Legacy777's 1990 Legacy Turbo

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Legacy777
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Legacy777's 1990 Legacy Turbo

Post by Legacy777 »

This has been way overdue, but since I actually sat down and did a write-up for the car show this past weekend, I figured I didn't have an excuse not to post it on the BBS.

Below is a quick history of the car and the current modification list. I still plan to provide more details about the mods, but that will come at a later time when I can get that all typed up. Thanks to Michael (DerFahrer) for the proof reading and feedback on the write-up.


A 1990 Legacy’s Journey from

this…


Image


to…


Image


History


This Legacy started life as a naturally-aspirated, front-wheel-drive, automatic 1990 Legacy L. It originally belonged to my grandfather, and I inherited it in 1995 when he passed away. It had 80,000 miles on it then and has taken me through high school, college, nine cross-country trips, and a transformation from something ordinary to what you see here today.

At currently over 196,000 miles on the chassis, this Legacy has seen its share of miles, modifications, and adventures. Almost every component other than the main chassis has been modified, replaced, or upgraded. It has undergone two major conversions/swaps in its lifetime, including a swap to all-wheel-drive and a manual transmission in 2004 and a swap to a rebuilt EJ22T engine from a Legacy Turbo in 2005. The engine has been rebuilt a second time with forged internals to compliment the larger turbocharger, custom air-to-water intercooler setup, and fully programmable standalone engine management system. Current horsepower and torque levels are approximately equivalent to a stock STi. In 2013 I completd an STi 6spd transmission swap to replace the Turbo Legacy 5spd I previously swapped in.

This car's transformation has been an amazing journey, and I hope you enjoy seeing it as much as I've enjoyed building it.


I recently had the engine tuned and it made 255 hp & 306 ft-lbs at the wheels. Dyno comparisons & plots can be found here in my build thread.


Modifications


Engine
  • • Ej22t engine swap
    • Late model Subaru 45 deg. intake box
    • Custom intake piping with fender snorkel removed
    • Deadbolt ported & polished and ceramic coated TD05-16G turbo
    • Samco turbo-intercooler silicone hose
    • Overseas Subaru AWIC core w/ aftermarket upgraded pump & custom front mount heat exchanger
    • Throttle body coolant bypass modification
    • Walbro 255 lph fuel pump
    • STi yellow top 550 cc/min injectors
    • Calico coated ACL race crank & rod bearings
    • Eagle Racing forged rods
    • Wiseco forged pistons (8.5:1 compression ratio)
    • ARP head studs
    • Delta Cams 220 “torque” reground cams
    • Crawford performance adjustable timing belt idler pulleys
    • STi oil cooler
    • MSD DIS-2 ignition
    • Diamond coil pack
    • NGK 8mm performance wires
    • High output (140 amp) WRX alternator
    • LinkPlus G3 ECU running G4 Xtreme firmware
    • Link DisplayLink
    • AEM 100 psig fuel & oil pressure sensors
    • Delphi oil temp sensor
    • Delphi intake air temp sensor
    • GM 3 bar MAP sensor
    • GM boost control solenoid
    • WRX knock sensor
    • Exhaust Gas Technologies EGT sensor & 5v amplifier
    • Swaintech “White Lightning” ceramic coated turbo up-pipe
    • Overseas Subaru equal-length exhaust manifold with Swaintech “White Lightning” ceramic coating
    • Custom Exhaust Systems 3” stainless steel turbo back exhaust
    • Zeitronix ZT-2 wide band O2 sensor
    • STi hardened rubber motor mounts
    • N1 lightweight aluminum power steering and alternator pulleys
    • Greddy oil catch can with custom crankcase vent system
Transmission / Drivetrain
  • • AWD & 6spd manual transmission swap
    • 2004 STi 6spd transmission w/ Surtrac LSD
    • DCCD Pro DCCD Controller
    • Subaru STi flywheel
    • Subaru STi clutch & pressure plate
    • STi hardened rubber transmission mount
    • VLSD rear differential
    • Larger diameter (FWD) front CV axles
    • Custom stainless steel braided clutch hose
    • Offset clutch master cylinder reservoir
    • STi shifter and linkage
    • Custom shifter joint bushings
    • Kartboy front and rear shifter stay bushings
    • TiC shifter lever bushings
    • Subaru Xtra-S transmission fluid
Suspension / Handling
  • • SPT front strut tower brace
    • GC Impreza rear strut tower brace
    • STi hardened rubber strut top mounts
    • Whiteline Control lowering springs
    • Whiteline coil quieters
    • KYB AGX adjustable struts
    • KYB bump stops & boots
    • Whiteline polyurethane steering rack bushings
    • Whiteline 22 mm front anti-sway bar
    • Whiteline front anti-sway bar end links
    • STi hardened rubber A-arm bushings
    • STi hardened rubber transverse (rear A-arm) bushings
    • Whiteline rear sub-frame lock bolts
    • Whiteline polyurethane rear sub-frame (outrigger) bushings
    • STi hardened rubber rear trailing link bushings
    • Whiteline adjustable rear lateral links
    • Whiteline HD rear anti-sway bar mount
    • Whiteline 20-24 mm adjustable rear anti-sway bar
    • Whiteline rear anti-sway bar end links
    • Performance alignment
    • TiC fender braces
    • Racing Gear Type M7 wheels
    • Goodyear Eagle F1 GS-D3 tires
Braking
  • • Impreza single diaphragm brake booster
    • 1-1/16” bore SVX 4-port non-abs brake master cylinder
    • MRT brake master cylinder brace
    • First gen. Legacy wagon brake proportioning valve
    • Goodridge stainless steel braided brake hoses
    • WRX front brakes (11.57” vented rotors)
    • Legacy GT rear brakes (11.42” vented rotors)
    • Slotted and cryo-treated Subaru rotors
    • Mintex 1155 brake pads
    • Valvoline Synpower brake fluid
    • Painted brake calipers (pin striped matched)
Lighting / Electrical
  • • EDM glass headlights with electronic levelers and city lights
    • Upgraded headlight wiring with relays
    • Osram H4 headlight bulbs
    • Optima Yellow Top deep cycle battery
    • Upgraded ground and power wiring
    • Tsunami TSBT-PN battery distribution terminals
Interior
  • • Custom manual seatbelt conversion
    • 2002 WRX seats
    • Autometer Z-Series vacuum/boost gauge
    • Custom leather shift boot & WRX shift knob
Miscellaneous
  • • Turbo Legacy hood w/ scoop
    • Turbo Legacy rear trunk spoiler
    • Custom painted front grill
    • STi B4 Legacy Rabbit emblem
    • Hella Supertone horns
    • Passport 8400 radar detector
    • 20% window tint
Audio / Security
  • • Rockford Fosgate power & ground wire
    • Rockford Fosgate RP7400 1 farad capacitor
    • Monster Cable RCA’s
    • Rockford Fosgate upgraded speaker wire
    • Alpine CDA-7940 CD receiver
    • Phoenix Gold PLD1 line driver
    • Phoenix Gold EQ215x equalizer w/ remote subwoofer gain control
    • Alpine MRV-F401 amplifier
    • Infinity Kappa 63.1i & 62i speakers
    • Custom front speaker spacers
    • Rockford Fosgate Punch 200x2
    • JL Audio 12W-D4 subwoofer
    • Custom subwoofer enclosure
    • Custom amplifier mount rack
    • Ported trunk/deck lid
    • Dynamat Extreme sound deadening
    • Clifford Intelliguard 800 IQ alarm w/ dual-zone proximity sensor
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

If you need to get a hold of me please email me rather then pm
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Re: Legacy777's 1990 Legacy Turbo

Post by legacywagon »

Sounds like quite a build, I bet that thing is fun as hell to drive. Looks good for sure.
Legacy777
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Re: Legacy777's 1990 Legacy Turbo

Post by Legacy777 »

Thanks for the comments.

Yeah it's been quite the project, spanning over 15 years.
Josh

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1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

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Re: Legacy777's 1990 Legacy Turbo

Post by soobrdad02 »

I've always loved the looks of your car, it's always had a kind of "quiet aggression" about it. It's even cooler though, to find out that it was originally your grandfather's car! 8) 8) 8)
"All four wheels spin? Huh, that's AWD..."

*1991 Legacy wagon, 4EAT, n/a*
*1966 Chevrolet C-10 pick-'em-up*
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Re: Legacy777's 1990 Legacy Turbo

Post by SILINC3R »

Josh never realised how involved your car was. Its how it would look back in the early 90's but with double the horsepower. Your grandfather sure put a good amount of miles on it when he owned it. That's one thing I have noticed is that people drive the heck out of there Subarus. I hope to have the sister car of yours one day. Fwd/NA manual but all upgraded with plenty of history but close to stock looking onto the outside. Have met and seen a lot of peope/car's from this forum but never had the chance to see your's. One, one day.
Tony
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90 Mazda Miata
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Re: Legacy777's 1990 Legacy Turbo

Post by kimokalihi »

I can't get over how clean it is! Makes mine look old and used. Which it is lol.
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Re: Legacy777's 1990 Legacy Turbo

Post by Legacy777 »

Thanks for the comments everyone! It's a been a long road with everything on the car and definitely has had its challenges, but I think that makes it even more satisfying when it's done.
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

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Legacy777
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Re: Legacy777's 1990 Legacy Turbo

Post by Legacy777 »

Well I got the Legacy inspected yesterday. This is the first time since 2008 that it has had a current inspection sticker....despite the fact I've still driven it.

The interesting thing is the emissions. Since the car is OBD1, they do an emissions test. I've got until 2015 I think and then I won't need an emissions test. Before I put in the stand alone EM I was some what close on the emissions for the idle test. After the stand alone, my numbers were dramatically lower. I will caveat that statement with the fact the car hasn't been properly tuned and was running lean yesterday due to the colder temps. Either way, the numbers were pretty impressive. Even the guys at the shop made a comment about it.

After the tune it still should be pretty good. I could probably pass without a cat, but it's not worth jacking with it.

Here's the scans from the past tests.

2007
2008
2012
Josh

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1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

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Re: Legacy777's 1990 Legacy Turbo

Post by Legacy777 »

Thought I'd update this thread.....I'm still gathering all the parts for the six speed swap. I've pretty much got everything except the clutch & flywheel. I'm still deciding on what setup to use.

I'm going to be swapping in an electronic speedo gauge cluster when I do the swap. Here's some info on that swap.

http://bbs.legacycentral.org/viewtopic.php?f=19&t=50076
Josh

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1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

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Legacy777's 1990 Legacy Turbo

Post by Dynamic Entry »

I lost track of all that you had done, good job Josh.

I did not catch your motivation for the 6sp swap. Is it a project of interest or of need? Did you end up making too much power for the clutch and/or gearbox?

Reason I ask is that as I need to make some decisions before I put the 5mt into Angel.

I was going to resuse the Exedy LW flywheel and stock WRX clutch I had in the last SS for about 5000 miles. But, now I will have TD05 and 550s instead of TD04 and bluetops. I know I won't be making the same power as you, but it crosses my mind that I might need to consider a different clutch going forward.
Andrew

02 WRB WRX
93 White SS "Angel": 4EAT to 5MT 550 Robtune !SOLD!
̶9̶2̶ ̶W̶i̶n̶e̶s̶t̶o̶n̶e̶ ̶S̶S̶ ̶5̶M̶T̶ R.I.P.
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Re: Legacy777's 1990 Legacy Turbo

Post by Legacy777 »

Andrew,

I wanted to do the 6spd because I am at the point that will be the next failure point. So I could have ran the 5spd and waited for it to break (which it may not have) or upgrade to the 6spd and benefit from newer syncros and overall better design. So the motivation was a little bit of potential neccesity, improved equipment, and desire.

As long as you don't beat the 5spds they hold up alright.
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

If you need to get a hold of me please email me rather then pm
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Re: Legacy777's 1990 Legacy Turbo

Post by NICO »

so clean looks amazing, more pictures please :)

where did you get the electronic speedo ? is it the NZ one ? i was so looking for that one good find that thing looks killer !!
1993 Subaru Legacy 44B STi 4Cam 16Valve Turbo Intercooled AWD
EJ22T, STi EJ207 DOHC, Vi-PEC (Spare Autronic) @ 426.20HP / 394.94ft lb @ 00psi
Tuned By: Franz Diebold ( DIEBOLD AUTOSPORT ) @ NVauto
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Re: Legacy777's 1990 Legacy Turbo

Post by Legacy777 »

Nico,

Here's pretty all the pictures I've taken during my work on the car:

http://main.experiencetherave.com/subaru/images/

Here are some of the more recent (but not super recent) I did during a parking garage impromptu photo shoot.

http://main.experiencetherave.com/subar ... s/legacy2/

I got the electronic speedo from the UK. I think one of the members here originally pointed me to a forum over there, and one of the guys over there had one. It was a very lucky find! I did look on the RSLiberty boards first and some of the guys down there were selling theirs, but they wanted a lot for them and I couldn't ever get anyone to send me pictures. From the research I've done, the electronic gauge clusters came on the turbo models overseas. So the JDM, Australia/New Zealand & European markets would have all had that electronic gauge cluster. As an added bonus the redline is 7,000 instead of 6,500.
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

If you need to get a hold of me please email me rather then pm
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Re: Legacy777's 1990 Legacy Turbo

Post by Legacy777 »

Updated the gauge cluster thread. I did my testing and everything worked as expected.

Here's a teaser video of the speedo gauge sweep



I also started cleaning up and doing a preliminary inventory of the parts I've got. I need to clean up the trans and gather the final parts I'm missing.

http://main.experiencetherave.com/subar ... s/6spdswap
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

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Re: Legacy777's 1990 Legacy Turbo

Post by Legacy777 »

I've decided I'm just going to go for the stock Subaru STi clutch for now. I was originally considering the Exedy OEM replacement or the Exedy Stage 1 setup. If it turns out I'm making a lot more torque than I anticpated and prematurely kill this clutch, I'll go for an upgraded setup.

Also, just to let folks know, there is a slight difference between the Subaru clutch & the Exedy OEM replacement. The Subaru clutch has dual springs, a larger outside spring and smaller inside spring. The Exedy OEM replacement only has one larger spring. This difference apparently can cause an annoying deceleration noise for some vehicles.

This thread has some pics of the difference:

http://forums.nasioc.com/forums/showthr ... ?t=2092146

So even though the equivalent Subaru parts are about $100 more, I'd rather spend the money and not have any additional annoying noises.
Josh

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1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

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Re: Legacy777's 1990 Legacy Turbo

Post by Alphius »

Dynamic Entry wrote:Reason I ask is that as I need to make some decisions before I put the 5mt into Angel.

I was going to resuse the Exedy LW flywheel and stock WRX clutch I had in the last SS for about 5000 miles. But, now I will have TD05 and 550s instead of TD04 and bluetops. I know I won't be making the same power as you, but it crosses my mind that I might need to consider a different clutch going forward.
Sorry for going off-topic here, but I wanted to chime in on this.

I am running a stock Legacy flywheel and a WRX stock replacement Exedy clutch with a TD05-16G and RevTronix chip. I run about 18psi and I've put about 20k miles on this clutch so far with no slipping or other issues.

Take it for what its worth, but if I was you I would run what you already have as it will probably be OK.
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Re: Legacy777's 1990 Legacy Turbo

Post by kimokalihi »

I'm also running about 18 PSI, EJ20G, TD05-18G, 550s and I'm using a clutchmasters 9lb flywheel with Exedy OEM WRX clutch kit and there's no slipping.
98 Metro Hatch Daily Driver :)
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Re: Legacy777's 1990 Legacy Turbo

Post by Legacy777 »

Kimo, how is that 9 lb flywheel in traffic? ;)


I hate to say it, but I'm getting older and don't want to jack around as much with "on-off" clutches, lw flywheels, and super stiff clutch pedals. :) I feel confident the setup I'm getting will be good and it'll be tolerable in Houston traffic.
Josh

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1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

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Re: Legacy777's 1990 Legacy Turbo

Post by ride_child »

Wow I bet thats what causing that stupid noise when I let of the gas, I thought my mounts were goin bad! Damming, looks like I'm going to have to replace the clutch... again.
Thanks for the info and link Josh!
Kris

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Re: Legacy777's 1990 Legacy Turbo

Post by kimokalihi »

I'm used to it. Not the best car to teach a newbie how to drive stick as I recently discovered trying to teach my GF to drive stick in my legacy. It doesn't really bother me but I still kill it once in a while mainly being lazy and not giving it enough gas. I don't drive in traffic much though. Country kid. It's mainly backroads driving for me. Just the way I like it. If I were commuting in traffic on the daily I'd probably buy an auto.
98 Metro Hatch Daily Driver :)
91 SS EJ20G Engine/Tranny/Diff Swap Build Thread Here
"Your testes are close to your bottom but you still play with them all the time." Jeremy Clarkson
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Re: Legacy777's 1990 Legacy Turbo

Post by ride_child »

What are the sick sti clutches rated to hold?
I have a lightweight flywheel as well and once I got used to it, its not too bad. Like Kimo I sometimes kill it out of laziness, but I live in the country too.
Kris

'91 Mica White SS - R.I.P.
'88 White RX Turbo sedan - SOLD
'91 Black SS - SOLD
'93 Silver Turbo Wagon - Hibernation/Project Mode
'91 Black Camry Alltrac - R.I.P.
'09 DGM Forester XT Limited - Daily
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Re: Legacy777's 1990 Legacy Turbo

Post by Legacy777 »

I've heard the stock sti clutches are good for 350-400 hp. The thing that will kill them is launches, so dumping the clutch at 4 grand probably will do them in a lot quicker.
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

If you need to get a hold of me please email me rather then pm
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Re: Legacy777's 1990 Legacy Turbo

Post by NICO »

man that cluster is amazing and i wish i lived in a hot area your car is like in mint condtion holy crap ! nice pics and work on everything man you got allot going on !!
1993 Subaru Legacy 44B STi 4Cam 16Valve Turbo Intercooled AWD
EJ22T, STi EJ207 DOHC, Vi-PEC (Spare Autronic) @ 426.20HP / 394.94ft lb @ 00psi
Tuned By: Franz Diebold ( DIEBOLD AUTOSPORT ) @ NVauto
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Re: Legacy777's 1990 Legacy Turbo

Post by Legacy777 »

Thanks for the comments Nico!

The remarkable thing is that this car spent the first half of its life up North!

1990-1995 - Eastern PA
1995-1997 - Seattle, WA
1997-2001 - Eastern & Central PA
2001-2002 - Memphis, TN
2002+ - Houston, TX
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

If you need to get a hold of me please email me rather then pm
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Re: Legacy777's 1990 Legacy Turbo

Post by Legacy777 »

Well I started cleaning up the transmission, was going to reseal the oil sump pan, and then ran into an issue with the oil sump pan bolt. It was damaged. I tried several different things, and then someone suggested getting these Craftsman Bolt-Out sockets. They are freaking awesome! I don't think I've been this impressed with a tool in a while. It grabbed the damaged pan bolt and I easily loosened with a breaker bar.

Anyway, I got the pan cleaned up and resealed to the trans. Next step is to take some degreaser to the transmission and try to get it cleaned up.

Here are the pics from this weekend's activities.

http://main.experiencetherave.com/subar ... spdswap/02

http://main.experiencetherave.com/subar ... spdswap/03
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
2020 Outback Limted XT

If you need to get a hold of me please email me rather then pm
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