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22B05STI 09-22-2012 10:29 PM

1991 Legacy sport into Legacy RS Type RA Spec bare shell complete rebuild
 
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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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22B05STI 09-22-2012 10:43 PM

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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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22B05STI 09-22-2012 10:49 PM

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The repair of the legacy photos
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22B05STI 09-22-2012 10:53 PM

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Well, this is really just the beginning of the story, I will continue again soon :)

bkblitzed 09-22-2012 11:08 PM

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

22B05STI 09-23-2012 02:00 AM

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mrruins 09-23-2012 02:05 AM

awesome! subscribed.

22B05STI 09-23-2012 02:07 AM

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theoutbackdream 09-23-2012 02:11 AM

Looks sweet! im interested in this.. Subbed!

22B05STI 09-23-2012 02:21 AM

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[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!

22B05STI 09-23-2012 02:34 AM

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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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22B05STI 09-23-2012 08:30 AM

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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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22B05STI 09-26-2012 07:39 PM

*
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
*

22B05STI 09-26-2012 07:45 PM

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Here is a little about the real legacy RSRA

theoutbackdream 09-26-2012 07:48 PM

Built list is Amazing man!!!

22B05STI 09-26-2012 07:52 PM

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And here is a real RS Type RA in New Zealand
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LEGACY RS type R & type RA

●RS-R
The debut of first Legacy was the end of January, 1989 (February 1 release). The turbo car was only sedan RS of 5MT at first.
In October, the same year, RS-R is added in accordance with a debut of GT which is a turbo car of a wagon (and 4AT version of sedan RS).
It is written with "a basic grade model of RS which is suitable as the material of a competition car for motor sports" and a new car commentary book.


RS-R、Atype
●RS-RA
 In November, '89 (December 1 release), pure competition car base for motor sports, RS-RA of a STi tune appear.Therefore the position of RS-R became considerably vague debut two months later.
It is written with a new car commentary book with "the order production RA memory model that executed engine fine-tuning same as the challenge car that 100000km speed records RS-R in a base."

RA seems to mean, 100000km speed record challenge "RECORD ATTEMPT" instead of RA of Rally.
(There is an opinion that RA means "Race groupA")

RS-RA put a fine tune to a rally and a dirt trial competition to be based on RS-R more.

As for the engine, forging piston and high resist pressure connecting rod metal are built in, and, as for the intake port and exhaust port, it is revised gap and polished up.
A crankshaft and the flywheel which got of balance are mounted the car with.If it is a beginner's class level, suspension is strengthened to the rank who can participate as it is.Variable ratio power steering is important, too.As for this, the steering gear ratio becomes quick.

Without close ratio transmission, it was announced as 100-limited model at first.Actually, seem to have continued job-order production of 20 monthly productions.
Long-awaited close ratio transmission was carried than a B type from May, '90, and increased with a catalogue model.

Engine specifications do not change from a latter period model C type, but ECU becomes 16bit, and a torque up in middle low rev .(be said by an emission control that became mild) and continued to exist to the last D type, and handed over a duty of RA of legacy to impreza WRX-RA with full model change-over, and the grade of RA disappeared from legacy.


↑100 limitation,A-type

↑close ratio transmission, B-type

↑After minor change model C-type

↑Last model D-type
Engine
RS-R
 The engine & Transmissions are the same as RS.

RS-RA
based on RS-R and handcrafted RA tuning same as 100000km speed record car(RA:RECORD ATEMPT)

crank shaft, flywheel and clutch cover hand finish balance
induction system(cylinder head、intake manifold) hand finish repair gaps and polishing
A gold Alumite treatment surface cam cover
A intake mani-fold decoration cover abolition
An inter air conditioner case special color
A forging piston
forging kelmet high resist pressure connecting rod metal
A double radiator electric fan
close ratio transmission from B type
engine performance curve

→ Traveling performance curve of RS



GT RS
Maximum power PS/rpm
Maximum torque kg・m/rpm
200/6000
26.5/3600
220/6400
27.5/4000
Turbine rotor diameters(in/out)
compressor Impellers diameters(out/in)
Maximum boost pressure
Intercept point
number of blade 52.5/43.0
56.0/41.2
450mmHg
2400rpm*
9 52.5/46.5
56.0/45.0

2800rpm
10
■CHASSIS
●RS-R

Hardened coil spring,damper and bush(equal with STi product)
(except rear differential mount, trailing arm rear side, a stabilizer)
Adoption of three spoke steering MOMO "COBRA"
Adoption of an advan "GROVA" high grip tire
The abolition of steering assist power change over switch
●RS-RA
 Difference with RS-R

A variable quick power steering
 gear ratio  In going straight:15
 (over all)  In full steering :13
Hardened coil spring、 damper
The level that can just participate in an intermediate class rally
Hardened bush(equal with STi product)
(except rear differential mount, trailing arm rear side, a rear stabilizer)
Suspension

GT
SEDAN
GT
WAGON
RS
RS-R
RS-RA
Spring rate
(kg/mm)




2.5-2.8 2.3
2.51
1.89
2.63
2.17
3.2
2.85
Damper damping force
(pull/push 0.3m/sec)


126/31
82/25
126/31 82/25
146/97 112/74
190/140 130/85
Stabilizer
(external diameter-mm)


17?
19?
18
18
17
19
■Body color

Apride model→ A B C D
RS-R Ceramic white#57
Dark blue#56 Ceramic white#57
Indigo blue-M#13
Black mica#52

RS-RA Ceramic white#57 Ceramic white#57 Feather white#30 Feather white#30
Black mica#52

Above is some info I was given a link to on the Internet.

22B05STI 09-26-2012 08:41 PM

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Ok so here it is...... This is where the project turns
I bought a EJ20 engine that came direct from STI in Japan and was a development engine sent to the U.S.A the project never happened. It was said to be a works WRC engine.
The Subaru Legacy was on the road for three weeks at this point, and we were about to go to Indianapolis for the month of May so I could work for one of the teams for the Indy 500.
The Legacy was going to have bumper covers painted while we were gone, the person that was going to paint the bumpers decided to paint the complete car as he said paint match would be difficult, so after talking with my Dad regarding this he went ahead and stripped the car for painting.....
So I came back to a legacy that looked like this
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22B05STI 09-26-2012 08:42 PM

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Once I saw the car stripped for painting, I decided to go all out and Fit the EJ20 Engine, remove the Sunroof as it was leaking.That was really how this build project began, I started to contact people in N.Z regarding parts and continued to research The Legacys and that was when I decided to source parts and build a Legacy in RS type RA specs
I found that Original Group A Legacy roof vents were Available, so I decided that when I filled the roof panel, I would have Bruce Terry from Specialty Metal Fabrication who was doing the Filler panel, fit roof vents also.

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Above is the Legacy dropped of at Bruces shop
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22B05STI 09-26-2012 09:08 PM

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Here is the Legacy the day I stripped the car out to a shell, I was already partially stripped out.
On A side note, the guy that was going to paint the car had just painted a Mercedes and It was a very very poor quality paint job, at that point I realized he was not a good painter, so I was now searching for a person to paint the car. It was disappointing but fortunate to find out before he painted my car.

22B05STI 09-26-2012 09:19 PM

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Now for the next small disappointment, although not big, the EJ20 Engine the was from STI was not A full spec Rally engine it was amazingly an early RA engine with hand ported cyl heads, as well as a second set of bare heads ( not ported ) this same engine was actually in The Legacy RS Type RA. For this project it is actually much more suitable for my needs and furthermore amazing to have the correct Engine For a Legacy in RS type RA specs. Really it could not have worked out better.
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fuzzypanda187 09-26-2012 09:27 PM

everything i want....you has......=p

22B05STI 09-26-2012 10:12 PM

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New Rods for EJ20
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BlackSheep 09-27-2012 07:49 PM

what an amazing build!!!!

22B05STI 09-29-2012 08:44 PM

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Once the parts were stripped from the shell I spent several weeks removing the underseal and sound proofing material. This has removed a lot of weight ( the RS type RA does not have the underseal either )

22B05STI 09-29-2012 09:05 PM

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During this part of the project I was working on a race engine for a Lotus cortina and I talked to the owner regarding his company (Kaminari) and he told my about Ray of DRC race craft and his Subframes, he bought one of Rays Subframes when he came to pick up his Cortina so I could take a look at it, which was before the first Sema show and I was very impressed with his work. I plan on fitting Front and rear Subframes from DRC to the Legacy.
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22B05STI 09-29-2012 09:20 PM

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Now the thread is nearly up to date, I had a friend of mine seam weld the Shell for me and I will be welding in bosses for WRC style car stands. I have also got one of DRC race craft front Subframes to check fit into the Legacy. This Subframe is actually designed for a Subaru Impreza however it has all the same pick up points as the Legacy.

The Rotissorie I bought for welding
On the shell
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The DRC Subframe installed
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Dominator 10-03-2012 02:34 PM

This build is awesome so far. Thanks for sharing all the pictures.

LOL_VTEC 10-03-2012 03:00 PM

So new Zealand gets that nice legacy and north America dosent?

22B05STI 10-07-2012 09:09 PM

[QUOTE=LOL VTEC;3300181]So new Zealand gets that nice legacy and north America dosent?[/QUOTE]

New Zealand has so many rare and valuable special models that we dont have here, like the spec c rar, the s204 03 02 etc & the soberg edition impreza, all the rare version Legacys and foresters. The only problem I would say with them being so easy to find is that some very rare cars are used as daily drivers and not appreciated perhaps as much as they should be.

22B05STI 12-05-2012 10:30 PM

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I have all the parts for my Legacy from New Zealand and also now have a Six speed from a 2001 RA Impreza with viscous center diff and Suretrac front and rear diffs. I have already stripped and cleaned the trans and rebuilt the starter that came with it. I have stripped and gone through the pump for the intercooler and cleaned up the radiator(cooler) for the intercooler.
Here's some pictures
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This is the six speed RA trans that I am going to use, this is before I recieved it.
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The box of parts shipped over from NZ including two new rear bumper covers (obselete in US) thes are shipped from japan to NZ and are different to USDM
One front bumper cover also from Japan to NZ
RS intercooler with all new lines and hoses
A used intercooler pump and Radiator (cooler) for intercooler
New coils. Used intake with wiring loom and hoses same as Rs and RSRA
A new RS type RA rear garnish
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Top bumper is new USDM bumper cover, lower one in photo is JDM
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New RA tach with higher rpm redline

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Rebuilding intercooler pump
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And cooler painted
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Starter repainted and rebuilt
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22B05STI 12-05-2012 10:31 PM

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22B05STI 12-09-2012 10:08 PM

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I Know I have posted other pictures of the prodrive Group A Legacy and the engine bay but here it is again, this is what I wanted my intake to look like, I did decide I wanted a little less of a polished look and this is my manifold which still has the air control passage as the McRae legacy in Rothmans colors did
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Alliedforces86 12-10-2012 05:14 AM

Great build! Keep up the good work. Can't believe I haven't seen this before.

22B05STI 12-11-2012 07:56 AM

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I am mocking up all the parts to check fit and routing of the hoses etc. I will need to change some things to make it all work.

Alliedforces86 12-11-2012 09:13 AM

^^ that is gorgeous :jawdrop:

22B05STI 12-12-2012 10:26 PM

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I spent the evening on the mill making a frame to protect my cooler that's mounted in front of the radiator, it cools the water in the intercooler, and it's vulnerable to damage and very expensive so it's worth the effort to make this frame to mount a meshscreen to protect it.
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22B05STI 12-12-2012 10:29 PM

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Had a double post so I thought I would go off. Topic here and show you a couple of photos of cars I have been working on at work, including this 41 Chev we just fitted this 292 Six cyl in
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Dominator 12-13-2012 10:15 AM

Nice work. No wonder your car is looking so good, seeing the level of quality at your shop.

22B05STI 12-14-2012 09:47 PM

[QUOTE=Dominator;3329510]Nice work. No wonder your car is looking so good, seeing the level of quality at your shop.[/QUOTE]

Thanks, I have worked at several different places over time, This shop belongs to my Dad, I am doing these projects while working for him!
I spent several years running a shop taking care of and restoring vintage race cars and spent nine seasons in Indycar so this build I guess is somewhat normal work for me but the Legacy is undoubtedly the most intense effort on me both financially and by the amount of effort it's taken to find parts for it from around the world. The engine build is also yet to be done, It will require some help from my dad who is extremely good at building race engines, and known throughout the world for his building of race engines

mr_silas 12-16-2012 01:08 PM

Hey! Its Silas from the Mount Hamilton event. You have been busy since we last talked! Alot of fun watching this build. Good luck with everything. Your doing a great job.

22B05STI 12-16-2012 06:58 PM

[QUOTE=mr_silas;3330924]Hey! Its Silas from the Mount Hamilton event. You have been busy since we last talked! Alot of fun watching this build. Good luck with everything. Your doing a great job.[/QUOTE]

Hi Silas, yes it's been a very busy year for me and I am trying to get a lot done before Christmas day. I have a goal of getting all the parts I have cleaned up and ready before then and also I want to have the car painted soon so I am working on it as well.
It will be great to get it painted, then I can work on fitting parts back on the car which will be the turning point of the project, things going back into the car at that point :)

TheFozz 12-16-2012 11:39 PM

A forum friend here suggested I read this thread. I love seeing the attention to detail that's covered in this thread. Right form the moment you received the car and even pulled the trim to see the truth about it. (Shows experience b/c those are the spots most places don't even know about.)

I'll be watching the rest of this build and welcome the chance to see it either on completion or beforehand.

Keep up the hard work. There's too many people these days that forget the skill-set that goes into this sort of work.

Shane

22B05STI 12-20-2012 10:22 PM

[QUOTE=TheFozz;3331108]A forum friend here suggested I read this thread. I love seeing the attention to detail that's covered in this thread. Right form the moment you received the car and even pulled the trim to see the truth about it. (Shows experience b/c those are the spots most places don't even know about.)

I'll be watching the rest of this build and welcome the chance to see it either on completion or beforehand.

Keep up the hard work. There's too many people these days that forget the skill-set that goes into this sort of work.

Shane[/QUOTE]

Thanks for taking a look at this build, I often see people make comments that they just now came across the build, I don't know what I could do to increase the exposure of my build, It is a Big project for sure and I appreciate the enthusiasm of the people that read it and enjoy watching the build. I will definately have it out once I get it built so you will have a chance to see it sometime I'm sure!

22B05STI 12-23-2012 10:00 PM

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Here is a look back at my 05 STI and the work I did to it
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azer408 12-23-2012 10:10 PM

My god...... I feel honored to even be seeing this level of quality. Builds/work like this is an inspiration. Hands down one of the best threads if not THE best thread on this site.

22B05STI 12-24-2012 09:23 PM

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22B05STI 12-24-2012 09:40 PM

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22B05STI 12-24-2012 09:45 PM

Above are photos of our Subarus at different stages The Forester is my wifes daily driver, its much better handling on STI springs and bars with STI trailing and lateral links. The 22B is the only car that I have not Done too much to.

22B05STI 01-03-2013 10:34 PM

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Some Legacy photos from the Net :)

22B05STI 01-03-2013 10:38 PM

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Some Legacy photos from the Net :)

bobb126 01-04-2013 10:19 AM

Legacy is looking more fantastic than your sti! ;)

You say you haven't done much to the 22B, what does that include?

22B05STI 01-05-2013 05:10 PM

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Above photos are original Pro Drive Legacys
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These two BMWs were running in a race we were racing a Legacy in ( Wellington, New Zealand. Nissan Mobil 500)
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This is the 1989 Pro Drive Legacy press photo. I plan on making my legacy look much like this, it is a great looking car

22B05STI 01-09-2013 08:57 PM

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I am in the process of rebuilding all the parts off the legacy and once complete I will offer the complete drivetrain from my Legacy all rebuilt for sale. Today I finished the knuckles complete with new factory bearing and seals, I will be using later Impreza ones on my car.
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LegAC_GT 01-21-2013 08:02 PM

This is nuts....

22B05STI 02-16-2013 09:40 PM

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Hi everyone, I am still on a massive search for Manual window door cards and I have not been able to find any, I have all the handles and mechanisms, I just need the cards ( panels ) if you know of any please contact me
Thanks
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22B05STI 02-16-2013 09:43 PM

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I have been sanding and prepping the car for painting, it's been a very big job but I am nearly finished and it should be away to the paint shop soon, then finally some assembly work can begin.
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22B05STI 03-01-2013 10:21 PM

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The Legacy is going away for paint next Saturday and I will start to focus on the engine again. I have stripped the Half shafts and will hopefully be plating these in a bronze color that is used on parts in F1 and Indycar. I am hoping the owner of the company that builds these parts will agree to process them for me, fortunately he has had my Dad do work for him before so that should help!
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22B05STI 03-23-2013 07:26 PM

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It was a fantastic day today, the painting has begun with the sealer now on the car and it looks awesome just having that done :)
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Dominator 03-24-2013 01:43 AM

I'm still in awe at this build. Thanks for keeping up with the pics.

22B05STI 03-24-2013 01:11 PM

I have been away working for an ALMS team so the Legacy project was set behind a few weeks, however the experience was well worth it

Here's a Video from the ALMS team I worked for in Sebring.
What a great experience it was !
[ame=http://www.youtube.com/watch?v=-eMrEi63HuY]2013 12 Hours of Sebring - Muscle Milk Pickett Racing - YouTube[/ame]
[ame=http://www.youtube.com/watch?v=E5U1-PHvXQ0&sns=em]2013 12 Hours of Sebring Preview - Muscle Milk Pickett Racing - YouTube[/ame]

22B05STI 04-12-2013 08:23 PM

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Project update......
One part of the project with this Legacy has been to rebuild all the parts that will not be going back on the car and sell them, It has added a significant amount of work to the project, however I hope that it will keep one or more Legacys out there running.
I am currently rebuilding the original 2.2 SOHC engine, last weekend I crack checked the crank, Cams, rods , pistons and pins and assembled block and measured bearing clearences
I also stripped and cleaned the heads and faced the valves and cut the seats, I think I will do a little clean up inlet and exhaust port work as the casting are very rough!
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22B05STI 04-27-2013 10:17 PM

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Today was a busy day, I modified a hood scoop to let more air into the engine bay and I plan on cutting luveurs into the panel on the inside of the hood to help lower temp of engine bay/intercooler. I also spent some time blending the ports on the original 2.2 cyl heads, they are very rough castings. Finally I stripped and inspected my original transmission, It looks in great shape so I will replace the seals and put it back together
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I plan on doing more work in the area of reducing ambient temps in Eng bay.

22B05STI 07-03-2013 04:37 PM

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Today I caulked all the seams on the Legacy, it will be painted soon.
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22B05STI 07-03-2013 05:33 PM

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This is the original 2.2 now all rebuilt and ready to sell!

Dominator 07-04-2013 12:08 AM

This is such a nice build. Keep up the great work!

22B05STI 07-11-2013 10:01 PM

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The legacy is now painted, it is awesome to see it now
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cwc16 07-11-2013 10:57 PM

looks so amazing! Such an amazing build!

p.s. Ive been seeing the forester around town! it looks good as well!

22B05STI 07-14-2013 12:01 AM

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Here are a few pictures of progress, I picked the car up today.
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22B05STI 07-28-2013 05:37 PM

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I have had a few people ask me about removing the trim so I will post a few photos that will show what holds the trim in place, once the rubber door seals are removed and the screws removed from the channel that retains the door seals, then the trim can be removed from the clips. There is a nut on the rear corner window trim that needs to be removed from the inside of the car, so the inside trim piece needs to be removed to get to it, I have taken a photo of that so it will make sence
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The last photo shows the trim with the channel removed, you can see that the screws go through the trim !

22B05STI 07-28-2013 06:55 PM

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Now for a project update, I have fit most of the trim on the car, I am missing the trim on the left front door(center moulding) and both rear doors I need the trim that runs against the glass. I have most of the fuel system in except for needing a few clamps to finish the job. I have all the window regulators in and all the glass and door seals installed as well as the locking Mechanisims. I fit the window wiper mechanism back in place and all the lock mechanisim back in place in the trunk.
Here's the photos
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22B05STI 07-28-2013 07:14 PM

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Here are some photos of the doors etc now all back together
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22B05STI 10-30-2013 09:02 PM

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Hi everyone, well I finally have an update, I have the front Sub frame painted and fitted to the car. I have to get a steering rack from a 05-07 Impreza STI and also need to modify a intermediate steering shaft to fit between the column and the rack as I have been told these are different spline on the Legacy Column compared to the Impreza. The front Bar set up is great, there are four positions on the ARB Arms to Adjust the bar from a soft to firm position (the Softest setting being the hole furthest away from the bar at the end of the arm which is where there is the most leverage action on the bar) also the splined bar itself can be easily changed.
Here are a few photos of the Subframe in place
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sigma pi 11-02-2013 11:10 AM

That sway bar set up is sexy

22B05STI 11-08-2013 08:06 AM

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For those of you on facebook please click this link and vote for my wifes photo, if you open the link click like on the actual photo that is counted as a vote. It is for the Subiegirls Calendar
[url]https://m.facebook.com/story.php?story_fbid=10151825388294858&id=734104857&_rdr#!/photo.php?fbid=680577758648425&id=139016112804595&set=a.680577288648472.1073741828.139016112804595&source=48&ref=m_notif&notif_t=share_comment&__user=734104857[/url]
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This is the Photo

22B05STI 11-11-2013 12:33 PM

Hi everyone, If you are reading through this thread through the link emailed to you then thanks for taking the time to look, I certainly apreciate that people are following the build, I hope you like the project and what I have done. There's much to be done yet !

sigma pi 11-12-2013 11:47 AM

:D good job

22B05STI 11-17-2013 08:38 PM

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The second part of this project is nearly finished. I have slowly been going through all the original parts and rebuilding them. I hope that someone will be interested in buying them to rebuild another Legacy back to it's former glory. Here is what I had in mind, I have to paint the diff housing which has rusted a lot just sitting around and go through the steering rack and fit bushings to lateral links and trailing arms and then this project is finished !
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22B05STI 11-18-2013 01:17 PM

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Today, I purchased these mirrors off another subaru Forum member. I am very happy, it will give my Legacy the Authentic Group A rally look.
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22B05STI 11-23-2013 08:40 PM

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I had to get the Legacy off of the Rotissorie today because I sold it. I will use the money towards the WRC stands which I just purchased. I decided to fit the bumpers to the car just to take a look at it also it keeps them under cover and safe. The front bumper cover is the USDM one and will not be the one I will fit to the car, It will have the JDM cover!

22B05STI 11-24-2013 04:07 PM

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Here's something I had not posted, It was going to be a surprise but I have found someone that has original style prodrive wheels, he has cast new wheels, actually he built the original wheels as a worker for the original manufacturer.
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I can have them machined as required
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Front seats I intend to find and purchase and fit to car

22B05STI 11-24-2013 04:25 PM

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There are a few things that I consider very important to this project, The Front and rear Sub Frames which are hand made and done by a true craftsman and fabricator, his welding is a work of art.
The Engine is also very important to me, and having the original hand ported cyl heads on an engine that was shipped direct from STI, well that is fantastic and a great part of this project also.
The wind up manual windows are also another great find and part of this project, having those and the correct engine to make it like the genuine Legacy RA is priceless. There are a couple of other items that I thought was significant when it comes to the RA Legacy, and Gerald at Strongs was able to find me a genuine rear garnish and the genuine Type RA decal attached as shown in this photo. It may have cost me a lot of money however it was well worth it.
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Then one of the members on here helped my significantly by finding this new badge for my intercooler as found on the RA Legacy, so a very special thanks to him. It is a very special find as they are no longer available, I have purchased the last turbo hood here in the USA as well as many other items that were the Last available and it makes it really awesome to know that many of the new parts used to build this car can't be found now.
Here is a picture of the badge
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22B05STI 11-24-2013 04:34 PM

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There is another part of the project that is amazing and that was the work done to remove the Sunroof and fit the filler panel. This was also done by a true craftsman
Bruce at Specialtymetalfabrication.com did this part of the project. The Possum Bourne roof vents are also another special part of the project specially having the opportunity to work with him on Several occasions thanks to Trevor Crowe running the Legacy. Here are some photos of the roof
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Possum Bourne Motorsports vents
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22B05STI 11-24-2013 05:39 PM

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A Diversion from the thread here but I wanted to mention this, as some of you know the Legacy project slowed down this year as I was Traveling a lot to work in the ALMS on a P1 car. After the season end we won eight out of ten races and one Fourth place and A DNF in the season final at Petit Lemans in Atlanta Georgia. We won the Drivers and manufacturers Championship and I finally attended the Championship Banquet as part of the Series champion crew.
I was lucky to have my Wife and boys there with me for the last race having spent so much time away traveling to races this year. It was also a special occasion to have my wife there with me on the grid holding the flag before the race.

Our race car was also parked outside the Banquet hall on the big night so it was a special event.
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22B05STI 11-24-2013 05:49 PM

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Here is a kit for the intake manifold that I also plan to get, it's basically a thermal spacer that replaces the factory gasket and helps prevent heat soak into the Manifold!

Dominator 11-25-2013 10:51 AM

Sweet rare parts! The attention to detail on your build (all your builds) is amazing. I love watching this one come together. Cool stuff on those wheels! Thanks again for sharing.

22B05STI 11-25-2013 07:12 PM

[QUOTE=Dominator;3467250]Sweet rare parts! The attention to detail on your build (all your builds) is amazing. I love watching this one come together. Cool stuff on those wheels! Thanks again for sharing.[/QUOTE]

Hey thanks for following ...... I apreciate the interest in my build.

jam007 11-26-2013 07:15 PM

Classic, this is such a great build!

huayra 12-09-2013 10:02 AM

Thats pretty cool... im writing you from Argentina and im about to buy one of the 3 japanese Legacy Turbo RS founded in Subaru Dealer with some misfiring stuff.

My plan was to make an everyday rally car so, the stength of the rally and some confort for every day.

I dont know if im gonna be able to such dismount but what im worry the most is that the legacy im about to buy has the modern body and even if people say to me that was only a restyling, it will be a massive change of bonnet, wheel arches and bumpers...

I will follow how you finish it as looks it will be soon...

By the way, i did 2 races (or attemp) in Petit 09 and R. America 10 with a crap Radical.. as driver. Even if car was crap, the sensation of LMP machinery was great.

22B05STI 12-09-2013 07:11 PM

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The stands arrived from England today so I went and put the car on them after work
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I have to say these things are a work of art !

thesubarukid111 12-13-2013 12:48 AM

you sir, are a god amoungst divine subaru creation. +1 inspirational.

22B05STI 02-08-2014 08:16 PM

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I know it has been a while since I have posted anything regarding my build and it's because I have been very busy with the race and test schedule this year and also got into fitting a supercharger to an 03 Corvette and the kit was a disaster so I have had very little time to work on the Legacy.
I did have time to fit a Walbro 255 LPH in tank fuel pump, I did not follow the instructions as I did not like the way they wanted to mount the pump, I modified the base mount which was rubber and I was able to fit it just as the factory had with the original.
This pump will easily support the 350 hp that I hope to make from this engine
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this is the original pump next to the new pump to be fitted
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The instructions called to wrap the body of the pump in supplied foam and tywrap to the mount
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I modified rubber base mount to fit as the factory pump was
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the finished pump install just as the original pump was mounted

22B05STI 02-08-2014 09:12 PM

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Today I was able to assemble the new STI Knuckle/Hub assembly which are the early 5X100 Press in Bearings which match the 2001 Subaru Impreza RA trans and Half Shafts and CV joints that I have. I also masked and repainted the Knuckles as the original paint is a thin coat from the factory.

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I will not have ABS so I will make Aluminum plugs and press into the Bores where the sensor would be.
I have all new parking brake assembly's and hardware, unfortunately I was not able to finish the rear knuckles as the dealer only sent two bolts for the backing plates, I will get them and finish Assembling them soon.

22B05STI 02-08-2014 09:23 PM

5 Attachment(s)
Today I was able to assemble the new STI Knuckle/Hub assembly which are the early 5X100 Press in Bearings which match the 2001 Subaru Impreza RA trans and Half Shafts and CV joints that I have. I also masked and repainted the Knuckles as the original paint is a thin coat from the factory.

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I will not have ABS so I will make Aluminum plugs and press into the Bores where the sensor would be.
I have all new parking brake assembly's and hardware, unfortunately I was not able to finish the rear knuckles as the dealer only sent two bolts for the backing plates, I will get them and finish Assembling them soon.

22B05STI 02-09-2014 03:04 PM

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I have also had time to work on the mirrors which were used and they have turned out ok, I have painted them in an finish that is slightly textured and colored to look like original factory plastic.
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the photos are not good but this set of mirrors will be great for this project as it give my car the look I am after!
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22B05STI 02-23-2014 09:19 PM

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I was faced with a decision regarding what to do with the nuts and bolts and all the original steel parts on the Legacy, I had bought a lot of new bolts for the struts and suspension and backing plates and they were all zinc plated (silver) and all the original were the green color which I was not able to confirm what process it was so I went with the silver, and actually two different processes depending on where the parts were being used. I also processed a lot of the hardware in gold As it wasoriginally.
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I also made the decision to go with STI front lower control arms and steering rack and Inow have those parts at the shop. I will buy the Ohlins struts this week also.
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G8R NZ 03-11-2014 11:43 PM

Hey bud.

I'm luckily enough to be in New Zealand longing watching this build thread.

I collect my legacy Rs Ra Type b on Thursday.

Thank you for all the information. Think there should be a place somewhere to conserve it all.

I'm struggling to figure out how many of each type were actually made any ideas.

sigma pi 03-12-2014 09:22 AM

[QUOTE=LegAC_GT;3345167]This is nuts....[/QUOTE]

for sure

sigma pi 03-12-2014 09:33 AM

[QUOTE=22B05STI;3383826]Project update......
One part of the project with this Legacy has been to rebuild all the parts that will not be going back on the car and sell them, It has added a significant amount of work to the project, however I hope that it will keep one or more Legacys out there running.
I am currently rebuilding the original 2.2 SOHC engine, last weekend I crack checked the crank, Cams, rods , pistons and pins and assembled block and measured bearing clearences
I also stripped and cleaned the heads and faced the valves and cut the seats, I think I will do a little clean up inlet and exhaust port work as the casting are very rough!
[IMG]hhttp://i936.photobucket.com/albums/ad201/nickardele/9FAC1934-B1A5-471A-9BAB-248D3AD1D6EC-223-00000023C35F7C3E_zpsa03c12a5.jpg[/IMG][/QUOTE]
I have an EJ22t long block and I dont think I am going to use the heads, if you want them, let me know.

22B05STI 03-26-2014 09:54 PM

6 Attachment(s)
I have had a lot going with the Legacy project The Ohlins coil over struts have arrived and I have been searching for a top strut mount to use as these are for an 05 STI and I knew I would need to find a good alternative and I think that I will be using Cusco adjustable camber top Mounts. The big surprise was the Clevis had changed between 04 and 05 STI with the change from 5x100 to 5x114 in USDM Impreza's. So I am going to make inserts and re drill the Clevis on the Struts.
I also finally got the Intercooler pump together, I was waiting for the metric O rings and the plated parts made this 20 year old pump look like new, which is great as these are really expensive. Unfortunately it looks like I am missing a bracket to mount the pump.
I also pressed apart the Steering Knuckle as I need to fit the Legacy steering colum joint to the STI assembly which I bought new with the rack. I will post pictures of that soon.
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22B05STI 03-27-2014 12:40 PM

3 Attachment(s)
Here is the steering rack joint/Knuckle I fit the original Legacy splined knuckle to the new STI joint. This took me several hours to do but it came out looking like an original part.
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