Free5ty1e's 1991 Legacy SS 5MT

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free5ty1e
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Free5ty1e's 1991 Legacy SS 5MT

Post by free5ty1e »

Here is the official build thread for my 1991 Subaru Legacy Sport Sedan 5MT.

Quick backstory on this car: Purchased in 2006 for $1000 in good running condition from Ogden, UT. Found sale on this board's car lot. Brought another driver from Elko, NV (residence at the time) there, ~4 hour road trip each way, drove the 91 SS back to Elko. Ran great. A/C even charged and working well.

As this was my 3rd car (OK, 3rd Subaru.... Legacy.... SS), it did not end up getting much usage. It ended up sitting for several months without being started, until one day a family member decided to take the keys and borrow this particular car. Which still worked just fine... except that it had sprung a coolant leak somewhere and had lost pretty much all of it by this time.

Car proceeds to overheat (I can only presume, since I had no knowledge of any of this transpiring until I went to check on the car at some point later), the family member makes it back and parks it slightly differently, and never tells me what transpired.

It had no compression on 2 of the cylinders and no chance of starting. I ended up managing to arrange for it to get delivered up here to Oregon when I moved here in 2013, but still it just sat. A local mechanic took a look at it for me and estimated several thousand dollars to rebuild the engine that I needed to come up with up front... well that's not going to happen.

Then at 2013's first annual Beatrsubi Oktoberfest beer n brats meet, Beatrsubi himself offered to let me store the 91 at his place until we could get together again and start tearing into it. I purchased a AAA Premier membership for the 100+ mile tow from Portland, OR to Tenino, WA (worth it!) and the car as sat there until this past weekend....

'91 EJ22T removal, head removal, valve / piston / cylinder wall examination, Oktoberfest bonfire and rallycross action

Original plans were to use my VF36 twinscroll on this thing, along with my other RobTune setup (still need fuel rails)... but I'm having second thoughts, perhaps selling the VF36 setup and going with a more common, serviceable turbo such as the VF39 would be more sensible as I could potentially finance this thing by selling the VF36. They are still worth exactly what they were when I bought mine several years back....

Current plans include:
RobTune550 perhaps with S-AFC 22+ PSI madness as I've read about someone awesome doing on this board
DOHC heads + COP conversion (EJ20G? K? E?)
Forged pistons one step oversized, due to condition of rusted side of engine (see photos)
Engine bore to match pistons
Engine & head decking
New (OEM?) head studs
New (OEM?) bearings
VF39 or big TD05 / TD06

More detail to come, but this is definitely the start of my 1991 build! Which I'm actually going to put up a build journal for, since it will involve some srs bsnss!
-Chris
91SS 4EAT stock
91SS 5MT awaiting engine rebuild and VF36...
92SS 4EAT - RIP :(
94SS 5MT4.11+rLSD 289k km: RobTune550,TD05-16g @ 18psi,FMIC,3"TBE,Forester lift
ride_child
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by ride_child »

what is that word at the end? bassness? :)
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
free5ty1e
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by free5ty1e »

er, that is to say, serious business (engine work)
-Chris
91SS 4EAT stock
91SS 5MT awaiting engine rebuild and VF36...
92SS 4EAT - RIP :(
94SS 5MT4.11+rLSD 289k km: RobTune550,TD05-16g @ 18psi,FMIC,3"TBE,Forester lift
cj91legss
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by cj91legss »

Chris, 20k heads and manifold.

http://www.rs25.com/forums/f178/t212098 ... parts.html

He's in washington tho.
91 L-TW Wagon with a full Swap -RIP
92 SS Prefaced, GD dash swapped, 22T/205 Hybrid 20 psi - BEAST!
93 SS Bone Stock Gone!
94 TW Bone Stock Gone!
91 SS 4EAT Sold!
98 LGT 4EAT
98 LGT Wagon 4EAT
86BRATMAN
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by 86BRATMAN »

^^ that guy is a good seller, I bought the STi ecu, wiring, maf, and some sensors off him
free5ty1e
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by free5ty1e »

O snap... the K is the designation with the better flowing heads and cams, right?
Washington is where the parts need to end up anyway :D

Thanks for the heads up!
-Chris
91SS 4EAT stock
91SS 5MT awaiting engine rebuild and VF36...
92SS 4EAT - RIP :(
94SS 5MT4.11+rLSD 289k km: RobTune550,TD05-16g @ 18psi,FMIC,3"TBE,Forester lift
cj91legss
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by cj91legss »

Depending on location, beatersubi or myself could check them out for ya.
91 L-TW Wagon with a full Swap -RIP
92 SS Prefaced, GD dash swapped, 22T/205 Hybrid 20 psi - BEAST!
93 SS Bone Stock Gone!
94 TW Bone Stock Gone!
91 SS 4EAT Sold!
98 LGT 4EAT
98 LGT Wagon 4EAT
free5ty1e
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by free5ty1e »

I inquired about the heads and location :D
-Chris
91SS 4EAT stock
91SS 5MT awaiting engine rebuild and VF36...
92SS 4EAT - RIP :(
94SS 5MT4.11+rLSD 289k km: RobTune550,TD05-16g @ 18psi,FMIC,3"TBE,Forester lift
cj91legss
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by cj91legss »

here's his CL ad as well

http://seattle.craigslist.org/tac/pts/4727619487.html

Looks like he's in the auburn area.
91 L-TW Wagon with a full Swap -RIP
92 SS Prefaced, GD dash swapped, 22T/205 Hybrid 20 psi - BEAST!
93 SS Bone Stock Gone!
94 TW Bone Stock Gone!
91 SS 4EAT Sold!
98 LGT 4EAT
98 LGT Wagon 4EAT
mike-tracy
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by mike-tracy »

Cheaper than what I spent. But... thats pretty messed up to put the mating surfaces of those heads on the cement like that.
1992 Legacy SS 5mt, build in progress
Josh Colombo wrote: Mon Jan 14, 2002 10:23 am Wait....I'm confused now.
free5ty1e
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by free5ty1e »

Wait... the EJ20K heads dont require a special ECU to run, right? Can I run a Robtune setup on EJ20K heads or do I need an EJ20K ECU and entire electrical setup...? I suppose I should figure that out before going any further, lol


Edit: I'm also guessing that if these are STi heads, perhaps the yellow 550 injectors will be compatible with its fuel rails? I need to get the heads and intake manifold and fuel rails for this setup, correct?
Last edited by free5ty1e on Sun Oct 26, 2014 7:02 pm, edited 1 time in total.
-Chris
91SS 4EAT stock
91SS 5MT awaiting engine rebuild and VF36...
92SS 4EAT - RIP :(
94SS 5MT4.11+rLSD 289k km: RobTune550,TD05-16g @ 18psi,FMIC,3"TBE,Forester lift
free5ty1e
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Location: USA: Portland, OR (Tigard, ~200ft elevation)
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by free5ty1e »

mike-tracy wrote:Cheaper than what I spent. But... thats pretty messed up to put the mating surfaces of those heads on the cement like that.
This is true. I figured I'd have to have them decked anyway but that isn't helping things.
-Chris
91SS 4EAT stock
91SS 5MT awaiting engine rebuild and VF36...
92SS 4EAT - RIP :(
94SS 5MT4.11+rLSD 289k km: RobTune550,TD05-16g @ 18psi,FMIC,3"TBE,Forester lift
mike-tracy
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by mike-tracy »

E20k heads can be used in place of ej20g heads with no other changes. Adding the ej20k intake manifold would open a huge can of worms. Ej20g manifold bolts on perfect however.
1992 Legacy SS 5mt, build in progress
Josh Colombo wrote: Mon Jan 14, 2002 10:23 am Wait....I'm confused now.
free5ty1e
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by free5ty1e »

Ah! That is excellent to know, thanks! :D
-Chris
91SS 4EAT stock
91SS 5MT awaiting engine rebuild and VF36...
92SS 4EAT - RIP :(
94SS 5MT4.11+rLSD 289k km: RobTune550,TD05-16g @ 18psi,FMIC,3"TBE,Forester lift
robertpaige
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by robertpaige »

20k heads flow amazing from what I have heard. In combination with the 20G manifold you should have no problems.
Had more Legacy's than I know what to do with...
Current: 92' SS
free5ty1e
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by free5ty1e »

Purchased the heads and am trying to arrange delivery to Beatrsubi's garage... excited for this build!
-Chris
91SS 4EAT stock
91SS 5MT awaiting engine rebuild and VF36...
92SS 4EAT - RIP :(
94SS 5MT4.11+rLSD 289k km: RobTune550,TD05-16g @ 18psi,FMIC,3"TBE,Forester lift
free5ty1e
Fifth Gear
Posts: 2266
Joined: Wed Nov 12, 2003 12:26 am
Location: USA: Portland, OR (Tigard, ~200ft elevation)
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Re: Free5ty1e's 1991 Legacy SS 5MT

Post by free5ty1e »

Wiseco Forged pistons and ring set $543.30

Code: Select all

Brand:Wiseco
Manufacturer's Part Number: K601M975
Part Type:Piston and Ring Kits
Product Line:Wiseco Sport Compact Piston and Ring Kits
Summit Racing Part Number:WIS-K601M975

Bore (in): 3.838 in.
Bore (mm): 97.500mm
Piston Style: Dish, with no valve reliefs
Piston Material: Forged aluminum
Compression Distance (in): 1.312 in.
Piston Head Volume (cc): +20.00cc
Wrist Pin Style: Press-fit or floating
Pin Diameter (in): 0.906 in.
Gapless: No
File Fit: No
Top Ring Thickness: 1.2mm
Top Ring Material: Steel
Top Ring Facing Material: Phosphate coated
Second Ring Thickness: 1.5mm
Second Ring Material: Cast iron
Second Ring Facing Material: Phosphate coated
Oil Ring Thickness: 2.0mm
Oil Ring Material: Stainless steel
Oil Ring Tension: Standard
-Chris
91SS 4EAT stock
91SS 5MT awaiting engine rebuild and VF36...
92SS 4EAT - RIP :(
94SS 5MT4.11+rLSD 289k km: RobTune550,TD05-16g @ 18psi,FMIC,3"TBE,Forester lift
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