Numbchux

did a clutch and oil pan (rusted through...) job today: and thought I'd post a few pics of my modified flywheel. I did this myself with a dremel, did not have the holes welded shut, or the wheel balanced. I've never noticed any vibration, and I've easily put 15-20k miles on it since I started driving it about a year ago. you can see the outline of where the bolts were. notice the bolt circle is a bit wider, and some of the holes are offset a bit: here's the 'nub' on the back of the engine that keeps the flywheel centered, the EA flywheel fits snug on this, so it's not possible to have it anything but perfectly centered: w00t! 'new' oil pan!

OK, I did a clutch job this morning, pulled the motor (so I could replace my rusty oil pan too). put it all back together, and it won't start, barely cranks over. First thought is that theres something binding in the clutch/flywheel/starter, but it's acting just like it has a dead battery....so I jump it with a known good battery (meanwhile cussing that my Red Top has failed me), with no change.....well.......the battery's good, so that's good, right?! well, after some fiddling, I find that it's the relay within the starter (ign on, hotwire the starter straight from the battery....same symptom). so I get out my hammer, give the starter a few good raps....and it works fine. I think I'm good to go. I go to work tonight (pizza deliver....lots of starting....oh boy!), and get to the first house (at which point it start overheating! crap....didn't get the coolant system burped all the way....but I brought extra coolant for just that reason, so no big deal), deliver the pizza, go out to start the car, and no go. same symptoms, I get out my 1/2" ratchet (left the hammer at home), and whack the starter a few times, after a few tries, it goes again, and is good for hours. this song and dance continues all night, happening at least 4 times. and of course, this is in an area where I would never leave my keys in the car, ever. if I'm on a hill, and pop the clutch to start it, it starts up fine, but the starter just can't turn it over fast enough. so, it's the starter....I've established that. it seems to me that this is a somewhat common failure. but a quick search didn't turn up anything conclusive. I can see how this relay could wear out over time, and intermittently give me troubles.....but how could it go to working 100% of the time, I do the clutch job, and get about a 70% success rate, if that. so.....coincidence? did I break something? is it fixable? I need to have this car working tomorrow (Sunday) evening for work again.....if worse comes to worse, I can pull the one off the '86 sitting here, but it's not a parts car, so I want to call that beyond the last resort.... also, I may have the starter left from the 3AT somewhere. any chance that would work?! days like this I wish I had a stock car with a warranty so someone else could deal with it I'm just so mad at the car. on the good side....the rest of the project went well....and the $100 closeout XT6 Beck/Arnley clutch kit I got from RockAuto works very well. plenty strong to hold the power of the EJ22, but very smooth, wonderful for daily driving!!

this help? as mentioned...lengths vary drastically from model to model, so would make that list incredibly complex..... BUT, that is a pretty good start. beware, these numbers were gathered from different sources, and as a result, are not entirely accurate (for example, BE legacy springs are not the same upper diameter as EA82 ones, I believe the 78mm number comes from the outside of the springs on the EA82, and the inside of the BE ones....making the BE ones noticeably bigger.)

that's probably the issue.....as most EA82s had power steering.....

yep, I just heard back from him. also....he's going to be in the US soon, so order now for cheaper shipping

haha....most places, people would shrug at a car with mismatched body panels, and a tweaked bumper. but here, we're drooling! nice brat man!!

the problem with AA....is they really aren't a subaru company anymore. they make a few things here and there, but they've moved their focus to weaponry (the armament part of their name...). what kind of steering do you have? I know the manual and power steering systems require a different steering shaft..... and yes, SJR > *

did you pm rguyver? the creater of this thread. he's making them, and is not SJR....

yep, the diagnostic port was retained in the harness modification.

wiring! still more work to do, but I moved the 2 plugs on the engine harness closer to the ECU plug, and then stripped the bulkhead harness down to just the necessities. I'll be shortening all those wires to the relays and such, and installing in the car before the swap. so when the time comes (I only have the garage for the weekend...and I'd like to do it all in a day), I can string it all through the firewall, plug it in, and be ready to rock.

here's a good shot of my yakima guttermounts: they're pretty thick (3/16s, maybe 1/4) wall steel tubing. and the gutter mounts do not interfere with the doors at all. even with the trim on (although I've pulled the trim off of my cars in some way or another....

I have higher res versions of all of these...and brace yourself....I stumbled across a lot that would make good calendar pics. love this shot:

I'm tentatively in for one, pending the final product....but I think it'll be hard to go wrong there.

ordered from performanceradiator.com last Friday.....this arrived today: single row (plenty of cooling capacity, and leftover engine space for the EJ22e). metal endtanks, made in Thailand :-\ , $158 shipped. with the straight outlet!

hmmmm:

problem with the XT6 pressure plate? how do you mean? like not holding the power? my 4-cyl one held the power of the 22e pretty well, but definitely failed before it's time. same number of bolts...same bolts too.

and will allow better brakes!

as I mentioned......the disc itself is interchangeable. you can use a WRX clutch disc on an EA82 flywheel.... the only difference is the teeth where the flywheel meets the starter.....and possibly how the throwout bearing lines up with the pressure plate.

I have the same yakima setup. awesome rack, extremely strong. I haul bikes, a spare tire, even hauled a 40ft extension ladder (2 20 ft sections) on it once. bought it used from a member here years ago, and have had it on 3 cars since then!

that's exactly right....however has no bearing on what flywheel can be used.... looks like I'll have the engine out of my car next weekend (doing a new clutch and replacing my oil pan with the rust holes in it ). I'll see if I can't get a hold of an EJ clutch kit and see how it all compares with the EA stuff....

the light duty part of the rack is the stock mounts. the roof is made of aluminum foil, I've seen those stock rails rip right out of the roof. if you need something more heavy duty than the stock crossbars, get a gutter-mount system.

no, that's why the adapter plate is 1/2" thick....

yarg....may need some creative throwout bearing picking. but the clutch disc itself is the same (or interchangeable, at least...). I think if you could find a way to make the starter engage the EJ flywheel with the EA trans housing....you could make the rest work.

the teeth where the starter engages the flywheel. there's been talk of re-mounting the starter to use the EJ flywheel. but nothing's become of it. I believe Phizinza was the one who's done most of the research, but he ended up just using an EJ trans, so it wasn't an issue. search for his posts....you may find the info to get you started.

no, it's not....I was putting off re-clocking it until I knew how to fix the turn signals while I was in there....maybe they'll fix themselves