Lifted Subaru Outback BH off road build on 30″s
- Capability Score: 45/70
- Build Level: Pro
- Mods Budget: $$$$$
Being a kid of the 90s obsessed with cars, I remember how I first saw the BH Outback on the pages of a car magazine. Even though it wasn’t as aggressive and cool-looking as the trucks and SUVs of that era, the Outback’s adventurous design immediately jumped out at me, suggesting that this could be a cool car for a road trip with my dad.
SUV-worthy ground clearance, plastic body cladding, fender flares, and a raised roof with built-in roof rack promised that this vehicle was much more than a utilitarian station wagon (which by that time were dying out as a class).
Despite the fact that market interest for station wagons was in a negative trend for years, the late 90s – early 2000s were the time of a major rise in Subaru sales, and the 2nd gen Legacy Outback BH is partially responsible for that. It became evident, that people didn’t want just “a wagon”, they needed a cool wagon, and the Outback was it. People simply loved it because it perfectly combined the capabilities of an all-wheel-drive SUV with the road manners and efficiency of a regular car.
Owner’s Insight
Why did you choose an Outback for your off-road project versus a more 4×4 dedicated vehicle?
The Outback chose me. My parents had bought it as a roadtrip vehicle, but realized later that the seats were too uncomfortable, and I was dailying a Saturn at the time, so they gave it to me because it was just sitting unused. Can’t turn down a free car! I have two Jeep XJ’s for offroading (one mild, one wild) but they get terrible MPG (~10 less than the Subaru) so I parked them and focused on making the Subaru ideal for longer drives to off-road destinations.
What was the most difficult part of the build?
Definitely the spacer lift kit install. The documentation needed a lot of work (I may have been the first customer for that engine/chassis combo), so I had to try to contact the manufacturer, figure stuff out along the way, and document it and send it back after I was done.
Some of the bolts didn’t want to line up properly due to component angles, some of the bolts didn’t have enough threaded length & needed washers. For the radiator hoses, I had to measure them and go through the entire universal catalogue of hoses from several suppliers and order a couple options for each main hose just to get ones that somewhat fit.
I also made the mistake of trying to swap in a thicker aluminum radiator at that time, and failed because I wasn’t prepared for the modifications it needed to clear everything. While not part of the build, something challenging was when I ripped the front control arms out of the unibody on the local Gambler 500 and spent weeks fixing it with the help of my neighbor.
What do you love the most about your project?
I love the experiences it brings. Growing up in the 90s, my family would go on “overland” roadtrips with our 2WD E150s (and prepare/repair them along the way) throughout the western USA. This car brings me back to that, but offers more of a challenge to make things work since space is limited. It’s all worth it though, as the build came together to let me experience the same type of adventure I had as a child, one remote trail at a time.
Off-road Build
The owner of the Outback we’re featuring today decided to push its off-road capabilities further into SUV territory and enhanced it with a whole bunch of awesome upgrades that improved all aspects of the vehicle.
Suspension
Being a long-term fan of 4×4 vehicles who owned off-road dedicated Jeeps before, he had major plans for improving the wheels, suspension, and drivetrain of the Outback. The suspension system has been dramatically upgraded with a 4″ lift kit featuring Flatout Suspension GR40R coilovers, providing approximately 10″ of travel.
Rear Locker
One of the most significant mods was the rear differential auto-locker which ensured that both wheels are spinning when the AWD is slipping off. The wheels have been upgraded to 15×7 Black Rhino Boxer rims wrapped in 235/75/15 Toyo Open Country AT3 tires.
Exterior
The exterior has been modified for both aesthetics and functionality. A VIS Racing carbon fiber hood with a custom hood scoop improves engine cooling, while a DIY custom ABS mesh front grille adds a unique touch. The vehicle’s protection has been enhanced with a Primitive Racing 3/16″ engine skidplate and a rare OEM steel rear differential skidplate.
Lights
To get more light on the night roads and off them, the owner installed a 3″ bixenon projector retrofit in the headlights and additional Diode Dynamics LED pods for improved visibility in various conditions.
Other mods
The interior has been reconfigured for overlanding purposes. The rear seats have been removed to create space for cargo and camping gear, and MOLLE panels have been installed on the front seatbacks for organized storage. A custom gauge cluster bezel houses additional gauges for monitoring transmission and engine oil temperature and pressure. The vehicle is equipped for extended trips with a 12V refrigerator/freezer, an EcoFlow River Pro power station, and a custom sleeping platform. Recovery gear, including a Smittybilt air compressor and various tools and spare parts, ensures the vehicle is prepared for any situation encountered during off-road adventures.
Full List of Parts
Exterior
- VIS Racing carbon fiber “STI Style” hood
- Carbon fiber hood scoop
- DIY custom ABS mesh front grille
- JDM hatch spoiler
- Sideskirt delete & bedlined rocker panels
- 3D printed exterior badges
Interior
- MOLLE panels & storage bags for driver & passenger seat back to organize supplies & gear
- Rear seat removed (space for cargo/camping gear)
- Custom gauge cluster bezel by OrtizCustomPods
- Innovate Motorsports Temp/Pressure combo gauges for both ATF & engine oil
- Thinkware X1000 2K front+2K rear dash cam
Lights
- 3″ bixenon projector retrofit into Legacy single bulb all-chrome housings with 35w 4300k HIDs
- Diode Dynamics SS3 Pro Flood pods for ditch lighting mounted on DIY designed/3D printed door jamb brackets
- Diode Dynamics SS3 Sport Combo pods for forward lighting mounted on ADF brackets
- Yellow rectangular-beam LED pods for fog lighting (replaced factory fog housings)
Wheels
- 15×7 ET15 Black Rhino Boxer wheels (5)
- 235/75/15 (28.9″) Toyo Open Country AT3 tires
Suspension & Drivetrain
- SLO “Monster” subframe spacers
- 4″ lift with Flatout Suspension GR40R (10″ travel, 40mm inverted front coilovers, front/rear external reservoirs)
- Rear diff auto-locker (R160 Torq Locker)
- Front coilover reservoirs mounted in-line with hood scoop inlet
Armor & Protection
- Primitive Racing 3/16″ engine skidplate
- Rare OEM steel rear differential skidplate
- Cusco front strut tower brace
- Class II tow hitch (essentially a rock slider for the bumper)
- Godspeed tubular adjustable rear lateral arms
- Godspeed tubular adjustable rear camber arms with extra gussets added for strength
- Modified Chevy Silverado rear bumpstops w/ 3″ spacers
- Swaybars deleted
Recovery Gear
- Misc. recovery gear (straps, shackles, MaxTrax, compact shovel, bottle jack, etc.)
- Smittybilt air compressor
- Spare full-size wheel/tire, all fluids, CV axles, sensors, and other critical parts (or supplies for band-aid fixes, e.g. wire, tape, epoxies, tire repair, etc.)
- DIY first aid kits
- 5lb ABC fire extinguisher behind passenger seat
Camping Gear
- 12V refrigerator/freezer (dual zone) or Massimo CX30 (single zone) for solo trips
- EcoFlow River Pro power station (also bring an extra battery and/or 160W folding solar depending on the trip)
- 2020 aluminum & Masonite hardboard sleeping platform
- Pop-up ground tent/footprints/ground cloth, sleeping gear (bag, pads, blankets, etc.) as needed
- Pop-up privacy tent for toilet/shower
Conclusion
This extensively modified Subaru Outback pushes the boundaries of this platform. Through carefully selected upgrades to its suspension, drivetrain, and body protection, the owner has significantly enhanced its capability to tackle challenging terrains. Based on our off-road capability rating, this build gaind a solid score of out of 70 points possible thanks to the full suspension lift with heavily oversized tires (30 points), Rear locker (10 points) and body armor (5 Points) making stand on the same line with dedicated 4×4 SUVs.
