It's a subaru

[donandal]

I am posting this build thread for anyone interested in seeing a different kind of Subaru
I started this car about five years ago, and have been driving it for a couple of years.
I wanted to build a car that had an old style roadster look and feel with modern drivetrain and
modern accessories. It has a Subaru 2.5 boxer engine,five speed manual, and all wheel drive.
It has cruise control, antiskid ( deselectable ),air conditioning/heat, tilt steering etc. It is emissions
eguipped and street legal. It is registered in New York state and has about 1500 miles since completion.
The chassis is steel tubing and the body is made from .060" thick aluminum. I " designed " and built
the car from scratch, using the engine, drivetrain, suspension and steering from a Subaru legacy. The
design was mostly trying to make a strong and safe chassis, and then covering it with an attractive
body. Most of the body was mocked up first in thin cardboard, then hand formed using a hammer and
bean bag, and then an english wheel. I hope you like it
http://i1218.photobucket.com/albums/dd418/homebuilt1/Suburuwithbrian005.jpg
I'll post pics and descriptions below
http://i1218.photobucket.com/albums/dd418/homebuilt1/P8310441.jpg
the shop... sort of a necessity in western New York in the winter
http://i1218.photobucket.com/albums/dd418/homebuilt1/P8310425.jpg
the chassis... not a lot of interesting pics prior to this
http://i1218.photobucket.com/albums/dd418/homebuilt1/PA020983.jpg
the radiator is in back... no room up front..coolant runs under floor in stainless tubing
http://i1218.photobucket.com/albums/dd418/homebuilt1/P1150618.jpg
some early ideas in cardboard
http://i1218.photobucket.com/albums/dd418/homebuilt1/P3060652.jpg
more cardboard... the car has coilovers on all 4 corners
http://i1218.photobucket.com/albums/dd418/homebuilt1/P1150619.jpg
making a cardboard mess....the seats are subaru
http://i1218.photobucket.com/albums/dd418/homebuilt1/P5140741.jpg
the first piece of the body...hammered over a wooden buck
http://i1218.photobucket.com/albums/dd418/homebuilt1/hoodopenatshop1.jpg
the hood taking shape.... no plans.. just build it as I go
http://i1218.photobucket.com/albums/dd418/homebuilt1/P9221069.jpg
some of the body as well
http://i1218.photobucket.com/albums/dd418/homebuilt1/PC311009.jpg
me with a future front inner fender... trying to match the lines of the doors
http://i1218.photobucket.com/albums/dd418/homebuilt1/PA081082.jpg
my wife with a future rear upper quarter panel
http://i1218.photobucket.com/albums/dd418/homebuilt1/PA081085.jpg
I smoothed with the english wheel... it became the triangle portion in this picture
http://i1218.photobucket.com/albums/dd418/homebuilt1/P9221066.jpg
a shot of the body coming together
http://i1218.photobucket.com/albums/dd418/homebuilt1/reardecklid.jpg
the rear deck lid is perforated aluminum in the center section for ventilation
http://i1218.photobucket.com/albums/dd418/homebuilt1/P1271112.jpg
what I hope the fenders and quarter panel will look like
http://i1218.photobucket.com/albums/dd418/homebuilt1/P1151015.jpg
the front is coming along nicely.... need to cover those strut towers
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0169.jpg
making a rear fender...
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0170.jpg
fitting it to the car
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0189.jpg
trimmed and fit... not bad!
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0020.jpg
making the windshield... it is made from .060 aluminum also, and has a solid bar running
up inside both sides for strength
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0031.jpg
filling in the corners for looks
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0025.jpg
just needs a little style in the center of the hood, and some safety glass
the mirror will go on the side of the windshield, it's from a motorcycle
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0130.jpg
the front fender.. the small turn signal is from a motorcycle too..I managed to
hide those ugly strut towers under the headlite buckets
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0148.jpg
the dash is made from aluminum as well, but will be padded and upholstered
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0119.jpg
the roll bars were made from prebent thick wall stainless tubing, and welded together
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0136.jpg
I think it needs a scoop
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0197.jpg
this shape looks good
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0204.jpg
I added a rounded edge
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0212.jpg
and added a flange so I could rivet it to the hood.. welding would really bow it
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0215.jpg
riveting
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0220.jpg
the hood tilts forward
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0222.jpg
I made this from stainless and polished it
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0228.jpg
it will go in here... I made one to go in the front grill also
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0251.jpg
I want a top for bad weather
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0288.jpg
so I started this tube frame
http://i1218.photobucket.com/albums/dd418/homebuilt1/IMG_0295.jpg
It should look something like this
http://i1218.photobucket.com/albums/dd418/homebuilt1/frontviewconvertible.jpg
this is as far as I got before my son got me going on his 240SX project
that is the 350Z donor car in the background..I should be back on this project this summer
http://i1218.photobucket.com/albums/dd418/homebuilt1/sideviewpanelsdone.jpg
I'm interested in ideas for a paint scheme
Thanks for checking it out

[blueshark123]

looks like something Volkswagen would make

[!Zar!]

That is some awesome work. It reminds me of a Caterham.
http://img1.loadtr.com/b-390495-caterham_car.jpg

Paint it british racing green.
Or like a deep blue like this.
http://www.flagworld.com/photos/d/519769-2/2011-02-01+-+AT_T+Williams+-+Valencia+-+Rubens+Barrichello+03.jpg

[dwadia]

Wow your project is very impressive and i'm amazed you can manage all of that on your own! That must be a blast to drive... best of luck with it!

[SILEIGHTY_DET]

if it were me i wouldnt paint the entire car . i would leave more exposed polished aluminum to show off all the hard work that you have put into the body . what an amazing car !

[B4THEZ]

You sir. have some skills. awesome built.

[Wake]

I love the idea and overall design. Awesome fab work that you do not see in this day and age.

Personally I would like the headlights down in front of the front wheels somewhere. Make it look a bit more sleek and less buggy looking. Just my opinion of course. I love everythin else and its relevant to me because im actually comsidering buying a legacy soon lol.

[donandal]

I love the idea and overall design. Awesome fab work that you do not see in this day and age.

Personally I would like the headlights down in front of the front wheels somewhere. Make it look a bit more sleek and less buggy looking. Just my opinion of course. I love everythin else and its relevant to me because im actually comsidering buying a legacy soon lol.
I like your sense of style.... the headlites are my least favorite part
also. They sort of ended up that way to cover up the strut towers...haha
this project was my "learning curve" , the next one I'm designing now
is going to be a high horsepower very lightweight tube chassis aluminum
skin indy style street legal two seater that is very sleek. It will be finished
in polished aluminum.
thanks

[Wake]

Glad to hear you arent going to be one and done. Too many people these days try to build the perfect car the first time and then are through. Im happy to hear that there will be a ver.2.0.
Its awesome that we agree on the style, And I see what you mean about trying to cover the the strith towers. I personally kind of like the exposed look. Or you could look into something like the prowler front suspension and possibly take some inspiration from their suspension/fender set up (ignore everything else, lol). Looking forward to updates in both your build threads.

http://i51.tinypic.com/34si5mw.jpg
http://i56.tinypic.com/wj9c81.jpg
http://i56.tinypic.com/2z6rok6.jpg

[Magical Trevor]

Creative fab work A+ on the fitment.

I can't wait for ver 2.0

[holemilk00]

I looked for this after seeing your sons build thread.

I have to say, it looks like something that might be a hybrid or an electric car, I'm sure more people think that when they see it, and then with the Subaru drivetrain you probably surprise a LOT of people. I'm still amazed at the workmanship and the fitment, and even more so when I read that this is your first full car project. Great work.

[ronmcdon]

Awesome project!!

[axiomatik]

Amazing work, you must have poured a lot of hours into it. How does it drive? Does it feel lighter than the Legacy? (Obviously the center of gravity is lower, but I ask because the steel spaceframe looks pretty beefy.) Has the wheelbase been shortened versus the donor?

My first thought on finish was polish as well. All that beautiful aluminum work would look great polished. But that may require a level of surface perfection that's not reasonable to attain. It's a cheerful looking car, so I suggest a bright color, like yellow or orange, just as long as it is not fluorescent.

I want to start a Lotus 7 replica/kit, but I am going to have to wait until my kids are a bit older before I will have the free time to start a project like that.

[Phlip]

My first thought on finish was polish as well. All that beautiful aluminum work would look great polished. But that may require a level of surface perfection that's not reasonable to attain.

I thought the same thing, up to and including the same hangups to doing such a thing, then I thought “what about brushed aluminum, anodized black or gunmetal in color?”
Then I went to bed without saying it.

[qwerth]

wow looks like fun building that thing!

[donandal]

Amazing work, you must have poured a lot of hours into it. How does it drive? Does it feel lighter than the Legacy? (Obviously the center of gravity is lower, but I ask because the steel spaceframe looks pretty beefy.) Has the wheelbase been shortened versus the donor?

My first thought on finish was polish as well. All that beautiful aluminum work would look great polished. But that may require a level of surface perfection that's not reasonable to attain. It's a cheerful looking car, so I suggest a bright color, like yellow or orange, just as long as it is not fluorescent.

I want to start a Lotus 7 replica/kit, but I am going to have to wait until my kids are a bit older before I will have the free time to start a project like that.
The car weighs 2460 lbs with a full tank of gas. It is very quick handling
and has almost no body roll in very hard cornering. The wheelbase was shortened to 101 inches and it's probably only making about 160 hp at the engine. I think the front to rear balance is pretty good too, but I haven't weighed it on the corners yet.
I like the idea of a bright color, and am considering burnt orange candy color I saw on a kawasaki motorcycle, or maybe a bright Blue metalic like the WRX.
I started this project when the boys were going off to college to fill the time.
The car projects have turned into a great excuse to stay in touch with them and gives us something to talk about and work on together.

[LimeLite Racing]

Amazing work.

[angzt]

Nice sheet metal work.

[PHX-S14]

props on all the hard work..

[tqstarburst]

For your second project you should create something like a new 240. I would love to see that. Awesome build btw.

[axiomatik]

Where do the radiators pull air in from? You have the mesh panel for exhausting the heat, but I don't see any corresponding intake.

Also, I think that hood scoop needs a top-mount intercooler underneath it. :)

[donandal]

Where do the radiators pull air in from? You have the mesh panel for exhausting the heat, but I don't see any corresponding intake.

Also, I think that hood scoop needs a top-mount intercooler underneath it. :)
The radiator fans draw air in from the bottom just below and behind the seats. The coolant lines are 304 stainless 1.5" tubing that run under the floor.
I wasn't sure if the factory water pump would have enough flow to run all the way back there, but it runs perfectly in the middle of the temp gauge, with or without the air conditioning turned on. The air conditioning is a must, believe it or not, for a convertible when in city traffic.

The hood scoop is funtional, only in the sense of more air into the engine compartment. I've thought about a turbo for this car, but there is just no room left in that skinny engine cowl.

[treken2t87]

I hate bumping old threads, but I cannot believe I missed this build. I always dreamed of designing and building my own car, and here's a real life example. I admire not only your skills, but also how you use them. Keep up the awesome work.

[TFD]

VERY nice work. Maybe the style is not everyones cuppa but you defenitly did your thing with this car, thumbs up for that one!

[zomgsohc]

This is an old thread worth a bump. While certain aspects of the styling aren't to my taste (the headlights come to mind), it is amazing to see such attention to details and fine craftsmanship. Some more aggressive rims would look great, as well as a bright yello paint job (and make the top black!!!). Wonderful to see stuff like this.

[yokotas13]

that is awesome fabrication, and tons of work

It just looks goofy.

[exitspeed]

that is awesome fabrication, and tons of work

It just looks goofy.

And by goofy you mean terrible...Fab work is crazy though. Just should have let someone with an actual eye for design pen the body for you.

[donandal]

Hey wait a minute......
I thought if you posted something on the internet
everybody had to like it......
hahahahahahahahahahahahahaha...

[yokotas13]

And by goofy you mean terrible...Fab work is crazy though. Just should have let someone with an actual eye for design pen the body for you.
ewell, i didnt want to be super mean lol

the front is just wayyy too wide and tall

[exitspeed]

Hey wait a minute......
I thought if you posted something on the internet
everybody had to like it......
hahahahahahahahahahahahahaha...

I mean don't get me wrong, I like it for what it is. I just don't like looking at it so much. It's still 100000x better then anything I could do. lol

[Darren]

You sir, have a talent for sheetmetal. Not everyone has the patience to plug away at an entire body!

I wish i had 1/4 of those skills, then my car might not look like such a pile of poo!! :D

[JDMDude]

Great build!

[Tantwoforty]

wow thats some impressive work!

[onehundredoctane]

Wow! I wish I was that talented at metal work! I bet that thing is pretty quick considering the weight of the car! Great work man!

[future]

Ive seen this build thread a coulle times and its still great. But that 240 build was crazy

[ZX88]

looks like something upstate NY would say looks cool.

[Gnnr]

http://www.meh.ro/wp-content/uploads/2011/01/meh.ro6405.jpg