BKafe's Build Thread

[Bkafe]

Thought it is time to kick off my build thread and contribute back to the community.

Donor: CoPart 2003 WRX, 130K...ran and was drivable off the car carrier. Winning bid $2550 + fees and delivery = $3926.20

Today I completed the disassembly, which took approx 20 hours. While I have done some basic auto work in the past, this is my first major project. I have never restored a vehicle, pulled an engine, or built a kit car before this project. My friends who have done this type of work assisted with the Engine/Tranny pull.

Pictures: www.flickr.com/x/t/0090009/photos/kafenbaum/sets/72157634268393475/

Next Steps:
Preform Inventory
Scrap the carcass
Prep Donor Parts
Identify replacement part for damaged donor parts
Receive 818 Kit (~July 30)

I got my call from Tony at Factory Five this past Friday, and was advised my kit should be ready Sat July 20. I added the powder coat, front splitter, rocker panel and rear diffuser carbon bits.

More to come...Lots more...

Brian

[metalmaker12]

Welcome, not bad for a rookie, the fun will begin soon, good luck man

[RM1SepEx]

sounds wonderful... I like that it is 10 days early!

[Frank818]

Great job! Continue the nice work and keep us posted!

[tks]

Bkafe - what specifically do you mean by "basic auto work" in the past? I may be in the same boat as you in terms of experience and am interested in what your strategy is for building this as a "rookie".

[Mechie3]

My original date was July 20th, wonder if its going to get moved up. No phone call yet. :anxious:

[RM1SepEx]

The when are you getting your 818 shows his date as July 6...

818-S
Erik W. Treves-----------------------June 15, 2013
Guns---------------------------------June 22, 2013--------------------Columbia, SC
Timmy318----------------------------June 22, 2013--------------------Owensboro, KY
BKafe--------------------------------July 6,2013-----------------------Phoenix, AZ
Mechie3-----------------------------July 20, 2013----------------------Indianapolis, IN
Wild Olive---------------------------July 6, 2013------------------------Indianapolis, IN
Wallace18--------------------------- August,3, 2013-------------------Alachua, Florida
RM1Sepex ---------------------------August 10, 2013 -----------------Freeport, Maine
Metalmaker12------------------------August 17, 2013------------------Exeter, R.I
bbatts
ehuwe-------------------------------Early August, 2013----------------Los Angeles, CA
AZPete------------------------------August 10, 2013-------------------Scottsdale, AZ
cmcintyre---------------------------Aug 31, 2013------------------------Danbury, CT

[Bkafe]

Tks- installed brakes and coilovers on an E36.

Mechie - RM1SepEx is unfortunately correct... My kit will be ready about 2 weeks behind schedule; hopefully a temporary as the ramp up production.

[Hammer-Dan]

Small world.. I see the 2012 Thunder In The Valley shirt. That is basically my hometown... The Rally was this past week.. I will make it home for one at some point.

[Bkafe]

Small world.. I see the 2012 Thunder In The Valley shirt. That is basically my hometown... The Rally was this past week.. I will make it home for one at some point.

That's my friend Erick, from PA. He flew out to AZ; we did a motorcycle ride to Jerome and a WRX engine/tranny pull...was a good weekend!

[Mechie3]

Tks- installed brakes and coilovers on an E36.

Mechie - RM1SepEx is unfortunately correct... My kit will be ready about 2 weeks behind schedule; hopefully a temporary as the ramp up production.

Oh, I see. I read the ~ July30th and then the July 20th and assumed they moved you up 10 days.

[RM1SepEx]

Damn, Jerome AZ what a road!!!! AWESOME!

[RM1SepEx]

Oh, I see. I read the ~ July30th and then the July 20th and assumed they moved you up 10 days.

so did I... then I went to the old thread to seen where he was on the list, to see who might update us next!

[metalmaker12]

Aug 17th is my date, I paid and I am picking it up then, hopefully sooner.:cool:

[AZPete]

Brian, you'll be 2-3 weeks ahead of me. My ship date is Aug 10 and I got a call from Jason @ FFR on Friday. Raised my deposit from the initial $99 to $1,000 with balance due close to shipping. He said 8/10 is still the ship date and then Stewart will bring it to AZ so I'm guessing 8/17-20 to me. Oh no, that's 59 days!
Pete

[Bkafe]

Brian, you'll be 2-3 weeks ahead of me. My ship date is Aug 10 and I got a call from Jason @ FFR on Friday. Raised my deposit from the initial $99 to $1,000 with balance due close to shipping. He said 8/10 is still the ship date and then Stewart will bring it to AZ so I'm guessing 8/17-20 to me. Oh no, that's 59 days!
Pete

That's great to hear! It good to know there is another 818 being built right down the street.

[RM1SepEx]

My date is also August 10... not a peep yet :-(

[AZPete]

Brian, I'll PM my contact info to you because we may be able to help each other since we're both pioneers with the 818 in AZ. (Wah, wah, I'm not the first! ) If you want 4 WRX wheels & tires let me know. They are snow tires which are very hard to find around here. :)
Pete

[JeromeS13]

Brian, I'll PM my contact info to you because we may be able to help each other since we're both pioneers with the 818 in AZ. (Wah, wah, I'm not the first! ) If you want 4 WRX wheels & tires let me know. They are snow tires which are very hard to find around here. :)
Pete

I'll let the both of you be the local guinea pigs. Hopefully this means my build will be super smooth. :-D

[RM1SepEx]

peep came today... :-) now July 27 for me! 2 weeks early

[Bkafe]

Thx Pete... I look forward to some greasy hands and a few beers.

I have been having a bit of trouble with my suspension bolts. Been giving them them a ftreatment of PB Blast and a hitting with my new ingrasoll impact gun. No luck...

[Bkafe]

peep came today... :-) now July 27 for me! 2 weeks early

That's awesome! Count down to payment day...

[JeromeS13]

Thx Pete... I look forward to some greasy hands and a few beers.

I have been having a bit of trouble with my suspension bolts. Been giving them them a ftreatment of PB Blast and a hitting with my new ingrasoll impact gun. No luck...

Breaker bar + cheater bar (jack handle). If you get about 3-4 feet of leverage, they should break loose.

[Erik W. Treves]

HEAT is your friend

[Bkafe]

HEAT is your friend

I was so hoping to goto the torch.

They came loose with a bit of motivation from my breaker bar.

Moving on to clean and prep now.

[mspice]

...

Moving on to clean and prep now.

I'm looking forward to seeing the pictures. I would be interested in before and after pictures of all of the major parts.

As you know from the thread of mine that you replied to, I picked up what I hope are most of my donor parts. The short descriptions in the "what you need" list leaves me with lots of questions -- googling for pictures with different results, lots of different parts/bolts that I don't know the real names of, not being sure of if the amount of rust on what I have is OK, and more. I'll also be interested in seeing the cleanup that you do too! I'll be starting with just a rag today.

[Bkafe]

Donor parts pictures: http://www.flickr.com/x/t/0098009/photos/kafenbaum/sets/72157634378767601/

[bromikl]

Bkafe, I really appreciate the photos. As a car newbie, I don't know what many of those parts are called. Would you mind naming the photos for us?

Thank You!

[Bkafe]

Bkafe, I really appreciate the photos. As a car newbie, I don't know what many of those parts are called. Would you mind naming the photos for us?

Thank You!

I added some comments to the pics to assist.

Also check out Metalmaker's build thread:http://thefactoryfiveforum.com/showthread.php?9028-Metalmaker12-s-build-thread-part-1-quot-Parts-you-need-quot

And Mechie's 818 thread: http://thefactoryfiveforum.com/showthread.php?9077-Mechie3-s-818S

They both have part close ups that can help.

[Bkafe]

Time to make room for 818 kit delivery in less than 30 days.
The donor carcass is gone. Local "we buy cars" company picked and towed to recycle yard and gave me a whole $30!
Kept some small parts to sell online.

19330

[Bkafe]

Advise requested....

In preparation for assemble, I am attempting to breakdown the rear suspension components.

For reference: http://opposedforces.com/parts/impreza/us_g11/type_3/suspension_and_axle/rear_suspension/
24, 19, 25 (talk about a bolt!)

Is it a recommended practice, to break all these bolts loose, while the suspension is on the donor?
How can I get some good leverage on these bolts, with these parts off now of the vehicle?

[Mechie3]

Bolt 25 may be likely rusted to the steel sleeve in the bushing. When I replaced mine 2 years ago I had to cut them off. Otherwise, use an impact to remove the nut on the end then try pressing the bolt out. If it's only mildly corroded it will come out with no problem.

[RM1SepEx]

heat is your friend... I also used a breaker bar and a long piece of steel "cheater" tubing

[flytosail]

Looking good.

[Bkafe]

heat is your friend... I also used a breaker bar and a long piece of steel "cheater" tubing

A bit of heat, breaker bar, and 6' steel cheater tubing did the trick. Thx... Next are the Axle nuts... ;^)

Any tips on bracing the component off the car...I was playing a balancing act trying to get leverage on this small part; literally standing on it trying to keep it stable.

[metalmaker12]

I just have a balls IR gun, but if not you must get creative :p

[AZPete]

I face the same problem with the rear suspension. From the AJW crates I started on the rear first but then put them aside when I couldn't loosen the nuts. Soon I'll have to tackle them.
To all others: Break the rear suspension nuts and bolts loose while still on the car!

[Bkafe]

I just have a balls IR gun, but if not you must get creative :p

By IR do you mean, Ingersoll Rand? or IR as in Infra Red?

I have a Ingersoll 2135TiMax, couldn't break it loose...maybe is my cheapie compressor thats slacking.

B

[metalmaker12]

Yea you need 90psi consistently to get the max torque, but a break bar with extension should work, it is is still stuck, cut them off, personally I cut most tiff ones off and I also got all new suspension bolts anyway. It is nice to have a set of torches to heat and cut stuff free.

[Bkafe]

Engine and tranny separated... And cleaned. Ready for new clutch and timing belt kit.

Any recommendations for clutch? Std 2003 WRX engine, turbo... Mostly street with a few track days.

http://www.flickr.com/x/t/0094009/photos/kafenbaum/9260625312/

[longislandwrx]

http://www.rallysportdirect.com/Exedy-OEM-Replacement-Clutch-Subaru-Models-inc-2002-2005%20WRX

perfect for a few bolt on parts and you can't beat the price.

[Wayne Presley]

Engine and tranny separated... And cleaned. Ready for new clutch and timing belt kit.

Any recommendations for clutch? Std 2003 WRX engine, turbo... Mostly street with a few track days.

http://www.flickr.com/x/t/0094009/photos/kafenbaum/9260625312/


SpecClutch.com stage 2 will serve you well. I am a dealer for them

[Bkafe]

Spent the last couple nights pressing in new wheel bearings and installing a new parking brake and ball joints.

Decided to take off the abs rings on the rear hubs, as I will not be reinstalling abs.

Some pics, of the parking brake install:
http://www.flickr.com/x/t/0093009/photos/kafenbaum/sets/72157634725652922/

[snowphun]

http://www.rallysportdirect.com/Exedy-OEM-Replacement-Clutch-Subaru-Models-inc-2002-2005%20WRX

perfect for a few bolt on parts and you can't beat the price.

That clutch has a bad reputation on Subaru forums, I was very unhappy with mine in a MY02 WRX. Noisy, decel noise, POS. It is certainly not the same as the Subaru replacement parts which I put in my current MY02 and have had zero issues.

[Bkafe]

My donor was in the passenger front corner and needed a timing belt cover. With 130 on the odometer, I also wanted to do the water pump and timing belt. The cam gears slipped a bit during disassembly, but Meaty's guide on YouTube helped break down the cam alignment visually.

Meaty's Timing Belt Vid
http://m.youtube.com/my_history#/watch?v=6mjCegTnB60

Some pics showing belt cam gear alignment.
http://www.flickr.com/x/t/0095009/photos/kafenbaum/sets/72157634741353342/

[Bkafe]

Today was delivery day!

My daughter was shooting, so please excuse the shaky footage on the unload scenes.


http://youtu.be/OtxbK7kmsL8

[Mechie3]

I'm in a hotel Toledo waiting for tomorrows race. With nothing better to do I watched the whole thing.

[Bkafe]

818 Unload from Steward Transport

Then here is another for your viewing pleasure... a bit time lapsed though, as it was over 1hr.


http://youtu.be/c-a9WOAMR-A

[NicksPapaw]

Sweet!!

[AZPete]

Congratulations on the arrival, Brian! I look forward to seeing it.
Pete

[Bkafe]

Day 1: Inventory and Prep


http://youtu.be/JTgiGIKTNeU


Pictures:
http://www.flickr.com/photos/kafenbaum/sets/72157634820159816/

[metalmaker12]

Nice setup, have fun

[NicksPapaw]

Ha ha, that video reminds me of every day that I worked on my roadster. Back and forth, back and forth, up and down....... ahhhh the memories. Looking forward to your build.

[longislandwrx]

Ahh sweet relief at 2:00.... was anything missing? Thank you for this video, it really puts an end to the "what's included?" question

[Bkafe]

Ahh sweet relief at 2:00.... was anything missing? Thank you for this video, it really puts an end to the "what's included?" question

Inventory was relatively smooth, but there are many parts without numbers, or in a bag with a number. Most you can figure out...some I had difficulty. I did have minor discrepancy with list and actual parts (all "O" on parts list should make it to the Parts Order List). In my case the door skins didn't make it to POL...and my carbon fiber parts are not on the list, not in the shipment. FFR will sort it all out I'm sure.

My parts list for reference:http://www.flickr.com/photos/kafenbaum/sets/72157634847654600/

[longislandwrx]

Thanks for posting those. Very helpful.

[Bkafe]

Assembly of Front Firewall:


http://youtu.be/a66Yqsj-QGo

[GUNS]

Video is private

[Samiam1017]

What are you shooting with. A Gopro strapped to your head? And I must say nicest garage I've seen on here yet. No that the others are too shabby

[Bkafe]

What are you shooting with. A Gopro strapped to your head? And I must say nicest garage I've seen on here yet. No that the others are too shabby

Chest Strap... I have to work on the angle.

New garage, so psyched to have extra room!

[Scott J]

Talk about a build thread! I'm dizzy!!!
Keep it up though
Good to see you're getting right to it

[longislandwrx]

Nice garage by the way.

[Bkafe]

Back from a bit of traveling...and have a video to upload soon. I added sound deadening to the front firewall, second skin.

INSTALL TIP: Shock mount install on lower control arm.
Be aware that when drilling holes for lower control arm, lean toward 1.75/2.0" from mid ball joint hole. My hole is about 1.6"... And now that I am mounting the coilovers...they hit the spindle.

I wanted a reason to upgrade to some aluminum ones...

[Stickshift84]

I recently finished up my control arms and targeted the holes exactly at 1.75" like the build manual says to. There is clearance to the spindle however the ball joint bolt head hits the shock prior to getting enough rotation of the spindle. Not sure what I am going to do about this yet.

[metalmaker12]

I recently finished up my control arms and targeted the holes exactly at 1.75" like the build manual says to. There is clearance to the spindle however the ball joint bolt head hits the shock prior to getting enough rotation of the spindle. Not sure what I am going to do about this yet.

Hit it with a big hammer!!! you slacking I see lol, I will be around here today

[Bkafe]

I recently finished up my control arms and targeted the holes exactly at 1.75" like the build manual says to. There is clearance to the spindle however the ball joint bolt head hits the shock prior to getting enough rotation of the spindle. Not sure what I am going to do about this yet.

I hear ya... This measurement should be re-evaluated.

I got my aluminum control arms and I will be marking proper location with the coilover and spindle attached. I will post the distance...

[Bob_n_Cincy]

I hear ya... This measurement should be re-evaluated.

I got my aluminum control arms and I will be marking proper location with the coilover and spindle attached. I will post the distance...

Would a button head cap screw work? or maybe counter-bore and use a socket head cap screw.

[metalmaker12]

I hear ya... This measurement should be re-evaluated.

I got my aluminum control arms and I will be marking proper location with the coilover and spindle attached. I will post the distance...

The hole tabs on the aluminum control arms is the right location for the AL lca's, no clearance issues lock to lock. I am certain they designed the suspension after the aluminum control arms and the steel ones are an afterthought. The distance in the build manual is obviously not correct for the steel arms, and needs a revision. FFR is aware of issue and will correct it.

[Bkafe]

Afterthought perhaps... But the pics in the manual shows the steel arms, with explicit instruction for each measurement. The aluminum arm instructions are in a separate section.

It is a Beta guide... I get that, just sucks throwing hundreds of dollars away on a pretty simplistic issue.

I have a pair of shiny new aluminum lower control arms, $291+shipping.

[metalmaker12]

I here ya, my arms are new and were 300 bucks to. I will pull my arms down, take pics and measure the distance for you Lata. I will pm you the stuff

[Wayne Presley]

Afterthought perhaps... But the pics in the manual shows the steel arms, with explicit instruction for each measurement. The aluminum arm instructions are in a separate section.

It is a Beta guide... I get that, just sucks throwing hundreds of dollars away on a pretty simplistic issue.

I have a pair of shiny new aluminum lower control arms, $291+shipping.


One of the guys on the GRM build put the bracket at 1.5" and not the 1.75" like in the manual so I just welded the bracket on the arms.

[metalmaker12]

One of the guys on the GRM build put the bracket at 1.5" and not the 1.75" like in the manual so I just welded the bracket on the arms.

I am welding Nicks brackets to his arms, I will post the results of his fitment, but he told me he measured 1.75".

[Bkafe]

One of the guys on the GRM build put the bracket at 1.5" and not the 1.75" like in the manual so I just welded the bracket on the arms.

Why didn't I think of welding the tabs!!
What a perfect excuse to buy a stick or mig setup. Been wanting to learn to weld for a while.

Very much appreciate the measurement info metal maker !

B

[Bkafe]

Got my new aluminum lower control arms on Friday! I completed the front suspension on Sun.


http://youtu.be/ssTAV1LxBeA

[Bkafe]

Finally got the right part for my axles, as 1 side did not come with tri-lobe (replacement?). These worked for my 2003 outers and Factory Five provided axle: www.amazon.com/gp/product/B00DMA2MN8 (http://www.amazon.com/gp/product/B00DMA2MN8)

Also dealing with a bad leak down test on my driverside bank. Dug into the engine a bit and found this: http://www.flickr.com/photos/kafenbaum/sets/72157636762502273/

Any suggestions? Subaru short block and refurb the heads? Rebuild? Junkyard low mileage? The donor was a Copart 2003 WRX Sedan, that ran...as I drove it myself...shame...

B

[Bob_n_Cincy]

Finally got the right part for my axles, as 1 side did not come with tri-lobe (replacement?). These worked for my 2003 outers and Factory Five provided axle: www.amazon.com/gp/product/B00DMA2MN8 (http://www.amazon.com/gp/product/B00DMA2MN8)

Also dealing with a bad leak down test on my driverside bank. Dug into the engine a bit and found this: http://www.flickr.com/photos/kafenbaum/sets/72157636762502273/

Any suggestions? Subaru short block and refurb the heads? Rebuild? Junkyard low mileage? The donor was a Copart 2003 WRX Sedan, that ran...as I drove it myself...shame...

B

Hey Bob
My friends at Turn in Concepts do walnut shell blasting on valves and heads. See picture I found on web. 22691

The cylinder that had water in it. Do you think head gasket or crack head or cylinder wall.

I'm not sure I would write off that engine just yet.
Bob G

[Samiam1017]

Spark plug holes are cracked if you look close. Better to not use.

[Bkafe]

Spark plug holes are cracked if you look close. Better to not use.

Where do you see cracks in the spark plug holes?

[Mechie3]

Cracks on the 2.0 cylinder heads isn't uncommon. Most of them don't affect anything.

[Bob_n_Cincy]

Hi Bob
Compare your heads to the cracked one in this picture22750

[Bkafe]

Hi Bob
Compare your heads to the cracked one in this picture22750

Thanks Bob... I will dig under the goop and take a peek.

I thought though that Samiam1017 said my heads "are cracked"... It didn't pop out to me in my pics.

B

[Erik W. Treves]

All mine were cracked... Replaced both heads... Didn't want to find out I had an issue later

[longislandwrx]

Thanks Bob... I will dig under the goop and take a peek.

I thought though that Samiam1017 said my heads "are cracked"... It didn't pop out to me in my pics.

B

It does look cracked, that yellow line of coolant, clean that up and see if its a crack.

22751

[Bkafe]

Any interest in a South Western AZ located 818 Roller?

http://thefactoryfiveforum.com/showthread.php?13288-FFR-818-Rolling-Chassis-in-Phoenix-AZ

B

[flynntuna]

What are you looking to get from it?

[JeromeS13]

:-(

[Bkafe]

:-(

I know... its not a done deal, but something I really want to consider!

I have to come down and check out your progress!
B

[AZPete]

:-( X2 I saw Brian's 818 just after it was delivered and also saw the nice work he had done restoring donor parts. A good opportunity for someone!

[Bkafe]

Looks like FFR is working through the list of backorders. I got 2 LARGE boxes in the mail...

Carbon Fiber, Door Skins...all parts are in.

If anyone is interested in purchasing a 818 kit with all donor parts, except engine...just send a PM.

---
Brian