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AWDfreak's (second) Subaru Outback
AWDfreak's (second) Subaru Outback
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Old 09-09-14, 11:40 AM   #1
AWDfreak
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Default AWDfreak's (second) Subaru Outback

UPDATE: objective has changed, NO LONGER INTENDED TO BE FUN VEHICLE. Current role is as a short trip vehicle.

MECHANICAL RESTORATION as a light-duty short-distance daily driver has become the priority as the severe rust damage is just not worth it, considering I'm barely getting by with my school commute.

Current wishlists OBSOLETE



Based off of the 3rd generation Legacy, this Subaru Outback is the generation that got the updated Ring-Shaped Reinforcement Frame. As a result, it's about a good ~400 lbs heavier than my previous Outback (a BG6 2nd generation Legacy-based Outback).

Album:
My Project Car - Imgur

Long story short, I wanted a cheap project car that still ran, and would be my off-road adventure project car so that I would stop my mod addiction to my XV. It will also serve as my study-guide to cars in general as I will tinker with it much more often than my XV.


This particular example has well in excess of 190,000 miles. I intentionally chose an example with many problems so I could tackle them myself and explore more about automobiles and servicing.

First photos:





























It won't be a thread by me without the silly list!

Quote:
Subaru Outback BH wishlist

Cusco Power Brace parts
Power Brace What's new English page CUSCO

BH5 M/T
BE5 M/T
http://www.cusco.co.jp/en/img/pb_bh5.gif
* Floor center - 680 492 C
* Floor rear side - 680 492 RS

Cusco strut tower braces
BH5
* Front Type OS - 682 540 A
* Rear Type OS - 680 541 A

* Cusco Rear Frame Reinforcement Bar P/N 680 487 A

* Cusco Type I Lower Arm Bar P/N 680 476 A
or
Gialla front lower aluminum bar フロント・ロアアルミバー for レガシィBH5・BE5
* Gialla floor side support bar フロアサイドサポートアルミバー for レガシィBH5・BE5
* Gialla rear lower bar リア・ロアアルミバー for レガシィBH5・BE5

Fluids:
* Motul Gear Competition 75W140
for transmission/front differential and rear differential
* Motul 6100 Synergie+ 10W40
* STI Sports Oil Filter P/N ST152084S000

Exterior:
* Primitive Racing skid plates front and rear
* Rallyarmor Universal MSpec Mud flap White logo
* SYMS rear wing for wagon P/N Y300066018
* ZERO/SPORTS rear wing P/N 0103024

Suspension and chassis:
* King Springs lift springs P/N KSFR-32 front, KSRR-29 rear
* KYB struts P/N 334276 Front Left, 334275 Front Right, 341276 Rear (2 req'd), SM5361 Front mount components (2 req'd), SM5214 Rear mount components (2 req'd)
* SJR 4" lift kit MY2000 or HighGuys 4" lift kit 2000-2009 Legacy/Outback, HighGuys Steering coupler for 4 inch lifts
* STI Group N strut mounts P/N B0310FE000 front, ST2037066000 rear
* Whiteline suspension components:
- W63393 Control arm - lower front inner & outer bushing
- W63395 Control arm - lower rear inner bushing
- W63396 Control arm - upper inner bushing
- W63397 Control arm - upper outer bushing
- KDT906 Diff - mount in cradle bushing
- KDT905 Diff - support outrigger bushing
- W63398 Trailing arm - lower front bushing
- KLC30 Sway bar - link assembly extra heavy duty alloy
- BSR12XZ Sway bar - 20mm X heavy duty blade adjustable
- W51710 Control arm - lower inner rear bushing
- KSR200 Steering - rack & pinion mount bushing (25 mm) or KSR202 Steering - rack & pinion mount bushing (30 mm)
* STI Suspension Bushings if not using Whiteline:
- STI Transverse Link Bushings P/N B0200FE000 (R-RH), B0200FE010 (R-LH)
- STI Rear Trailing Link (Front) P/N B0220FE000 (2 required)
- STI Rear Trailing Link (Rear) P/N B0220FE010 (2 required)
- STI Rear Trailing Link (Front & Rear) P/N B0220FE020 (4 required)
- STI Rear Trailing Link (Front-In) P/N B0220FE030 (2 required)
- STI Rear Trailing Link (Rear-In) P/N B0220FE040 (2 required)
* custom stiffer stay assemblies (side cowl stay, fender brace)

Intake:
* APEXi Power Intake Panel Filter P/N 503-N101
or STI Air Cleaner Element P/N ST165464S000
* custom snorkel intake

Cooling:
* STI Radiator Cap P/N ST4511355010
* custom heavy-duty silicon radiator hoses
* custom motor oil cooler (w/ Auto Meter 3627 2 1/16" (52.4mm) oil pressure sensor and gauge)
* custom power steering fluid oil cooler

Drivetrain:
* 6-speed swap from 2010-2014 Outback, custom gear ratios:
- 1st gear: crawler 1st gear ratio (4.997 or shorter)
- 2nd gear: MY2009 1st gear ratio (3.454)
- 3rd gear: MY2009 2nd gear ratio (2.062)
- 4th gear: MY2009 3rd gear ratio (1.448)
- 5th gear: MY2009 4th gear ratio (1.088)
- 6th gear: MY2009 5th gear ratio (0.825)
OR Australian Forester dual-range 5-speed swap
OR custom final drive ratio (redline limited to 100 MPH or less, probably shorter than 5.750)
* retrofit Exedy Stage 1 Organic Clutch Kit P/N 15801
* clutch-type LSD's front and rear:
Type MZ pair
- Cusco rear LSD Type MZ (set to 1 way)
LSD 181 A
- Cusco front LSD Type MZ (set to 1 way)
LSD 180 A or LSD 180 B
or
Type RS pair
- Cusco rear LSD Type RS (set to 1 way)
LSD 181 F
- Cusco front LSD Type RS (set to 1 way)
LSD 180 C15
* STI Center Viscous LSD (5MT) P/N ST3891355000 Rallispec P/N RST-1215 [20kgfm/100rpm, 20kgf]
* STI Short Throw Shifter P/N C1010FA002
* STI Shifter Bushing P/N B0220FG300
* STI Duracon Shift Knob P/N C1010FG310
* STI Transmission Mount P/N D1010FE020
* STI Upper Transmission Mount P/N D1040FE000
* STI Motor Mounts P/N D1010FE110 (RH), D1010FE120 (LH)
* STI Stainless Mesh Brake Hose Set P/N ST265504S000 or custom/retrofit Goodridge
* extended differential and transmission breathers for water crossings

Wheels and tires:
16" dual-purpose setup
* SG Forester X steel wheels 16X6.5 ST:OFF48 P/N 28111SA000
* all-terrain tires:
- General Tire Grabber AT 2 215/65R16
- BFGoodrich Rugged Terrain T/A P235/60R16
- Yokohama Geolandar A/T-S 215/65R16
15" off-road setup
* BFGoodRich Mud-Terrain T/A KM2 LT215/75R15 P/N 36630 off-road tires
* Subaru Forester 15 inch (SF) steel wheels P/N 28111FC020
17" touge pavement setup
* Yokohama AVID ENVigor (H-Speed Rated) 225/55R17 97H SL
* Subaru Forester 17 inch (SJ) steel wheels P/N 28111SG000

Brakes:
* Project Mu Sports Inner Shoe BH P/N IS900C
* STI Stainless Mesh Brake Hose Set P/N ST265504S010 retrofit or Goodridge stainless mesh brake hose P/N 24215-CL retrofit
* DOT4 brake fluid
* Hawk Performance HPS brake pads P/N HB434F.543 front, HB424F.665 rear
* StopTech Sport Cryo Slotted Cryo Rotor P/N 126.47012CSR RF, 126.47012CSL LF, 126.47017CSR RR, 126.47017CSL LR

Electrical:
* OPTIMA Batteries 8040-218 D35 YELLOWTOP
* Subaru EZ30 alternator swap P/N 23700AA401 or Subaru EZ36 alternator swap P/N 23700AA581
* radiator cooling fan cutoff switches
* ABS cutoff switch
BH chassis Subaru Outback wagon
Quote:
BARE MINIMUM off-road modification list (basically if I'm dirt-broke and/or don't want to spend much money on the Outback)


* Gorilla Offroad Company OBK - Offroad Bar 00-03 Subaru Outback
- Skid Plate
- Winch Mount w/D-Ring Shackle Tabs
* Whiteline KDT906 Diff - mount in cradle bushing
* Primitive Racing 3/16" rear differential skid plate (2000-2004)
* Subtle Solutions (00-04) Outback - 1" Lift Kit
* KYB struts P/N 334276 Front Left, 334275 Front Right, 341276 Rear (2 req'd), SM5361 Front mount components (2 req'd), SM5214 Rear mount components (2 req'd)
* King Springs lift springs P/N KSFR-32 front, KSRR-29 rear
* Cusco LSD's front and rear
* extended rear differential breather
* custom rock sliders
* Subaru Forester 15 inch (SF) steel wheels P/N 28111FC020
* BFGoodRich Mud-Terrain T/A KM2 LT215/75R15 P/N 36630 off-road tires
- OR dual-purpose tire 15" wheels: General Grabber AT2 205/75R15 [97T SL (1609 lbs per tire, 118MPH speed rating)] all-terrain tires
* Cusco Power Brace Floor rear side - 680 492 RS
* Cusco Power Brace Floor center - 680 492 C
* Cusco Type I Lower Arm Bar P/N 680 476 A
* Gorilla Offroad Company Sticker Pack - Rally Rated
Attached Thumbnails
AWDfreak's (second) Subaru Outback-hjyugor-jpg  

Last edited by AWDfreak; 11-10-15 at 02:30 PM.
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Old 09-09-14, 11:44 AM   #2
AWDfreak
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Default Re: AWDfreak's (second) Subaru Outback

reserved
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Old 09-09-14, 11:45 AM   #3
AWDfreak
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Default Re: AWDfreak's (second) Subaru Outback

reserved because potential big plans
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Old 09-09-14, 05:49 PM   #4
Neanderthal Racing
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Neanderthal Racing is just really niceNeanderthal Racing is just really niceNeanderthal Racing is just really niceNeanderthal Racing is just really nice
Default Re: AWDfreak's (second) Subaru Outback

you make me look completely sane, freak. i never imagined it possible. thank you.
(i crack myself up)
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Old 09-09-14, 07:35 PM   #5
AWDfreak
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Default Re: AWDfreak's (second) Subaru Outback

Quote:
Originally Posted by Neanderthal Racing View Post
you make me look completely sane, freak. i never imagined it possible. thank you.
(i crack myself up)
I went past my comfort level and got me this rust bucket!

Aaaaaaaaaaaand the oil pan started leaking today


The oil pan is leaking from RUST, not from where it seals. The rust made its way into the oil pan and it finally ate through as soon as I got it.
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Old 09-10-14, 04:58 AM   #6
Neanderthal Racing
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Neanderthal Racing is just really niceNeanderthal Racing is just really niceNeanderthal Racing is just really niceNeanderthal Racing is just really nice
Default Re: AWDfreak's (second) Subaru Outback

hey, if you don't push past your comfort level, you'll never know what you can do in life. you have my admiration for taking on a reclaimation project like this.
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Old 09-10-14, 07:16 PM   #7
AWDfreak
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Default Re: AWDfreak's (second) Subaru Outback

Rust eating away the oil pan

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Old 10-10-14, 01:35 PM   #8
AWDfreak
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Default Re: AWDfreak's (second) Subaru Outback

The past days, I've put the XV out back (no pun intended) and have been driving the Outback wagon more often. The Outback is worse than the XV in almost every way (except the dual moonroofs, extra space, better-feeling controls, and low-end torque), but I really am finding more excuses to drive it. Heck, I even found it more fun to drive through the local mountain roads!

I have to steer the wheel more than my XV but with the good-old hydraulic power steering, I can feel the road a little better than the XV's electric power assisted steering.
__________________
"Why would I want to profess my feelings for some 3D girl?" - Tomoya Aki from the anime Saekano
some large image
'muricuh, **** yeah!

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Old 10-12-14, 11:27 AM   #9
AWDfreak
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Default Re: AWDfreak's (second) Subaru Outback

I experienced moderate brake fade on the touge last night in the Outback. Brake upgrades will no longer be delayed and will be implemented ASAP. Also, the parking brake is terribly weak.


Parts to be ordered:

* Stoptech Street Performance front brake pads
309.07210

* Stoptech Street Performance rear brake pads
309.07700

* StopTech Racing STR 600 High Performance Brake Fluid (DOT 4)
501.00001 (2 req'd)

* C-TEK Brake Shoes
110.07580 (2 req'd)

* C-TEK Standard Rotors front
121.47012 (2 req'd)

* C-TEK Standard Rotors rear
121.47017 (2 req'd)

* StopTech Stainless Steel Brake Lines front
950.47006

* StopTech Stainless Steel Brake Lines rear
950.47505
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Old 10-22-14, 08:08 PM   #10
AWDfreak
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Default Re: AWDfreak's (second) Subaru Outback

As the Outback is expected to be on more adventures in the future, the kit will be more extensive than the already-overkill one on my XV.

For comparison, here's the XV's kit:
Quote:
Emergency kit:
* basic metric ratchet tool set
* small crescent wrench
* 6 30-minute emergency flares
* 3 DOT reflective emergency triangles
* 10 flare-alternative chemical lightsticks
* flexible recovery ramps
* 2 D-ring shackles
* 20 ft recovery strap
* First Alert A:B:C fire extingusher
* Subaru Severe Weather Companion P/N SOA868V9500
* Vaughan Solid Steel Campe Axe With Sheath SKU AS1-1/4
* Chinook Medical Gear EPMK (Emergency Preparedness Medical Kit) Level 2, (Pelican Storm Case iM2100, yellow) hard case Chinook Medical Gear P/N 01375HC
* Deka commercial service booster cables P/N 00158
* Silky Super Accel 210 straight blade folding saw P/N 119-21
2000 Outback recovery and emergency kit wishlist (will continue to be updated and grow like mod list)

* Chinook Medical Gear Life Kit
Chinook LIFE Kit | www.chinookmed.com
#01310

* Chinook Medical Gear EPMK - Level 4
EPMK - Level 4 | www.chinookmed.com
#01377HC (hard case)

* Wyeth-Scott Co More POWER Puller
The Wyeth-Scott Co. Established 1906
3-35-A-SLT (3 ton dead lift, 6 ton dead lift, 35 feet Amsteel blue synthetic rope)

* Pull-Pal
Pull-Pal Land & Winch Anchor specifications - off-road, 4x4s, ATV, UTV, buggies, all-terrain-vehicles
RW11,000 ** w/ Carrying Case GVW Weight & Under - 6,000lbs

* Off Road Trail Tools Off Road Wheel Chock
Off Road Trail Tools
SKU: 5008

* Bubba Rope Bubba (purchase two)
Professional Grade Mudder's Recovery Rope : Breaking Strength: 28,600 lbs. : Bubba Rope
7/8" x 30'

* cutting tools
- foldable handsaw (for wood)
- hatchet
- full-size shovel
- recovery ramps (such as MaxTrax)
- heavy-duty versatile flashlight
- metal snips
* auto mechanic's starter tool set
* zip ties, heavy duty duct tape, etc
* jerry cans for fuel and water w/ roof rack mounts
* MRE boxes

* qty 2, Orion 6030 6-Pack Emergency Flare Kit
* 3 DOT reflective emergency triangles
* qty 4, 10 pack Cyalume 10" Flare Alternative SnapLights, red
* 6 PowerFlare Soft Pack
* MagLite LED 3-Cell D Flashlight
- Accessory Pack W/ mounting brackets (ASXX376)

* Deka Copper Clad Aluminum Booster Cables P/N 04370 (4 gauge, 20 feet) [buy and swap with XV]
* Bubba 3/4" Shackles (qty 4)
3/4" Shackles : Clevises : D-Rings : Connecting Hardware for the Bubba : Bubba Rope
* H3R Performance MX500R - Dry Chemical Fire Extinguisher
H3R Performance | MX500R - Dry Chemical Fire Extinguisher
- H3R Performance SM01BK - Black Fire Extinguisher Seat Mount
SM01BK - Black Universal Seat Mount | H3R Performance
* Vaughan Supersteel Camp Axe SKU SC1-1/4
Supersteel Camp Axe - Vaughan Manufacturing
* Silky GENKI Temagari 500mm ( XL Teeth )
Silky GENKI Temagari 500mm ( XL Teeth ) | SherrillTree.com
* Bully Tools Super Heavy Duty - Fiberglass Handled Shovels Model #92510
http://www.bullytools.com/images/BullyTools82510.jpg
__________________
"Why would I want to profess my feelings for some 3D girl?" - Tomoya Aki from the anime Saekano
some large image
'muricuh, **** yeah!

Last edited by AWDfreak; 10-28-14 at 04:00 PM.
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