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Thread: rkrenicki's 1992 Subaru Sambar SDX - 2021-05-07 - Stirring from slumber...

  1. #121
    Th3 EviL OvErLORd Reason's Avatar
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    Quote Originally Posted by rkrenicki View Post
    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.
    Attachment 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.
    Attachment 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.
    Attachment 2478
    Attachment 2479
    Isn't that in your line of sight?
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  2. #122
    Administrator rkrenicki's Avatar
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    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.

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    Alright Sounds good
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  4. #124
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    http://www.duncanimports.com/used/Su...9c1a13f0c9.htm

    You could a Sambar fire truck to your collection

  5. #125
    Administrator rkrenicki's Avatar
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    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...

  6. #126
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    Yeah, that place has a lot of really cool imports. But all of them seem overpriced by a good amount.

  7. #127
    Administrator rkrenicki's Avatar
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    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)


    Dyno graph
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    Code:
                          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..

  8. #128
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    Engine upgrades?? YES!

    This thing is a BEAST

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  9. #129
    Administrator rkrenicki's Avatar
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    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
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    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.
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    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.
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    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.

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    Wow! You're going to have a brand new Sambar pretty soon by the looks of it!

  11. #131
    Administrator rkrenicki's Avatar
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    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.

  12. #132
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    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.
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  13. #133
    Administrator rkrenicki's Avatar
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    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.
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    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.
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    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.
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  14. #134
    Administrator rkrenicki's Avatar
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    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.
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    I think they look pretty good once installed.
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    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
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    And this is the output of the Low beams
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    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.

  15. #135
    Administrator rkrenicki's Avatar
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    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).

  16. #136
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    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.
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    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.
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    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..
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    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.
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  17. #137
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    Quote Originally Posted by rkrenicki View Post
    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?
    Legacys are like potato chips-You can't stop at just one!

  18. #138
    Administrator rkrenicki's Avatar
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    That is indeed the plan. I have my ticket and he is registered for the car show as well.

  19. #139
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    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)
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    Here is the bar itself attached.
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    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.
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    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.
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  20. #140
    Administrator rkrenicki's Avatar
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    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
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    New Wheel
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  21. #141
    Administrator rkrenicki's Avatar
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    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
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    With lens, and before/after. Aluminum tape on left, original on right.
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    Rain Visors installed.
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    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
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    New Carpet and trims
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  22. #142
    Administrator rkrenicki's Avatar
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    I also managed to locate a proper Double-DIN install kit, so I no longer have a gap around my radio.
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    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.
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    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.
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    I still need to deal with the wiring for all of the lights, which I hope to take care of this weekend.

  23. #143
    Administrator rkrenicki's Avatar
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    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.
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    Lights mounted.
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    And Lights tested!
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    I do have a few more packages from Japan on the way, and I hope to have them in time for WBM..

  24. #144
    SLi Resident thenines''s Avatar
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    Maybe it was done for the "smoke" effect-thought, it is more common for head and tail light lens
    Legacys are like potato chips-You can't stop at just one!

  25. #145
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    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.
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    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.
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    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.
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    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.
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    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.
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  26. #146
    Administrator rkrenicki's Avatar
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    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.
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    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.
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    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!
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  27. #147
    SLi Resident thenines''s Avatar
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    you had a lot of competition-well done!
    Legacys are like potato chips-You can't stop at just one!

  28. #148
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    Congrats on the award, its coming along great.
    4Zero1 Motorsports

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  29. #149
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    Well done. You have put in a ton of hard work and you deserve it.

  30. #150
    Administrator rkrenicki's Avatar
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    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.

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