91 SS to RSRA Spec bare shell complete restoration/build

[BC622B05STI]

The shell looks great! Looking forward to seeing some assembly.

Is that a non-turbo shell? I thought that all the Japanese built cars (all turbos AFAIK) had the firewall pre-punched for the clutch master cylinder. Maybe it is and I can't see it through the shine?

This shell is a original 91 Legacy sport USDM market Turbo car with the 2.2 SOHC engine.
It will be repowered with an original 2.0 Legacy RS type RA engine with Correct intercooler and RA Legacy parts.

[Legacy777]

Yeah, it's a turbo shell, and the hole is pre-punched. It's just hard to see due to the paint.

[BC622B05STI]

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!

[BC622B05STI]

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






I plan on doing more work in the area of reducing ambient temps in Eng bay.

[BC622B05STI]

Today I caulked all the seams on the Legacy, it will be painted soon.

[BC622B05STI]

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

[CAV3MAN227]

-That is so purdy!!!!

-Joe

[xise]

Nice, a rock solid factory rebuilt motor!

[BC622B05STI]

The legacy is now painted, it is awesome to see it now

[SILINC3R]

Wow, looks beautiful. So is there a Pearl in the paint or just white. And man I wish I could buy that motor from you!

[CAV3MAN227]

-WOW, that is just awesome!

-Joe

[BC622B05STI]

The paint has no pearl in it, this is the same paint code as found on many of the Legacys, It is the color that the genuine RA was painted

[CAV3MAN227]

-You're literally going to have the best legacy out of all of us. Looking forward to more updates!

-Joe

[BC622B05STI]

I am already well underway with the assembly of the trim and I have all the glass in the doors and manual window regulators in and the trunk assembled, I have the brake lines and fuel lines run through the car. I will post more pics soon, here's a few to give you all a glimps

[Legacy777]

You're going to have a brand spanking new Legacy

[jefferson]

Actually, better than brand spanking new. If I win the lottery you are going to be commissioned to do my car. Love the work you do.

Jeff

[BC622B05STI]

Here are a few pictures I have not posted, it shows just how bad the car was in a lot of areas, I did not actually want to post them because it looked so bad, however it shows what can be done with a massive effort and a huge amount of time

[BC622B05STI]

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




The last photo shows the trim with the channel removed, you can see that the screws go through the trim !

[CAV3MAN227]

-Are those manual windows I see? If so, I didn't even know our cars even had them.

-Joe

[Legacy777]

I need a new right rear triangle trim piece because that triangle window was replaced and they broke the tabs and most likely the bolt.

Got any leads for a new or a used one in good shape?

[BC622B05STI]

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

[BC622B05STI]

Here are some photos of the doors etc now all back together

[BC622B05STI]

-Are those manual windows I see? If so, I didn't even know our cars even had them.

-Joe

Yes these are manual windows, they were the only option that the Legacy RS type RA came with as part of the weight reduction. There were also manual windows in base model Legacys, This is where I got this set from and they were in perfect condition, the door cards are the problem, I need the ones that have the same color and Pattern that the RA had!

[BC622B05STI]

I need a new right rear triangle trim piece because that triangle window was replaced and they broke the tabs and most likely the bolt.

Got any leads for a new or a used one in good shape?

Let me check into that for you, I will get back to you as soon as I can!

[CAV3MAN227]

-Are those manual windows I see? If so, I didn't even know our cars even had them.

-Joe

Yes these are manual windows, they were the only option that the Legacy RS type RA came with as part of the weight reduction. There were also manual windows in base model Legacys, This is where I got this set from and they were in perfect condition, the door cards are the problem, I need the ones that have the same color and Pattern that the RA had!

-Well that explains the rarity.
-I love what you are doing with your car. There has been plenty of times I have thought about giving up on my 92ss cause I spend more money repairing 21 year old crap on it then ever getting to more performance things, but a thread like this really helps me out. Like you said earlier on, just goes to show what can be done with a lot of time, patients and money for that matter. But you really got to love this car to invest so much time and money into it.

-Joe