Phizelishus, EJ22 and Tri-Hybred Brumby

Phizinza · Post by **Phizinza** » Sat Apr 14, 2007 2:39 pm

Now that I have the EJ in the Brumby running good I thought I may post it here.

First off some pics from a while ago. This is before the EJ, but you can't tell the difference on the outside.

Some extras you'll have to click on to see:
http://offroadingsubarus.com/images/sub ... _water.jpg
http://offroadingsubarus.com/images/sub ... _25-07.jpg
http://offroadingsubarus.com/images/sub ... _peake.jpg

It was a dual carb EA81 with a standard 4sp D/R box.
But she now runs a EJ22, Uni Filter, Modded radiator and fans, Home done cut down loom, modded standard ej y-pipe to fit, 2" straight thru exhaust from my old EA.
And what I've come to call the tri-hybred AWD. It's a Liberty casing (to bolt to the EJ with standard EJ clutch) with the L-series low range, the EA AWD centre locker, pinion, diff and rear casing, along with the standard L-series 2 piece prop and 3.7 diffs. I cut up a EA82 gearbox crossmember and reinforced it to fit the MY.

At the same time I put modded EA82 control arms, custom radius robs and custom camber adjusters.

General picture of the interior on the beast as it is right now.
Subaru Liberty D/R cable lever, start button, diff lock switch, etc.

The clutch and throttle pedals were modified from L-series to fit the MY box. Using a Mazda 626 throttle cable and L-series clutch cable.

Fuel pump is from a MPFI L-series using a new 8mm return line from engine to a t-adapter for it to return into the original 3mm and one of the tank vent 6mm hoses.

The loom I cut down myself and fitted it through the left side of the car, ECU sits by the passengers feet. Relays up behind the glovebox on the left hand pillar. Hidden kill switch plus fake distraction kills switch wired in. Push button start wired in, because sometimes my ignition is stuborn and won't click to start. It also makes it easy when you've stalled it offroading.

Then theres the old mods I have done myself.
Digital ammeter with 150amp shunt.
Tread plate heater cover with gauge(s) and PDA mount.
Radio (soon to be CD player) and amp in the glove box along with the PDA's GPS.
6.5" speakers in each door with boxes (makes all the difference in sound having them in boxes, not just screwed to the doors.)
VHF roof mounted with roof aerial, UHF mounted behind the handbrake with aerial next to the GPS aerial on the bull bar.
2 Hella spotties on the bullbar.
Bought and installed the 'Sports Bar', 3" stainless steel.

Then theres what it came with.
2" lift kit.
310mm steering wheel.
Coupe dash.

I'm sure theres more I can't think of, but oh well...

Some pics to look at.
http://offroadingsubarus.com/images/ej2 ... lines7.jpg
http://offroadingsubarus.com/images/ej2 ... ounted.jpg
http://offroadingsubarus.com/images/ej2 ... stall1.jpg
http://offroadingsubarus.com/images/ej2 ... _guard.jpg
http://offroadingsubarus.com/images/ej2 ... _test1.jpg
http://offroadingsubarus.com/images/cam ... it_cam.jpg
http://offroadingsubarus.com/images/cam ... _final.jpg
http://offroadingsubarus.com/images/ej2 ... nkages.jpg

Pretty much all work was done by my brother or I. With exceptions like the radiator, and the original 2" exhaust. Most of the welding I got my brother to do, as he is better at that then I.

Now.. Wanna take a guess at how much it cost for the EJ22 and gearbox swap? I'll sort out my time log of the swap and post that later.

theclick · Post by **theclick** » Sat Apr 14, 2007 2:57 pm

nice man,

How'd ya do the boxes for the speakers? Im interested in this for my ea82, didnt think it would make that much difference.

Subafury · Post by **Subafury** » Sat Apr 14, 2007 3:08 pm

very sweet setup. in particular the custom "tri-hybrid" gearbox arrangements- has the best from all the suba parts. id love to see haow that compares to others.
well done with all the custom work

Phizinza · Post by **Phizinza** » Sat Apr 14, 2007 3:09 pm

theclick wrote:How'd ya do the boxes for the speakers? Im interested in this for my ea82, didnt think it would make that much difference.

http://offroadingsubarus.com/images/sub ... ction2.jpg
http://offroadingsubarus.com/images/sub ... ction4.jpg
http://offroadingsubarus.com/images/sub ... ction5.jpg
http://offroadingsubarus.com/images/sub ... spacer.jpg
12mm MDF, cut to fit in with clearnce for the window. Lots of silicon and some 6.5" Jaycar speaker spacers.

Start with carboard, then cut out your MFD.

subi wrote:id love to see haow that compares to others.

With open rear diff it's pretty average at the moment. But I have plans to fix that.

stinky · Post by **stinky** » Sat Apr 14, 2007 7:04 pm

I've been following this on USMB and take my hat off you to Phiz. You've done a magnificient thing.

Brumby Boy · Post by **Brumby Boy** » Sat Apr 14, 2007 7:45 pm

Im in the same boat as stinky, been following it on usmb, id love the box in my ute but just dont have the time or the parts to build it, standard L box will have to do.

Again good work man, some time in the furure once ive done my ej convert we should go for a roady to go wheeling with the WA crew

Phizinza · Post by **Phizinza** » Sat Apr 14, 2007 10:21 pm

Brumby Boy wrote:Istandard L box will have to do.

You can always run in 4WD on the road when you want to push it hard.. That's what I done when I had my Superlites on with the 215/60's on with the ol' 4sp... No noticeable damage to the diff or gearbox, but I think my inner DOJ cups were opening up and creating slop.. Not the greatest thing to do, but boy did that thing handle 200% better in 4WD..

Fang · Post by **Fang** » Sun Apr 15, 2007 8:25 am

I'm curious - why didn't you just change the low in the Full Time box and use an adapter plate? I have heard of using EJ boxes with Full Time boxes to get a better final ratio.

Phizinza · Post by **Phizinza** » Sun Apr 15, 2007 10:20 am

Fang wrote:I'm curious - why didn't you just change the low in the Full Time box and use an adapter plate? I have heard of using EJ boxes with Full Time boxes to get a better final ratio.

I had a EJ D/R box sitting their, the other box would of had to of been split open to fit the better dual range, and the more it looks "stock" the better.
To use the center diff lock you have to have the pinion shaft and crown wheel that came with the FT box. And in my case that is a 3.7. You can however get a XT6 FT box which is S/R 3.9, you could convert that to a D/R box and have a 3.9 diff.. But if you say the FT box is as rare as hens teeth, can you imagine how rare the XT6 box is??

Basically I used the Lib box because it looks more stock and didn't cost me anything. Plus, I can, so why not...

Fang · Post by **Fang** » Sun Apr 15, 2007 10:28 am

Phizinza wrote:I had a EJ D/R box sitting their, the other box would of had to of been split open to fit the better dual range, and the more it looks "stock" the better.
To use the center diff lock you have to have the pinion shaft and crown wheel that came with the FT box. And in my case that is a 3.7. You can however get a XT6 FT box which is S/R 3.9, you could convert that to a D/R box and have a 3.9 diff.. But if you say the FT box is as rare as hens teeth, can you imagine how rare the XT6 box is??

Basically I used the Lib box because it looks more stock and didn't cost me anything. Plus, I can, so why not...

Fair enough

I was speaking to Daza a couple of months ago - and apparently you can move the internals of a L Series Full Time box into an EJ box and use its final ratio of (4.444 etc). Maybe he can clarify further.

Phizinza · Post by **Phizinza** » Sun Apr 15, 2007 11:14 am

Fang wrote:Fair enough I was speaking to Daza a couple of months ago - and apparently you can move the internals of a L Series Full Time box into an EJ box and use its final ratio of (4.444 etc). Maybe he can clarify further.

If you use the EJ's center VLSD then yes, you can use the 4.44 or 4.11 or whatever. The problem lies in the pinion shaft, as the pinion gear is part of the shaft and the FT pinion shaft is different to the AWD pinion shaft.

Unless you can cut it off and weld another on there 4.44 diff locking AWD box isn't going to happen. Although it would be VERY awesome if it would work..
I hold little faith in AWD with non-locking center diff offroad. So I will put up with 3.7 for now.

So, anyone have any ideas on what gauge I should put in that empty spot? I have the ability to add one below those two pods and three more to the left of those.. But I think one or two more gauges will be enough..
I was thinking of fuel/air ratio, and maybe an oil temp, or fuel pressure? I gotta replace that vacuum one too as it is screwed up.

Phizinza · Post by **Phizinza** » Sat Apr 21, 2007 7:09 pm

Back from a 4 day trip to Loveday 4x4 Park. Great place, I highly recommend going there if you love your 4WDing. They have a website, just google the name.

Suspension held up well. Engine wasn't happy on the way home, it wouldn't idle. I have been having issues with the IAC. So I have to fix that.

The car done pretty good I reckon considering I didn't have an LSD or locked rear. Although a mate with an EA82 L series and welded rear made it up a hill much easier then I did. But I did get up there. The almost stock Feroza and 3L TDi Hilux did make it. So all this modding has done something..

I added up all the cost of the whole conversion and it came to $1521.

Phizinza · Post by **Phizinza** » Sun Apr 22, 2007 11:24 am

Lol, yeah, so much for the $3500 to $5000 I was told it would cost.

I'm going to put the 215/60 directional road tyres on today and fix a wobble I was having on the way back home from the trip. Then I'm out to have some AWD fun. Damn I want a rear handbrake.

I just added up my time log and it comes to about 110 man hours. That includes building the box, all custom parts to fix the engine and box, exhaust mods, radiator fans, fuel system, loom removal, cut down, install, etc.
I reckon about 3 times that in research and part sourcing starting from May last year.

tim_81coupe · Post by **tim_81coupe** » Sun Apr 22, 2007 1:24 pm

You've done a good job on the ute. It does have a tough side on look to it. Good conversion price too, you obviously managed to source a lot of parts cheaper than the average punter. Plus the EJ conversion know how is online too, back when I did my first EJ conversion in 2002/2003 there was very little online help.

stinky · Post by **stinky** » Sun Apr 22, 2007 5:25 pm

Hope you guys don't mind my cleaning up this thread a bit. Too much off-topic and friction for a thread about an awesome car.

SuBaRiNo · Post by **SuBaRiNo** » Sun Apr 22, 2007 6:09 pm

Thanks Stinky.... love what u did with the gear box Phizinza.... thats something i have not yet attempted.

Dave

AndrewT · Post by **AndrewT** » Sun Apr 22, 2007 6:20 pm

Guess I'll re-add my compliment minus the harmless joke...

Great car, love the gearbox!

Phizinza · Post by **Phizinza** » Mon Apr 23, 2007 9:29 am

Now the thread works how it was suppose to in the first place. To let people know what can be done to a Subaru..

The next modification will be side and rear facing lights I'm thinking. Time to go ebay shopping lol.

stinky · Post by **stinky** » Mon Apr 23, 2007 3:51 pm

don't forget under-car lights for those night runs!

Phizinza · Post by **Phizinza** » Mon Apr 23, 2007 8:11 pm

stinky wrote:don't forget under-car lights for those night runs!

Yeah, good point. I saw those on another car somewhere. Where would you mount them? I was thinking maybe up in that fuel pump area so they are out of the way. And maybe up next to the gearbox?

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Phizelishus, EJ22 and Tri-Hybred Brumby

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