Club 80-90 Forums

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Exhausting work For the exhaust I started with the original Subaru manifold and front pipe with cats. Much choppy choppy and hot metal gluing later and we have something which resembles an exhaust, maybe I'll get remade in stainless one day, but not today. Silencer to complete once all installed. U...

Custom Sump Made my own sump which has the same oil capacity as the original but is reduced by 60mm in height. Made from 2mm Steel to give it some longevity and allow some good hot welds to be applied. Dipstick in original position and retained the original internal baffles too, pickup pipe was sho...

Engine out and cleaned up then in The engine was removed from the Subaru legacy donor vehicle along with the full wiring loom. The bolt on bits including the inlet manifold where them removed and give the usually treatment of clean, inspect, replace seals and repaint before re-assembly. https://i.i...

Progress updates....gearbox rebuild . Time to overhaul the gearbox and install the Subaru bell housing from RJES. No major issues here, had to make some tools for removing the stub axles and the main locking ring for the pinion gear/shaft. https://i.imgur.com/XJE53nd.jpeg https://i.imgur.com/xFN1tM...

A VPN works for me to make the pictures visible... The project is still alive, but haven't updated here for ages. The engine is in and complete, wiring nearing completion and and all running gear is done. Currently in process of modification for the dashboard to accept the Subaru dash cluster assemb...

Also worth mentioning I have 2 slave cylinder pushrods, these are the original and a new replacement. Slightly different lengths, neither allows for full disengagement. The slave master cylinder has been checked, the pushrod and nut allow for a small amount of slack before pushing on the cylinder, I...

Hi All, I have been trying to get my clutch to release on my conversion, ej20 engine, RJES bellhousing and release bearing, VW clutch disc. Initially the problems were from the clutch bracket bending and not allowing the clutch release arm to travel enough, I have checked the arm position on the tee...

Perfect I will blank it off. thanks both for the info.

Hi All,

What have others done with the fuel breather line on their Subaru conversions?
The EJ engine has fuel feed, return and breather connections.

Blank off?
Tee into VW breather setup?
Leave open to atmosphere?

Thanks

I checked the Subaru hose, definitely just a hose with nothing inside, suspect it is part of the servo in that case..
Anyhow I will proceed with the VW valve.

Hi All, Original van engine 1.9dg had a one way valve on the vacuum line at the engine. The Subaru EJ engine removed from donor vehicle did not have a valve, direct to servo from manifold. Do people tend to fit a valve anyway or will it work without, I'm not certain on the operation/protection the v...

Hi All, I'm not convinced I have set my gear linkage up quite correctly after a gearbox rebuild. All gears select fine (including the detent spring for 1st/reverse) but the natural position the gearstick sits in appears to be 4th/5th gate, this is due to the spring pressure on the selector shaft wit...

This is an amazing restoration,fantastically documented. You are doing an amazing job . It’s fantastic to see how bad the van was at the start and how well you have made the repairs. Thank you for taking the time to share all this valuable information. Can I ask what your background is , how did yo...

@Irishkeet -  to remove the underseal, paint and rust was a combination of tools. Underseal (the thick rubbery VW stuff) Propane Blowtorch to heat it up then various scrapers to remove. Old Cavity Wax Same process as underseal Old Paint and rust 13mm electric Belt Sander from screwfix Flapdiscs, 40g...