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View Full Version : 2nd Generation Wagon (BG/BK) chuckthefuk - 96' BG7 Outback EJ22E 5MT - Lifted & Overhaul!


chuckthefuk
09-21-2009, 02:21 AM
So if you don't know yet my 97' BD GT got totaled :-(

I replaced it with this sweet scooby.

1996 Subaru Outback BG7 EJ22E @ 350,000km running like a champ w/ cracked windshield and seized brakes. First owner happened to be a police department up north. They maintained everything on this car its so mint. Second owner a very friendly dyke who used the car for 3 years. All in all a very well kept high mileage subaru!

http://img147.imageshack.us/img147/7431/dsc01183c.jpg
http://img132.imageshack.us/img132/1362/dsc01184m.jpg
http://img28.imageshack.us/img28/9026/dsc01319m.jpg

Price = $460 CAN

Needed:
-Windshield = $150
-Both left calipers (all brake stuff $420 :-D)
-Rotors and pads
-Ebrake shoes w/ springs and adjusters.
-Rust repair = Free
---------------------------------------------------
Total cost = $1030 CAN

http://img198.imageshack.us/img198/4809/dsc01191large.jpg
The old ---> viewtopic.php?f=6&t=10911 (https://sl-i.net/FORUM/viewtopic.php?f=6&t=10911)
The new :-D

http://img41.imageshack.us/img41/8714/dsc01266qd.jpg
getting ready

http://img96.imageshack.us/img96/889/dsc01260large.jpg
Windshield removed and rust repair begun

http://img29.imageshack.us/img29/4420/dsc01261largeq.jpg
The uglyness, most rust removed just need to patch the holes and prep for paint.

http://img29.imageshack.us/img29/5876/dsc01262large.jpg
Most common spot for a scooby to rust out. Not so bad though just surface rust thankfully.


UPDATE: finished..

http://img195.imageshack.us/img195/1305/dsc01263mx.jpg
bondo sanded

http://img39.imageshack.us/img39/2720/dsc01264k.jpg
bondo sanded cont'd

http://img195.imageshack.us/img195/7823/dsc01265bj.jpg
Notice anything missing :-D

http://img3.imageshack.us/img3/6664/dsc01268ou.jpg
turns out the rust on the quarter panel was much worse then I expected. After some old school brazing the quarter was mint.

http://img28.imageshack.us/img28/9558/dsc01269.jpg
diff angle

http://img195.imageshack.us/img195/3971/dsc01271a.jpg
fiberglassed over the welds and bondo over the fiberglass

http://img195.imageshack.us/img195/5150/dsc01272sw.jpg
primed the roof

http://img195.imageshack.us/img195/7920/dsc01275sv.jpg
primed the roof cont'd

http://img39.imageshack.us/img39/9341/dsc01273h.jpg
primed the quarter / duragaurd the inside of the wheel well / under the bumper / inside the quarter from the trunk

http://img195.imageshack.us/img195/1188/dsc01274l.jpg
roof rack removed. time to sand

http://img28.imageshack.us/img28/3383/dsc01276.jpg
headliner removed (oem roof rails consist of 10x 12mm or 10mm bolts that on the inside of the roof skin.

http://img195.imageshack.us/img195/3941/dsc01279y.jpg
shoots some green
http://img39.imageshack.us/img39/2447/dsc01285zj.jpg
quarter end result without clear coat (not sure if i am going to clear it or paint the car flat black)

http://img29.imageshack.us/img29/4/dsc01287ku.jpg
roof sanded (yeah yeah... i didn't take off the rubber strips.. who gives a shit its a beater.)

http://img39.imageshack.us/img39/851/dsc01289q.jpg
sanded..

http://img32.imageshack.us/img32/3053/dsc01290h.jpg
3-tone :-D Flat Black/Green/Outback Grey vinyl

http://img41.imageshack.us/img41/4927/dsc01291i.jpg
2nd coat done.

http://img29.imageshack.us/img29/7862/dsc01295oc.jpg
Repairs finished waiting for windshield and an emissions test.



http://img188.imageshack.us/img188/2540/dsc01313wh.jpg
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http://img25.imageshack.us/img25/1730/dsc01321go.jpg
http://img29.imageshack.us/img29/3993/dsc01311pb.jpg

http://img262.imageshack.us/img262/9137/dsc0257yp.jpg
STi fancy isn't it :lol:

At home parked next to my roommate's GD Outback.
http://img171.imageshack.us/img171/2521/dsc0258z.jpg
http://img510.imageshack.us/img510/9743/dsc0259f.jpg
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http://img543.imageshack.us/img543/2854/dsc0263rq.jpg
http://img638.imageshack.us/img638/1691/dsc0264r.jpg


@ Neetronics w/ Seven's GC8 and randoms.
http://img7.imageshack.us/img7/1594/dsc0035hd.jpg
http://img717.imageshack.us/img717/5076/dsc0036vp.jpg
http://img148.imageshack.us/img148/7703/dsc0041yb.jpg

Winter mode.
http://img233.imageshack.us/img233/2658/dsc01491b.jpg
http://img222.imageshack.us/img222/2825/dsc01492f.jpg
http://img21.imageshack.us/img21/2463/dsc01493vmx.jpg

Engine: EJ22E @ 405,000km !
- STi / SPT air filter
- 2.5" catback w/ HKS burnt tip canister style
- A/C delete (condenser, drier, compressor, etc.) left the evap for lazy reasons
- Optima red top battery
- Group N engine mounts
- Hill-holder spring (replaced with heavy duty spring.. mmm Stage 1 hheeh)

Replaced @ 415,000km
- valve cover seals, spark plug o-rings, oil filler neck o-rings
- cam seals
- crank seal
- rear main seal (RMS)
- Revised metal Oil Separator Plate (Plate of DOOM) + new screws!
- idler pulleys
- Timing belt
- Tensioner
- Water pump
- Thermostat (OEM!)
- Oil pressure switch
- single port exhaust manifold gaskets
- repaired flex pipe between pre & post cat
- NGK plugs & Wires
-

Transmission: 5MT 4.44 FD
- B&M short shifter w/ stay bushings
- Group N 5MT mount

Suspension:
- Subtle Solutions 1" lift kit with extended studs
Replaced @ 415,000km
- New top hats (strut mounts)

Fuel System:
Replaced @ 395,000km
- Fuel filler neck
Replaced @ 415,000km
- Fuel tank :-/

Interior:
- Stainless Steel Gauge Cluster Bezel
- JDM GT center console w/ raised arm rest
- Sti titanium shift knob
- Custom 3" shifter extension
- JDM Nardi wheel w/o airbag
-- No click spring
-- modified steering column cover
- Cruise control delete
- 04' WRX 6-disc (double-din)

Exterior: BG7 Outback
-Antenna delete
-Tint [fronts = 30 / rears = 10)
-JDM taillights (corners)
-DIY center tail light lense blacked out
-Stainless Steel Cluster Bezel (SS Bezel)
-hvac and radio dash panels sticker bombed.. random stuff..
-stickers.. stickers.. stickers.. stickers.. stickers.. stickers.. stickers..
-SLi decals.


Tires:
-Summer = 03' WRX 16" twin 5-spokes w/ Toyo Proxy (205/5/R16)
-Winter = 96' OB 15" 6-spoke w/ Dunlop Graspic DS-3 (205/70/R15)

What broke:
--------------------------------------------
-Real Main Seal (RMS)
-Rear brake lines (BOTH) :shock: ... replaced to the rear proportioning valve...
-ebrake release button.. :smt012 replaced with 04' STi ebrake (modified)
-Fog lights.. several... oh the dumb things I do when I see dirt and hills.
-Exhaust system.. several times .. all with pieced together oem items from random years..
-Clock spring.... Caused all functions to not respond.. No horn.. No airbag.. No Cruise Control... (replaced with nardi wheel)
-Shifter retaining spring

Waiting list:
---------------------------------------------
- Forester Suspension
- Mud tires
- Hella supertones
- Debadged
---

-Chuck

The outback got extensions put in :-p well just one actually.

http://img846.imageshack.us/img846/977/img20120110134636.jpg
http://img818.imageshack.us/img818/9961/img20120110134715.jpg
http://img835.imageshack.us/img835/7969/img20120110164412.jpg

I removed the threaded insert and cut it half way to allow the bottom portion to thread into the shifter and the top portion to thread into the extension.

Overall I am really happy :-D My right hand is level with my left when I drive and the distance from 1/2/3/4 is 5 inches to the right of the steering wheel. Much easier to drive around town :-D

Oh and don't mind the mess.. its my work vehicle.. my other legacy has no interior :-p

------------
7/27/2012 - lifted & overhaul

Decided she needed some serious TLC!

The list:
Replaced @ 415,000km
- valve cover seals, spark plug o-rings, oil filler neck o-rings
- cam seals
- crank seal
- rear main seal (RMS)
- Revised metal Oil Separator Plate (Plate of DOOM) + new screws!
- idler pulleys
- Timing belt
- Tensioner
- Water pump
- Thermostat (OEM!)
- Oil pressure switch
- single port exhaust manifold gaskets
- repaired flex pipe between pre & post cat
- NGK plugs & Wires
- F/L caliper
- rotors & pads all around
- drive side e-brake cable
- gas tank (used from the track car)
- ball joints
- R/L top hat
- Subtle Solution 1" body lift kit (1" spacers w/ extended studs)
- Group N 5MT mount
- Group N engine mounts
- fluids fluids fluids!


http://img27.imageshack.us/img27/4695/20120708202402.jpg (http://img27.imageshack.us/i/20120708202402.jpg/)
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Huffer
09-21-2009, 02:05 PM
Nice!
hallowpoint
09-21-2009, 02:25 PM
looks like you have some work ahead of you. keep that motor goin ej22 ftw!!
chaksq
09-21-2009, 09:23 PM
I was under the impression Outbacks had the EJ25 not the EJ22, I know mine does. Good luck with the car either way, Outbacks are fun.
hallowpoint
09-22-2009, 12:05 AM
^^not in 96
d1giPhux
09-22-2009, 12:46 PM
Nice job on the rust repair man! The rust around the window.. how hard was that to fix up? Definitely wanna see more pics as this progresses!

Btw.. how the other one get totaled? Why you decide on a wagon this time around?
chuckthefuk
09-22-2009, 01:03 PM
Nice job on the rust repair man! The rust around the window.. how hard was that to fix up? Definitely wanna see more pics as this progresses!

Btw.. how the other one get totaled? Why you decide on a wagon this time around?

The Rust:
Basic windshield removal ->> Remove silicon sealer -> Grinding bit with die-grinder and remove all rust -> 180 grit sand paper to prep the areas. -> A few mig welds to fill in the rusted gaps -> some mixed fiberglass to fill in the pits and grooves from sanding -> 240 grit sand -> thin layer of body filler -> sand 240 -> primer -> sand with 320 grit -> then 400 grit -> then base/clear

Its around 5 hours of work once the windshield is removed and the sealer is gone. Not for the faint of heart.

The story: Read first post --> https://sl-i.net/FORUM/viewtopic.php?f=6&t=10911

The Wagon: I'm an IT Professional blah blah blah I work with workstations, desktops, racking equipment, ups's and printers. My BD slowly became... whats the word.. "not street legal" and it made it very hard to transport gear around. Since I joined this forum 2 years ago I have said from the beginning that my BD was going to be a track car and I would purchase a BG/BK for work. When the accident happened I put up a poll on SLi and everyone voted for the BG outback. So thats how it happened.

Will post more pictures tonight. I am going back to the shop after work to finish the sanding and prepping for paint. Unfortunately the rear quarter panel was worse then I expected. Total of 4 nickle sized holes. Anyways till then,.
-Chuck
chuckthefuk
09-22-2009, 01:06 PM
^^not in 96

They did come EJ25D in 96' it just depends on the production date of the chassis.

Example mine was 06/95. If my car were 11/95 it would of had the EJ25D if i am not mistaken.

-Chuck
chuckthefuk
09-28-2009, 06:44 PM
Repairs finished (first post)

Now I have to deal with a wonky steering wheel. It doesn't feel smooth, almost clunky when you turn the wheel. Steering rack? Power steering pump? Bad bushings?

Any ideas before I call my mechanics and bother them once again..
-Chuck
Zac
09-28-2009, 06:53 PM
Nice work man! Where abouts in ontario are you? Maybe you can do the work on my BG! :D:D
chuckthefuk
09-28-2009, 07:08 PM
chuckthefuk
SLi Resident

Posts: 640
Joined: Sun Jun 08, 2008 9:31 pm
Location: Toronto, ON, Canada

I am part time auto body. I am full time IT Professional.. Spare time is rare for me so don't count on anything. My father however is full time auto body but he will not work on RUST. He helped me out since I am blood.

But hey if you get nailed (which I hope this does not happen) feel free to come down to Concord/Woodbridge.

If your around the 401/400 area pm and lets talk scooby.
-Chuck
Matt S.
10-05-2009, 09:32 AM
They did come EJ25D in 96' it just depends on the production date of the chassis.

Example mine was 06/95. If my car were 11/95 it would of had the EJ25D if i am not mistaken.

-Chuck


Chuck, in the US at least, ALL MY96 Outbacks with a 5spd were 2.2s. ALL MY96 with the auto were 2.5s. Similar to when our Imprezas first got the 2.2 in 1995. Autos=2.2, 5spds=1.8 . Also why all of our 1996 Legacy GT's were autos. No 5spd 2.5s in 1996, again, in the US at least.

-Matt
chuckthefuk
01-27-2011, 06:47 PM
minor update..
nikolaus.conrad
08-22-2011, 03:10 PM
They did come EJ25D in 96' it just depends on the production date of the chassis.

Example mine was 06/95. If my car were 11/95 it would of had the EJ25D if i am not mistaken.

-Chuck


Chuck, in the US at least, ALL MY96 Outbacks with a 5spd were 2.2s. ALL MY96 with the auto were 2.5s. Similar to when our Imprezas first got the 2.2 in 1995. Autos=2.2, 5spds=1.8 . Also why all of our 1996 Legacy GT's were autos. No 5spd 2.5s in 1996, again, in the US at least.

-Matt

That explains it, I was under the impression all MY1996 Outbacks came with only 2.5 auto setup, my production stamp is 11/95. Damn.
chuckthefuk
01-10-2012, 07:15 PM
mods list updated.. yay 405,000 km!
mike-tracy
04-20-2012, 07:14 PM
Nice. quick maths conversion - 251k miles. Still got you beat, I'm at 299k miles or 481k km, lol
chuckthefuk
04-20-2012, 07:32 PM
grrrrrrrrrrrrrrrrrrrrrrrrr
mike-tracy
04-20-2012, 08:41 PM
grrrrrrrrrrrrrrrrrrrrrrrrr

In your favor, almost nothing on my car is original, cept for the f'ing 4eat which refuses to die!
Seven Automotive
07-24-2012, 05:36 PM
Oh look ! Its that beat up Outback I rebuilt :-D
chuckthefuk
07-27-2012, 02:36 AM
------------
7/27/2012 - lifted & overhaul

Decided she needed some serious TLC!

The list:
Replaced @ 415,000km
- valve cover seals, spark plug o-rings, oil filler neck o-rings
- cam seals
- crank seal
- rear main seal (RMS)
- Revised metal Oil Separator Plate (Plate of DOOM) + new screws!
- idler pulleys
- Timing belt
- Tensioner
- Water pump
- Thermostat (OEM!)
- Oil pressure switch
- single port exhaust manifold gaskets
- repaired flex pipe between pre & post cat
- NGK plugs & Wires
- F/L caliper
- rotors & pads all around
- drive side e-brake cable
- gas tank (used from the track car)
- ball joints
- R/L top hat
- Subtle Solution 1" body lift kit (1" spacers w/ extended studs)
- Group N 5MT mount
- Group N engine mounts
- fluids fluids fluids!


https://sl-i.net/FORUM/ (http://img27.imageshack.us/i/20120708202402.jpg/)
https://sl-i.net/FORUM/ (http://img37.imageshack.us/i/20120708202405.jpg/)
https://sl-i.net/FORUM/ (http://img651.imageshack.us/i/20120708202408.jpg/)
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https://sl-i.net/FORUM/ (http://img689.imageshack.us/i/20120708202437.jpg/)
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Huffer
07-27-2012, 10:13 AM
Umm... dang. That's a lot of rust work!
chuckthefuk
07-27-2012, 10:31 AM
weight reduction :-D
Zac
07-27-2012, 07:52 PM
Damn those EJ22's are amazing for reliability, I miss mine!

Love the progress keep up the good work!
chuckthefuk
07-29-2012, 02:46 AM
Thanks! I love how I can push her to redline in every gear and she still purrs


Update!!!

Found a set of all-terrain tires (215/75/15) for dirt cheap ($300 = 4 x BFgoodwrench (@7000km) + 4 x Legacy SS 15" rims + 1 x brand new spare) and he threw in a set of used Forester XT struts w/ springs and top hats. The owner had a lifted GD impreza and gave me some useful info about the swap (info from dirtyimpreza).

http://img818.imageshack.us/img818/471/img20120728134145.jpg (http://img818.imageshack.us/i/img20120728134145.jpg/)
http://img594.imageshack.us/img594/1005/img20120728134153.jpg (http://img594.imageshack.us/i/img20120728134153.jpg/)

Apparently since the the height is so drastic just bolting these on will give me positive caster

https://sl-i.net/FORUM/images/imported/2012/07/attachmentphpattachmentid15906stc1d12975-1.jpg

So after a long conversation he told me that I would need the Forester trailing arm bracket to correct the caster back to zero.

http://opposedforces.com/parts/info/20540SA010/

#22 [ '04 Forester left and right trailing arm brackets (PN right: 20540SA000 and PN left: 20540SA010) ]

https://sl-i.net/FORUM/images/imported/2012/07/383494920101png-1.jpg

..

Now the shitty part.. well the most expensive part

Extended endlinks or adjustable endlinks in order to have sway bars..

..

While trying to figuring things out I came across some threads that have said that the springs and perches are wider then GD/BG and may rub the wheel wells.. BUT. I have already added the 1" spacer kit w/ extended studs so this should eliminate any clearance issues.

Here is the thread from dirty impreza.

http://www.dirtyimpreza.com/forums/show ... hp?t=24190 (http://www.dirtyimpreza.com/forums/showthread.php?t=24190)
http://www.dirtyimpreza.com/forums/show ... hp?t=25287 (http://www.dirtyimpreza.com/forums/showthread.php?t=25287)

..

I know the disadvantages of moving towards the offroad direction...:
- road noise = wont be louder then my HKS exhaust
- fuel mileage = don't give a SH%T
- speed vs tire size = I don't use my speedo I look at my scan gauge and it has a +% / -% value for speed adjustments :-D

BUT... this will allow me to add the following: <-- future want-to-buy list
- Skid Plate
https://sl-i.net/FORUM/images/imported/2012/07/skidplate_unbolt-1.jpg

- Brush Gaurd
https://sl-i.net/FORUM/images/imported/2012/07/IMG_7025JPG-1.jpg

- Hella 500 fog replacements + 4 for the roof light bar
https://sl-i.net/FORUM/images/imported/2012/07/76110-1.jpg

- roof light bar
https://sl-i.net/FORUM/images/imported/2012/07/DSCN3615-1.jpg

- Roof Basket
https://sl-i.net/FORUM/

.. I'll update the OP when I add these items.

Till next time
-Chuck
chuckthefuk
08-27-2012, 01:55 PM
Showed up at the Toront-Subaru-Club.com Hyper Meet with my friends Vendor booth. Decided that in order to be show worthy it was time to step it up and go off-road. Funny thing is that more people checked out my outback compared to our 400+ AWHP monsters parked next to me :-D..

https://sl-i.net/FORUM/

https://sl-i.net/FORUM/

https://sl-i.net/FORUM/

https://sl-i.net/FORUM/

https://sl-i.net/FORUM/

Specs are :
Front 06' FXT struts/springs/upper perch - 96' BG top hats w/ Subtle 1" spacer
Rears 06' FXT struts - 96' BG springs/upper perch/top hats w/ Subtle 1" spacer
---> 06' FXT trailing arm brackets (to correct caster)
BF Goodwrench All-Terrain 215/70/15 on BG 15"
chrish8r
08-27-2012, 09:25 PM
I love it when Legacys get more love at shows than the WRXs and STIs. I really like the lifted and beefy tire look.
chuckthefuk
08-27-2012, 10:37 PM
Thanks!! unfortunately when I play I always seem to pay :-( Took out a brake line when I was transporting a 5MT and random parts in the back.. the rear end was almost tucking and well lets just say my brake line repair job from last year was not the tight to the chassis... I hate when the brake pedal hits the floor.

-Chuck
nikolaus.conrad
02-19-2013, 10:41 PM
Any updates on your car Chuck?
chuckthefuk
02-19-2013, 10:53 PM
Well this happened.
http://img543.imageshack.us/img543/4448/img20130124200109.jpg

and then that caused this
http://img197.imageshack.us/img197/174/img20130124203855.jpg

and that got fixed.. and now my 3rd & 4th synchros are going :-(..

.. but all in all shes a champ.. no other mods to report.. just having a blast in the snow
nikolaus.conrad
02-20-2013, 09:51 AM
Oh damn, well as long a she's getting you places then that's all that matters right?