1991 Legacy sport into Legacy RS Type RA Spec bare shell complete rebuild
 

Hi, I have trouble keeping up with all my threads already but this build is a big one so I can post over time. I will start off by telling you why I chose a Legacy as the most serious and complete build project I have ever done. The whole Subaru interest started for me because I worked for a Subaru Dealership in New Zealand and I carried out my apprenticeship there. Fortunately for me my employer was a well known race car driver ( who my dad had built racing engines for) so I was very actively involved in his motorsports activities which led me to work on a Subaru Legacy RS in races and Rally's throughout N.Z and also worked several events with Possum Bourne who was a well known Subaru driver with a full spec Group A prodrive Legacy. He co drove our Legacy with Trevor in Street races in the NZ touring car series for a few events.

Anyway years gone by and I found this old Legacy sport in Texas and really wanted to buy it as seeing it reminded me of where it all started and I really like those good old cars
Here's a few old photos of the Legacy I worked on and Possums Group A legacy which I spent one weekend at the Local track while he ran it. It also stayed at our dealership for a while.

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The legacy arrived and was in way worse shape than I expected so I did a lot of work to it.
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The repair of the legacy photos
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Well, this is really just the beginning of the story, I will continue again soon :)

oh cool you're from monterey. I think you know my friend Jody

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awesome! subscribed.

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Looks sweet! im interested in this.. Subbed!

[QUOTE=mrruins;3296308]awesome! subscribed.[/QUOTE]

Thanks, the story is far from over yet. As you can see I did a heap of work and replaced all the belts and hoses and all the cambelt pulleys. I made a short throw shifter and bought all new trim pieces for around the windows. The car was starting to Klondike.
Here are a few Legacy Rally pictures
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This is really how I remember the Legacy.... As a rally contender!

Ok Guys, this is really just a glimpse into the past here, I was contacted by one of the Legacy Forums and asked if they could do on online magazine article on this car
So here is a little fast forward glimpse into this project ...... But it's still very far from over at that point..... Much yet to be told
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At this point I have rebuilt the Turbo, replaced almost all the belts and hoses, Fit new Exterior trim pieces. Fit new Grill and rear Garnish. Fit slotted brake rotors, stripped out the interior and resprayed the vinyl with an airbrush which works extremely well
Fit brand new OEM muffler. Replaced all the door seals, and fit a new radio DVD player.
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*
Interior:
·******** Momo Cobra three spoke steering wheel
·******** RA specific seat fabric (velour inserts the same as RS)
·******** Low grade headlining
·******** Deletion of passenger visor vanity mirror
·******** Manual windows (RS – power windows)
·******** Manual locking (RS central locking)
·******** Air conditioning – factory option – none climate control version (RS – climate control)
·******** Addition of rear scuttle brace (TBC)
*
Exterior:
·******** Rear spoiler deletion
·******** Rear windscreen wiper washer deletion
·******** Black side skirt deletion
·******** Black, manual adjustment side mirrors (RS power mirrors)
·******** Manual radio aerial – located at top of right A pillar (RS power aerial – rear left flank)
·******** Blue tinted glass (RS Bronze)
·******** Paint colours:
o*** Type A: Ceramic white#57
o*** Type B: Ceramic white#57
o*** Type C: Feather white#30
o*** Type D: Feather white#30* or Black mica#52
*
Engine:
·******** Internal:
o*** Hand built / blue-printed engine by STi
o*** Crank shaft, flywheel and clutch cover - balanced and hand finished
o*** Cylinder heads and intake manifold *- hand finished / casting lines and gaps removed / polished
o*** Forged pistons
o*** Forged connecting rods
·******** Turbo (TBC):
o*** Turbine rotor diameters（in/out): 52.5 / 46.5 (RS: 52.5 / 43.0)
o*** Compressor Impellers diameters（out/in): 56.0 / 45 (RS: 56.0 / 41.2)
o*** Maximum boost pressure: 450 Hg (RS – same)
o*** Intercept point: 2,800rpm (RS: 2,400rpm)
o*** Turbine blades: 10 (RS: 9)
·******** External:
o*** Gold painted cam covers
o*** Gold painted intercooler reservoir
o*** Intake manifold cover - deleted
o*** Twin electric radiator fans (larger capacity than RS)
·******** Output:
o*** Power: 220 PS @ 6,400 rpm (RS: 200 PS @ 6,000rpm)
o*** Torque: 27.5 KG m @ 4,000rpm (RS: 26.6 KG m @ 3,600rpm)
*
Transmission:
·******** Close ratio gear set (Types B – D only)
*
Chassis:
·******** Aluminium sump guard – custom sub frame mounting bracket and side splash guards (plastic)
·******** Deletion of under body sound deadening
·******** Hardened bushes (STi grade - except rear differential mount, trailing arms, and stabilizer bars)
·******** Hardened coil springs (measure is: KG / mm) – Front: 3.2 / Rear: 2.85 (RS: Front: 2.51 / Rear: 1.89)
·******** Revised damper rates (measure is: pull/push and 0.3m/sec) – Front: 190 and 140 / Rear: 130 and 85 (RS: Front: 126 and 31 / Rear: 82 and 25)
******** Adoption of an advan "GROVA" high grip tyre
·******** Quicker steering ratio / rack
·******** Deletion of driver / switch operated ‘variable assistance’ power steering
·******** Deletion of ABS system
*

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Here is a little about the real legacy RSRA

Built list is Amazing man!!!