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Old 04-01-2009, 01:28 PM   #1
dangerousatom
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Location: Quakertown/AREA1320 391whp
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2002 04STi Swaped RS
w/PPGS & 02 Wagon w/PPGs

Default Dangerousatom's new turbo crap box "91 Leg SS"

- 91 Legacy 2.2L Turbo 165k
- AWD Auto......swapping in a 06RS Manual due to teh Autos clutch packs are blown


The car is getting teh full motor rebuild clean up and once over minus piston rings. It is unbelievably filthy ( the motor looks like its covered in greasy brownie batter ) It is leaking from just about every seal that is oil related . I have already gone through a gallon of Simple Green and Purple Power

















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Last edited by dangerousatom; 04-01-2009 at 01:36 PM.
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Old 04-01-2009, 01:29 PM   #2
dangerousatom
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w/PPGS & 02 Wagon w/PPGs

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Old 04-01-2009, 01:30 PM   #3
dangerousatom
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w/PPGS & 02 Wagon w/PPGs

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Old 04-01-2009, 01:33 PM   #4
dangerousatom
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w/PPGS & 02 Wagon w/PPGs

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Auto Trany is out ( what a boat anchor!! ) and the bay is still quite filthy





After about a gallon of paint thinner and then a gallon of simple green it was finally clean!!




Cut the bumper beam out and mounted up the home brewed FMIC.....I'll finish the pipe routing after the motors is back in



Last edited by dangerousatom; 04-02-2009 at 04:05 PM.
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Old 04-01-2009, 01:34 PM   #5
dangerousatom
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2002 04STi Swaped RS
w/PPGS & 02 Wagon w/PPGs

Default

2004 Impreza SOHC Heads......unbelievable valve size difference from the 91 Leg Turbo heads



All new H2O and oil pumps - Timing Belt Kit - WRX H2O cross over pipe - home made upper and lower UHMW 1/8" intake manifold gaskets
When swapping over from the 91 turbo heads to the newer 04 SOHC heads the issue of intake manifold bolt patterns became obvious. The old bolt pattern is smaller and tighter than the new TGV type manifolds. Therefor a WRX - STi - Leg GT TGV type manifold was needed. In addition to finding that out there were some throttle body issues as well. I had hoped to continue the use of the 91 Legacy SS throttle. It does bolt on, but the linkages hit the intake runners and the cables need to be pulled form a directions that can not be hard mounted......so a WRX throttle body was need. None of the sensors are wiring plug compatible, but they are not necessarily needed for OBD1 either, in exception of the throttle position sensor. The old sensor is for the most part "same same" in mounting and mechanical turning connections as the WRX....minor mounting location modifications where needed.


WRX Alternator & Power Steering Pump......stock AC Compressor will not fit with new intake manifold....will have to get WRX compressor

WRX Header & UP .......the UP needed modification ( 1-1/2"-2" addition to the length and minor angle articulation for proper turbo mounting ) due to the SOHC Heads




Transmission - Clutch Master & Pedal Set are in



WRX Cat Back - Shorty DP and custom extra long flex connection ( where the CAT would be ).....oops!! need to get the rite pic in here



I had some minor hick-ups with the drive line conversion Luckily I had a 04 RS rear to swap out the connections The 91 Leg rear is not a square bolt up, and due to the shorter length of the manual trans I needed to get a drive shaft extension.....this could have been quite a nightmare!!



Installed!!


Last edited by dangerousatom; 06-18-2010 at 11:38 PM.
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Old 04-01-2009, 01:44 PM   #6
02fastWRBLUE
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siqqqqqqqqqqqqqqq
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Old 04-01-2009, 01:46 PM   #7
scrape
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sweet project, im definitely a fan of the older legacy.
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Old 04-01-2009, 03:23 PM   #8
Aaron'z 2.5RS
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Dude, this is SWEET...


Your pics also allowed me to better understand where my coolant leak is and what I need to do to fix it.. (first pic, post #5) The little extension off the coolant crossover pipe, I would guess there is just an O-ring in there.. THANKS..!!

Oh, you plannin on painting the FMIC? totaly stealth mode.. lol..
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Old 04-01-2009, 04:12 PM   #9
blakkboxer
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nice project. annnnnnnd Subscribed!
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Old 04-01-2009, 04:25 PM   #10
vik_wrx
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WRB

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Wow nice project man !
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Old 04-01-2009, 04:27 PM   #11
JC
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One word. Awesome.
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Old 04-01-2009, 04:52 PM   #12
dangerousatom
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w/PPGS & 02 Wagon w/PPGs

Default

Thanks guys....

Hope to be on the road in a week or two, as long as I dont have too rich a fuel mix. The old side feeds are 300cc the WRX top feeds are 380cc. I dont feel that it will be too much of an issue. Its nice to find out the old side feed wiring plugs are the same pattern minus the guide barbs ( slicing them off the top feeds ) to accommodate the old harness. Hopefully I wont have to swap +/- wires around even though its a 180 flip from side feed plug to top feed plug.......I'll have a few pic's to better explain the scenario
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Old 04-01-2009, 04:54 PM   #13
White out
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Great build!

What turbo are you running, VF11, or bigger?

Nick
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Old 04-01-2009, 05:10 PM   #14
dangerousatom
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w/PPGS & 02 Wagon w/PPGs

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Stock WRX TD04 The stock VF11 is in good shape with 168k but I had a TD04 with under 25k so it was a no brain-er.....more efficient and more boost 12-15lbs Its going to be a daily beater. . . . . I have a good car for big boost:


http://forums.nasioc.com/forums/show...t=swap&page=12
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Old 04-01-2009, 05:27 PM   #15
shadowmd
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nice project...!
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Old 04-01-2009, 06:25 PM   #16
sparspecker
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It's odd to see the charged air go straight from the turbo to the intake manifold.
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Old 04-01-2009, 06:31 PM   #17
pearljam11
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looks great that'll be a nice sleeper!
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Old 04-01-2009, 06:39 PM   #18
turntable
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awesome build!

can't wait to see more pics as time goes on
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Old 04-01-2009, 09:02 PM   #19
rice h8r
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Wait so what are you using for rear diff and driveshaft? GL finishing up the project.
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Old 04-01-2009, 09:07 PM   #20
grippy monkey
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coming along really nice man!
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Old 04-01-2009, 09:20 PM   #21
fzel07wrx
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props to you for pulling through that leaky engine, the results are looking great!
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Old 04-01-2009, 09:57 PM   #22
naggg
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wow that looks like a whole bunch of work. all fun tho i bet!
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Old 04-01-2009, 10:56 PM   #23
Flat4TW
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nice restoration
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Old 04-01-2009, 11:03 PM   #24
ReubenH
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Great work. Pitty you didn't stick some more "exciting" heads on there though
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Old 04-01-2009, 11:43 PM   #25
dangerousatom
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w/PPGS & 02 Wagon w/PPGs

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Quote:
Originally Posted by rice h8r View Post
Wait so what are you using for rear diff and drive shaft? GL finishing up the project.
97-98ish Forester drive shaft from the look of what I pulled it out of at the junk yard

Rear Diff is the stock 91 Leg SS.......the 90-93 Legacy SS auto's and oddly enough manuals too where 390:1 final drives and the 06RS manual trans is a 390:1 as well. I have already made sure the final drive ratios are same same on top of spinning the drive line numerous time after getting things all connected.

I should mention as well:

The installation of the 06RS trans into the 91 auto was not as difficult as I was assuming it would be. The newer Subaru transmissions ( 05-ish I believe was the switch year ) went to axles that inserted into the trans but the older transmissions where with front studs/splines for axle connection. All that was needed to be done was to pull the front studs from the old 91 auto trans and insert them into the new 06 with the "C" clips in place...... like popping in 05 and up front axles. Older style transmission seals where needed to take up the gap around the front studs ( the seals exterior diameter has remained the same, its the inner hole or axle/stud size that changed to about 1/8" larger)

The 91 leg transmission is a cable driven speedo and the 06RS is an electronic but they both work in the same fashion. ( cable driven = speedo turns a flat key that connect to and spins the cable . . . electronic driven= speedo turns a magnet that in-turn is picked up by the electronic sensor ) So all that is needed is the guts/sensor from one to go into the other.....thread patterns are same same.

Last edited by dangerousatom; 04-06-2009 at 03:13 PM.
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