'Lucy' Daily driven Subaru Legacy RS replica

Subaru

Legacy

1996

0

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Nov. 2019 - First check up after buying it and driving it for an hour
Nov. 2019 - Front view from the first check up, bonus my trusty first and support vehicle the Opel in the back
Nov. 2019 - Proof of really having an EJ22
Nov. 2019 - Cracked 86000km when I got back home
Nov. 2019 - Quiet dirty
Nov. 2019 - The carpet should be grey not brown
Nov. 2019 - Weird shadows on the backseat
Nov. 2019 - A friend came by a made some photos. Happy me about my purchase
Nov. 2019 - Peek-a-Boo
Nov. 2019 - First motion shots of the car
Nov. 2019 - Motion shot from the back
Apr. 2020 - Getting the car back after the winter while Lockdown just started
Apr. 2020 - Of course the battery was dead, so first time jumpstarting a car
Apr. 2020 - First thing was to clean the car. I hate working on something dirty when ist doesn't have to be.
Apr. 2020 - Went further than I initially thought when cleaning and wet vacuumed everything.
took me 2 days just cleaning the chassis
Apr. 2020 - Also wet vacuumed the seats. brushed in a carpet cleaner and vacuumed afterwards
Apr. 2020 - Before I cleaned the driver seat. It was in very good condition, only small stains
Apr. 2020 - After cleaning, no more stains and just like new
Apr. 2020 - Rear bench got the same treatment
May 2020 - Made a anti slip matt to fit the OEM trunk tub. Got it to cover up some weird stains in the plastic
May 2020 - Just like fresh from the dealership
May 2020 - Center console did get a treatment with an plastic paint restore paste from DDR times. Worked wonders to scratches just a little darker than original.
May 2020 - the old speakers were bridle or disintegrated themselves upon touching
May 2020 - modifying the bracket for the new tweeters
May 2020 - Hot glueing the new Tweeters in the OEM brackets
May 2020 - Tweeters barely fit
May 2020 - Amp mock up
May 2020 - final product which lifes at the ceiling of my trunk
May 2020 - delivered Don Silencioso muffler, reached way beyond my bumper
May 2020 - OEM muffler is far back under thje rear bumper
May 2020 - difference between the two mufflers, seems like Don Silencioso design it for the wagon
May 2020 - trimming line for optimal stickout
May 2020 - shortened and mounted muffler
June 2020 - installing speakers in the front door
June 2020 - mount the tweeter
June 2020 - routing the power supply for my amp
June 2020 -neatly routed
June 2020 - subaru definetly thought on placing am amp up there!
June 2020 - old bushings on the left
June 2020 -  old bushings on the right
June 2020 - rear crossmember found its way out
June 2020 - finally getting my Wheels and tires after 5 month of waiting
July 2020 - got the crossmember painted and new bushings installed
July 2020 - Mc Gyver tool invention for bushing installation
July 2020 - first time standing on it desired wheels
July 2020 - First drive and photoshoot with friends in the mountains
Juli 2020 - beautyshot powersteeringpump reservoir
August 2020 - found an oilleak and the culprit
August 2020 - OEM replacement, fingers crossed it hold up
August 2020 - oil drenched timingbelts are no good. First belt change in 24 years
April 2021 - CAD modell for a mounting plate
April 2021 - improvised bending rig
April 2021 - the CAD modell got reality
April 2021 - fire extiguisher safefly mounted
April 2021 - dirty enginebay
April 2021 - detailed and cleaned enginebay
April 2021 - detailed and cleaned enginebay side view
May 2021 - instrumentcluster as I bought it
May 2021 - swapped the Trailer controllight for the foglight switch
May 2021 - replacing parts for factory cruise control
May 2021 - cut a hole for the switch to fit. Subaru lined it our for me
May 2021 - found the OEM mounting position and plug under the dash
May 2021 - vacuumpump and accessories
May 2021 - OEM position vacuum powered cablethrottle, even the clips for routing were there
May 2021 - had to search a bit to find the place where the vaccumpump belongs.
May 2021 - front facial as I bought it
May 2021 - looking what I work with for a bumper swap
May 2021 - mint condition sidebracket
August 2021 - got weird vibrations from the Drivetrain, engine mount doesn't look bad
August 2021 - tranmisson mount also looks fine
August 2021 - new OEM front bumper side brackets
August 2021 - using advanced CAD techniques for modeling a foglight bracket
August 2021 - printed a prototype
August 2021 - extra bolt at the back needed
August 2021 - "new" JDM front bumper mocked up
August 2021 - noticed the car got louder, found the source
August 2021 - right in front of the cat
September 2021 - extra fresh air ventilation for the cat I suppose
September 2021 - it's worse than it looks
September 2021 - decided to weld  a clamp around it than cut it apart and put a new pipe in
September 2021 - the thinnest parts of rust removed
September 2021 - heatshield also repaired and painted with zink paint
September 2021 - it will hold long enough before the clamp will rust through, considering its 2mm thick
September 2021 - mounted back under the car with fresh gaskets and hardware
September 2021 - shifterbushings worn, replaced with PU bushing for less play
September 2021 - the back bushing completly disintegrated
September 2021 - swapped in a Impreza shifter linkage, Legacy's didn't had a rubber sleeve
September 2021 - replacing OEM transmount with a group N mount, OEM was compressed
September 2021 - fits like glove
September 2021 - old OEM engine mounts out, new group N mounts in
September 2021 - Oem mounts were also 5mm compressed
September 2021 - first time lifting the engine
September 2021 - prototyping finished and final foglight brackets fabricated
September 2021 - prep work for paint. Use a solvent to clean your parts from machinist blue, it will shine trough
September 2021 - way to good of a paint job considering no one will ever see it
September 2021 - brackets with mounted foglights
Oktober 2021 - everything mounted and wired up
Oktober 2021 - parked for winter storage
March 2022 - decided to fix the mint rear bumper to make it mint++
March 2022 - printed a PP patch I welded in to close the gap
March 2022 - bending back the dent was not possible, so welding it was
March 2022 - more plastic welding
March 2022 - roughly sanding the high spots from the welds
March 2022 - while I am at lets refurbish the trailer hook, wire brushed
March 2022 - then quick and dirty primer from the spraycan
March 2022 - decided for an matt black spraycan
March 2022 - first layer of filler and sanding done
March 2022 - 7 layers and 40h of sanding later
March 2022 - pretty okay for my first time
March 2022 - ready for primer and paint
March 2022 - I could use the makeshift paintbooth my neighbor made in his garage
March 2022 - quiet small but made it work
March 2022 - fill primer sprayed and sanded with 400 grit
April 2022 - back in the booth ready for paint
April 2022 - first time using a paint gun and waterbased paint, a lot of first times
April 2022 - a run there
April 2022 - more runs there,
April 2022 - runs sanded down, trying to hide them a little bit
April 2022 - prepped everything for 2K clearcoat.
April 2022 - trailerplugbracket got the same treatment as the trailerhook itself
April 2022 - saved the cut out below the trailerhook, seemed like a worthy thing to do
April 2022 - freshly painted Bumper, at this point just dry enough to get lighly touched
April 2022 - runs weren't visible when fresh
April 2022 - a trailerhook which looks way to nice to hide in bodywork and behind a Bumper
April 2022 - stripped rear end
April 2022 - looking real good
April 2022 - yes there is enough space
April 2022 - adjustment were it was
April 2022 - adjustment were it went, 8mm down
April 2022 - roofrack now fits without smashing my windows all around
Juli 2022 - test fitting 4-Pot Calipers
Juli 2022 - wheels clear the bigger caliper
Juli 2022 - rear one only in slightly used and rusted condition available
Juli 2022 - slightly used and rusted was maybe not the right wording
Juli 2022 - O-ring rusted in place
Juli 2022 - wirebrush and wirewheel got me that far
August 2022 - adding a boiling vinegar solution to the mix helps a lot
August 2022 - rear caliper bracket didn't came with the first set of calipers
August 2022 - yes, two sets of rear calipers. everything powdercoated in RAL3032, accents in cherry blossm pink
August 2022 - assembled front 4-pot caliper
August 2022 - assembled front 4-pot caliper
August 2022 - not only two sets of rear calipers, also two Legacy RS spoilers. Only one came with a breaklight
August 2022 - mockUp on the trunk
August 2022 - took 1h to split that on the hub without damaging the ABS sensor
August 2022 - the new bigger one is a split OEM one, like they should be delivered
Oktober 2022 - comparisson OEM front strut VS. KW V1
Oktober 2022 - the coilovers are quiet a bit lighter than expected
Oktober 2022 - DIY springcompresser, not recommended, would do again
November 2022 - rear tophead problem, bought the new one from the VIN, but not one fit
November 2022 - fits on rear coilover like it should
November 2022 - drillhole spacing won't fit however I put it and whatever I buy for it
Dezember 2022 - KW helped me out and had this exact problem exactly one more time
Dezember 2022 - dual spring replaced for an 06' WRX coil
Dezember 2022 - this BMW OEM rubber part
Dezember 2022 - and this adapter from KW themselve
Dezember 2022 - 06' WRX Tophead an my 96' Legacy rear coilover, combined with an OEM BMW rubber part
Dezember 2022 - on the far right coil assembly as delivered for 96' Legacy's, both working Coilovers for my Legacy and the OEM Strut
Dezember 2022 - mounted and set to rideheight
Dezember 2022 - first glimpse at the new stance, 320mm front , 330mm rear
April 2023 - first trip on new coilovers 320km just to borrow a boat for the year
April 2023 - trailering it back home, pulling a boat on fresh coilovers. Even a project car need to be used!
Mai 2023 - rooftent borrowed for a sailboatrace I attended
Juni 2023 - time to get rid of the rear trim at the wheelarch
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Mods

- Enkei Nagato rims in 17"x7,5" JJ +42 in bronze
- Continental EcoContact6 215/40R17 XL
- KW Variant 1 coilovers
- Brembo remanufactured brake calipers from an Impreza GC8, 4-pot at the front and 1-pot at the rear
- Brembo brake discs in the front Ø296mm and in the rear Ø266mm but vented instead of solid
- braided stainless brake hoses
- Legacy Outback powersteering pump
- NGK iridium sparkplugs
- Group N STI engine mounts
- Group N STI pitch damper
- Group N STI transmission mount
- added OEM cruise control which it didn't had from factory
- Impreza shiftlinkage
- Powerflex PU differential bushings
- Legacy BD/BG facelift front bumper
- Legacy BD/BG facelift projector fog lights
- JVC radio with USB, BT and multicolor to match the interior lightning
- Eton mini 150.4 amplifier
- Hifonics Titan TS kompo speakers
- Hifonic Titan TS 62 coax speakers

Build story

This is my Legacy GX named 'Lucy' which I'll try to build a Legacy RS replica from.
The car came with an EJ22E SOHC 16V producing 94kw and 196Nm at the crank, coupled with an 5-speed manual.
GX was one of the highest trim levels available in europe.
For now I'll try preserve the car and improve it with the OEM parts and some aftermarket stuff when OEM is not good enough for me.
For now I am happy with the NA Engine, the boxer sound and the mileage I get.
Average mileage is 8,3 l/100km (28,3mpg), when I try I get down to 7,5 l/100km (31,3mpg). I once got it to 7,2 l/100km (32,7mpg) don't ask me how did that.
Of course I'm playing with the idea of adding a turbo and swapping the heads to DOHC with AVCS (Subarus cam timing).

Swapping exterior parts to get the look of the Legacy RS and adding missing optional features like fog lights and cruise control
to make the car nicer is the main course.
Upgraded to GC8 brakes all around, because the original brakes weren't up to the task with the new wheels and tires I got. For a better looking stance I got myself a set of KW coilovers. Getting a 6-speed manual and Projector Headlights are still on my bucketlist.

For how I got the car...
In 2019 I decided to buy a project car. Mostly influenced by Richard Burns Rally I played as a kid and the Isle of Man TT Record Lap from 2016 driven by Mark Higgins, somehow Subaru was very high on my list.
The Impreza's, I looked up here in Germany, were to expensive and most of the time in a rough shape. So I expanded the models and Year of make I searched for to find something nice.
At that point I registered that the engine used in the 22B and the rally cars at the time, was also available in Legacy's till 1996. Sadly the turbocharged Models of the EJ22 weren't sold in Europe.

So knowing that the Iconic 2.2 liter Boxer is in Legacy's which were (and probably still are) cheaper than Impreza's.
Legacy's (most likely) didn't got trashed on like most Impreza's,
while having the same Engine options, as well as the desireabel EJ22.
They are more practical and have a tow rating of 1800Kg or 3968lbs (in Europe at least).
All that and on top I got the same aftermarket as everyone else for Impreza's, because the first gen Impreza's and second gen Legacy shared almost everything.

Found the car on the internet 680km (422Miles) away in south Germany. Called the dealer, which was selling the car for a long term customer.
At the time I didn't had much support for buying a project Car. So I needed it to drive home by itself. Wasn't allowed to rent Cars back then. So towing was no option.
After two calls I bought the car for 2000€ and drove with a friend to south germany to pick it up.
At the dealer I learned that the car had only one owner which bought it new at that same dealer as a retirement present to himself.
He was just selling it because he couldn't drive it anymore. He was 93 years old at the time.
On the way home I lost all powersteering because all three seals of the steeringrack decided to let go, emptying itself on the header.
My friend driving behind me told me that the car smelled like hot rubber and hot oil. But there was no visible smoke that you could see at night.
Only when I parked it at home a big cloud of smoke came out of the hood and driverside wheelarch.
The hot rubber smell was explained by the rock hard and old tires in combination with an bad alignment.

All in all it was a very good purchase, only two rust spots and a leaky steeringrack.

Exterior

Front bumper (EUDM facelift bumper similar to USDM GT bumper from 99)
57730AC160

Lighting

Projector fog lights
KOITO 114-20620

Audio / video

Eton mini 150.4 amplifier
MINI150.4
Hifonics Titan TS 6.2C 16,5cm kompo
4500
Hifonic Titan TS 62 16,5cm coax
4497
JVC Radio with USB, BT and Multicolor
‎KD-R992BT

Transmission

Group N STI transmission mount
ST4100055200

Powertrain

Group N STI engine mount
ST4100055110-120
Group N STI pitch damper
ST410404S000
Powerflex PU differential bushings
PFR69-122

Ignition

Iridium spark plug
BRK6EIX-11 | 3764

Brakes

Brembo brake caliper (front left)
F78 018
Brembo brake caliper (front right)
F78 019
Brembo brake caliper (rear left)
F78 020
Brembo brake caliper (rear right)
F78 021
Front brake disc Ø296mm
09.9077.11
rear brake disc Ø266mm
09.9147.10
Techlinger braided stainless brake hose
TS116598-V
Brembo brake pads front
P 56 034
Brembo brake pads rear
P 78 005
Brembo parking brake pads
S 78 508

Rims & tires

Enkei Nagato Bronze 17"x7,5" JJ +42
EN04-751742-X5-55
Continental EcoContact 215/40 R17 XL
0313871000

Exhaust

Don Silencioso Roar
1A03019A-1C85SL

Suspension

KW Coilover V1
10245005
Map of location
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