Date:         Tue, 2 Jun 1998 17:06:33 -0300
Reply-To:     Tim Smith <smitht@UNB.CA>
Sender:       Vanagon Mailing List <Vanagon@vanagon.com>
From:         Tim Smith <smitht@UNB.CA>
Subject:      Subaru DIY swap info
Comments: To: vanagon@vanagon.com
Content-Type: text/plain; charset="us-ascii"

Hi, and nope it's not on the road yet!

Have made up the main adapter plate for engine to trans, 'aircraft grade'
aluminium alloy,  and a steel 20x50mm box tubing engine carrier. Instead of
the KEP approach to a hybrid Sub-agon flywheel I have made a smaller hub
adapter that allows the use of ALL vanagon drive train. Stock
flywheel/PP/clutch or flexplate in stock positions, no starter meshing probs.

All my components are designed to be bullet proof (on paper), testing in the
crewcab will tell. The crew is an autobox, like KEPs test vehicle, and will
be easier on the small adapter hub than a heavy footed user with a manual
trans could be. Design can be beefed up again if needed.  I was looking for
low budget/low tech conversion kit, and it seems to be feasible now.  The
flywheel hub has been a major  PITA. Nothing like the exhaust is going to be
I suspect. :(  KEPs stainless system may be a smart move, $160?  Subaru
wiring harness has been cut out, just needs re-wrapping to install :)

A wimpy battery and starter made it hard to spin the Subaru engine over, but
I suspect even in good shape they would be hard pressed due to high CR.
Another problem down the line. Buying premium will cost a bit more too.
Engine does have a knock sensor, could handle mid-grade I suspect, for a
performance penalty. I was only oiling the engine and doing a (cold)
compression test.

If you are engine shopping grab ALL the throttle stuff including cables, the
cruise control system and its pump and computer. Trace back the components.
I didn't get the pump, now I'll have to go back and pay again. It looks like
factory Subaru cruise would be very little extra work, but some sort of road
speed sensor is needed, possibly stripped from Subaru? Forget the ABS system.

I'm not offering a kit yet, but would like to do so eventually, once I've
tested it all for a while.  If anyone has questions just pmail. I should put
together a 'salvage guide', as stripping out everything you need takes a few
hours and it is easy to leave something behind.

The engine fits well, tons of clearance around, Subaru oil pan is 4" too
low, a billet aluminium one may get machined out, but getting a small sized
4" thick chunk is hard/$$. It will likely be a welded up unit initially.
Would also reduce oil capacity, KEP cut/welded up the original Sub's steel
one. Amsoils 'dual remote bypass' oil filter system would be advisable, adds
back about 1-2qts of oil.

I should be able to fire it up this weekend and go for an exhaust-less spin.
Say at 3AM 'coz the plates/MVI are expired?  bye all, Tim