Photo journal - Subaru conversion

[Fin]

How does the system exit on the naturally apirated ones?

I have a full Turbo Exaust system in 2.5 in pipe ready to bolt on with a nice big silencer - if it'd fit...

[Dazco]

Think I'm gonna be on the lookout for a doner car sooner rather than later.

[bradders89]

Come on pull yer finger out. Suns been out all this weekend .

I'd have to take your word for that - we were in Portugal for 5 days - the sun was definitely out there!

Hoping to get something done this weekend. I have the same rubber mounts from ebay - as well as a rubber sleeve between the mount and the pump - hopefully will keep things quiet.

Still not sure about the exhaust - was thinking of just getting the RJS system, but they're not in stock, and no date for when they will be...
Was considering getting something welded up using the Scooby manifold and the original VW box as a temporary measure - any thoughts?

James

I had a temp exhaust made up for my van using the subaru manifoid. I turnt the manifold so it was facing the back of the van then just had a box welded to it. It worked tempory but was as noisey as hell. Did think using the std vw box and connecting the subaru manifold to it woulda been a quieted bet. The manifolds do hang abit low but as a temp exhaust it does work.

[jmdlister]

Finally got round to loading a few more photos...


Scooby in place at last - with a little help from a friend and a simple ratchet winch over the engine bay.

Dsc_8516.jpg

New cone air filter and MAF mounted on RJES supplied bracket. Behind the air filter is the ECU. This will need to be weather-proofed, as I have ignored the advice not to put it in the engine bay!

Dsc_8603.jpg

Expansion tank relocated on right side of engine bay, mounted on new bracket. Should probably get a new cap really...

Dsc_8602.jpg

[jmdlister]

... and finally, almost everything in place now except the exhaust...

Dsc_8604.jpg

Wiring is all in place. New fuel pump and filter installed. All coolant pipes connected. All it needs now is some oil (and a new filter), some coolant, and some petrol, and an exhaust system! Then it will be time to connect up the battery and see how many error codes I get.

[Dazco]

Looking good that .what error code reader are you using ?

[Fin]

Looking good

I got a couple of weather proof boxes for my ECU's and mounted them in the bay....

http://www.facebook.com/photo.php?fbid= ... =3&theater

[jmdlister]

Looking good that .what error code reader are you using ?

I'm planning just to count the engine management light flashes (malfunction indicator lamp) if that works OK - if not I'll be looking for a code reader.

James

[jmdlister]

Looking good

I got a couple of weather proof boxes for my ECU's and mounted them in the bay....

http://www.facebook.com/photo.php?fbid= ... =3&theater

Looks neat (actually, the whole thing looks pretty amazing!). Where did you get the boxes, were they purpose made for housing ECUs?

James

[Fin]

Got them from Maplin, they're fire proof and water proof

[jmdlister]

Gave up trying to find someone to weld together the various bits of exhaust/mainfold, and ended up buying a Clarke MIG welder and doing it myself. Probably too embarassed to post pictures of the results, but I think it's all fairly solid.

Since the sump was "glued" on with sealant, I decided to look for an alternative point to hang the rear box off. In the end, I went for the spare power steering pump bracket, bolted a 4mm steel plate to it, and welded some more plate to the seam of the back box. I think it will be stronger than anything hanging off the sump anyway.

Just a few bits and pieces to do now before trying to start her up. Won't be this weekend as I'm away in Milton Keynes, but hopefully next weekend will be the moment of truth,...

James

[Tel87]

Hi Fin
How much will your Insurence go up by doing this convertion ?

[Fin]

Mine was £315, I've got it on a limited milage policy for just under £500

[jmdlister]

Finally got the thing started yesterday! It fired up immediately, which was very satisfying. Ran it for about 5 minutes, then the engine fault light came on, and started to run rather rough. Turned it off, and connected the black test connectors, and read a fault 24 (By pass air control valve). Started it up again, and same thing happened but a bit quicker this time. Today I've been running it a few more times (trying to bleed the cooling system), and the error hasn't come back, so hopefully all will be well. It has been suggested that this fault can be cured by fitting the speed sensor (I was waiting to see if I needed it, so haven't got one yet), so I may have to do that.

Apart from that (and some small leaks in the exhaust system I built), the biggest problem seems to be getting the coolant into it. I've been following the RJES instructions, but the water in the header is refusing to go down much. So far I think I've got about 7 litres into it, but it's supposed to take 15 at least, and it's taken me half a day to get that much in. Tempted to run it till it gets hot enough to open the thermostat, but nervous about getting it that hot with not much coolant in it. Any suggestions?

James

[mrmule]

Silly question, but are you bleeding it from the top of the rad at the front?