Stickshift84's Build Thread

[Stickshift84]

I have remained almost silent on the forum so far but I figured now would be a good time to start sharing.

I started my donor tear-down on 6/29/13 with an 06 WRX donor with 18K miles and a salvage title.

20218

All I can say is wow do these cars come apart fairly quickly and easily.

20219

After breaking down the car I spent most of my time detailing and adding parts to the engine.

20221

I picked up my kit on 7/27/13 using an open trailer. If anyone has questions on that let me know.

20220

Inside on the trailer.

20222

In its place and time to start working...

20223

[Stickshift84]

I have a long list of items that I am adding to my build and for those interested some of it is as follows:

Interior:
OMP TRS seats
NRG 300mm steering wheel with Splash hub

Engine:
Grimmspeed TMIC, EBCS, X-pipe, Up-pipe, phenolic spacers, pulley
Moroso aos
Fidanza flywheel
GFB BOV
smog and TGV delete
AEM CAI

Misc:
Carbonetic LSD
Mishimoto radiator
ARP lugs

There is more and there will be a lot more to follow. This is addicting, be warned.

[Stickshift84]

Tomorrow I will be starting on the aluminum. I have completed inventory and I have built the new axle assemblies so far. Also all of mine and metalmakers raw steel parts have been blasted and are at the powdercoaters. I will try to update when I have time.

[metalmaker12]

I like what you did to your engine, it's hard for me to break away from tradition, but I think it looks like the nicest engine on here. Can't wait to get our parts back so I can build the suspension.

[Scott J]

You're engine is absolutely stunning!

[wallace18]

WoW! what a cool engine. Looking great so far. Keep up the pictures.

[longislandwrx]

very nice, looks sharp. I guess the Ford Mustang sign is coming down?

I am super excited about my Grimmspeed TMIC. Did you get in on the GB?

[Stickshift84]

Not sure if the Mustang sign is coming down but it will most likely be moving....

I got the TMIC on the GB and I got the thermal dispersant coating. It is a thing of beauty and I just hope it functions as well as it looks.

Forgot to mention that I also added a Killer B oil pickup and baffle when I did the engine. However when I removed my original pickup it looked perfectly fine.

[Mechie3]

The pickups often failed with little notice.

The motor does indeed look nice. Here's two suggestions if you want them: The tangle of hoses/valve that bolts to the manifold near the silicone inlet can be removed. It's used for purging the charcoal canister which we most likely won't have. Cap those lines and delete the CEL codes in the ECU. It's quite an ugly birdsnest that hides that nice manifold.

Also, if you want to ditch the bracket for the power steering line you can make a simple bar like the picture below (not my pic). It's similar to the bracket I made for my car, except I moved my alternator over to the right. Buy rod ends from mcmaster (or other place), one is right hand threaded, one is left. Tap a piece of aluminum rod with one left hand one right hand thread. It's easy enough to make with hand tools if you don't have access to a lathe.

http://i255.photobucket.com/albums/hh154/LOW145/58%20Rag%20Bug/lastStretch193.jpg

http://i255.photobucket.com/albums/hh154/LOW145/58%20Rag%20Bug/IMG_2860.jpg

[rjh2pd]

Very nice detail, even gold bolts on the timing belt cover. If you guys are using old blocks how are you getting them so clean?

[Stickshift84]

I have no idea why I have waited so long to post any updates... But tonight after my first start I figured I would post some pictures. And sorry guys the video did not work out so well so I will work on that again tomorrow.

27152

[Stickshift84]

27153271542715527156

[Stickshift84]

PS the grimmspeed intercooler will fit.

27158

[Stickshift84]

oil temp and pressure gauge senders under the alternator.

27159

[Stickshift84]

Even if I did an almost full wire diet there are still tons of wires to try to neatly hide.

27160

[Stickshift84]

air oil separator set-up.

27161

[Stickshift84]

Well that is all for now. If anybody wants to see something particular let me know. Or feel free to ask me any questions.

[Stickshift84]

On final assembly. Will post pictures as I finish up.

32767
32769
32768
32770

[wleehendrick]

NICE color! Is that a satin finish?

[Mechie3]

What catch cans are you using?

[wallace18]

Very nice work. I am glad to see I am not the only one with a bunch of wires to hide even after a diet. LOL.

[metalmaker12]

That junk is coming together, finally!!!

Honestly I am not a fan of plastic dip, but nick did a really good job applying the product and I like the satinish metalic peralish blue he mixed. Hopefully he can get plates soon and we can go for a drive

[Frank818]

Spray can or gun?

[Stickshift84]

The paint is plastidip using the dipyourcar spray gun. It sprays nice and smooth. If I were to do it again I could do even a better job. Put down a matte black base first. Then mixed 50:50 gloss and matte plastidip clear with a blend of sapphire blue and sage green pearl. It took a lot of thin coats for good coverage. We shall see how it holds up. Never did a whole car before.

[Stickshift84]

Catch cans are from moroso and I ordered the wrx kit and adapted it to the 818.

No kidding on wiring... Completely sick of it. Just had to wire in some led load resistors so my turn signals would not blink so fast. Of course I melted some of my trunk carpet while soldering... At least that was the last of the wiring... I hope.

[Stickshift84]

Door panels are finished with satin black plastidip, silver vinyl inserts, and powder coated handles.

32783

[Stickshift84]

Spoiler is a attached. Very thin fiberglass so be careful not to crack it. Painted it gloss black to match my front splitter and side skirts. Attached with 10-24 screws which seem to hold it in place well enough.

32784

[Boog]

If you find the time, please post a couple more shots of the spoiler. I can't seem to find any profile/side shots with the street spoiler.

[Stickshift84]

Here are some more pictures of the spoiler. Finished the trunk and engine cover last night and will try to get the doors done tonight.

32802
32804

[Stickshift84]

32805
32806
32815

[Kurk818]

Looks awesome. Great work!

[Stickshift84]

I made my own front splitter and splitter frame to support it from the chassis. It is now complete and installed. What do you think?

32816
32817

[Stickshift84]

I made my own front splitter and splitter frame to support it from the chassis. It is now complete and installed. What do you think?

32816
32817

[tango68ss]

Oh my GOD this ride looks fantastic!! PlastiDip seems to be the way to go! If you don't like it, just peel and redo! I love your color choice! get her out in to the light and post up! Great job!

[Boog]

Here are some more pictures of the spoiler. Finished the trunk and engine cover last night and will try to get the doors done tonight.

32802
32804

Cool, thanks.

[Boog]

How well do you feel the plasti-dip covered the imperfections of the body? I love the whole concept and the colors available. Less body work would also be a huge bonus.

[Mechie3]

I'm interested in that as well. May be a lower cost lower time investment way to go vs vinyl wrapping or painting.

[Stickshift84]

First I have chassis 16 so an early body. I had a ton of void spaces so had a lot of body work to do. I went through the entire body, sanded everything, primed, and then sanded more. It took forever. In that time I experimented with paint vinyl and plastidip. I hate vinyl and cannot get good results except for on a flat surface. I also did not want to spray automotive paint in the garage attached to my house. So plastidip it was.

Plastidip will not really cover imperfections. When properly thinned before spraying you can see everything. For example sprayed over a surface roughed up with 80 grit you can see all the lines through it. On a newer body with hopefully less void spaces I would just clean the gelcoat and spray. It would work perfect that way.

[Mechie3]

So no benefit over paint except maybe cost?

[longislandwrx]

PS the grimmspeed intercooler will fit.

27158

:cool::cool::cool::cool::cool::cool::cool:

[Stickshift84]

One benefit of plastidip over paint is if the body cracks somewhere it does not show. The dip is permanently flexible. I already has this happen and you would never know. I figure the plastidip is perfect to atleast make the car look good and for the body to develop any problems before I either redo it again or end up painting it.

Paint is definitely a better permanent option as it is easier to fix small imperfections if needed and is overall more durable. I can say the dip is very abrasion resistant and resistant to any chips ( I have had it on the front of my mustang for years without any problem.

As far as using pearls with plastidip, it does look awesome but I am not sure the finish is as durable as a standard color plastidip. Time will tell how it works out.

One negative to plastidip is it will be stained by gasoline so you have to be very careful when filling up.

[Stickshift84]

Got the passenger door back together last night.

32844
32845

[STiPWRD]

Very nice interior, looking good!

[flynntuna]

+1 elegant and functional :cool: What. No cup holders! LOL

[Stickshift84]

Registered, insured, inspected, and first drive was yesterday. Big smile on my face. No problems. Everything went smooth. I managed to get it on the road for my 30th birthday (today). All I can say is this thing is absolutely awesome and is worth all the time and money spent. Will provide more feedback as I drive it and tune it further.33445
33446

[Bob_n_Cincy]

Happy Birthday and congratulations
Looks awesome
Bob

[STiPWRD]

No temp tags? Congrats though, I hope to be celebrating the same accomplishment next summer when I turn 30. The car looks great!

[Stickshift84]

Took the picture before the tags went on. They are on now. Will get some better pictures this weekend.

[Kurk818]

That thing looks amazing. Great work man!

[Frank818]

Wow awesome!

[wleehendrick]

I've been thinking about dipping mine as well. I shared your photos with my wife, her response? "that's gorgeous. Yours is screaming....dip me baby, dip me!!!"

[GUNS]

That looks really good! Do you mind sharing your plasti-sip experience? Difficulty, prep work, time involved, etc.

[Kalstar]

Fantastic!

[longislandwrx]

nice job making the FFR facebook page. Car looks awesome.


PS is that bat wrap on the roll bar?

[Stickshift84]

Took the girlfriend and then her son for the first two rides tonight. They loved it.
33491

[Stickshift84]

The roll bar is wrapped with grip tape from McMaster Carr. I did this as I had to touch up the powdercoat in that area as the body wore it away. The wrap protects and cushions the tight fit in that area.

[Stickshift84]

I will do a plasti dip guide another time when I have more time.

[Stickshift84]

some good news is more pictures and it is a blast to drive.
33728337293373033731337323373333734

[Stickshift84]

some bad news is after having trouble trying to tune it I found low compression in cylinders 2 and 4. Rebuild time for me.

Please everyone to take note and ensure the health of your engine before installation.

[Stickshift84]

I drove the car for around 80 miles keeping rpms below 4000 for the most part. Saw boost numbers as high as 11 psi.

With my extra intercooler ducting I monitored intercooler temperatures. While driving/moving the temperature of air in the manifold would settle between 110-120 degrees. Turbo outlet temps before the intercooler were around 180 when in boost.

When parked after driving the temperature would get up over 140 in the manifold. Driving after parking took a few minutes to settle back down. Everything heat soaks when parked. Not sure if an air to air intercooler would be a problem with a street car. Track/autocross I would anticipate problems.

[shinn497]

It seems a lot of people are having issues with the intercoolers. :/

[Stickshift84]

Just to clarify for everyone. I am not having any problems with my intercooler. I am providing information on the functionality of the intercooler only to aide in the decisions of others. Engine problem existed from the donor.

[Frank818]

Very nice pictures. What prep you did on the body before plastidipping? Maybe you mentioned already, I'll read earlier post and see.

[metalmaker12]

Just to clarify for everyone. I am not having any problems with my intercooler. I am providing information on the functionality of the intercooler only to aide in the decisions of others. Engine problem existed from the donor.

You have yet to have an issue with the intercooler is a better way to put it. Your running 12psi right?, and you were not staying in boost long and driving short distances in 70 degree max weather. Once you turn boost up and drive it for real like it's intended and it's hot outside is when you will see a major problem. Isn't it a car you wanna drive fast and stay in boost I would think. I am not saying the air to air can't work guys , just not in it's current form under hard load, and Nick setup the ducting exactly as FFR intended. His car is looking great and I am going to help him through this difficult time.:)

It is obvious you had motor issue from your donor and it is a shame, I feel the pain bro!! But you got options and an extra hand anytime.

[Hindsight]

I have been planning on painting mine black but after seeing yours.... the lighter color allows the black trim pieces and add ons to show better.... looks really nice. Red just doesn't accomplish the same thing somehow.

Sorry to hear of your engine troubles, but use it as an opportunity to build a crazy motor that makes way more power than you'll ever need!

[Samiam1017]

Wow I luv that color. Was thinking of matte blue vinyl wrap. What kinda of time did you put into making everything fit tight and what kinda of body prep before you coated it? Thx

[Mechie3]

12psi right?,

Awww, that's cute. ;)

[billjr212]

what do you have in the way of heat shielding for the intercooler? Are you using a turbo blanket, heat shield, and/or gold tape on the bottom side of the intercooler itself? You mention heat soak is primarily an issue when sitting, but then cools down a bit after driving and then jump to the statement that you anticipate a problem for track/autocross. How do you make that jump? Not saying it isn't true (particularly with all the sitting around at an autocross), but can you elaborate a bit?

I'm hoping to avoid the cost of upgrading to an air-to-water intercooler and thinking a bit of planning as far as heat insulation/shielding will go a long way. Glad there are so many guinea pigs ahead of me as I'm just getting started! Thanks!

[Stickshift84]

First quick post. When filling up your gas tank just take our time and only insert the nozzle a little bit. Worked out fine tis time with no dripping but also did not completely fill the tank.

On a side note, remember to put your gas cap back on. I got home after a drive and panicked when I forgot to. Luckily I had put the cap on the engine cover and it had managed to go into the intercooler duct opening and stayed trapped on my ducting. Got lucky lol.

[Stickshift84]

While my engine has been hurt I have been focusing on trying to optimize the TMIC/AAIC design. See the pictures below to see what I have done for extra ducting. Essentially what I did was better duct from the openings in the engine cover to the intercooler, somewhat seal the top of the intercooler to the engine cover, and box behind the intercooler (as best as I could for now). Hopefully this draws air through the core and out the upper duct in the trunk lid. I also added a gauge with thermocouples that is measuring air temperature prior to the intercooler and inside of the manifold.

34496344973449834499345003450134502

[Stickshift84]

While driving the car I have not seen manifold air temperatures over 130 degrees. This is while revving to a maximum of 5k and seeing a max boost of about 14 psi. Ambient air has been in the 60-70 degree range around here. While cruising tonight temperatures were between 100-110 degrees and when driving aggressively around an empty parking lot (2nd gear speeds) temps got up to the mid 120s. On a side note I saw temperatures up to around 190 degrees pre intercooler tonight.

Temperatures within the intake manifold get into the mid 140s when parked with the engine and trunk covers closed after driving. I believe due to heat soak. Temperatures get back below 130 when driving for a few minutes.

My plan is to work with Chris (metalmaker) and use his gopro to get some videos of the gauge during different driving situations. If anybody is interested in that?

[Stickshift84]

Samiam1017, I spent a lot of time fitting the body. Was not too bad really but I went into it planning to take my time and get it all as close as possible before drilling any holes. I am happy with how it came out but it is not perfect. That being said the issues are ones that only I really see. After fitting the body I got overly aggressive with sandpaper and trying to perfect the lines. This resulted in a lot of extra time smoothing the panels to get the paint ready. I also had a lot of the same cracking/void spaces within the fiberglass/gelcoat which took a bunch of time to fix. In the end though it came out great.

If I were to do it again I would fit the body and only fix the body where cracks/chips developed and then plastidip it. All the extra body work had little to no benefit.

[Evan78]

My plan is to work with Chris (metalmaker) and use his gopro to get some videos of the gauge during different driving situations. If anybody is interested in that?Definitely interested. I'm sure many others are as well.

[metalmaker12]

We will be collecting a lot of data and try to help everyone out with this data. I will be running Wayne's setup with road testing and dyno runs to see if I can get the same results. Nicks going to stay with the aaic for now and we will be trying to maximize its efficiency. Stay tuned.....lol

[Boog]

If I were to do it again I would fit the body and only fix the body where cracks/chips developed and then plastidip it. All the extra body work had little to no benefit.

What level finish do you think is need for plastidip to hide the rest?