Metalmaker's build thread begins

[metalmaker12]

Tomorrow 9am FFR pickup of my 818s!!! Wicked Woohoo

[michael everson]

Awesome. Cane wait to follow along.
Mike

[FFR-ADV]

Congratulations.

Have you finalized your upgrades list?

I expect between Wayne, Mike and your build upgrades will induce many upgrades to my build?

Cheers!

[metalmaker12]

I am staying with what I have had for most if the way, no big surprises here. I am saving up for a ppg gears to build up my 5 spd or a possable 6 spd install, but that would be it. I am also staying with the sti intercooler cause I see no real need to use the other unit..yet. I do like the Boyd tank and I think that is a great upgrade. I will be posting over the next week as I go along.

[FFR-ADV]

Hi Metalmaker,

My upgrade list currently is somewhat extensive:

Wayne's K-Tuned No-Cut Shifter looks pretty cool and makes me smile just to look at and will probably be just as fun to shift.
the Boyd tank looks great and gives more leg room which is important to me.
The traction control with launch control might save my 818 from some unexpected directional changes
I think I will hold back on tranny updates such as LSD (I was leaning toward Quaife) until other issues such as gearset changes or potential 6 speed solution is better resolved.
I am leaning toward the BiMarco FIA homoligated seats (Grip or Futura) which is available with low cost custom embroidery and even leather priced reasonably.
I have a stainless unequal length header which will get a Lava Header Wrap.
Your downpipe exhaust upgrade looks sweet. I will need to keep a high flow CAT to get thru NH inspections.
Windshield wipers are also required by NH. I look forward to seeing what Wayne does with a single blade wiper.
My brakes stay stock, but are painted red and I will upgrade the PADS and already have new electroplated Stoptech rotors which I have run WRX donor since last fall.
The modifications to the stock brakes looks effective with a bias valve, so I plan to stay with stock pedals for now.
Depowered & welded steering is in my plan (will need help with the welding)
I will definitely get the rear diffuser (looks cool and works), (and front splitter once I know it will hold up on the street) but in a holding pattern on the spoiler or wing until the removable hardtop is resolved.
Still considering other interior finish options.
The NRG Innovations removable steering wheel looks cool and gives some security so is under consideration
Wheels and Tire upgrades come as I get closer to getting it on the street.
Killer-B oil pan & new pickup planned as there is some rust on my oil pan and while changing it, why not get rid of the weak WRX oil pickup.
Probably doing a new radiator as they don't age well.
Aluminum STI lower control arms and upgraded rear suspension are planned.
Koni racing shocks and spring upgrade to carry as much handling and create a 818SR.
Replacing the timing belt and waterpump and clutch before installing an otherwise stock 2 liter engine (upgrades in the future as they make sense) I want to take this in stages (crawl, walk then run....fly ;) occasionally sleep)

Cheers!

Steve

[shim2]

Congratulations! Can't wait for the pics.

[riptide motorsport]

Sweet!!!!!!

[metalmaker12]

A lot of good ideas, in which I have done most as you have been part of over the last two years. I will be getting seats and a wheel soon, along with some different rims once I get her registered, I will most likely get the whole aero kit at some point. I am going to paint this thing a sick color scehme once I prefit all the body panels. I am not set on any color or colors, I will have to give this great thought. I will be fitting my exhaust soon. My tranny is getting some newer parts swapped into it, cusco rs 1.5 way LSD and some needed parts to make in run smoothly for now, via my friend who wanted my business, I should have it back this Thursday or I will just go get it and do it myself.

[metalmaker12]

At FFR right now, a bit excited

[Stickshift84]

Awesome!!! See if you can spot my kit for me.

[Mechie3]

Awesome!!! See if you can spot my kit for me.

Ditto. Take a pic of mine (Craig Hudson). You can even touch it just to say you did. hahaha

[JAubin]

Awesome, Let's see if you can catch up to Erik and Wayne now. I would say see if you can find mine, but the steel probably isn't out of the ground yet. Hah. Really stoked to see the first EJ207 based 818 get built!

[metalmaker12]

Got you Craig, post lata

[metalmaker12]

En route

[RM1SepEx]

Mine's been delayed from Saturday... Fingers crossed for Wednesday...

[metalmaker12]

Dan yours will be ready weds

[David Hodgkins]

Great stuff! But, no pics?

:)

[Mechie3]

We needs pics of dangerously installed seats, windshields, and hoods. HAHA!

[RM1SepEx]

Metal, thanks for the positive words...

BTW your PM box is full!

Serial # for yours?

[timmy318]

Hey, remember, pics or it didn't happen ;)! Can't wait to see your build evolve!

[metalmaker12]

Number 13, eating and will post Lata, I can't post from phone, gotta set up a photobucket

[Stickshift84]

Lucky number 13. I can't wait until Saturday for mine.

[RM1SepEx]

Stickshift84 no delay on yours?

[metalmaker12]

http://m1319.photobucket.com/albumview/albums/metalmaker12/Mobile%20Uploads/IMG_4850_zpsa9c0b902.jpg.html?o=0&newest=1
Here are some pics in my bucket

[Mechie3]

:D I see mine.

[metalmaker12]

Yeap it was there mechie

[FFR-ADV]

Congratulations!

[metalmaker12]

Any questions ?

[Mechie3]

Are you done yet?





Well, you asked. ;)

[metalmaker12]

Lol, a no, but I did remove all body panels and do some inventory and other bits, I am going to gather all the exposed steel components and either get them powder coated or paint them up. The aluminum panels I am going to prefit, grain and use shark hide or clear on, I like the aluminum look and it's contrast with the black frame. I also got the axles do I am going to build them. I am waiting on some minor stuff, and some new designed very nice stuff, go FFR

[wallace18]

Please post photos on your build thread. I can't wait to see your build progress. Have fun!

[metalmaker12]

Please post photos on your build thread. I can't wait to see your build progress. Have fun!

Hey Wallace, I posted in a photobucket, it is easier to set up the link from my phone, if not I have to send them to my email blah blah, if you want detailed close ups I can do that, just send me your email and I will send them to you

http://m1319.photobucket.com/albumview/albums/metalmaker12/Mobile%20Uploads/IMG_4850_zpsa9c0b902.jpg.html?o=0&newest=1

[Samiam1017]

Metal. You sponsored by subway or something? How do I stop the pop ups between pics?

[metalmaker12]

I am going to post some pics Lata today on the forum

[metalmaker12]

Sorry for the lack of pics, but my laptop charger is broken. I Prefit the front firewall aluminum, grained it with scotch brites, silicones rubber gaskets to the back and riveted on. Looks great! I used some sharkhide on the panels for protection. It just wipes on and give a lite sheen and protects for like ever. I prefit the front and rear suspension brackets. Those brackets with various other bare steel and off to blasting them tomorrow, than powder by weeks end. Btw box 6 has alot of aluminum, and I am happy with the quality of the kits components.

[metalmaker12]

Heres some 20112201132011520116201172011820119201212012220123

[metalmaker12]

2012520126

[shinn497]

I'm confused about something. Do the lights come cut out or not?

[metalmaker12]

It seems some have small holes and others don't. Regardless no issue, just a part of the build.

[wallace18]

Looking good so far. You are moving right along. Thanks for the photos. I like the rear suspension so far.

[GUNS]

Looks great!

[longislandwrx]

I like your idea about texturing the firewall. back in shop class we used to use a eraser in a drill press to swirl polish aluminum panels. I've been on the fence about aluminum prep. now the gears are starting to turn.

Your build is looking good already!

[CHOTIS BILL]

Very exciting. I know you can’t tell from pictures but it looks like the rear roll center is awfully high. But it has to be looked at in conjunction with the front and apparently it does work well.

Keep up updated,

Bill Lomenick

[metalmaker12]

I had the rear put all together to fit the bare steel braces, I am blasting them and powdering coating them black this week into next. I don't have the front springs yet with some other back ordered stuff. The rear arms are sitting on jack stands, they sit much lower

[metalmaker12]

Nick (Stickshift84) and I live within 10 minutes of one another and we just blasted all our 818 bare steel pieces to get powder coated, heres a pic of one set 20183

Along with fitting up my bare steel parts I assembled the rear coilovers20184

I also ruff fit my pedal set and brake and clutch masters, I actually used some subaru bolts to give it an OEM feel. my whole build theme will be Subaru Oem 20185 201862018720188

[GUNS]

Looks great!

[metalmaker12]

yours does too Guns!!

[Stickshift84]

Wow, I love seeing all of our clean parts. Just finished them all up and packed them up. To the powdercoaters tomorrow afternoon.

Thanks again for the help with blasting Chris.

I guess I really should start my own build thread, I think it is due.

[metalmaker12]

Wow, I love seeing all of our clean parts. Just finished them all up and packed them up. To the powdercoaters tomorrow afternoon.

Thanks again for the help with blasting Chris.

I guess I really should start my own build thread, I think it is due.


It is all part of the fun! This is a cool experience for us all

[wallace18]

Looking Good! I like the OEM fasteners.

[metalmaker12]

Stay tuned, parts coming back from powder, tranny back together with cusco and all FFR parts, motors going in this weekend

[metalmaker12]

Heres some updates, I have the front panels in, column mounted, and brake and clutch pedals mounted, also the front suspension and moving on to rack and rear suspension tonight. tomorrow motor and tranny are going in, heres some quick snaps.
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[RM1SepEx]

Metal, your inbox is full again... :-(

[Samiam1017]

Metal. What do you think the best way to attach the motor install? No headers? With headers? Motor /trans sep or together?

[Mechie3]

Nice. I wish I could powder coat myself. I'd be much farther ahead. Well, that and if my wife stopped coming to the garage every hour asking me to do other things like watch a movie, go shopping, or go to bed. Aint nobody got time for dat!

[RM1SepEx]

eastwood, powder coat for 100 and an old oven for free from craigslist

I blasted and PC my OEM 16 in wheels, they didn't fit in the ove so we pulled the door off and made an extened door to give 20 x 20 capacity! we used the drawer from under the oven for the inside of the extension and some .050 aluminum for the outer box... single oven donor build... 2 inches between in and outer box filled with fiberglass. heats up fine. All my parts will be done tomorrow except the door frames. We will use an IR lamp to cure those... takes longer in sections. You should see the hot pink wheels on my wife's Miata..

[C.Plavan]

Did you spray can your trans?

[metalmaker12]

Yea, nick had a hook up for our powder

I would say you should mount the engine and trans connected with the headers removed, it is tight getting under the crossbraces, I will post pics if I can, I think I might be going solo on my engine install. I blasted my tranny case and sprayed it with Kbs high heat silver at around 17psi reduced with Kbs reducer. I like the Kbs stuff for this type of thing. Btw my tranny is spotless inside, and my cusco 1.5 diff should work just like the 818r's cusco. I have been looking at old tune maps and I think I want just around 285-310 whp max for this build.

[longislandwrx]

Very nice! Called it quits at 1am? I guess you ran out of 5 hr energies?

[Xusia]

Or perhaps the 5 Hour Energy ran out on him?!?

[metalmaker12]

I literally fell asleep in my garage around 1am lol, I got a lot done this morning, will post Lata, my beautiful wife and daughter want to go get some sun and maybe a cruise, post Lata

[metalmaker12]

I literally fell asleep in my garage around 1am lol, I got a lot done this morning, will post Lata, my beautiful wife and daughter want to go get some sun and maybe a cruise, post Lata

Heres some pics203422034320344

First Ej207 in a 818 2034520346

I removed the up-pipe and the headers along with oil filler and coolant tank , which I highly recommend on all, I broke my factory inlet boost bung, I was replacing the inlet so no biggy, but if you want to be careful and your using I would take it off. I had help from my dad line it up. I used so plywood to slide in with the engine hoist and it worked well

[Samiam1017]

Metal I accidentally posted this on a different thread but I ment to post here for you. Can you get me the widest width of your gocart. I want to see if I can fit it thru my basement doors.

[metalmaker12]

Yea hold up, about 65-66 inches or so

[metalmaker12]

So I put my bushings in the right way. Funny thing is no cutting gussets, no oblong holes, just a piece of 2x4,couple screw clamps, vis clamps, pry bar and some redneck engineering and poof they fit right in, well I did drill the holes out 1-2 drill sizes bigger( I could not read the drill bit size and my mic is at my dads) ,and it is not an easy task, but somehow I did it just fine.

2056220564205652056620567

[metalmaker12]

"After the bushing re-fit of 2013" I assembled my front end, also my turbo coolant tank is getting a custom bracket soon

205742057520576

night folks

[Mechie3]

Do your front control arms move freely? I didn't have to pry mine open like RM1, but I did have to slot the steel on the driver side, slot the aluminum on the passenger side, trim 1/2" of gusset on the driver side and 1/8" of gusset on the passenger side. They're both even within 1/32" and rotate freely. The angle of the bushings isn't quite the same though, though it's hard to tell just eyeballing it.

[metalmaker12]

My holes lined up with the bushing pretty good before i put the arm together.They would move more freely if I loosened the rear bolt on the back of the bushing, but once I tightened them up they got tighter. The drivers went in pretty easy, the passengers was more of a pain. The reason we have to cut the gusset ( though i somehow did not)it seem is for install clearance so you can slide the arm rearward, but once it is set in the front hole it seem to actually have a tenth of clearance from the gusset, at least on my frame. I would like the arm to maybe be more free, but it moves and I also don't want it to move out of place every time I hit a bump or something. I think I am good and it is safe. Yea the angle might be a very slight difference if any, but Noting i am going to worry about, I can't see to much if a difference.

[freds]

My kit arrives next week, so I don't have any fitting knowledge yet!

However my donor was an 06 with a left LCA damaged. I got a replacement which had a completely different bushing/mounting pivot. I don't know what vehicle it came from.

The black one is my 06 part.

The difference is enormous!

205772057820579

[metalmaker12]

That's a wagon one, you need two of the same arms and bushings, or maybe just the bushing if the arms are the same. Problem is idk if you can just get that bushing.

[longislandwrx]

AWESOME WORK. Any backordered parts holding you back?

I am really digging the contrast of the calipers. I was going to leave mine black but I'm thinking I'll end up going rally yellow like the new WRX concept


I'm also glad I ordered the msi trailing arms, with all those beautiful tubular links, those oem ones just don't cut the mustard.

[metalmaker12]

As some of you may know, there is a slight clearance issue with some headers on the drivers side engine mount. I trimmed 1/4 off the forward edge and it gave me the desired clearance. I have oem Jdm equal length headers.

20583 Before

2058420588 After, but not a final trim yet, was just checking clearance.

20585 headers

20586 20587final trim, and some chassis paint

Longisland, thanks man, yea I like contrast on everything and the kawasaki green powder pops, yellow is cool too

[07FIREBLADE]

That green is making my miss my zx7r right about now. Loving your build. Quick question for any of the current builders. How are you guys running the brake lines?

[metalmaker12]

Along the drivers side frame, I will be running my set this week.

[metalmaker12]

Headers sprayed with KBS High heat ceramic2072720728

Swapped down to a normal size Koyo from this monster20729 to this20730
Heres the clearness now,20731 before it was hitting rack and I would have had to mod the whole setup.

Heres my pedal, with gas pedal semi installed20732

Heres my fuel pump setup and tank, btw tank fit no problem 207332073420734
More to come tomorrow

[FFR-ADV]

Looking great Metalmaker!

Are you planning to use the ABS?

[wallace18]

Looking good! Do you have to have the exhaust off of the engine/trans to install in the chassis? Also that fuel tank looks a lot like a 33 tank to me.

[metalmaker12]

FFR-ADV: thanks, and no I have no plans of using Abs, I deleted it from my harness.

Wallace: I removed the up pipe and headers for my install and I highly recommend that. It is a 33 tank.

[Kalstar]

FFR-ADV: thanks, and no I have no plans of using Abs, I deleted it from my harness.

Wallace: I removed the up pipe and headers for my install and I highly recommend that. It is a 33 tank.

Looking good, REAL good!

[metalmaker12]

Looking good, REAL good!

You better warm up your gtm! Thanks man, hope to meet up soon

[JeromeS13]

20730


I wonder if we could mount the radiator BELOW/FORWARD of that support, instead of on top of it? (Just lean it at more of an angle)...

[metalmaker12]

I lined the underside of the tank with 1/16 flat roofing rubber and siliconed it down, also I placed insulation tape on the back firewall frame sections that meet the tank. I did this for sound deadening

2073920740

[Mechie3]

How far away are the headers from the gas tank? My headers are still off being coated.

[metalmaker12]

I will measure exactly later but I would say 6-8 inches as a guess

[Mechie3]

Just wondering if a behind the gas tank firewall with a reflective coated would be beneficial or not.

[metalmaker12]

I am thinking a piece of alumium riveted to the frame in front of the engine to the frame with reflective material on it would work well, I got a couple ideas.

[Frank818]

The best (or almost) material to reflect heat is gold, do like the inner panels of the 92-98 McLaren F1. lolll
http://commons.wikimedia.org/wiki/File:1996_McLaren_F1_engine.jpg

[shim2]

The best (or almost) material to reflect heat is gold, do like the inner panels of the 92-98 McLaren F1. lolll
http://commons.wikimedia.org/wiki/File:1996_McLaren_F1_engine.jpg

That would be ungodly expensive and completely unnecessary, but it would look nice.

[metalmaker12]

They have that stick on reflective material that's cheap and very effective, which I will be using in various locations.

http://m.ebay.com/search?kw=Gold+heat+wrap&isNewKw=1&pgn=1&epp=24&mfs=SBCLK&acimp=0&itemId=&cnm=&cid=&sqp=Gold+heat+wrap&_trksid=p2056088.m2428.l1313.TR0.TRC0.XGold+heat+w rap

[metalmaker12]

So I have had some issues during my beta build, but my friends at FFR have helped me out and made the proper revisions along the way, I am going to develop a punch list of the problems and solutions in my next few post. Questions comments welcome.

[flynntuna]

That's a very good idea. A place in the WIKI section of the forum would be extremely helpful to future builders (meaning me) for those problems that make you just sit and stare at for hours with a glazed look scratching your head :confused:

[Wayne Presley]

Just wondering if a behind the gas tank firewall with a reflective coated would be beneficial or not.

I put one in my car

[metalmaker12]

FFR has been great working with me, Wayne, Erik, Craig, Dan, Nick and others on sorting out problems and coming up with fast solutions. All the future 818's will be that much better due to all our hard work. Here are some issues and revisions, anyone else can jump in and add a few.

Problem: The lower control arm bushing needed to be mounted under the outside frame point and on top of the inside frame point. There is a little bit of gusset in the way and you have to trim to fit along with enlarging the mount holes a couple sizes.
Revision: All FFR 818 frames going forward will not have this issue

Problem: The filler neck tube is the wrong bend for the top fill provision on the body. Is the old location like the 818 R 20769
Revision: A new filler tube has been created by FFR, it just did not get updated in time for the first few kits, but all the beta kits forward will be corrected, will post pics when I receive the new setup

Problem: The wrong axles were sent out to a good chunk of us betas, due to a miscue.
Revision: The correct axles have been ordered by FFR and we will get all new sets

Problem : The left engine mount may be to close to certain headers, and we have to trim the mount by 1/4 inch on its forward facing side.
Revision: The FFR 818 frames going forward will no longer have this issue.

Problem: The kit comes with two right upper control arms
Revision: you have to trim down the welded side on one arm by 1.100' to make it a usable left arm.

Heres some pics of my brake line work
207702077120772

[07FIREBLADE]

Question for you metal. Are all the brake lines supplied and bent by builder or do we use any portion of the stock lines. Trying to figure out if I meed to keep pieces or not from the donor...

[metalmaker12]

Supplied and we must bend all lines and flare 3-4 ends

[Wayne Presley]

You have to bend your lines, you do not have to flare them. I'm sure MM flared his to have the lines an exact length instead of a loop in the line.

[metalmaker12]

True, you could loop them if you want, but I found it easier to cut cut and fit certain ones. Plus they sent me a lack of shorter line sizes so I had to get resourceful, since I set out to install lines. I also may replace the lines with nickel copper or stainless ones down the road, but I have a solid pedal and they are working nicely now, so there staying as is for some time.

[Bkafe]

Axles are next for me...

How do we tell if we got the wrong axles?
Any idea if Factory Five is being proactive, or do we have to figure it out and call for new axles?

Thx,
B

[Wayne Presley]

do they have the same spline size on both ends? if so you have the right axles.

[metalmaker12]

If you have aftermarket cv's it changes what your asking. Oem and aftermarket inner cv's fronts have a different female spline design. Oem is fine and aftermarket is coarse. So if you have oem axles you want fine/fine spline axles and if you have aftermarket you want fine/ coarse splines to your axles. FFR will send you the correct ones if you have the wrong axles, just let them know. I am thinking at some point they will be sending only oem style axle shafts, but maybe they will offer both, I will ask about this .

[FFR-ADV]

Thanks Metalmaker, Wayne, Erik, Mechie & Timmy318 for blazing a path for us.

My build is getting close! I am scheduled to pick up my 818 less than a month from now. Hopefully most of your catches will be fixed by then (thanks to your efforts).

Cheers!

[Bkafe]

20865

Looks coarse/fine

[metalmaker12]

20865

Looks coarse/fine

from the looks of it they might be the ones that only fit aftermarket cv's, try them, if no luck you need the other ones, whats your part number?

[metalmaker12]

From time to time you might get a part that is bent wrong or wrong in some way. FFR will send you a new one, or you can be resourceful. This tranny bracket had a tab bent the wrong way, I cut and welded it in the correct position.

209162091720918

I decided to cut my axle ends down, came out better than I thought with a crude angle iron saw.

2091920920209212092220923


Also, everone, I am working with Nick (stickshift84) On some different seat mounting and the steel arm spindle to shock clearance, we will post results.

[GUNS]

Good job man, wish I had your welding skills.

[Erik W. Treves]

I have an extra one :D

[FFR-ADV]

Nice looking welds!

I expect I might run into the spline issue with a probably typical twist. I replaced my donors CV on the passenger side when I first purchased it last September with a aftermarket one from NAPA. What is not clear to me is how an aftermarket shaft with a different spline pitch could work at all?

The only other fix on my donor was to replace the O2 sensor (got a Bosch one).

Cheers!

[metalmaker12]

Nice looking welds!

I expect I might run into the spline issue with a probably typical twist. I replaced my donors CV on the passenger side when I first purchased it last September with a aftermarket one from NAPA. What is not clear to me is how an aftermarket shaft with a different spline pitch could work at all?

The only other fix on my donor was to replace the O2 sensor (got a Bosch one).

Cheers!

FFR did not know they had aftermarket axles/cv's and went forward to create axles for the kit from after market splins.
That weld was with a short arc mig, nothing crazy, thank you though, I was really just showing that it was a minor fix .Soon you will see some nice looking tig welds from some fabricated brackets.

[RM1SepEx]

Chris, PM me I'm interested in a modified Factory Five 818 exhaust adaptor... I want to bell mouth the adaptor... Any interest in some side work?

[metalmaker12]

pm sent Dan, I have some ideas also to chat about, send my your number again, lost in old pm's, call you lata

[metalmaker12]

Here is some progress on pedals, shifter/cables and e brake etc. I got my brake lines ran and I have a clutch and brake pedal right at the top and ready to drive. I also have my 02 gas pedal in a great location with some modification. I am finishing up my harness re-working and I am about to start installing
2110021101211022110321104

[FFR-ADV]

I look forward to seeing your custom exhaust mounted up in your 818.

Nice work!

[metalmaker12]

I am going to start a re- worked version and see how it looks with the rear section mounted possibly this weekend

[metalmaker12]

A little carbon wrap goes a long way, I am very happy with the results of the wrap I purchased.I also put some skate board gripper on the dead pedals.

211232112421125

[Xusia]

I like it!

[Frank818]

Nice wrap!
Is that the one from the guy here on the forum? Damn I lost the website and the guy's name... I'll find the thread.

Got it. Kalstar and http://www.ultimatepremiumplus.com/

[C.Plavan]

I like it. looks really good. I may just cover my raw aluminum with that.

I would love to see the modifications to your gas pedal. Looks way better closer like that, and more functional for Heel/toe.

[metalmaker12]

I like it. looks really good. I may just cover my raw aluminum with that.

I would love to see the modifications to your gas pedal. Looks way better closer like that, and more functional for Heel/toe.

All I did was cut the pedal shaft down one 1" and re- welded it together. Remember to remove plastic pedal!!!! I also added some small rivets in the top of the oem- FFR mount to make more ridged. The wrap came out good, it it an art form though and takes practice. My mod for pedal is only for the 02-05 dbc

[metros]

Looking really good. Quality of the wrap looks great and the pedals look perfect with that minor modification.

[C.Plavan]

All I did was cut the pedal shaft down one 1" and re- welded it together. Remember to remove plastic pedal!!!! I also added some small rivets in the top of the oem- FFR mount to make more ridged. The wrap came out good, it it an art form though and takes practice. My mod for pedal is only for the 02-05 dbc

Thanks for that info. My pedal is from a 2007 wrx- So what your saying is, I might not need to modify?

[metalmaker12]

Thanks for that info. My pedal is from a 2007 wrx- So what your saying, is I might not need to modify?

07 is dbw so it should be in a desired location, the earlier dbc mounts different in the car and due to size differences in mounting locations on the FFR 818 frame it has to be modded a bit

[Frank818]

Where's the wrap coming from?

[wallace18]

Those carbon look panels are so cool!:cool:

[metalmaker12]

I came across a coolant adapter that will help burp our systems.

21140

I also grabbed a perrin inlet 21141

I also got something done today.... I mocked up cut down harness, got power to the cluster and it cranks over, Hell yea first man in flight!! well with the factory harness off coarse. It is not super difficult if you have some background, but you gotta cut it down if you want to fit it in the car.

21143211442114521146211472114821142

[Samiam1017]

MM. Does the "assembly manual" have recommendations on where the fuss box and other components should go

[metalmaker12]

Yea kinda, and my locations pretty much match there's. Honestly they can really only go in certain spots unless you want to cut it all apart.

[NicksPapaw]

Is that last pic the wiring harness AFTER your dieting? Dang, that is one big clump of wire you got there. Apparently you kept the wiring for the missile launchers and ejection seats. :). Good job getting to this point. You will be on the road before you know it.

[skullandbones]

So it looks like you haven't actually shortened the harness yet and dieted it. So you should loose about 25 lbs. shouldn't you? You are doing it the right way! It would be depressing to carry around all that extra junk in a seriously light race car. Good luck. Keep us atuned of the big pile of loose wires. That would be a good pic to keep for memories of the build. WEK.

[metalmaker12]

I have dieted abs, srs, cruise, fuel pump extension harness, and all that would be left is the heating and radio stuff. You have to diet and I would like to even more, but it might be more of a pain than its worth. This harness is a cluster @&$@$, but were cranking. I just have to see why I am getting no power to the fuel pump and sendor, when the relay is snapping on, but its late and I am not helping anything half eyed.

[wallace18]

You are coming along very nice. It is good to see a factory harness install. I am still debating which way to go.

[RM1SepEx]

Nice job Chris... I'm hoping that we can pull more than that from the harness...

what gauge wire did you use to extend the harness? I'm looking to order some wire before I drag that 45 lb plastic box out and dig into the rats nest!

[metalmaker12]

There is some 8 gauge, 16 and 18, also there is some 10, I have just mocked up the connections with connectors, but once I have it all set I will go back and solder the connections and heat shrink. To be honest I have reused factory wires to extend most wires and I only bought some 8 gauge to extend the main fuse box power cord. I am going to trouble shoot a little lata, takings break from it so I can look it all over fresh, I was up till 230am sorting out certain stuff.

[RM1SepEx]

So you took and stripped out some obviously unused wires like speaker wires etc and reused them as control wires etc... no concern for the color etc... just matters where the splice starts and stops.

I see how the large diameter wires are for the starter circuit etc... I have some bigger wire on hand. I'm hoping to get to the wiring next week.

I had another autocross yesterday and it was about 90% humidity all day... need to take it easy today I'm spent! That shifter kart really beats me up. :-)

[Xusia]

Wow. I had planned on using the factory harness, but seeing that mass of wires is really making me consider buying Wayne's solution.

[metalmaker12]

2k is what kept me from that, but it is a good solution, but I think in time there will be others

[Xusia]

Fortunately for me, I start a new job Tuesday - and it pays a lot more. So now I don't mind spending some extra to make my life easier! Hahaha

[RM1SepEx]

did you delete all the power window and stereo stuff? how "deep" does your current delete go?

Like you I believe that there will be a better soln using the factory ecu soon...

[2006 WRB 818]

...but I think in time there will be others

I actually love wiring and I do a lot of it as a mechanic at Delta Airlines. My 818S kit arrives tomorrow morning, and as soon as I get my harness done, I will be offering a full service custom harness mod hopefully with a swap out option as I have an extra complete 02 wrx harness.

[metros]

Is that what Wayne is anticipating asking for the plug n play harness? That's pretty pricey for a harness.

[metalmaker12]

I did not delete all the power window and or radio because i might use them at some point. I was going to try deleting it more, but I don't have the time to cut it all the way down and basically rebuild a harness. If it works I am happy, and it is getting close to being where I want it.

[skullandbones]

OK I think I get what you are saying now. You didn't have time to shorten the wires that worked but are way too long. You dieted what you could and added pieces into the wires that were too short. That makes sense. It would be a big task to take all those long wires and solder/heatshrink every one. Also, it adds a variable into the equation which is: making a mistake and misattaching or leaving a bad connection. It would take a lot of continuity checking and added work. Don't blame you at all!!! Good luck on the first startup. WEK.

[JeromeS13]

All of this was only 16 lbs... All AC wiring, power steering, ABS, SRS, airbag, radio harness, door harnesses, etc. have been removed. And it takes FOREVER!

http://i157.photobucket.com/albums/t43/JeromeS13/IMG_20130628_230055_zpsedd656dc.jpg (http://s157.photobucket.com/user/JeromeS13/media/IMG_20130628_230055_zpsedd656dc.jpg.html)

[Wayne Presley]

Is that what Wayne is anticipating asking for the plug n play harness? That's pretty pricey for a harness.

Thats a complete harness, Electromotive TEC-s, sensors, software, and the ECU will come loaded with a tune file.

[metalmaker12]

So got power at fuel pump controller and pump. I had a bad 30a fuse at SBF-5, but now it is all coming together and soon I will be filling tank a bit and trying to start

Ps, in fairness to Wayne, his wire setup is very nice and worth every cent, I just don't have the extra cents

[rangerbay]

Wow. I had planned on using the factory harness, but seeing that mass of wires is really making me consider buying Wayne's solution.

Wayne's system is an organized and customizable time and frustration saving system. You need to talk to him before you make your final decision. Ive wartched him do 2 of his systems on 2 818's, and it is a fairly simple and quick install.

Bill

[Frank818]

Thats a complete harness, Electromotive TEC-s, sensors, software, and the ECU will come loaded with a tune file.

Unless the engine is different than what you tuned in the TEC software, then it will require a re-tuning/mapping.

[Wayne Presley]

Unless the engine is different than what you tuned in the TEC software, then it will require a re-tuning/mapping.

Frank, I have tune files for a stock WRX and a WRX with normal upgrades. The tune will be really close out of the box.

[Erik W. Treves]

Unless the engine is different than what you tuned in the TEC software, then it will require a re-tuning/mapping.

the same could be said for every ECU out there...even the "self tuning" systems requires some tweaking to be optimum... I have one of Wayne's ECU's with preloaded tune and it was good enough to go out for a drive....on 2 cylinders!

[Frank818]

Frank, I have tune files for a stock WRX and a WRX with normal upgrades. The tune will be really close out of the box.

Ok Wayne, I see. Depending on the upgrades, it will most probably run, but then of course to be optimal a good tune is required. Sounds much better than what I did on my VW with the DTA S80 Pro, I did everything from scratch with very very little reference to something.

I'm done for these questions in this thread, since this is Metal's build thread :), but I appreciate I got an answer. :)

[metalmaker12]

Same goes for my setup, I am running a Usdm ecu emission re flashed ecu, but when I bring to dyno I will be re- mapping the jdm edu.

[EricScottZehnder]

All of this was only 16 lbs... All AC wiring, power steering, ABS, SRS, airbag, radio harness, door harnesses, etc. have been removed. And it takes FOREVER!

http://i157.photobucket.com/albums/t43/JeromeS13/IMG_20130628_230055_zpsedd656dc.jpg (http://s157.photobucket.com/user/JeromeS13/media/IMG_20130628_230055_zpsedd656dc.jpg.html)

This is my nightmare...

[metalmaker12]

It is not that bad everyone, got my setup almost ready to go. I did not mean to intimidate anyone, the oem harness is completely doable and will have an assortment of options for factory accessories like a/c etc. There is also a wide range of subaru tunable products that can be used with the oem stuff all the way up to open source tunes and stand alone Ecu's etc. Wayne's setup is great and if you got the extra coin go for it, but you can still have the same bang for a donor harness.

Note: none of this statement is made to sway any decisions, just stating the factory harness is completely doable

[metalmaker12]

It's alive.....it's alivvvve .... Hoohaaaaaaaa.haaaaaa. Haaaaaaaa. Will make vid when I install coolant system, sounds wicked mean with the equal length/ twin scroll spinning and less rumble, I mean wicked nasty mean. Ps kinda needs a muffler but we will see. I have a short magnaflow and some other bits.

Footnote: 1st customer to use factory harness and get it started, jdm ej207 with a vf37 twinscroll" I feel like the few of us first builds our the pioneers of the 818

I will try to post a quick video tomorrow morning of her running

[JeromeS13]

Sweet. Looks like I'll be running the VF37 setup on an EJ25. I wonder how it'll sound in comparison? :-D

Congrats!

[wleehendrick]

6 weeks to first start... great job! Looking forward to the vid...

[wallace18]

Super Job! Take a bow and have a beer.

[metalmaker12]

Had like 4 Sam lights, and a shot after I got it running, just relaxing now. I just gotta run coolant and build axles along with finishing lights, and various brackets along with a full diagnostics and tweaking of any system that might throw a code, I have a couple minor codes, but I know what I have to mod to get it right, just standard tweaking, but at least set a canvas for others and I have some details on various harness mods etc when you all need advice.

[RM1SepEx]

congrats Chris!

I just dragged my fuel tank and tote with the harness into the garage this morning... another stock harness attempt about to begin! :-)

[Frank818]

Yes sir man!!! Great job, pretty quick too!

Do you have a cat on or currently you got no cat and no muffler?

[metros]

Thats a complete harness, Electromotive TEC-s, sensors, software, and the ECU will come loaded with a tune file.

That makes more sense. Just a harness should have gold plated connectors for $2k.

Congrats to metal! Great progress.

[FFR-ADV]

WOW that wiring sure gets packed in there! And that after removing unused circuits (or those with no future plans).

21287

I look forward to hearing your 818! Congratulations on your progress!

[Mechie3]

Nice work.

[metalmaker12]

No cat, but slipped on a shorty muffler, pretty
Raspy without

[longislandwrx]

Will there be enough room for the shifter cables with all that in there? It looks great though, I am very confidant at this point thanks to you, I'll be pulling the hvac, speaker and radio harness as well so I should have a little extra room. Looking forward to hearing it start.

[RM1SepEx]

shifter cables go over the tunnel...

[Mechie3]

If you use the cobb AP you might want to leave 1 wire on the HVAC for the rear defrost. They used that button for setting and turning on/off launch control.

[metalmaker12]

shifter cables go over the tunnel...

Yes shifter cables go over, also be careful what you delete, some needed wires tie in other systems. Like you need the flasher to have lights and some keyless entry stuff has to do with the lights also. I got in running, but I am by no means done, I am now trying to get head and brake lights, reverse, and stop. I got flashers, but so far my 15 minute check has come up blank on why certain things are not running. I have to look it all over tonight, and think i will sort it all out.

[longislandwrx]

If you use the cobb AP you might want to leave 1 wire on the HVAC for the rear defrost. They used that button for setting and turning on/off launch control.

good call, I haven't looked at the diagram yet, how is that tied into the ecu?

[Mechie3]

good call, I haven't looked at the diagram yet, how is that tied into the ecu?

Not sure. I'd have to look and find the pinout for the HVAC board.

[longislandwrx]

Cobbs new launch control maps for v2 and v3 APs don't require the hvac or cruise to set anymore, it's all set through the AP.

Cobb says:

A few older models set launch control via defrost/cruise control buttons, but this was not consistent across all models. This feature will not be carried over in the new version. The launch control for all models will operate the same and the LC/FFS RPM thresholds will be able to be tweaked by the AccessPORT. The AccessPORT tunes the real-time LC/FFS RPM thresholds so those settings will remain even if you remove the AccessPORT or turn the ignition off. Only if you reflash another a map or disconnect the battery will the LC/FFS real-time thresholds return to their defaults (which is determined by the map reflashed to the ECU).

So feel free to delete cruise and hvac if you were worried about it.

[C.Plavan]

Cobbs new launch control maps for v2 and v3 APs don't require the hvac or cruise to set anymore, it's all set through the AP.

Cobb says:

A few older models set launch control via defrost/cruise control buttons, but this was not consistent across all models. This feature will not be carried over in the new version. The launch control for all models will operate the same and the LC/FFS RPM thresholds will be able to be tweaked by the AccessPORT. The AccessPORT tunes the real-time LC/FFS RPM thresholds so those settings will remain even if you remove the AccessPORT or turn the ignition off. Only if you reflash another a map or disconnect the battery will the LC/FFS real-time thresholds return to their defaults (which is determined by the map reflashed to the ECU).

So feel free to delete cruise and hvac if you were worried about it.

That makes me feel a ton better. Thank Long

[Mechie3]

Shows you how much I've used the launch control features (zero times).

[longislandwrx]

No problem Chad, how about you stop hoarding all of North America's LGT transmissions as a thank you. :D

[metalmaker12]

Heres my first start up video, kind of grainy, next time video comes rolling it will be fully running and driving and in HD with my GoPro

http://www.youtube.com/watch?v=dvRB59cchBo

[FFR-ADV]

Congratulations Metalmaker. Very nice work!

[metalmaker12]

Thanks Steve, heres some other helpful pics
2136921367213682137021371

I am putting an overflow tank in front and in back, I used the spacers from the shifter for the radiator alignment and I just mounted the factory tranny line with FFR supplied hardware and it works great and has proper safety clearance

[Erik W. Treves]

There ya go! sounds great...now I can really tell that I have been down those cylinders all along!...lol.

[metalmaker12]

Lol Erik, Glad I could help, now going to wire up the rest of it all

[Wayne Presley]

Congrats!!!!!!!!!!!

[metalmaker12]

Thanks guys,

but there is still much work to be done on the lights, fans, brake light wiring, reverse light( need new switch) some other stuff I am sure and than the axles, coolant system, new exhaust mock up and i am also waiting on a throttle cable.

[Mechie3]

How did you mount your shifter?

[metalmaker12]

Craig send me your email so I can send quick snaps from my phone

I mounted it 17 inch from back firewall and cables go over and through some wires, to the front wall and loop on drivers side to the tranny.

[RM1SepEx]

Chris, Craig is having problems getting the shifter's bolts to line up on the tunnel with the offset washers... I talked to Tony yesterday and played with mine a bit. It looks like if you put the inserts towards the edge of the tubes it can align on mine.

[Mechie3]

My email is my username here @gmail. I might have to remove my inserts and replace them with the shifter slightly farther forward.

[longislandwrx]

Nice work. Harness looks awesome. How did you manage to start it with your ecu in a cardboard box though :D

are you going to wire in the door and trunk sensors for that oem feel?

[JAubin]

Nice! Awesome to see/hear since I'm also planning on a V8 EJ207...I'm partial to the UEL headers, but that sounds really good. Congrats!

[metalmaker12]

They are equal length but with such a short exhaust they have a rumble and a nice roar to, trust me in person there is no mistaken that the equal length sounds the best, offcoarse just my opinion

[metalmaker12]

No prob not just yet with the doors, but maybe of I feel like it lol. That's my other jdm ecu, running a flashed 02 Usdm ecu

[ehansen007]

AWESOME!!! nice work. I can't wait to see and hear all your cars whooping up on 911s out there!

[metalmaker12]

Heres some coolant line routing and a turbo coolant tank mount with some dream wheels and a little carbon.

2175021751
21753[/ATTAC[ATTACH=CONFIG]21754217552175621757

[JeromeS13]

Your front coolant overflow will present a problem. The small outlet on the passenger side is pressurized when the engine is running. Only the outlet beneath the cap should be going to the overflow.

[Wayne Presley]

Your front coolant overflow will present a problem. The small outlet on the passenger side is pressurized when the engine is running. Only the outlet beneath the cap should be going to the overflow.

Agreed, cap the one on the passenger end of the radiator.

[Mechie3]

What hose did you use on the upper engine outlet? The manual says to use the 70deg bend from the OEM bottom hose, but the next picture says "place the 90 deg bend". My 70 deg bend comes too close to the frame IMO. My upper hose was trashed in the accident so I need to figure out how many hoses I want to buy. I think that a silicone 90 coming around the back corners of the frame would be nice too and eliminate the long snaky bend required to not kink the corrugated hose.

[metalmaker12]

Mechie, yea I am going to come up with with a mount of some kind and play with different bends. I just bought the two subaru required coolant hoses.

[RM1SepEx]

What hose did you use on the upper engine outlet? The manual says to use the 70deg bend from the OEM bottom hose, but the next picture says "place the 90 deg bend". My 70 deg bend comes too close to the frame IMO. My upper hose was trashed in the accident so I need to figure out how many hoses I want to buy. I think that a silicone 90 coming around the back corners of the frame would be nice too and eliminate the long snaky bend required to not kink the corrugated hose.

use the 90 on the upper engine

the manual tells you to use the tubing connector in one place and the 70 degree bend from the lower in another for the lower tube. Chris used the connector, I used the 1/2 lower radiator hose, I think if fits better and gives mmore clearance to the flex hose

[Mechie3]

I actually found a bunch of 90 degree silicone couplers in the basement!:cool:


I then measured and found they were all 1.75" not 1.5" :( I'm thinking of cutting them up and using them as sleeves over certain areas where the hoses come close to the frame.

[metalmaker12]

Good idea, I wrapped my hardlines with rubber to serve the same purpose.

On the coolant overflow lines the pass side one will be caped off, my dad ran that section not knowing, I have just left it till I get the proper barb plug

[metalmaker12]

some quick interior work and bracket mockup 22137221382213922140221412214222143

[FFR-ADV]

Looks great Metalmaker!

The Kirkey seats look comfortably positioned with the shoulder belts lined up to the cross bar. Nice.

With that JDM STI v8 you are going to fly!

Congratulations on your progress.

Cheers!

[RM1SepEx]

I like that coolant pipe standoff and CF look vinyl looks damn good
Are you planning on street use Chris? I wasn't aware that the G Force belts were DOT approved.

[Mechie3]

They aren't DOT approved. I think that camlock belts aren't allowed on street and must use a single button release. Not that I'm going to try and get away with using pretty much the same harnesses. ;) Helps that we have ZERO inspections in Indiana.

[metalmaker12]

Thanks guys, I am using it on the street, I am almost certain the five points are not dot approved

[metalmaker12]

http://www.youtube.com/watch?v=WT2VAXoeYkA&feature=em-upload_owner

To be continued, just a dry run, adding coolant this week and this is with boyd tank and aeromotive 340 pump, @ stock boost-race tune capable with noting really buttoned up yet

[metalmaker12]

video up

[Erik W. Treves]

congrats! #3 gocart!

[metalmaker12]

Thanks, will be buttoning it up this week and on to body work

[Mechie3]

Awwwww yeah!

[metalmaker12]

Awwwww yeah!

Did I mention I left ten foot wheel spin burn marks in my driveway and my street. it spun but moved forward at the same time with zero effort. It is very snappy and very controllable, it will be nuts when I actually can hit it. I have about 285whp with the current mid power tune. I think about 300-325 is my goal. It is like a big kid go kart

[Frank818]

That looks promising. :)

[Bob_n_Cincy]

Great job Metal.
Bob G

[Mechie3]

Did I mention I left ten foot wheel spin burn marks in my driveway and my street. it spun but moved forward at the same time with zero effort. It is very snappy and very controllable, it will be nuts when I actually can hit it. I have about 285whp with the current mid power tune. I think about 300-325 is my goal. It is like a big kid go kart

Awesome. I've still got a little ways to go. Keep getting sidetracked with modifying this or that.

[metalmaker12]

Awesome. I've still got a little ways to go. Keep getting sidetracked with modifying this or that.

Yeah I hear ya, I had to modifiy a lot to get things where I wanted them etc. It is starting to all come together. Parts in mail for interior stuff so I can button that up, and start to button up the lines, linkage etc

[Wayne Presley]

Looks like fun!

[FFR-ADV]

Looking great Metalmaker!

[longislandwrx]

Very cool. Congrats on all the hard work.

[RM1SepEx]

congrats! #3 gocart!

wayne, erik, grm, Chris

who doesn't count? :-)

[Mechie3]

wayne, erik, grm, Chris

who doesn't count? :-)

Wayne and GRM are pretty much one and the same anyways, right? Weren't there pictures of GRM standing around while Wayne did all the work? ;)

[Erik W. Treves]

Ok so #4 then....

[JAubin]

Awesome, congrats! Still think this is the best motor setup for the 818... (even tho Wayne's motor will make a very compelling case)

[Justen]

Wow, that was quick. I was planning on working on this all winter and hopefully have it done for next summer, but seeing how quickly all these builds are coming together, I may try to shoot for the February open house!

[metalmaker12]

http://www.youtube.com/watch?v=GLfAjangWbs&feature=youtu.be

just letting it get up to temp, test drive was way more fun!!

[FFR-ADV]

I see a fall foliage 818SR tour in the making...

Congratulations on the progress!

[Frank818]

Your engine sound is very smooth!
Equal length headers if I recall?

[metalmaker12]

Yea equal, it's running pretty solid thanks

[Wayne Presley]

Wayne and GRM are pretty much one and the same anyways, right? Weren't there pictures of GRM standing around while Wayne did all the work? ;)


LOL, that's funny!

[metalmaker12]

Yea 818 central aka Wayne's world

[Frank818]

Wayne's world

lollll if you are referring to that old movie. :)

[metalmaker12]

Got 14-16psi and alignment really needed, but oh damn. I was going to video, but spent time tuning and fixing some bugs, but it's sorted out and making way to much power just like I like it. Need an alignment cause it is like dancing the tango. So my and stickshift84 "nick" are going to get the alignment close.

[metalmaker12]

http://youtu.be/8ov4RdbuGhs

[flynntuna]

It's alive.....
congrats

[metalmaker12]

I am finishing buttoning up wiring, onto the interior, waiting to get a set of wheels, and body fitment work

[AZPete]

Congrats! That's nice work.

[Frank818]

Yeah! Another one running!! :D

[Kalstar]

Congrats Buddy, Sounds fantastic!

[Scott J]

Sounds and looks awesome! Maybe I should be building mine in Hawaii too.
If your temp sensor is correct...25 degrees this am?

[metalmaker12]

My outside temp sensor, don't have one, just the cluster outside temp gauge. I am working on trying to work that in to the 02 harness that does not have it.

[metalmaker12]

It's been running for awhile lol

[longislandwrx]

Sounds good! All these startup videos really get me motivated to keep putting the hours in!

[metros]

Coming along nicely.

Were you the builder that was using the killer bee headers? Wondering how they ended up working out as far as fitment goes.

[Wayne Presley]

Come on....Catch up!!!!!!

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/IMG_9917_zps04a1ee25.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/IMG_9917_zps04a1ee25.jpg.html)

[metalmaker12]

Come on....Catch up!!!!!!

http://i213.photobucket.com/albums/cc175/vcpinjectionpb/IMG_9917_zps04a1ee25.jpg (http://s213.photobucket.com/user/vcpinjectionpb/media/IMG_9917_zps04a1ee25.jpg.html)

Thanks for the motivation, I am getting there, starting on the body next week or so

[metalmaker12]

new wheels
23202232032320423205

[longislandwrx]

I can't get mad because they fit and look so good.

[metalmaker12]

Lol beat you

[metalmaker12]

I have a video coming Lata tonight

[longislandwrx]

BRZ fitment?

18x8.5 +33 F / 9.5 +40 R

[Mechie3]

Such a tease!

Sizes? Have you fit a body panel to check?

[metalmaker12]

17x8 +35 215/40
18x9 +42 with 3mm spacer 255/35

[longislandwrx]

17x8 +35 215/40
18x9 +42 with 3mm spacer 255/35


THANKS. calculator time.

[metalmaker12]

You know what they are I am assuming. I am running a drives for now