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lurking Subaru whore
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823 Posts
Discussion Starter #1 (Edited)
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!

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
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
 

Attachments

·
'do right & fear no one"
Joined
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8,564 Posts
you make me look completely sane, freak. i never imagined it possible. thank you.
(i crack myself up)
 

·
lurking Subaru whore
Joined
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823 Posts
Discussion Starter #5
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 :lol:


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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'do right & fear no one"
Joined
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8,564 Posts
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.
 

·
lurking Subaru whore
Joined
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823 Posts
Discussion Starter #8 (Edited)
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.
 

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lurking Subaru whore
Joined
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823 Posts
Discussion Starter #9
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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lurking Subaru whore
Joined
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823 Posts
Discussion Starter #10 (Edited)
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:
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
 

·
'do right & fear no one"
Joined
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8,564 Posts
damn, freak. that's some list of stuff. an emergency kit like that needs a firearm...or two.
 

·
lurking Subaru whore
Joined
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823 Posts
Discussion Starter #12
damn, freak. that's some list of stuff. an emergency kit like that needs a firearm...or two.
Firearms and firearm mounts won't be done until I move out of this ****in extremist anti-freedom state we all know as California. :rolleyes:


New brake rotors, new brake pads, and new parking brake shoes installed on the Outback.

Bedding in StopTech pads is truly a chore... I spent more than an hour bedding them in because I live in a busy metropolitan area. The road I thought I wouldn't see a single car ended up having well over a dozen cars pass me by during the bed-in proccess.

Bite is definitely better but I think there's an issue with the hydraulic system.


The pedal still feels mushy. I thought it was a lack of vacuum, but a quick check of reserve power assist and a pedal drop during start up only shows that the vacuum assist is working fine.

I'm hoping the issue isn't so bad as it seems. At least I can finally kick in ABS, a welcome improvement over its previous condition in which I couldn't even activate ABS in panic stops.
 

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'do right & fear no one"
Joined
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8,564 Posts
Firearms and firearm mounts won't be done until I move out of this ****in extremist anti-freedom state we all know as California.
I'm staying right here in the belly of the beast on the right coast. at least we've got sheriff's standing up for citizens here.
 

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lurking Subaru whore
Joined
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823 Posts
Discussion Starter #14
I'm staying right here in the belly of the beast on the right coast. at least we've got sheriff's standing up for citizens here.
That's awesome! I wish my county's sheriff would support our second amendment rights, the people keep re-electing a sheriff who's completely against citizens owning firearms.

I can't even get a CCW permit in this county and I'm technically a combat veteran! :mad:
 

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lurking Subaru whore
Joined
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823 Posts
Discussion Starter #15
So, reality has been hammering my logic.

Logic is convinced, current mod list for the Subaru Outback is obsolete. Instead, I'm going to focus on partially restoring the car from a mechanical standpoint. I'm going to do only just enough to be a reasonable short-distance commute vehicle.
 

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lurking Subaru whore
Joined
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823 Posts
Discussion Starter #17 (Edited)
So.... I hate my Stoptech Street Performance brake pads. I hate the way they feel, and want something with a stiffer feel and higher torque. The Stoptech Street Performance brake pads have a MOT (maximum operating temperature) of 1200 degrees F, so they actually do deliver on that claim.

So I decided to do a bit of research on brake pads (again). My Outback has switched from being a backup vehicle to a daily-driven short-trip vehicle that I now intend to use for experimenting on various racing brake pad compounds usable on the street.

I put the Akebono PRO-ACT as a baseline that would be comparable to an OEM brake pad compound. Otherwise, the other ones listed are ones I'm considering using on the Outback.


universal brake pad part numbers for USDM MY 2000 Subaru Outback
721 front
770 rear


Akebono PRO-ACT Ultra-Premium ceramic brake pad compound (OEM quality)
MOT of
572 degrees Fahrenheit (300 degrees Celsius) front ACT721, rear ACT770



Carbotech XP8 brake compound 200 degrees F min op temp
MOT of
1250 degrees Fahrenheit (676 degrees Celsius) front CT721, rear CT770

Winmax W4 racing brake compound 122 degrees F min op temp
MOT of
1202 degrees Fahrenheit (650 degrees Celsius) front WM-349-W4, rear WM-378-W4

Project Mu HC+ and HC+ 800 brake compound 32 degrees F min op temp
MOT of
1472 degrees Fahrenheit (800 degrees Celsius) front PH8F913, rear PH8R912
 

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lurking Subaru whore
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823 Posts
Discussion Starter #18

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lurking Subaru whore
Joined
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823 Posts
Discussion Starter #19
So, I bought an additional set of Made in USA booster cables by Deka.

The 2 AWG booster cables I got were actually heavier than the 4 AWG booster cables I already have in the plastic case... so the 4 AWG booster cables to the left in the plastic case will remain in the Subaru XV Crosstrek, while the heavier 2 AWG booster cables on the right will be put in my secondary vehicle (currently the 2000 Subaru Outback).

Imgur: The most awesome images on the Internet



After inspecting my Stoptech Street Performance brake pads on my Subaru Outback, I can safely say that cheaping out to get any Stoptech products was a very bad call on my end for my uses... they're glazed :(

Imgur: The most awesome images on the Internet
 

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lurking Subaru whore
Joined
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823 Posts
Discussion Starter #20
I just found out DBA makes brake rotors for my Outback!

* Disc Brakes Australia (DBA) 4000 Series T-Slot T3 brake rotors P/N 4648S front, 4657S rear

I'm going to pair these brake rotors with the Project Mu HC+ 800 that are shipping in. With the brake temperature paint they have standard, I can now tell just how hot my brakes will get and determine if the 800 degrees Celsius maximum operating temperature of the HC+ 800 will be sufficient.
 
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