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ya bro sorry to hear about the loss....

Dude what ur doing to ur car is great. Gives me the drive to do something great to mine. And it really sucks with ur lose i had a friend who just passed a few weeks ago.. Remeber drinking and driving is not the way to go.. May ur family member R.I.P.

Thanks all of the supportive feedback posted up here! Thanks and I will get more pics up this weekend.

updates?

OK, I got the front axles in, driveshaft in. I now have to install the new shifter cables that got in today. I was hoping to have received them this weekend so I could get everything buttoned up. But the shipment didn't arrive until today. Once I get the cables in place and some of the minor items cleaned up...I will post the pics up to give everyone a look.>

i might get to see it in person

I want!!! so how much has this cost you start to finish, if you don't mind me asking.

Very impressive. Hopefully it will become a kit where we can buy it and be able to bolt on and make it AWD. That would be really awsome to have a 3sgte and AWD in the US..

>
It is
(sorry, couldn't resist )

FYI, the T case for the 165/185/205 have the same physical dimensions. The difference in the 185 and 205 is simply the lever on the 185 that allows for different viscous coupling configurations [only for the dyno, before anyone asks. ]

As I'm sure you know the rear diff is the same as well.
Hubs are also the same [NOT the whole knuckle, just the hub] as far as I know.
You might be able to use the propeller shaft from a 185, but I believe it's a slight be shorter. Same type though, and very similar.
I think the same goes for the front and rear CV shafts.
I believe the rear subframe is also different, but similar. If you were going to make a bracket that it bolts up to, I don't think it would be that different enough to matter.
But I've never done this, so it's all supposition at this point.

The question is how well the 205 superstrut suspension would bolt up to it.
Or would you want to use the 185 suspension?
No joints in the front to go bad at 60k miles.

And for the record, when I state a part is the same, I mean it will bolt on. For example the rear diff for the 205 might have an extra groove in the heatsink, and so have a different part#, but it will bolt right up to a 185 subframe.

this is great info ^^^ excited to see this project.

Which parts? The whole project or just the rear?>

>
everything, the whole AWD conversion (not including 3sgte engine). Cost of parts, labor, specialty tools, custom fabrication, etc. everything needed to go from FWD to AWD.

The parts cost me approx 2k (excluding the tranny, driveshaft, rear diff - I got those with my clip). The hardest part about that was finding a place that would part out a car ship them out to me. I got them from a guy in Europe. It is a junk yard. I would suggest we go through someone on here rather than taking a chance like I did through e-bay. But I got the parts and that price included shipping. Since it was me and a friend of mine doing the work the price on labor is a rough guess. Looking at what we did and the time it took us, I would say that would have probably been about 5k (a lot of time spent figuring it out as we went) if it was done at a shop. I talked to my friend and he said he would probably do the work for anyone on here for around 3-4k. Now some of the parts can be gotten cheaper as a couple people have pointed out on here that the rear is the same on a ST165 and ST185. The arms and hubs also appear to be the same. The difference is those monster calipers and discs. Not to mention the sway bars....I should have gotten them from the guy at the Junk yard as well. By going fuel cell instead of the tank like I did, would probably save a lot of time and money or be a wash between the cost of the cell and fabrication. My guess at this point would be it can all be done if paying someone else for everything for around 5+k.>

This post has been edited by Green_MachToy: Feb 22, 2007 - 1:24 AM

is it possible to get any better pics of each area of the subframe and so forth

I will give it a shot. Not promising anything.>

5K? wow! a lot less than I expected! I always assumed that a full AWD conversion would cost like 20K+

and i live in so cal. sweet. time to start filling up my piggy bank.

>

I believe that there is some untapped potential for money making I bet that alot of swapped people, including me, would drive any distance within US with to get that conversion done for anything under $7k
Maybe you should open up a shop.

I'd drive a distance to get it done.

My Garage is open and talked to the friend of mine that did most of the work with me and he is game. >

Sorry for the lack of infomration....things have been crazy at work. I have had no time for the car. I have finished the hard lines for the new gas tank location and the drive shaft is in. I was a little confused as to why there was a gap in the drive shaft with the front shaft all the way in the transfer case. I then figured out that it is not supposed to be in flush with the transfer case and the shaft, but it should be closer to flush on the dust shields. Once we lined everything up it looks like everything is a good fit. THe reason for the spacing in the transfer case (in case anyone wondered)....is for torque on the engine. When the engine torques down under load the trandfer case slides further down the driveshaft. I verified this with 2 ST165 owners and reviewed pics and the book I have on the st205. I will have to finish the re-wiring of the gas tank due to the differences in the placement of the float, etc. On ours it is pretty much all in one. On the ST205 you have two different ports and wiring to go with. I have tried to take some better pics and placed them up on a shared viewing location. I hope this works! I have tried to allow you to view most of the pics that I have in there. I didn't think you were interested in the family pics, so I tried to remove all of those. I have also changed out the lugs in the front. Due to the caliper size, the offset on my original 18" rims still did not clear them. I was about 3/8" off. In order to at least use a spacer to get this running I cheanged to a longer lug for now until I can afford new rims. The current problem I am focusing on is the front sway bar, end link, and strut mounting point. The stock sway bar appears to be different than the stock gt4. For those that are thinking of this...a rear sway bar new and upgraded is $200. I would imagine the front is the same, but haven't found one yet. I am still looking. If anyone knows where I can get a front st205 sway bar, please let me know. I have also added the OBX Style manifold with extra support and downpipe. I have been told that the OBX style manifolds crack because there is little support for them and the crack due to stress/weight of the down pipe, turbo, exhaust, etc. I have also upgraded the injectors to 680's and added the Aeromotive regulator. I will be sending out a turbo I have and have it upgraded (we had to clock the turbo and lift the intercooler for the new turbo and wastegate to fit...will eventually go to external wastegate). I have also installed the FCON V. Hopefully I will have it running soon. Until I have the new turbo back I have installed the stock one and changed the coolant lines. In the ST165, the coolant runs through the turbo. I have drilled a hole and added a spot on the front side of the turbo cover plate to allow for the recirc line to be on the opposite side of the turbo to allow for flow. What I have left is:
Bumper Modification
Gas tank wiring
Gas Tank fill neck - Adjust to fit into this setup
Front swaybar and end links
Finish putting everything back together in the engine when new turbo gets back
Re-check all bolts
Repair front cross-member bolt on car body (I will have to cut and re weld from the inside of the body. It appears to have broken free and will not let me tighten last bolt on front cross-member

good luck ! hope you get it done!!!

Awesome.

>

Thanks. I have the gas tank wiring and fill neck done. I should have the rest done by this weekend.

sweet. so cal meet at your place this weekend.

>Lol... I could head down there too if it was on Sunday.

-Charlie

any updates

I will post them tomorrow...I want to get some better pics to post with it.>

what happened to this??

iunno, the dood hasnt been online for about 2 weeks.