2.5 Legacy conversion - finished at last

[ricp]

Finished at last. I have completed my 2.5 legacy upgrade to my T25 Camper. What a difference it makes - we can go up hills without being reduced to 2nd gear and it is even slightly more economical than before. However now feels a bit undergeared.
So I thought I'd give all a bit of a summary.
Thanks must go to RJES for all the bits, which fitted off the shelf, and make for a much less stressful experience but as importantly, the advice. Also to the Haynes Motor Museum, who did most the spanner work for a very reasonable rate. They even knocked some of the hours off as it was a voyage of discovery for all. The cost was more than hoped but most of this was due to doing all the gaskets and seals on the engine before it went in as a precaution and the their desire to make it as professional a job as possible down to placing all the wiring in new conduit, re-undersealing the underneath where the cross member was attached, sorting an oil leak on the gearbox, etc, etc. It looks a fantastic job and worked straight from the box, which says a lot for all parties work, but I paid for it!
Also thanks to the Subaru guys at Used Subaru Parts nr Cullompton for second-hand bits.
In total, the Legacy with FSH and 53K miles was £700 plus £300 to deliver from Newcastle to Someset.
RJES stuff was £2000 approx inc exhaust
Haynes gave 50 hours approx at £50/hr to remove VW and Legacy engine, recon and then refit the Legacy engine and parts etc.
There was other stuff that gets paid as you go along but you get the idea
I got £600 for the VW engine and £250 for the remains of the Subaru.
Was it woth it - financially probably not, I guess the van is worth more but as a keeper to use, yes. It has made it much easier and more relaxing to drive especially 4 up with bikes and kit, running cooler and further, rather than having to cane the 1.9 VW engine within an inch of it life constantly.
Next to do is to go up a size in tyre profile to try to raise the gearing a little before looking at gearbox ratios possibly.

[ElusiveStranger]

I'm glad you like it

50 hours labour though in a T25 that's 2.5k, around 1k more than my complete conversion
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The advice you receive on here is worth the paper it's written on.
Your experiences are worth shed loads to others, including the f'ups - live and learn.
Wouldn't YOU rather learn by someone else's mistakes? So would they.

'78 Bay, 2 litre 091 box, EJ20 NA & the ashtray's on the 'right' side.
I don't lean forward for hills any more
Bugger, missed out on "Live fast, die young"

[gerrelt]

Sounds good!

Now, let's see some pictures!
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VolksRomeo 13033 S 1.4 IE
(VW 1303 S with Alfa Romeo 33 1.4 IE engine)
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[ricp]

Pictures - ahh, I'll try as they paint a thousand words etc.
It was basically a week's work rather than the 3 days I'd hoped and budgeted for. However they got carried away in their professionalism and enthusiasm so even the immobiliser and ECU fault lights loom was extended to run to the instrument binacle. I got belts done as they were only 25 K miles but 5 years old and head gaskets as it was a '99 DOHC engine and these were original and OK but a known weak point. Other little jobs cropped up but it does now look as if it is an original VW set-up. I could and should have done more of the preparatory work rather than just removing and stripping the loom etc and also then completing the job including a lot of the tidying but once the van is there and they are getting on, it was too easy to let them run.
It will be all forgotten in the mists of time and French red.
The new 205/15/70 tyres have dropped the revs 300 to 400 rpm at 70 mph compared to the previous 205/15/60s. Time will tell if a further reduction would benefit.

[rjes]

Hello Ric,
Glad it is all up and running, and you are pleased with the results. 50 hours is a lot of labour for a T25 conversion. However, The first time anybody does a conversion they will a lot more learning to do compared to someone who already knows them inside out. It sounds like you have gone to town with the conversion details though, which all eats up time.
The optional front extension harness I do takes all relevant wiring to the front of the bus (engine and immobiliser lights, VSS, radiator fans, etc). The intention is that it makes the wiring as 'plug and play' as possible.
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Regards,

Richard,

R J Engineered Solutions
Quality Subaru Powered VW Components
www.rjes.com