818 Assembly Manual - Download the Donor Disassembly Section!

[Jason Lavigne]

Jim and Jesper have ok'd the release of a preliminary version of the 818 Donor Disassembly section from the Assembly Manual - thought you guys would like to have a look! Appendix A, near the end of the document, has an updated list of parts needed from the donor car.

Here's a link to where you can download a PDF version:

818 Disassembly Instructions - http://bit.ly/1cQxmtb

Just keep in mind this is still a Beta version that hasn't been completely finalized for publishing.

Enjoy!

Jason @ FFR

[blueoval_bowtie_guy]

Wow! What a difference compared to what I got for donor dis-assembly for my Mark II. Really nice to see all the pictures!

[68GT500MAN]

What a great reference tool for the 818 builders! Great job FFR!!!!!
Doug

[Mechie3]

Just keep in mind this is still a Beta version that hasn't been completely finalized for publishing.

Psst: Page 7, last paragraph, 2nd sentence: "Late" should be "later" unless we're supposed to wait until it's dark to do that part. ;)

Can I get my name added to the list of editors now? :D lol.

I looked over the list. I think I'm missing a few things (sway bar, maybe brackets?). Mine weren't factory anyways. Already printed a copy to read this weekend!

[RM1SepEx]

All of my brackets are in a 1.5 x 1.5 x 1.5 cardboard box! damned if I can ID the right ones w/o photos! LOL

[narkosys]

the 818s on the cover page looks like it's farting fire! :p

P

[FFR-ADV]

Thanks Jason, Jim & Jesper,

I read it cover to cover with great interest and am really looking forward to getting on with my 818 build.

Will there be a windshield wiper, defroster and/or A/C option at launch?

I hope to see you at the open house. Thank you to the whole team at Factory Five.

Steve

[C.Tree]

Correct me if I'm wrong: this is non-turbo tear down? One for the NA's; makes a good daily driver!

[metalmaker12]

So Jason and FFR I just went over the list, I have everything on it except radiator hoses and my doors are in my shed, but I think I am missing something made of metal, plastic, glass and fiberglass, can you guys help me with this? :D

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[flynntuna]

Looks great, how much time have put in so far?

[metalmaker12]

about 5-6 hours to strip donor clean with no motor, 10 hours to blast and paint (had brakes and wheels powder coated), 4 hours of clutch, oil Killer pickup/ Sti pan swap. 5-8 hours of reassemble work ( spindle bearings and hubs), Custom fabricated downpipe, etc etc maybe 40 hours, but I have done this many times before

[Mechie3]

I hope you guys at FFR don't mind my comments on the manual (I'm an engineer, so I do this kind of stuff sometimes...and people still manage to assemble it wrong :o )

Page 28, where it talks about removing coolant lines the picture shows coolant lines, but the persons hand is holding the brake boost line. It might confuse people not terribly familiar with the Subaru motor.

I read the whole thing though, can't wait to read the rest!

[wallace18]

So Jason and FFR I just went over the list, I have everything on it except radiator hoses and my doors are in my shed, but I think I am missing something made of metal, plastic, glass and fiberglass, can you guys help me with this? :D

1826018261182621826318264

Where did I see photos like this before? LOL. I guess I am paying the price for starting early. I am missing the rear door stuff and hood hinges. Also I don't have the shifter console or the shift linkage end piece. I scrapped all of it months ago. I guess it is off to the bone yard.

[gwader]

about 5-6 hours to strip donor clean with no motor, 10 hours to blast and paint (had brakes and wheels powder coated), 4 hours of clutch, oil Killer pickup/ Sti pan swap. 5-8 hours of reassemble work ( spindle bearings and hubs), Custom fabricated downpipe, etc etc maybe 40 hours, but I have done this many times before


Post like this. Priceless!

[riptide motorsport]

thanks.

[metalmaker12]

Mechie, you coming to the open house, because I will make sure they lock you out. Lol , I can't wait to build this thing how about you?

[flynntuna]

Where did I see photos like this before? LOL. I guess I am paying the price for starting early. I am missing the rear door stuff and hood hinges. Also I don't have the shifter console or the shift linkage end piece. I scrapped all of it months ago. I guess it is off to the bone yard.

I'm really enjoy both your builds. Taking the time to setup your parts in the place where they will be installed to photograph is a nice touch I wouldn't have thought of . Creating an entertaining scrapbook is an added bonus in this project.

[FFR-ADV]

So Jason and FFR I just went over the list, I have everything on it except radiator hoses and my doors are in my shed, but I think I am missing something made of metal, plastic, glass and fiberglass, can you guys help me with this? :D

...about 5-6 hours to strip donor clean with no motor, 10 hours to blast and paint (had brakes and wheels powder coated), 4 hours of clutch, oil Killer pickup/ Sti pan swap. 5-8 hours of reassemble work ( spindle bearings and hubs), Custom fabricated downpipe, etc etc maybe 40 hours, but I have done this many times before

1826018261182621826318264

Love the custom exhaust. You could sell a bunch of those if you want to. Very Nice Work!

[metalmaker12]

I plan on setting up a site to sell some custom 818 stuff

[FFR-ADV]

I plan on setting up a site to sell some custom 818 stuff

That is great!

[IMPREZvWRX]

After reading the donor disassembly manual, it's apparent that my donor is missing a lot of needed odds and ends, namely anything that begins with "rear door."

[GUNS]

After reading the donor disassembly manual, it's apparent that my donor is missing a lot of needed odds and ends, namely anything that begins with "rear door."

Yea, I sold one of my rear doors, not thinking I would need the latches from it. Oh well.

[IMPREZvWRX]

Also, is the rear view mirror part from another manual? It's been a while since I've been in a GD chassis, but I thought the rear view mirror was attached to the roof and not the windshield. It is in my older GM chassis.

[GUNS]

Also, is the rear view mirror part from another manual? It's been a while since I've been in a GD chassis, but I thought the rear view mirror was attached to the roof and not the windshield. It is in my older GM chassis.


Nope, my mirror from my 02 looked like the one in the manual.

[IMPREZvWRX]

Nope, my mirror from my 02 looked like the one in the manual.

Thanks, I'll add it to the list of parts I need!

[Wayne Presley]

All 4 of my donors have had windshield mounted rear view mirrors.

[IMPREZvWRX]

Yeah, I dug up some old pics and confirmed that my memory is terrible and I have a big mouth.

[AZPete]

Great work FFR!

[flynntuna]

I plan on setting up a site to sell some custom 818 stuff

Thats great, will they be "one offs", or specific line of parts?

[07FIREBLADE]

Please say they will be a specific line. Anything in mind right now?

[Samiam1017]

The Manual shows two modifications to stock parts. Are these the only parts that get or need to be moded? It's nice to have these things done prior to getting kit. Although easy mods there done and ready.

[longislandwrx]

no that's just a start... I know for a fact you will need to drill the lower control arms for the shock mounts. There will definitely be more.

[Samiam1017]

Would be nice if they released all these mod how toos

[Mechie3]

Mechie, you coming to the open house, because I will make sure they lock you out. Lol , I can't wait to build this thing how about you?

Lol, no. I'm too far away with too few vacation days. I'm not poo tjng things out to be picky, just providing free services. ;). Growing up I always had to edit all three of my brothers' English papers and then my wife's thesis. The way I see it, FFR can get free proofreading from a few hundred people.

Km pumped to start building this thing!

[Wayne Presley]

Would be nice if they released all these mod how toos

The 818 isn't released yet, you don't have your 818 yet, FFR releases the beta dis-assembly guide for the car that you may or may not already have, and you want the mods from the not released assembly manual? Seems a bit premature... :D

[Erik W. Treves]

did I mention that my invoice now says I owe $0.00 (paid in full!) and I can pick-up next week :D :D I also ordered my wheels!!! now I close my 80 tabs of wheel websites....ah what relief!.. manual...who reads those...lol...the best manual you are going to get is actually going to be the FORUM...just dive in..the water is fine...

[metalmaker12]

The 818 isn't released yet, you don't have your 818 yet, FFR releases the beta dis-assembly guide for the car that you may or may not already have, and you want the mods from the not released assembly manual? Seems a bit premature... :D

+1 Wayne, it is not even out yet everyone, lets calm down, having the exact parts you need is a huge plus and just confirms those questions, thank you FFR

[RM1SepEx]

did I mention that my invoice now says I owe $0.00 (paid in full!) and I can pick-up next week :D :D I also ordered my wheels!!! now I close my 80 tabs of wheel websites....ah what relief!.. manual...who reads those...lol...the best manual you are going to get is actually going to be the FORUM...just dive in..the water is fine...

so can you pick it up before the open house?

[Samiam1017]

The 818 isn't released yet, you don't have your 818 yet, FFR releases the beta dis-assembly guide for the car that you may or may not already have, and you want the mods from the not released assembly manual? Seems a bit premature... :D

The first kits will be out next week. So I'm sure the manuals are ready to go. So if there's more mods needed for the donor parts it would be nice to have them done. I don think that premature at all.

[metalmaker12]

It is not reasonable to think the complete build book will be released before June 15, if your getting the kit after that, like 95 percent of us you will have time to do what you need. The kicker and time consumer will be the harness, I have tried to get my head around it today, and have pretty much figured out what FFR has done from viewing the gocart and what just makes sense in my brain. It is really going to benefit from a reconfigure and wire diet. The thing is it is going to take some time to work on it to get it right. To me the harness will be the biggest hill to climb, the rest seems like a snap. Also the Manuel's are not complete yet, they are still revising. Heres a look at the start of the madness

18273

[Samiam1017]

Metalmakers. Did you happen to notice if they have a jumper harness between the subaru wires for the headlights and the toyota lights? Also I believe the headlight wire clips change between years? Also after looking around and at the wrx harness better i think the 500 you mentioned is a good deal.

[RM1SepEx]

Metalmaker12, I agree :-) the aluminum panels are easy... bolting on the suspension, just a few bolts, drop in the engine and tranny etc... bolting in mechanical stuff is pretty straightforward.

The trick is cleaning up the rats nest of a harness, I bet we give it a 40% or more diet! Between removing unused wire and extending some of them it is the real challenge to keep straight. You mentioned doing them as a business... a couple sheets of plywood marked up with finish nail connector locations and wire routes should make replication pretty straightforward.

Add in "custom touches... I'll need to wire for aftermarket stereo and perhaps extra blinkers in the mirrors depending what I buy for them... LEDs ??? who knows

The deconstruction manual actually helps quite a bit and I'm finalizing bolts, nuts etc based on it... Eastwood easy wash done, media vibratory bowl next, perhaps some wire brushing... I need to prep and paint the hood and door hinges and latches... sounds like we need to do our own thing for the hood hold downs... truck latch... etc...

I'm getting excited! Can't wait for the open house in less than a week now!

[metalmaker12]

They are giving us hood pins, and hatch latches, I am thinking it can be dieted down about 40 percent also, but I can not start until I get my manuel and kit. The harness business idea would be a build per order setup, you mail it we diet it the way you want, we send it back ready to plug and play. I just have to work on getting it to function flawlessly, look good and be cost effective. It is a viable option, but it is looking to be somewhat involved to get where I want it.

[Xusia]

Continuing in the spirit of helpfulness, on page 8, the word in red is missing:

Engine/Exhaust parts: The 818 kit is configured to accommodate the EJ 2.0L or 2.5L engines. The
kit comes with polished stainless steel exhaust parts to adapt to either the turbocharged WRX or
naturally aspirated Subaru Impreza engines.

[wallace18]

It is not reasonable to think the complete build book will be released before June 15, if your getting the kit after that, like 95 percent of us you will have time to do what you need. The kicker and time consumer will be the harness, I have tried to get my head around it today, and have pretty much figured out what FFR has done from viewing the gocart and what just makes sense in my brain. It is really going to benefit from a reconfigure and wire diet. The thing is it is going to take some time to work on it to get it right. To me the harness will be the biggest hill to climb, the rest seems like a snap. Also the Manuel's are not complete yet, they are still revising. Heres a look at the start of the madness

18273
I started my own wire harness diet months ago. I know what I will use and what I won't. I am waiting for my kit to finish it. I wish there would be an aftermarket option on the harness. It is always good to start with new wiring IMO.

[Xusia]

I'd be more inclined to buy a new reasonably priced wiring harness than to diet the old one. If dieting is my only reasonably priced option, however, I feel very confident I can tackle that myself.

[Silvertop]

I'd be more inclined to buy a new reasonably priced wiring harness than to diet the old one. If dieting is my only reasonably priced option, however, I feel very confident I can tackle that myself.

I have a concern -- based on a general lack of personal knowledge -- that there may be enough difference from year to year and from turbo vs NA application that there may be no one custom harness that will work. That changes in ECU's, sensors and other components could sabotage any attempt to come up with a single appropriate harness. Has anyone given any thought to this?

[Xusia]

I really don't think that would be an issue. We need only a basic set of wires compared to the donor vehicles. All you would need to do is develop a harness based on the "superset" of needed wires. Any functions not present/utilized/needed are just wires that don't get used.

[IMPREZvWRX]

The ECU pinouts change between models, so there would have to be a per-order build service. There's a few people who do custom harness merging for Subaru swaps, but they require you send your two harnesses.

[metalmaker12]

I dieted the engine bay abs and srs, now on to some accessory wires and that harness is ready to get FFR extensions for the headlights and radiator fans

[tks]

Did FF5 release the full build assembly manual today?

[RM1SepEx]

Did FF5 release the full build assembly manual today?

No, they didn't

[metalmaker12]

No Manuel yet

[Evan78]

No Manuel yetWho's Manuel?

[metalmaker12]

Lol I am tired plus auto correct does not like me

[D Clary]

was unable to download the disassembly manual, any suggestions., I just end up at ff website unable to locate on screen

[Mad Dog]

Sorry about that. The link has been fixed and here it is - http://bit.ly/1cQxmtb.

[nikbrewer]

The ECU pinouts change between models, so there would have to be a per-order build service. There's a few people who do custom harness merging for Subaru swaps, but they require you send your two harnesses.

i fthis is true, you would build a harness with an adapter at the EDU end. Basically a 6-12" harness that adaps the plug on thr harness to the ecu pin out. Then you would just product the small adapter for each engine, not a whole harness

[Dale]

Hi Dave, looks like the link doesn't work. Is the disassembly manual still available?

Thanks!

Dale

[metros]

I have the same question^^^

[pt00323i]

Jason link not working, about to take my donor apart and selling the rest, just want to make sure I keep all I can from Donor.

thanks

[theburner9]

you can download the entire manual for free - There's a promo code for people who have an 818 on preorder. You should have got the code in one of the last email updates.

[pt00323i]

got it.