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1991 Loyale 4x4 build thread. 1st timer here


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Hey guys. This is my second Subie, my first being my 2009 Impreza. This one is gonna be a bit of a sleeper if everything goes my way, though.

 

Backstory:

Met with the guy from Craigslist and test drove it with intention of buying it, but he couldnt find the title. So I gave him a couple days to round up paperwork and we met up again to do the deal. He went to install the battery and got the poles backwards. He saw smoke, it didnt crank and he assumed it was all dead. I didnt know much, but I figured there was some sort of fail safe built in, so I offered $250 and he took it! I did some Googling and found that the fusible link is all the burns up usually. So I checked it and it was fried. Made a new one quick and she started right up!

 

Currently waiting on the title from DMV, but I keep getting parts thrown at me for stupid cheap and am a machinist by trade. Soooooo this project is going to be getting under way sooner than anticipated.

 

Plan at this time is:

 

- 2" lift at the strut tops/1" lift at the cross member and rear diff

- EJ22/EJ25 frankenmotor swap. (OBD1 harness, EJ22 intake, throttle body and a good set of heads all scored for $120 today. Coworker might also have a nice EJ25 block for sale soon)

- Cut 2/3 of the roof and hatch off (for hauling dirtbike), but fab up quick release bracketing for re-mounting the hatch. Will also make a large clear sheet to make a sealable top for the winter months. Will double as a gigantic moon roof ;)

- Probably 27" tires until I can find a dual range or a 4.11 transmission.

- Upgrade seats

- Hardwood floor in the hatch

- Stereo system with a 10 or 12 inch sub in a truck box for conserving space.

 

I'll pop in tomorrow with a link to an imgur album of my current progress. Gotta take some more pictures since I got more parts today and didnt get home until dark. Gonna go check out some new seats at a semi-local old subie junk yard tomorrow afternoon.

 

Heres a picture of her on jack stands in my barn: https://imgur.com/gallery/CmJPt

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just mentioning in case, there are a couple different EJ22 head phases.  search around here to make sure you know which generation you have.

 

with the EJ in it I wouldnt worry about the tire size.  dual range is nice and Id definately do that, but just get the tires you want now instead of later.  I have a tired ea82 and a little over 25 inch tires and it has no issues.

 

if your gonna build the lift yourself I would go a bit higher.  Id say 27's are pushing it with a 2 inch.  you can cram more, but I personally like to leave room for chains and such. 

 

do the full cross member drop.  1 inch wont make much difference and it is much nicer on the axles (and for installing them)

 

look into getting peugeot wheels.  they are the only real way to get 14 and 15 inch rims with our lug pattern.  opens up all kinds of tire options.

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just mentioning in case, there are a couple different EJ22 head phases. search around here to make sure you know which generation you have.

The harness and heads came from a 1996 Legacy. I think most of the frankenmotor swaps ive read about are that gen car. Regardless, they were cheap and I can find a block to fit them somewhere. Itd just be fun to rip around in a 2600lb car with 180hp.

 

with the EJ in it I wouldnt worry about the tire size. dual range is nice and Id definately do that, but just get the tires you want now instead of later. I have a tired ea82 and a little over 25 inch tires and it has no issues.

 

if your gonna build the lift yourself I would go a bit higher. Id say 27's are pushing it with a 2 inch. you can cram more, but I personally like to leave room for chains and such.

I was planning on 32" tires with a 6-inch lift and a divorced transfer case once it becomes not really streetable anymore. 27s or 28s will give me what im looking for with the current trans. I also want this to be my daily for a couple years, so I'm doing my best to keep it kinda sporty feeling. So 26" might be the size I keep around for daily duties. Definitely stick with the 2" + 1" body lift instead of 6 haha. I will probably end up cutting a little bit of my fenders up.

 

do the full cross member drop. 1 inch wont make much difference and it is much nicer on the axles (and for installing them)

 

look into getting peugeot wheels. they are the only real way to get 14 and 15 inch rims with our lug pattern. opens up all kinds of tire options.

What is the bolt pattern? I'm thinking about making conversion plates to make it 5X100 so I can run my 16" steelies with my winters once I get summers put on the Impreza. That would space the stance out a bit, too.

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Go to a 4" lift with 235/75/15 or 30" tires and redrill the hubs for 6 lug ej if you must but that little ea82 has its moments like for instance throughing a timing belt in the middle of the desert in the middle of the night in the middle of a mud hole and slip the belt back on and drive a hour back to the house its the little things that make the ea82 what it is

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Go to a 4" lift with 235/75/15 or 30" tires and redrill the hubs for 6 lug ej if you must but that little ea82 has its moments like for instance throughing a timing belt in the middle of the desert in the middle of the night in the middle of a mud hole and slip the belt back on and drive a hour back to the house its the little things that make the ea82 what it is

The EA82 is gonna stick around for a while. Its a running engine that justhad the timing belts and stuff done, so I'm gonna run it while I get the suspension dialed. That way I can take my time with building up an EJ that I like. This will be my first harness trimming and spilicing, so its gonna take a while to get that figured out too.

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if your going to do the 2nd transfercase 8" of lift is about minimum to

fit a 2nd rear diff up front to run your front axles, the EJ is key if you

stick with a dualrange the EA82 just doesn't have the low end power to turn

large tires offroad, I build these cars for offroad and can help with any

custom stuff, Scott @ www.sjrlift.com

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if your going to do the 2nd transfercase 8" of lift is about minimum to

fit a 2nd rear diff up front to run your front axles, the EJ is key if you

stick with a dualrange the EA82 just doesn't have the low end power to turn

large tires offroad, I build these cars for offroad and can help with any

custom stuff, Scott @ www.sjrlift.com

Second transfer case is a future project at this point. When I no longer want the car as a daily, it'll happen.

 

I think I am all squared away on custom stuff. I got an extended steering shaft with the other parts yesterday and am a machinist, so I'll be making my own things for the most part. Have gotten schematics and drawings of most everything. Could use a CAD solid of the EJ/EA conversion spacer plate if you're willing to share ;)

 

Will definitely contact you with questions if I do need help. Might send the harness off to someone if I cant make sense of it. The car was already stripped of everything that plugged into the harness, so I didnt get a chance to tag it up much.

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The ea82 can make good low end power if your willing to put in the work switching back and forth between my ea82m and my 2000 impreza with the ej2.2 witch has more power than the older 2.2s there isent that much difference in fact I'm guessing if the impreza had 30" tires the difrerance wouldent be noticeable the ej is a much better engine hands down but the ea82 can make good usable torque and seem to lug down way less than the ej engines i have 2 ej2.5 powered rigs to and there bottom end power is a joke so much that I did a 2.2 swap and tossed the 2.5 on my forester but off road i still prefer a high compresion ea82

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The ea82 can make good low end power if your willing to put in the work switching back and forth between my ea82m and my 2000 impreza with the ej2.2 witch has more power than the older 2.2s there isent that much difference in fact I'm guessing if the impreza had 30" tires the difrerance wouldent be noticeable the ej is a much better engine hands down but the ea82 can make good usable torque and seem to lug down way less than the ej engines i have 2 ej2.5 powered rigs to and there bottom end power is a joke so much that I did a 2.2 swap and tossed the 2.5 on my forester but off road i still prefer a high compresion ea82

The Impreza is so much heavier though. They feel like the same power because the power:weight ratio is close to the same. Throwing 100 more horsepower at a 2500 pound car (loyale) will make a huge difference.

 

My Civic Si has 165hp in a 3600lb car. This loyale is planned to have 180hp for 2500lbs. Low end is great on EJ engines, imo, and Ive been driving my pig of a 2009 Impreza for years. Use it for towing my dirtbike around without any problems.

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There's only a couple of hundreds pounds difference mostly motor weight the impreza only weighs 2700-2800 pound a loyale is around 2500 mine weighs more because of the tube bumpers and other parts add the winch high lift I'm over 3k

Edited by ferp420
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Got the hub drum off! Had to get shwifty and remove the mounting bolts from the backplate to just get the whole assembly off. Am now searching for a disk swap conversion!

 

https://imgur.com/gallery/Z6iSd

 

Up next is the wheel bearing job. Gonna order another to do the other side soon since im doing the disk swap anyways.

Edited by Hamsamsquanch
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Took a break from brake stuff and drew up my front lift blocks! Took the solid to work with me and a coworker offered to 3D print me one to test fit. Took him up on it of course ;) If it mocks up nicely, I will probably make a couple small tweaks and then make a set out of billet aluminum.

 

https://imgur.com/gallery/GKy1O

 

Will be test fitting tomorrow if the water has cleared from the floor of my barn.

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Did you get the off set on that lift block its hard to tell but I don't see any there should be around 15-18* of off set to keep the camber right

Yeah, I have it set at 16 degrees right now. Might make a set out of high density plastic first to see what the alignment looks like with both sides installed. Going outside soon to mock it up on the passenger side.

 

Will be taking dimensions for the rear lift while I'm out there. Not gonna bother with the 3D printing for that though. Should be pretty cut and dry.

 

Any ideas on material to make replacement body and control arm bushings with? Coworkers have used Delrin with good results on wheelers, but that stuff is RIGID. I guess bigger tires and new suspension might make up for it if I do go that route, though.

Edited by Hamsamsquanch
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https://imgur.com/gallery/jPXzC

 

Heres the print I drew up quick for the rear lift. I believe 45° is what I have read in my digging through old threads? Anyone care to make some revisions to my design? Planning to do nuts and bolts for securing the strut to the plate.

 

Also included a picture of the hole I'm designing a cab light for.

 

Remembered why I dont care for 3D printed parts haha. The holes came out way undersize so I'm gonna have to bore those out Sunday night at work. Looks like the bolt pattern is slightly too large as well, but that could also be the printers fault.

 

Left my dang laptop in my toolbox at work, so I wont be able to do any CAD work this weekend.

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