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1991 Legacy sport into Legacy RS Type RA Spec build

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1991 Legacy sport into Legacy RS Type RA Spec build

Old 02-08-2014, 08:16 PM
  #91  
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Join Date: Aug 2012
Location: Monterey, Northern California
Posts: 192
Car Info: 05 Subaru Impreza STI
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
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Old 02-08-2014, 09:12 PM
  #92  
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Car Info: 05 Subaru Impreza STI
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.
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Old 02-08-2014, 09:23 PM
  #93  
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Car Info: 05 Subaru Impreza STI
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.
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Old 02-09-2014, 03:04 PM
  #94  
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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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Old 02-23-2014, 09:19 PM
  #95  
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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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Old 03-11-2014, 11:43 PM
  #96  
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Car Info: Legacy BC5 Rs Ra Type b
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.
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Old 03-12-2014, 09:22 AM
  #97  
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Originally Posted by LegAC_GT View Post
This is nuts....
for sure
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Old 03-12-2014, 09:33 AM
  #98  
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Originally Posted by 22B05STI View Post
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!
I have an EJ22t long block and I dont think I am going to use the heads, if you want them, let me know.
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Old 03-26-2014, 09:54 PM
  #99  
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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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Old 03-27-2014, 12:40 PM
  #100  
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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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Old 03-27-2014, 07:42 PM
  #101  
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Here is a look at the Ohlins DFV Road and track dampers, I will post a few so you can see the difference between an 04 and an 05 STI, I will post pictures of what I have come up with as a solution after I have the peices made.
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Old 03-29-2014, 10:04 PM
  #102  
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Today I spent the day at the lockal Auto dismantlers and I pulled a whole lot of clips and plugs in excellent condition and some exterior trim pieces which were in good condition but the best part of the day was finding a complete Non ABS brake line set up which was in perfect condition, I basically wiped it off and fit it in my car and it looks awesome. This part is dealer obselete so I was concerned about the likelihood of finding one so it was a great day today with my project :-)
I also found a head liner which I will have to modify for the roof vents, it looks like it will be another tricky project, but I will get on to that soon and then I will have it re upholstered to be a material like my 05 STI, I dont like the vinyl, it looks cheap.
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Old 04-03-2014, 07:56 PM
  #103  
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Today I turned my attention to something that will put a smile on my face one day when I get to use it.... The Throttle pedal
Here are a few photos from the process


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Old 04-09-2014, 08:13 PM
  #104  
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Last night I finished assembling the steering column, I replated just a few of the parts

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Old 04-17-2014, 08:33 PM
  #105  
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I have my new Cusco strut mounts for the Ohlins so now all I have to do is modify the front Clevis for the 04 STI knuckles
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I have been working on some smaller projects also which included cleaning up a lot of the rubber plugs that fill the holes in the body of the car and fitting them in the correct places and I also fit the Legacy badges By the rear windshield and chrome trim to the rear bumper cover.
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