yet, but the wiring runs into the dash, and the whole pod is double sided taped down.
2478
2479

98legwag
09-14-2017, 08:24 AM
Thats a lot of work. Well done sir.

Somac
09-18-2017, 09:20 PM
Holy cow. Talk about unexpected maintenance! Crazy how much you've torn this apart. Glad to see it's running right though! Hopefully that'll be the last of your major troubles for a long time now that it's all fresh.

rkrenicki
09-18-2017, 09:48 PM
It has been going very well since the last build. The supercharger idler pulley should be here any day... I finally connected and plumbed in the gauges, and I now know for sure that the supercharger produces a little over 0.5bar of pressure (about 7psi) I also know that my oil pressure is 90+psi at full tilt.

I also dealt with a very minor leak on one of the coolant hoses. I was able to repair it, but with all of the hoses being 25 years old.. I figured I should order a new set of hoses today.

Matty2Hotty
09-19-2017, 04:00 PM
Gezzz all that trouble and you probably could of done a electric motor swap in her.

Reason
09-20-2017, 12:59 AM
I also decided to get my gauge pod installed. I am not really convinced on the placement here, so I double sided taped this down until I can come up with a more permanent solution. This will do for now and I will readdress this after the RI meet. First step was to trim the gauge pod to somewhat match the curve of the dash.
2476

The curve is pretty good, but I cannot get it to sit flush on the sides. This is what bugs me the most about this setup.
2477

This is the end result for the moment. I do not have the vacuum hose run yet nor the wiring connected to the truck yet, but the wiring runs into the dash, and the whole pod is double sided taped down.
2478
2479

Isn't that in your line of sight?

rkrenicki
09-20-2017, 01:05 AM
Oh no, it is quite a bit below my line of sight. The windshield on the Sambar is huge. It is a lot like driving a bus or RV.. just way smaller. You will see what I mean in a week and a half.

Reason
09-20-2017, 01:12 AM
Alright Sounds good

98legwag
09-28-2017, 05:39 PM
http://www.duncanimports.com/used/Subaru/1990-Subaru-Sambar-133060950a0e08f7044e749c1a13f0c9.htm

You could a Sambar fire truck to your collection

rkrenicki
09-28-2017, 11:10 PM
Ouch! Not for that price.. There are at least 3 Sambar Fire Trucks that I can get imported for well under $5k each. In fact, my wife has had her eye on a Sambar Fire Van for the last month or so, but it is a little too new for import...

98legwag
09-28-2017, 11:20 PM
Yeah, that place has a lot of really cool imports. But all of them seem overpriced by a good amount.

rkrenicki
10-06-2017, 07:52 PM
Now that the engine is fully broken in, I got him up on a dyno to see how it is performing before doing any engine upgrades.

This is the 5th pull of the day, up to 7000rpm. (Redline is 7250)

https://www.youtube.com/watch?v=1YnfPZIDxhY

Dyno graph
2509



HP Torque
Spec (crank): 55BHP @ 6200rpm 51lbs/ft @ 3800rpm
Dyno (wheels): 50WHP @ 6400rpm 46lbs/ft @ 3500rpm


The numbers look good, assuming a 10% driveline loss in 2WD mode. The dyno I used today was a single drum, so I could not test 4WD. Overall, I am very happy with the results as it is spot on to what it should be making. Next step is to try to increase the boost pressure a bit from the 0.5BAR (7PSI) that it is making today. The Vivio RX-R is closer to 0.8BAR (11.2PSI) on the same engine, but does have an intercooler..

Reason
10-06-2017, 09:51 PM
Engine upgrades??:shock: YES!:hello1:

This thing is a BEAST

:happy1:

rkrenicki
10-29-2017, 11:36 PM
The patch that I did on the muffler back a few months ago, didn't hold very long. I ended up buying a new muffler and most of the heat shields as they were not in the best of shape to begin with. The muffler was backordered, and the one that I received was built this month, so they may build them on-demand.

What I started off with
2582

Mufflers side by side. I did not buy a new Catalytic Converter as they are extremely expensive.. I just swapped the old one over with new gaskets.
2583

All replaced, both shields around the flexpipe are new, and the shield under the muffler is new as it was all bent up and rusty.
2584

The truck is CONSIDERABLY quieter now. I have not taken it for a spin yet as it is storming here tonight, but it is almost shocking how much of a difference there was between the old and new just on startup in the garage.

Somac
10-30-2017, 04:44 PM
Wow! You're going to have a brand new Sambar pretty soon by the looks of it!

rkrenicki
11-01-2017, 09:22 PM
Pretty much! I have a new clutch, accelerator, and speedometer cable showing up tomorrow as my clutch cable snapped a couple weeks back and replacing all three at the same time is just about as easy as just one.. I also ordered new front diff mounts, as bad/old mounts apparently kill the front struts and I have brand new struts waiting to go in.

Once those are done.. that should be it for a while except for messing around with the supercharger pulley at some point.

rkrenicki
12-12-2017, 03:34 PM
It took me a couple of weeks, but I finally replaced all of the control cables, except for the shifter cables. The Clutch cable took a little fiddling to get right. The old speedometer cable had a big crack in the plastic where it screwed into the transmission which kind of gave me a hard time during removal, but the speedometer is no longer bouncing which is an unexpected benefit.

I did not take really any pictures except for this one when they were half installed. The new cables are the top set, and the old cables are the bottom set.
2638

rkrenicki
02-01-2018, 09:13 PM
I have no progress on the truck, as it has been parked since October. I drove it once after finishing the Clutch/Speedo/Accelerator cables to get them adjusted, but other than moving it around my driveway.. it hasnt gone anywhere.

I did replace all of the radiator hoses after a small leak developed on one of them. I figured they were 25 years old and a little brittle and disturbed a few times with my various engine work, so it was time to be replaced. There are 6 hoses in total since the engine is in the rear and the radiator is in the front, there is a hardline section in the middle and the hoses connect the engine to the hardline, and another set for the hardline to the radiator. I actually replaced these just before my Dyno pull, but never posted it.
2678


I also have a bunch of bits that are waiting to go on. Some new front diff mounts and front struts are sitting in boxes, as well as an oil cooler and filter relocation kit. I picked up a rivnut kit to help mount these things, but I have not yet messed around with it.
2680


And lastly, I do have a new Bosch Group 51R AGM battery to go in which is the same height and depth, but a couple of centimeters wider than the original Japanese battery. It does "sort of" fit inside the battery box, but I do not have a good way to secure it. I will have a new battery box made up, as it just bolts to the frame and comes off very easily.
2679

rkrenicki
03-01-2018, 04:06 PM
I started to finish up some projects now that it is starting to warm up a bit. I began working on the front struts, only to find that the foam bumpstops are essentially disintegrated, the strut mount rubber is very dry-rotted, and the spring seat bearing was also pretty dry. I ended up ordering new stops, strut mounts, and bearings.. so the truck is stuck on stands until they show up.

I also have been piecing together a set of DOT approved tires for the original 12" wheels. I keep finding good deals and I now have a pile of 7 tires in my basement (4 for use, 1 for full size spare, and 2 for "just in case"). The last two were an amazing deal that I couldn't pass up. I need to clean up the original wheels before I get them mounted, but it will be nice to have the OEM wheels on there again.

The other day, I found that The Retrofit Source had some Morimoto Sealed7 LED Headlights on closeout. These are a very significant upgrade from the generic Halogen bulbs I picked up at Advance Auto.
2682

I think they look pretty good once installed.
2683
2684

I tried to get some output shots. Pardon the mess in my garage, the truck is up on stands at the moment so I couldnt move it to a different wall. This is the output of the Sylvania Halogens that were on the truck
2689

And this is the output of the Low beams
2690

Since Subaru uses a switched ground arrangement, I had to re-wire the sockets to make the Low Beams work at all. That also means that I cannot use the high beams at all until I can rig up some relays. Once I do that, I will get some more shots. Overall I am extremely happy with the improved light output. I need to re-aim them and at some point I will get the LED DRLs wired up and the high beams situated.

rkrenicki
03-18-2018, 03:22 PM
I received the new front Bumpstops, strut mounts, and updated strut bearings, along with a bushing for the shifter cable, a new timing belt cover set, and new door weatherstrips. I finished reassembling the passenger side, turned the truck around in the garage and pulled the other side apart. Apparently one of the CV boots was split. I had bought some boots to replace them all as I figured they were not going to last too long, but it turns out the company sent me the wrong boots. I found some new aftermarket CVs in Japan that I ordered last night.. hopefully they will be here soon.

In the meantime, I replaced the rest. New Timing Belt Cover is looking pretty nice, and should keep the road dirt out of the timing components. The door gaskets should be a nice improvement once I get the truck driving on its own again. I installed the bushing on the shifter cable, but I want to replace the rest of the bushings too. that is still on my to-do list. I did assemble the new strut assembly for the drivers side,but until the CV shows up, it will stay on the bench. I do also have the front diff mounts to replace (highly recommended in the manual when doing the struts) so that will be done sometime this week.

I expect the CVs to be here in a week or so, then I am done with the mechanical work for the time being. I will just have the bed to get lined, and some electrical work to get the rest of the lights going. Then, I will be "done" (tm).

rkrenicki
04-02-2018, 10:46 PM
The truck is now back on the ground and driving around. In addition to the suspension work, I ended up completely tearing down the shifter assembly, replacing all of the bushings and re-greasing everything. I took him for a drive on Saturday out to Rhode Island, and all of the suspension work and the refurbished shifter makes it fantastic to drive. I need to adjust the clutch cable a little bit as it grabs a little higher than I would like, but that is about it. I was hoping to start dailying it again, but it snowed here again today and they dumped a bunch of salt on the roads. :(

Now for some pictures. First is the shifter. It was never really "sloppy", but it is quite a bit nicer to use now.
2739

The manuals recommended that when replacing the Struts, I should also replace the differential bushings. Since I had to remove the diff to do that, I changed the gear oil while it was out.
2740

Now that the truck is back on the ground again, I was able to re-aim the LED headlights. I have not had a chance to drive it at night, but the output is significant..
2741

And lastly, I picked up a bed cover from Amazon.co.jp and installed it. It is a rubberized canvas held down with rubber straps for easy removal. I did not look at the directions close enough and put too many straps on the rear and ran out working my way forward before taking these pictures. I have since corrected this, but I haven't taken any new pictures since.
2742

thenines'
04-15-2018, 07:26 PM
The truck is now back on the ground and driving around. In addition to the suspension work, I ended up completely tearing down the shifter assembly, replacing all of the bushings and re-greasing everything. I took him for a drive on Saturday out to Rhode Island, and all of the suspension work and the refurbished shifter makes it fantastic to drive. I need to adjust the clutch cable a little bit as it grabs a little higher than I would like, but that is about it. I was hoping to start dailying it again, but it snowed here again today and they dumped a bunch of salt on the roads. :(

Now for some pictures. First is the shifter. It was never really "sloppy", but it is quite a bit nicer to use now.

The manuals recommended that when replacing the Struts, I should also replace the differential bushings. Since I had to remove the diff to do that, I changed the gear oil while it was out.

Now that the truck is back on the ground again, I was able to re-aim the LED headlights. I have not had a chance to drive it at night, but the output is significant..

And lastly, I picked up a bed cover from Amazon.co.jp and installed it. It is a rubberized canvas held down with rubber straps for easy removal. I did not look at the directions close enough and put too many straps on the rear and ran out working my way forward before taking these pictures. I have since corrected this, but I haven't taken any new pictures since.

will it be at WBM this year?

rkrenicki
04-16-2018, 11:06 AM
That is indeed the plan. I have my ticket and he is registered for the car show as well.

rkrenicki
04-16-2018, 09:55 PM
I finally bit the bullet and found a spot to install my light bar. I have not yet wired it up, but at least it is physically mounted now.

I ended up chopping out much of the grill on the bumper to install the 24" LED light bar. There is still plenty of room all of the way around for air to get to the radiator and engine intake (yes, that is in the front.. even with the engine in the back)
2751

Here is the bar itself attached.
2752

As I said, I have not yet wired it up.. but I powered it on with my little portable jump-box, and the light output is quite impressive.
2753

I also replaced the single horn with a set of Mitsuba Alpha II Compacts, the same kind of horns that was on the RS30 before I moved them to the Blitzen. The original horn was impressively loud, but was only single tone. This horn upgrade is just about the same loudness, but is dual tone and lower pitched.
2754

rkrenicki
05-03-2018, 07:46 PM
I finally found a suitable steering wheel upgrade. It turns out the Subaru Vivio KK and KW series have the same ring for the horn system, and that the Vivio RX-R has a leather wheel with red stitching. I snatched one up and put it on today.

Old Wheel
2825

New Wheel
2826

rkrenicki
06-15-2018, 10:36 AM
I have been very busy with upgrades and replacing items before Wicked Big Meet 2018 next weekend.

There has been a little bit of slop in the steering column since I have owned the truck, so the first thing was replacing all of the bushings and bearings in the steering system. I also picked up new tie rod ends, but I have not yet put them in, but the slop is already much much better already.

I did find out that original rain visors are still available, so I ordered a set along with a full set of turn signal lenses since half of mine are faded. For some reason, the front turn signal locations have black plastic "reflectors", so I also spent some time with aluminum tape to make them reflective and increase the light output.

With aluminum tape installed
2842

With lens, and before/after. Aluminum tape on left, original on right.
2843

Rain Visors installed.
2844

After this, I decided to upgrade from the 25 year old vinyl mat to a brand new carpet from a Sambar Van. It was a significant improvement over the old ratty mat for sure.

Original mat
2845

New Carpet and trims
2846

rkrenicki
06-15-2018, 11:55 AM
I also managed to locate a proper Double-DIN install kit, so I no longer have a gap around my radio.
2847

The seatbelt catches were quite faded and scratched up. The newer version of the truck (TT chassis) uses the same mechanism, so I was able to find some much newer/younger catches which are in very good condition.
2848

And, lastly.. I found some OEM Option Fog Lights. They required that I cut out some parts of the bumper, but I think they came out pretty good. I also took the opportunity to properly center the light bar as it was off by about 1cm.
2849

I still need to deal with the wiring for all of the lights, which I hope to take care of this weekend.

rkrenicki
06-17-2018, 09:26 PM
The wiring is half done now. The external wiring is complete and ran into the cab, I just need to finish connecting the relays and switches which I will get done in the next day or so.
2850


Lights mounted.
2851


And Lights tested!
2852

I do have a few more packages from Japan on the way, and I hope to have them in time for WBM..

thenines'
06-18-2018, 08:31 AM
Maybe it was done for the "smoke" effect-thought, it is more common for head and tail light lens

rkrenicki
06-27-2018, 07:49 PM
The last couple of boxes showed up in time for WBM, and I scrambled to get things done. First was a set of Défi Advance BF gauges to replace the GlowShift gauges. The GlowShift boost gauge was mechanical, and required a 15 foot long hose all of the way to the back which means that it had quite a bit of a delay as the entire length of it would need to pressurize and depressurize. The oil pressure sender was also quite massive and required a relocate kit to work on this engine. The Défi sensors are much smaller, and the boost gauge has a sensor that I could use a 3" long piece of hose for.

I found the whole set on Croooober/UpGarage for a decent price, and it included a full set of brand new sensors and cables. I was a little nervous about the cables reaching to a rear engined setup, but I managed to get it all to work.

Here is the full setup as received from Croooober. A 2.0BAR Boost, Oil Pressure, Oil temperature, and water temperature gauge. As I said before, it came with all brand new sensors and cables, as well as the Advance Defi-Link computer and controller. The picture on Croooober did not show the Boost sensor, so I assumed it did not have one. As such, I also purchased a brand new Défi 1.2BAR Boost Gauge, which is a more appropriate boost scale for the little supercharger anyways.
2856

The cables for most of the sensors are 3 meters long, with the exception of the boost sensor which is 2.5 meters long. I ended up installing the computer behind the drivers seat, directly onto the ECU as from there, all of the sensor cables would reach. I did have to extend the cable for the gauges themselves as it was only 1 meter long, but that was pretty simple with some DE-9 connectors and some 4 conductor wire I had kicking around.
2857

I started messing around with gauge positioning based on where I had drilled the hole for the old mechanical gauge, and I ended up doing a bit of an offset arrangement biased towards the center of the dash. I wasnt sure if I was going to like it, but it has really grown on me. It also allows me some options with an additional meter that I am not quite ready to show off yet.
2858

At this point, I discovered that I had purchased the wrong temperature adapter for my radiator hose size. I had two different hoses in my box of spares, and I measured the one for my Legacy (38mm) instead of the one for the Sambar (30mm). This was Friday late afternoon, and there was no way I was going to get the correct adapter in time for WBM. This photo was taken after the correct adapter showed up, but you can see the vast size difference. The old adapter was big enough to go completely around the hose instead of inside of it.
2860

Since I also knew that the oil temperature was not going to be ready in time, that means that neither of the temperature gauges was going to work for Sunday. Oh well, at least the oil press and boost gauges worked like a charm. Oh, and the gauges are the blue versions.. which I greatly prefer to the red version sold here in the US. Here is a shot of them displaying peak after a quick spin around the town.
2859

rkrenicki
06-27-2018, 08:10 PM
This is the setup as of right now. As I said before, I do have more to do with this, but I do not yet have the rest of the parts needed to make it work so it will be a bit of a surprise. Don't mind the alert lights, I just didn't want to start the truck while the garage was closed.
2861


Otherwise, Wicked Big Meet was a blast. I registered Sammie into the car show and talked to hundreds of people, handing out his business card and answering all sorts of questions. I let people sit inside of him as well, as many had never been in an actual Japanese vehicle before.
2862


At the end of the day, Sammie won his class.. taking home the "Best Old School (Pre 1995)" trophy! I never really expected him to win, and I am extremely happy that he did!
2863

thenines'
06-27-2018, 10:57 PM
:thumbup: you had a lot of competition-well done!

Reason
06-28-2018, 08:25 PM
Congrats on the award, its coming along great.

98legwag
06-29-2018, 10:04 AM
Well done. You have put in a ton of hard work and you deserve it.

rkrenicki
07-02-2018, 10:46 AM
I decided to tackle the water temp sensor yesterday. I removed one of the coolant hoses, cut it up and installed the adapter and sensor.. Turns out that I cut the wrong hose, as this is the return line from the radiator... I guess I lost track of which was which when I was underneath the truck. I have ordered a replacement hose, but I guess I will be measuring the much cooler return line in the meantime.

2864

rkrenicki
02-07-2019, 11:23 AM
It has been several months, and in the meantime I have largely been doing some maintenance tasks. The distributor had a failing oil seal, so the cap was accumulating oil. Subaru does not sell the seal on its own, so I ended up replacing the entire distributor base. I also replaced the valve cover bolts to spruce it up a little bit since they were only $1 each.
3038

Last night, I decided to tackle the wiring situation. It has a super simple wiring harness, and I have probably doubled the amount of wiring behind the dash with things like the auxiliary lighting, LED Headlights, power windows, and radio. Since all of these things were done at different times, it just became an intermingled mess of wires, relays, fuses, and random connectors. I also never really cleaned behind the dash, it is still covered in JDM dirt. Here is what it looked like just after the dash coming off:
3040

I am working systematically across the dash, relocating relays and zip-tying all of the cables so that there will be none exposed, and cleaning up all of the dirt while I am in there.

I have also found that Subaru Japan has been discontinuing parts left and right as of late.. I have been busy sourcing and acquiring spare parts to keep this truck on the road for another 25 years. I now have several boxes full of hoses, gaskets, bearings, bushings, etc.. My own little parts store in my garage just to keep it going. In my research, there is a surprising number of mechanical parts shared with the DL/GL platform and the Justy. I bought a NOS steering universal joint from Subaru here in the US that was made back in 1995. This particular part has been discontinued in Japan for quite a while and is not available in Japan or Europe, but it has been sitting quietly in a US warehouse for 24 years waiting for me to put it on my shelf.
3039

dodik
02-07-2019, 11:53 AM
Just saw one of these this morning by my son's school. They are very tiny.
Good luck on the wiring, its a finicky job but once its done its easy to fix any issues that may arise in the future. You of all people probably know this the most that if its messy back there you will get gremlins and after a few years you tend to forget what goes where.

rkrenicki
02-07-2019, 12:56 PM
Just saw one of these this morning by my son's school. They are very tiny.
Good luck on the wiring, its a finicky job but once its done its easy to fix any issues that may arise in the future. You of all people probably know this the most that if its messy back there you will get gremlins and after a few years you tend to forget what goes where.

Yep, I am fixing those gremlins now, actually. This will also give me a chance to finish my gauge setup and leave provisions for the additional lighting that I have not yet installed, but still allow me to remove the dash without cutting wires or zip-ties. My goal is to have 2 or 3 interconnects between the "bulkhead" and the dashboard, and no more. Fun fact, the stock interconnect between the two is just one connector with 10 wires.