It's done....

[Legacy777]

Got everything finished up on the project yesterday, and with just enough time to make it to the aligment shop.

I'm happy with the results. Shifting is a little notchy, but it's gotten better since driving, so I think things are wearing in. I had to swap cruise computers to get it to work, and adjust the clutch pedal clevis assembly to get rid of this dead pedal area, as well as this rattle.

I'm getting a 92 ecu from Vikash, which I think will help smooth things out a little bit. Other then that, I just have to find a nagging rattle, probably zip tie some wires up, and get a custom shift boot made and choose a shift knob.....oh and clean up the mess that is my garage

My only complaint is that I could use some more power....hahaha.

anyway...check out the page for more info and pics
http://www.main.experiencetherave.com:8 ... yswap.html

i'll be working on a pretty detailed page with info on the swap. I'll post when I finish.

[douglas vincent]

More power? Just bolt on a supercharger and nitrous. Garranteed to give more power. I PROMISE no damage will ever, ever happen. (had my fingers crossed). Psyche!

Good job! Now come to Portland please and rebuild my motor.

[elkaboom]

Awesome Josh! I've been following your AWD, 5mt swap "blog", if you will, for some time (particularly since we have what is essentially, the same car) -although, even with a 5MT, mine is still prolly faster...
Mine isn't as pretty (I have all the exterior parts ), but you have the "ummphh".
Great job man!

[entirelyturbo]

Josh, I for one stand up and applaud you. This is no simple project for the most experienced mechanic, and I don't think anyone would have done things as perfectly as you

Get everything to where you're happy with it, enjoy all the work you just did, take plenty of pics like you always do and shift that tranny nice and easy

[Legacy777]

Thanks guys....I'm sure I'll be enjoying it

I've got a rattle I need to find now.......

[evolutionmovement]

Good work! I can't wait to get to mine for the AWD conversion. Cable clutch? The rattle might be the shift fork. I set my pedal up with almost no free play to keep it from buzzing at idle. Hill holder also helps quiet it when hooked up.

Steve

[BAC5.2]

Steve - Next time I see you, you've gotta show me how the hillholder works (I know HOW it works, but I've never been in a Subaru that's had it.)

I wish I had a hillholder in my car

Congratulations Josh! That's one hell of an acheivement for ANYONE! One of these days, I'll do an uber-unique swap for something. But until then, I'll drool at the impressive projects that others are doing.

[evolutionmovement]

Phil - Hill holder is just a cable that runs from the clutch fork to the master cyl. When the clutch pedal is in, the cable is pulled and holds the brakes on to prevent the car from rolling back. There's a little valve or something in it that only lets it work above a certain degree of incline. When you release the clutch, the brakes are also released. It's cool because it's very simple, but I'd have to look at it again to remember exactly how it works. My '83 sedan had the same deal (which I disconnected to teach my ex to drive stick). It's presently not hooked up on this car eoither (got impatient with the engine swap), but I think I'll do it soon to get rid of the light clutch fork buzz I have.

Steve

[BAC5.2]

I wish I could have that in my car. Probably pretty cool for getting out of steep parking spots.

[evolutionmovement]

It's ineffective on real steep surfaces - nearly worthless in San Francisco.

Sorry for the OT, Josh.

Steve

[scottzg]

I've used my hill holder in san fran, it worked fine.

[vrg3]

Nice, Josh. That must feel great. I remember when my brother and I converted his car to a stick, and our feelings after completing the project were a mixture of elation and disbelief. 'Twas nice.

You don't have the hill holder, right, since you're using the hydraulic clutch?

[Legacy777]

The rattle was the slave cylinder piston I believe. I adjusted the clevis pin so there's pretty much no play. The pedal doesn't have that dead spot at the top, and there's no more rattle. I still can barely move the pin on the slave cylinder a mm or so when the car's cold. After driving around and the engine bay heats up, the slack is all taken up.

Yeah I don't have the hill holder since I have a hydraulic clutch. The hill holders are ok, however they can be finicky to adjust and get cranky some times.

[Legacy777]

Ya know I just thought about the damper thing that comes stock....it may do soemthing to help this.....not sure.

My friend with an Sti drove my car yesterday. Stalled it twice. Not sure if he was just used to driving the sti, or not used to the lightweight flywheel. I really haven't had any problem with it. It still gives more feedback before it dies compared to my mom's toyota pickup

I looked at the select monitor and the calculated engine load was around 20%. The load with the stock flywheel is around 40% I believe. So that's a good reduction in load.

[vrg3]

Yeah, it's possible the damper helps with it. But...

My car had the dead travel at the top of the pedal even when it was stock. And I believe RHD BC/BF turbos had the same master and slave cylinders as us but they had no damper. They had a hard line from the master cylinder to a junction (did you notice how the master cylinder's fluid port can take either an M10x1.0mm inverted flare or an M10x1.00mm banjo?), and then a rubber hose from the junction to the slave cylinder. Much like the brakes.

Are you sure that once it warms up it's not actually disengaging the clutch slightly?

Nitpick - the load isn't a percentage; it's just a number. It goes up to 255.

[Legacy777]

yeah I'm pretty sure it's not pushing on the clutch slightly. There's a few things, this being one of them, I'll be checking this week when I get some time.

hmmm....load isn't a percentage.......interesting.

[vrg3]

Yup, it's just a number the ECU computes. It has no meaningful units or anything.