818 Donors/ AJW Performance 818 Build Thread

[AJW Performance]

Time to build this thread, will start adding to it today.

We will be documenting the build on this thread here for anyone who cares to follow it!
Anything specific you want us to take note of please let us know and we will do our best to do so in order to help provide valuable information for the community. Kyle our head tech will be posting his progress on the build weekly, and I will be posting updates as well on this thread and on our blog.
Thanks for looking!

Dates:
July 25 2013- Picked up our 818S @ FFR
http://i167.photobucket.com/albums/u160/awalla5150/818loading.jpg (http://s167.photobucket.com/user/awalla5150/media/818loading.jpg.html)

Parts Used (this will be updated as we move forward):

Donor:
A mutt between numerous 02-07 Parts, obtained from 818donors.com ;)

Wheels:
2011 STi BBS painted black (pic coming)
15mm ISC 5x100 to 5x114 wheel adapters (pic)-http://ajwperformanceproducts.com/store/#!/~/product/id=22044044

Brakes:
Front:
ISC 6 Piston Front Brake Calipers
ISC Pads
ISC Stainless Lines
Link for pictures/ product info:
http://iscsuspension-na.com/store/#!/~/product/category=4449016&id=19087442
Rear:
Goodridge Stainless Rear Lines
DBA 4000 Series Rear Rotors
Hawk HPS Rear Pads
Link for pictures/product info:
http://ajwperformanceproducts.com/store/#!/~/product/category=4295185&id=3882078

Engine (2.5l STi):
CP Pistons (stock bore)
ARP Studs
ACL Bearings
STI Nitrated Crank
Manley I Beam Rods
Killer B Baffle
Killer B Oil Pickup
Killer B Oil Pan
BC Stage 3 Cams
BC Valves/Springs/Retainers
Gates Racing Timing Belt Kit
TGV Deletes
8mm Intake Spacers
Ported and Coated Intake Manifold
Balanced and Printed Engine

Torque Solutions Air Pump Delete
Torque Solutions Engine and Trans Mounts

Drivetrain:
Clutch Masters Fx300
OEM Subaru Flywheel
Redline Fluids
Short Shifter
ISC Race Knob (Gold)

Fuel:

DW 1300CC Injectors
DW Pump

Turbo:
Top Secret Turbo (TBA)
Thermotec Turbo Blanket
Perrin 3 inch Inlet
KSTech Big Intake

Exhaust:
Headers TBA
GS EWG Uppipe 44mm
Tial 44mm EWG
AJW Custom Turboback (pending production for public offerings)
Thermotec Exhaust Wrap

Intercooler:
Top Secret ;)

Electronics:
AEM Oil Pressure
AEM Wideband
AEM Boost
AEM EGT Temp
AJW/ Perry Tuned Mapping


Interior:
MOMO Wheel
Works Bell Quick Release Hub
Takata Harnesses
STI Limited Leather Seats

Suspension:
Whiteline Sway Bar
Whiteline Bushings
Adjustable Coilovers- TBA ;)

Exterior:
Lamin-X Protective Films
Aero- TBA

Other:
Silicone Hoses Throughout
Assorted Aluminum Shrouds/ Dressup


Preferred Brand Sponsors:
COBB Tuning (818 Accessport development partner with AJW)
ISC Suspension
DW
AEM Electronics
ThermoTec
Killer B Motorsports


Thanks,
Andrew

[ehansen007]

Good god man. Leaving no stone unturned or to this point, not part un-modified! Can't wait to see this one. Should be amazing!

[07FIREBLADE]

Sounds sick... Can't wait plus Cobb is down the block from me too

[blueoval_bowtie_guy]

Look forward to watching your progress!

Steve

[AJW Performance]

Good god man. Leaving no stone unturned or to this point, not part un-modified! Can't wait to see this one. Should be amazing!

Thank you sir, going all in on this one. It will probably be at SEMA, not sure who's booth yet though :)
I can't wait to drive it!

http://i167.photobucket.com/albums/u160/awalla5150/8181.jpg (http://s167.photobucket.com/user/awalla5150/media/8181.jpg.html)

http://i167.photobucket.com/albums/u160/awalla5150/8182-1.jpg (http://s167.photobucket.com/user/awalla5150/media/8182-1.jpg.html)
http://i167.photobucket.com/albums/u160/awalla5150/818loading.jpg (http://s167.photobucket.com/user/awalla5150/media/818loading.jpg.html)

[AJW Performance]

20693

Got the roller up and going (and no those are not the wheels/tires we are using).

[AJW Performance]

Reserved for future

[AJW Performance]

one more

[AZPete]

"a build thread for anyone who cares to follow it"
Andrew, are you kidding? We all will follow your build with so many mods!
And, thanks again for the WRX goodies in my garage awaiting my 818.
Pete

[AJW Performance]

Haha thanks Pete

[VD2021]

"a build thread for anyone who cares to follow it"
Andrew, are you kidding? We all will follow your build with so many mods!


Just subscribed to this one.

[flytosail]

I may have to drop by sooner than I had planned to. Will call first.

[AJW Performance]

We are going to dive into this build by this time next week. We have a few projects/builds we want to finish up before taking this on so we don't have 4x 818 donor projects/ a STi build AND our 818 all out in the shop... it would be a bit hectic haha.

Once Kyle gets on this next week we will basically only stop working on it when we are waiting on parts or sleeping (oh yeah and working on our customers projects as well of course, can't forget about that! ), other than that its going to be put together full force.

[timmy318]

This is gonna be a helluva 818 when y'all are done!!! Subscribed!

[AJW Performance]

As is yours Timmy :)
Thanks!

[AJW Performance]

20693

Got the roller up and going (and no those are not the wheels/tires we are using).

[EricScottZehnder]

Video of it running or is it just rolling?

[Xusia]

Looks great!

[AJW Performance]

Just rolling.
Got the wiring all situated for the headlights and tails this morning.
Engine is getting assembled next week then we are dropping it in just waiting on some Grimmspeed parts :)

[flynntuna]

Ok, who's who?

[ehansen007]

If I may, that's Jason LaVigne at the left front, Nate is behind him. Andrew is on the right. Not sure about the other two gentlemen.

[Kyle@AJW]

More updates to come.

[Kyle@AJW]

the start of the build pics.
http://i202.photobucket.com/albums/aa254/streetsideracing/DSCN2697_zps63a99daf.jpg (http://s202.photobucket.com/user/streetsideracing/media/DSCN2697_zps63a99daf.jpg.html)

http://i202.photobucket.com/albums/aa254/streetsideracing/DSCN2696_zps4bf410d7.jpg (http://s202.photobucket.com/user/streetsideracing/media/DSCN2696_zps4bf410d7.jpg.html)

http://i202.photobucket.com/albums/aa254/streetsideracing/DSCN2698_zps78a45e1e.jpg (http://s202.photobucket.com/user/streetsideracing/media/DSCN2698_zps78a45e1e.jpg.html)

[Kyle@AJW]

We swapped the steal front control arms for aluminum ones. The rear lateral links and trailing arm have now been swapped out for aftermarket adjustable ones. More inside panels and under seat panel has been installed. Pedal box, fuel tank, DW fuel pump and sending units are also installed.
http://i202.photobucket.com/albums/aa254/streetsideracing/DSCN2745_zps4045a5ab.jpg (http://s202.photobucket.com/user/streetsideracing/media/DSCN2745_zps4045a5ab.jpg.html)
http://i202.photobucket.com/albums/aa254/streetsideracing/DSCN2746_zps3769cb2b.jpg (http://s202.photobucket.com/user/streetsideracing/media/DSCN2746_zps3769cb2b.jpg.html)
http://i202.photobucket.com/albums/aa254/streetsideracing/DSCN2749_zpsba420905.jpg (http://s202.photobucket.com/user/streetsideracing/media/DSCN2749_zpsba420905.jpg.html)
http://i202.photobucket.com/albums/aa254/streetsideracing/DSCN2758_zps91069472.jpg (http://s202.photobucket.com/user/streetsideracing/media/DSCN2758_zps91069472.jpg.html)
http://i202.photobucket.com/albums/aa254/streetsideracing/DSCN2756_zps1d0cf825.jpg (http://s202.photobucket.com/user/streetsideracing/media/DSCN2756_zps1d0cf825.jpg.html)

[Kyle@AJW]

I have been doing some assemble of the motor as time allows. So far the long block is assembled. Killer b oil baffle and pick up installed. The timing components along with a gates racing timing belt and tomei belt guide. Next we moved on to a pile of goods from Grimmspeed starting with ported intake manifold and tgv deletes with 8mm phenolic spacers and gaskets. Then we moved on to DW injectors and agency power fuel rails.

http://i202.photobucket.com/albums/aa254/streetsideracing/DSCN2780_zpseb2a6cea.jpg (http://s202.photobucket.com/user/streetsideracing/media/DSCN2780_zpseb2a6cea.jpg.html)

http://i202.photobucket.com/albums/aa254/streetsideracing/DSCN2781_zpsc1f13640.jpg (http://s202.photobucket.com/user/streetsideracing/media/DSCN2781_zpsc1f13640.jpg.html)

[Kyle@AJW]

Some up to date pics of the motor.
http://i202.photobucket.com/albums/aa254/streetsideracing/112E88D9-0EEA-49D4-B658-3FDB34D62962-25226-0000096FAAFF564C_zps05821da4.jpg (http://s202.photobucket.com/user/streetsideracing/media/112E88D9-0EEA-49D4-B658-3FDB34D62962-25226-0000096FAAFF564C_zps05821da4.jpg.html)

http://i202.photobucket.com/albums/aa254/streetsideracing/24E45FA8-24FD-4F99-BE60-B001A171ED54-25226-0000096FA1C29266_zps387654e6.jpg (http://s202.photobucket.com/user/streetsideracing/media/24E45FA8-24FD-4F99-BE60-B001A171ED54-25226-0000096FA1C29266_zps387654e6.jpg.html)

[Kyle@AJW]

So we now have the motor and transmission installed. Axles have assembled after having some issues with non OEM axles not working with the FFR shafts. Waiting on some more goods from grimmspeed.

http://i202.photobucket.com/albums/aa254/streetsideracing/A48E3687-37B4-453F-9640-596CFCA196B8_zps7fiu42zp.jpg (http://s202.photobucket.com/user/streetsideracing/media/A48E3687-37B4-453F-9640-596CFCA196B8_zps7fiu42zp.jpg.html)

[AJW Performance]

CURVEBALL, A customer wanted the best motor that we could possibly build so we've replaced the previous motor that was in it with an STi motor with a VF39 turbo and all supporting modifications.

http://i957.photobucket.com/albums/ae53/nancarrowa/AJW818Motor_zpse493c9c7.png (http://s957.photobucket.com/user/nancarrowa/media/AJW818Motor_zpse493c9c7.png.html)

The motor was out in a day, and the STi motor was put in the same day. We will be updating this thread more often now as we push into finishing this build.

Here is the new motor (ignore the gross turbo)

http://i957.photobucket.com/albums/ae53/nancarrowa/AJW8182_zpsac767037.png (http://s957.photobucket.com/user/nancarrowa/media/AJW8182_zpsac767037.png.html)

Also a shot of our own take on the custom expansion tank mount.

http://i957.photobucket.com/albums/ae53/nancarrowa/AJW818Mount_zpsf235286e.png (http://s957.photobucket.com/user/nancarrowa/media/AJW818Mount_zpsf235286e.png.html)

[Allen@AJW]

Ok, who's who?

Haha, was wondering when I would see this picture. I am in the blue and Jorel (A close friend) is in back on the right there.

[longislandwrx]

I notice your lateral links are installed at track height and the rest of the suspension at street... any reason?

[Kyle@AJW]

I notice your lateral links are installed at track height and the rest of the suspension at street... any reason?

The lat links are at street height. Had to look and double check because it looks like that are at track height in the pictures.

[AJW Performance]

Got the Radiator and the Shifter installed today!

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_49991_zps866e62eb.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_49991_zps866e62eb.jpg.html)

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_49982_zpsff4b848d.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_49982_zpsff4b848d.jpg.html)

[AJW Performance]

Got the 818 Started today!


http://www.youtube.com/watch?v=LGixdhez6rw&feature=youtu.be

[BC Huselton]

Would you be willing to keep a $ accounting of what is going into this build so others will know what to expect if they want to build a car of this quality?
BC

[AJW Performance]

So we ran into a small snag, it looks like the frame was only really designed for the TD04 Turbocharger. The VF39 that we are using did not fit as you can see here.

http://i957.photobucket.com/albums/ae53/nancarrowa/photo1_zps1b9e8fab.jpg (http://s957.photobucket.com/user/nancarrowa/media/photo1_zps1b9e8fab.jpg.html)

Looks like we needed to improvise.

http://i957.photobucket.com/albums/ae53/nancarrowa/image2_zpse2e1e5a1.jpeg (http://s957.photobucket.com/user/nancarrowa/media/image2_zpse2e1e5a1.jpeg.html)

The finished product, viola!

http://i957.photobucket.com/albums/ae53/nancarrowa/image1_zps09ec8a13.jpeg (http://s957.photobucket.com/user/nancarrowa/media/image1_zps09ec8a13.jpeg.html)

Body panels are starting to go on now and the dash is almost finished. We should have more updates through the week. Kyle works pretty fast.

[Kurk818]

I dont know if that cut out within the brace and the reconfiguration will stand up to the rigors of hard use.

Heres what i did.

http://i.imgur.com/ADdVwCBl.jpg
http://i.imgur.com/QNlz9Jzl.jpg

[AJW Performance]

https://www.youtube.com/watch?v=1bDZCculS0Y

She drives!

[AJW Performance]

Body Panels are coming together nicely!

http://i957.photobucket.com/albums/ae53/nancarrowa/photo3_zps495d1c52.jpg (http://s957.photobucket.com/user/nancarrowa/media/photo3_zps495d1c52.jpg.html)

Also another shot of our custom AJW Performance Exhaust which can be purchased here: AJW Performance Custom Exhaust (http://thefactoryfiveforum.com/showthread.php?14145-Gauging-Interest-AJW-Performance-Custom-Exhaust-for-the-818/page3&highlight=)


https://www.youtube.com/watch?v=H_Zjch2qvac

[AJW Performance]

Ordered our harnesses today! Pretty excited to put them in!

[Kyle@AJW]

http://i202.photobucket.com/albums/aa254/streetsideracing/Mobile%20Uploads/2014-09/DD8FA212-78E9-4B26-9007-C084C7C09039_zps0wxrljg6.jpg (http://s202.photobucket.com/user/streetsideracing/media/Mobile%20Uploads/2014-09/DD8FA212-78E9-4B26-9007-C084C7C09039_zps0wxrljg6.jpg.html)

[Allen@AJW]

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_2847_zpsdf4b40f0.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_2847_zpsdf4b40f0.jpg.html)

Car is really coming along now!

[AJW Performance]

Our 818 is 90% Finished! Seats are going in today, and wheels are on their way!

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_1188_zps42eb26f8.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_1188_zps42eb26f8.jpg.html)

[Mechie3]

Little bit of moon there.

hahah!

Nice work.

[AJW Performance]

Little bit of moon there.

hahah!

Nice work.

Just a little bit of fan service! :P

[AJW Performance]

She's 99.9% finished!

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_1434_zps081ee659.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_1434_zps081ee659.jpg.html)

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_1433_zpsd3665add.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_1433_zpsd3665add.jpg.html)

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_1432_zps8d48ec75.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_1432_zps8d48ec75.jpg.html)

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_1437_zps7fb16501.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_1437_zps7fb16501.jpg.html)

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_1441_zpsb42619cf.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_1441_zpsb42619cf.jpg.html)

New Wheels will be coming next week, and the Tow Hook will be installed as well!

Other than that, we are almost wrapped up. Glass was installed yesterday and harnesses are good to go!

[AJW Performance]

Here she is!


http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_1459_zps7957814b.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_1459_zps7957814b.jpg.html)

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_1455_zps94a48d4a.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_1455_zps94a48d4a.jpg.html)

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_1449_zps0e2df417.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_1449_zps0e2df417.jpg.html)

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_1447_zpsd3daa271.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_1447_zpsd3daa271.jpg.html)

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_1454_zpsc9734cfa.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_1454_zpsc9734cfa.jpg.html)

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_1453_zpsf0b9e1fe.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_1453_zpsf0b9e1fe.jpg.html)

http://i957.photobucket.com/albums/ae53/nancarrowa/IMG_1450_zpscde4c001.jpg (http://s957.photobucket.com/user/nancarrowa/media/IMG_1450_zpscde4c001.jpg.html)

[Mechie3]

I like that second pic. The sideview is my favorite view of the car.

[Bob_n_Cincy]

WOW, Looks great.
Bob

I'll take the boat in the top left of the second picture.

[thall818]

Looks great! Great motivation.

[MrDude_1]

Is it just the angle of the pics or is the back end higher than the front?

[metalmaker12]

U mean the fronts higher than the back, looks like it is, a little suspension adjustment needed.

[RM1SepEx]

How did you attach the top of the inside door panels?

You should notch the engine cover where it meets the rear fenders, it will sit down better

[MrDude_1]

U mean the fronts higher than the back, looks like it is, a little suspension adjustment needed.
yes. I was thinking i wrote "back end lower than the front" bottom line looks like its raked a bit and the rear fender looks closer to the top of the wheel than the front. I am shooting zero these last 2 days. lol.

[Bob_n_Cincy]

Andrew or Kyle,
Did you check the thread engagement of the rear upper link. I don't remember the end link being that long.
'Bob

http://thefactoryfiveforum.com/attachment.php?attachmentid=35419&d=1415145430

[AJW Performance]

Car has not been aligned yet, should be going to the alignment rack soon.

[flytosail]

Awesome photos!

[AJW Performance]

Awesome photos!

Thank you!

[longislandwrx]

LOL at snow tires.


35621

[tmoretta]

Yes, but can someone like your neighborhood tire shop be trusted to align a 5 link rear? I think a race car specialized shop might have to be sourced.

[AJW Performance]

Yes, but can someone like your neighborhood tire shop be trusted to align a 5 link rear? I think a race car specialized shop might have to be sourced.

Not sure, we will be the ones aligning the car though.

[Quiny]

I see you have an 818S listed on eBay. Good luck looks like your getting a lot of bids. Car looks terrific.

[AJW Performance]

I see you have an 818S listed on eBay. Good luck looks like your getting a lot of bids. Car looks terrific.

Thank you! It's a great and very unique vehicle. I hope it goes to a great home! :D

[wallace18]

Super job! looks great.

[metalmaker12]

Good luck on your sale, I hope it goes for a good price and to a good home!!

[AJW Performance]

Thanks guys!