Wleehendrick's Build Thread

[wleehendrick]

Yesterday was the big day... my kit arrived! After seeing so many photos online, it seemed almost familiar, but still surreal realizing that this will be my 818.

A big thanks to George (flynntuna), his son Johnathon, and Gary (Mifune), for coming to help. The extra hands were certainly appreciated since the delivery did not proceed exactly to plan. Local zoning did not allow trucks over 7tons in the neighborhood, and the local police were not willing to make an exception for a local delivery, even though access was not an issue. :mad:

So, we hooked up a neighbor's flatbed, and had to unload in the parking lot of the high school about a mile away:

22894

22896

We dropped the kit onto Stewart's dolly on the flatbed, and rolled it into the garage:

22897

We then brought the dolly back, and loaded the boxes:

22895

And now the fun begins:

22899

I still have to complete the full inventory, but there were few back ordered items.. I got a lot of the big pieces others have been waiting for (all the aero parts, door liners, etc...)

P.S. I have to complement Stewart's driver Joe. He was a little late (which was fine), but was friendly, helpful, accommodating to the change in plans, letting us take his beloved dolly! Overall, I would not hesitate to recommend them.

More to come...

[Rockraven]

Congratulations! How do moving trucks operate in your town? Do they have to deliver your stuff to the local high school parking lot, and you have to shlep your sofa and bedroom set from there to your house on your own?

[Frank818]

Crap thing about the truck's weight but at least you got your 818!!!!!:)

Can 4 people lift the chassis instead of 6 on your pic? Do you think.

[wleehendrick]

Congratulations! How do moving trucks operate in your town? Do they have to deliver your stuff to the local high school parking lot, and you have to shlep your sofa and bedroom set from there to your house on your own?

Good question... I'm actually building at a friend's garage, so wasn't expecting that issue; the roads are more than adequate to allow it in. I'm sure the ordinance is to deflect through-traffic, and I imagine a lot of delivery trucks are over 7 tons, so it seems silly. Stewart was, understandably, reluctant to drive an 18-wheeler in without permission, and local LE was totally unhelpful. All's well that ends well, though!

[wleehendrick]

Can 4 people lift the chassis instead of 6 on your pic? Do you think.

Umm.. no. Not unless all four are serious dead-lifters!

We never lifted it by hand; we used the crane on Stewart's truck to drop it onto the dolly on the flat bed; we then rolled to dolly off the flat-bed into the garage and used a floor jack to lift it up and drop it on the jackstands.

I wouldn't want to risk trying to muscle it around. It is a beefy frame and very heavy as shipped with the panels attached.

[Frank818]

Ok so a dolly or fork lift is really needed. Tnx for confirming. :)

[Mechie3]

My Stewart guy said he passed a sign saying he shouldn't be there but did the don't ask don't tell method.

[riptide motorsport]

Congrats.........Enjoy the build!

[wleehendrick]

My Stewart guy said he passed a sign saying he shouldn't be there but did the don't ask don't tell method.

I guess my driver was a bit more conservative... can't blame him, it's his commercial license/points!

[wleehendrick]

Congrats.........Enjoy the build!

Thanks!

I'll probably be making a bit slower progress than a lot on here. Projects at work are behind, and we're still getting settled in after a recent move. When it rains it pours!

[longislandwrx]

Congrats! I feel like when people get their FFRs they should come with one of those plywood cutouts that dads put on the front lawn when a baby arrives.

Best of luck with your build.





Crap thing about the truck's weight but at least you got your 818!!!!!:)

Can 4 people lift the chassis instead of 6 on your pic? Do you think.

Frank, I put mine on a skid and slid it off the trailer into the garage, was just me @ 180lbs and a friend @150lbs?

Then my father in law who is a big guy (aren't they always) and I deadlifted it onto the dolly that night.

You can do it with 2 people with no problems. just need to get creative.

[Bob_n_Cincy]

Ok so a dolly or fork lift is really needed. Tnx for confirming. :)
Nobody except FFR uses a fork lift.
To lift my chassis off my trailer I used my harbor freight engine hoist connected to the point on the rear firewall where all the tubes come together.
At that balance point, the front of the chassis can be handled by on person.
http://thefactoryfiveforum.com/attachment.php?attachmentid=22965&stc=1&thumb=1&d=1377048846

[wleehendrick]

Congrats! I feel like when people get there FFRs they should come with one of those plywood cutouts that dads put on the front lawn when a baby arrives.

Thanks... Funny, I was talking to my boss last week, and when I mentioned delivery day was coming up he was surprised, thinking I meant my wife (no, we're not expecting). When I clarified, we both got a good laugh out of it!


Frank, I put mine on a skid and slid it off the trailer into the garage, was just me @ 180lbs and a friend @150lbs?

Then my father in law who is a big guy (aren't they always) and I deadlifted it onto the dolly that night.

You can do it with 2 people with no problems. just need to get creative.

Wow, was that just the frame, or as shipped with the panels attached? I would have been very reluctant to try that (and I squat/deadlift regularly!), but goes to show that a little ingenuity goes a long way. Frank, with either a hoist or floor jack, a dolly and some patience, you should be OK without a big group of guys.

[wleehendrick]

Last night I went through most of my boxes last night inventorying. (I checked off the fastener package, but did not count every nut and bolt in there; if something's missing, I'll get it locally)

I had a full page of parts listed as back-ordered, but most of these were subsequently packaged in Box 12, a last-minute "make-up" box, I assume. I went put them in the box they were originally listed in.

The only parts currently listed as back ordered are: two 350# springs, headlights/brackets, shifter cables, and the reverse/turn signals. Not bad, FFR is really getting there 818 supply chain in order! I won't need the cables, since I have Wayne's K-tuned shifter, and I may end up getting the Spyder Auto headlights instead, so I have just about everything.

Just a couple questions:

The only parts I haven't found so far are:

Box 1: 80307 (1" x 1" Plastic End Cap) x4

Box 4: 14164 (3/4" Plastic End Cap) x2

I assume that they're attached to another part and I missed them, not knowing what to look for. Could someone point me in the right direction?

I'll be getting all the welded steel brackets powder coated in gloss black. I'll also want my four diffuser strakes done the same and it makes sense to do them in the same batch. However, I won't get to them for a while; any issue with coating them now and drilling/fitting later? they're thin/flexible Al and I'd hate to scratch/crack the coating. I assume if I'm careful, it should be alright.

Thanks!

Lee

[longislandwrx]

Thanks... Funny, I was talking to my boss last week, and when I mentioned delivery day was coming up he was surprised, thinking I meant my wife (no, we're not expecting). When I clarified, we both got a good laugh out of it!



Wow, was that just the frame, or as shipped with the panels attached? I would have been very reluctant to try that (and I squat/deadlift regularly!), but goes to show that a little ingenuity goes a long way. Frank, with either a hoist or floor jack, a dolly and some patience, you should be OK without a big group of guys.

Just the frame, all the body parts went into the basement where I wouldn't trip and fall on them.

The plastic end caps look like these... 22988 I didn't realize there were two sizes, they go in the frame.

[wleehendrick]

The plastic end caps look like these... 22988 I didn't realize there were two sizes, they go in the frame.

Thanks... they definitely weren't in the boxes they were supposed to be in; I'll check the frame.

[Joe Scott]

Hey Guys, correct those are mounted into the frame holes from FFR before we mount the body panels on. Joe@FFRTECH

[longislandwrx]

That must be new, mine came in the box, I had 2 extra as the R doesn't have the front square bar only the rear by the transmission.

[wleehendrick]

Hey Guys, correct those are mounted into the frame holes from FFR before we mount the body panels on. Joe@FFRTECH

Thanks for the quick response, Joe!

[Joe Scott]

yes we decided to place the plugs in the frames here at FFR after Nate cut himself several times haha

[metalmaker12]

I cut my knee nice before I put them on lol.

[flynntuna]

More pics of the day.
http://i97.photobucket.com/albums/l240/socal_a4/IMG_20131026_125503_326_zps3998d583.jpg (http://s97.photobucket.com/user/socal_a4/media/IMG_20131026_125503_326_zps3998d583.jpg.html)

How it came in the truck. The Driver said he can fit eight cars in the truck with the crane they have in there. Pretty cool!
http://i97.photobucket.com/albums/l240/socal_a4/IMG_20131026_124729_792_zps8fa45d13.jpg (http://s97.photobucket.com/user/socal_a4/media/IMG_20131026_124729_792_zps8fa45d13.jpg.html)

[wleehendrick]

More pics of the day.

Thanks, George!

[flynntuna]

The thanks go to my son Jonathan, he took the pic's and posted last night when he came over.

[wleehendrick]

Well, family in town and travel have slowed the start of my build down some; just not enough time :mad:. I'll be hitting it hard when I get back next week, but for now, here's some fresh powder coat:

23312

For anyone in San Diego North County who needs a powdercoater, I'd recommend Olympic Coatings (http://www.olycoatings.com/) in Escondido. The two door frames and 26 small parts (all the bare steel) were less than $200. They did a good job and they're car guys.

[Ray]

One thing that we found helpful was to write the contents (or put a photocopy) of the inventory on the outside of the box and stack the boxes so that you can see the list. Then, as you remove/use that package/item, etc. you cross it off the list.

Ray

[wleehendrick]

One thing that we found helpful was to write the contents (or put a photocopy) of the inventory on the outside of the box and stack the boxes so that you can see the list. Then, as you remove/use that package/item, etc. you cross it off the list.

Ray

Good tip. I have the boxes stacked in order, and I photographed all the pieces before powdercoating so I know what they are in which box they go! I think I will put a checklist on each one.

Thanks,

Lee

P.S. Getting back next Monday from vacation in Monterrey and just found out I have to fly up to Portland early Tuesday for the rest of the week for work. Ugh... I just want some quality time I can spend with my kit!

[wleehendrick]

Well, finally had some free time at home and got to work... I got the front firewall and most of the cockpit Aluminum done. I went with ~2" rivet spacing, and re-used the shipping holes, so a few rivet locations are a bit off, oh well.

I coated the outside of the panels with 3M rubberized undercoat. Not the prettiest, but should be a good noise reducer. It really deadens the panels, and I also plan on adding EZ Cool insulation on the inside (a lightweight and non-porous heat/sound insulator). I'm going for a solid, relatively civilized chassis without adding a lot of weight or cost.

I figured out the upper control arm geometry and got them mounted; thanks for the pointers!

I also got the lower shock mounts attached to my 06 wagon LCAs (and learned that H.F. drill bits are utterly useless), so I should get the rest of the suspension together soon.

http://thefactoryfiveforum.com/attachment.php?attachmentid=23597&d=1385403233

http://thefactoryfiveforum.com/attachment.php?attachmentid=23598&d=1385403236

http://thefactoryfiveforum.com/attachment.php?attachmentid=23596&d=1385403230

[Xusia]

I'm not seeing the pics.

Also, have you used EZCool before? I'm still trying to decide on the best route to go. I'm looking to weatherize, deaden sound, and insulate (both keep heat out in the summer, and keep heat in during the winter) via some combination of treatments (I was planning on using LineX or ArmaCoating on the underside to seal out the rain and other road crap). I'm not overly concerned about weight. I'd love to hear any feedback you have.

[wleehendrick]

I'm not seeing the pics.
Funny, they appear in my browser. Here they are as attachments, rather than inline images.


Also, have you used EZCool before? I'm still trying to decide on the best route to go. I'm looking to weatherize, deaden sound, and insulate (both keep heat out in the summer, and keep heat in during the winter) via some combination of treatments (I was planning on using LineX or ArmaCoating on the underside to seal out the rain and other road crap). I'm not overly concerned about weight. I'd love to hear any feedback you have.

No, I haven't. I saw in in another thread and decided to give it a try. For your goals, I'd definitely use a bed-liner or undercoat for the outside/underbody. The EZCool is fairly thin, light and inexpensive, and doesn't have an adhesive (I plan on using a 3M spray). If you don't mind adding more weight, you could consider Dynamat, etc...

[Scargo]

Nice pics!

[wleehendrick]

Nice pics!

Thanks, but nothing special (yet).

P.S. where in CT are you? I'm originally from the SE corner of the state (Groton/Noank area), before I headed west.

[Scargo]

New Haven area. Do you know Steve Hanford? Old Saybrook/Haddam area. He has been into Subies and track days for over eight years. Also an instructor; perhaps one of the best in NE for AWD people. Tried hard to get him to put down a deposit when we visited FFR.:o
I may be setting myself up, but I'm a photographer off and on (www.glynphotos.com (http://www.glynphotos.com)). I liked the sharpness and lighting of your stuff.

[wleehendrick]

New Haven area. Do you know Steve Hanford?

No, I moved to CA over 20 years ago for grad school. I don't really know anyone in the area any more.


I may be setting myself up, but I'm a photographer off and on (www.glynphotos.com (http://www.glynphotos.com)). I liked the sharpness and lighting of your stuff.

Nice work. All the shots above were just taken with my crappy phone camera, believe it or not. As I'm sure you know, Megapixels are less important than a bit of thought put into composition and lighting!

I'm an amateur shutterbug myself. I have Nikon DSLR, but don't use it as much as I should. I just don't want to carry the weight on so many of my 'adventures'. Just recently, we hiked the Zion Narrows 'top down'... backpacking two days, with 12 miles of it in the river, I didn't want to risk or carry my big system. I got some nice shots with my little P7100 (carried in a drybag around my neck). Here's one of my favorites that (to me at least) captures the grandeur of the terrain and gives you a sense of the experience. (it's a bit soft since I grabbed it off Google+)

23665

[RM1SepEx]

I've got some great Zion photos from 25 years ago. I actually recognized that photo as Zion before reading the post! Wonderful area

[Scargo]

... I just don't want to carry the weight on so many I didn't want to risk or carry my big system. I know that feeling. I lugged a medium format Pentax camera and big lenses above treeline and all over S. Europe at one point.
Here's some fun photo stuff (http://forums.nasioc.com/forums/showpost.php?p=39275974&postcount=523)I did with my D300 while porting the heads that will be on my motor.

[wleehendrick]

So, I decided I just couldn't deal with "Impreza" on my instrument cluster. No problem, a little clip art and copyright permision from FFR...

http://thefactoryfiveforum.com/attachment.php?attachmentid=23800&d=1385862789

(bad photo, I know)

23800

[Frank818]

Can't really see (you said it yourself, bad photo loll), but is it paper?

[wleehendrick]

Can't really see (you said it yourself, bad photo loll), but is it paper?

It's a vinyl decal, the FFR logo in the center with boxer pistons on either side.

[Frank818]

Ah yeah! The pistons I get it, nice! :)
Made me think of something, I have kept a note for when I'll be there, tnx.

[SkiRideDrive]

Encinitas! Hello neighbor, I am in Carlsbad. If you ever need a hand or are cool with me stopping by to check out your build please let me know.

-Kevin (mccoykn@gmail.com)

[Wayne Presley]

Very cool

[wleehendrick]

Encinitas! Hello neighbor, I am in Carlsbad. If you ever need a hand or are cool with me stopping by to check out your build please let me know.

-Kevin (mccoykn@gmail.com)

Of course! My build is in a friend's garage in San Marcos, not too far away.

Last night, I got the cockpit aluminum footbox area finished, and my pedal box with brake and MC cylinders mounted. I'm going to adjust the position of the DBW throttle to fit my preference for heel/toe operation.

[wleehendrick]

Very cool

Thanks... that means something from "Very Cool Parts"! :o

[SkiRideDrive]

Of course! My build is in a friend's garage in San Marcos, not too far away.


Awesome, San Marcos is right up the road.

[wleehendrick]

I'm going to adjust the position of the DBW throttle to fit my preference for heel/toe operation.

FYI, I used the throttle pedal bracket mounted to the vertical frame piece. I found a 1" spacer between the bracket and the frame on the lower mounting hole to be ideal, and bent the upper mounting tab to sit flush. I will probably design a stop for the pedal and 3D print it.

[wleehendrick]

I also got my NRG seats and harnesses from Erik (33 Machine). I adjusted the sidemounts and set them in to validate pedal position. I'm glad I ordered the Boyd tank, as I'll want to push my firewall back at least an inch for my preferred seat placement.

http://thefactoryfiveforum.com/attachment.php?attachmentid=24103&d=1386610755

24103

[Frank818]

I will probably design a stop for the pedal and 3D print it.

Now that I wish I could do for an entire engine... someday, someday...

[wleehendrick]

OK, finally a long overdue update. I haven't been posting too actively here, because 1) my progress is slower than expected, and 2) I'm not doing much really unique (yet).

Anyway, my suspension is on, just a couple minor things to do. I have new swaybar mounts coming. I know I'll have to drop the rear hubs to get the axles in, but I needed to motivation of seeing things come together, so I just had to put the brakes on.

I turned the OEM rotors, and decided to try StopTech Street Performance pads. Still would like to get some SS braided brake lines; any recommendations? I sprayed the calipers with Duplicolor red caliper rattle can and put white '818' graphics on. I like the color, it's a deeper red than Subaru's, but it doesn't seem too durable.

I dropped the Boyd tank in place, but haven't mounted it yet, that's up soon. The outside of the Al panels I've sprayed with 3M rubberized undercoat, which really dampens the sound. On the inside, I plan on EZCool insulation (there's a roll of it in the cockpit) under the carpet.

http://thefactoryfiveforum.com/attachment.php?attachmentid=24921&d=1388856583

Unfortunately, I'm missing a couple pieces of hardware to button up the rear suspension. I need two M14 1.5 nuts, which shouldn't be too tough to find, but I'm also missing one of the cam washers for the rear lateral, toe-control, link. Anyone know where I can source just this washer? :confused:

http://thefactoryfiveforum.com/attachment.php?attachmentid=24922&d=1388856603

So, the chassis is ready to install the motor, and I've worked ahead since the motor isn't ready to go in yet. I'm a Subie newb, so unfamiliar, and a little intimidated, by the EJ. I've already pulled the AC compressor and PS pump and installed Mike's alternator bracket and tensioner. I'm sure I could slowly work through everything else I want to do to the motor with help from the forum, but it would probably be much quicker to get a hand from someone skilled with the EJ. I'd be willing to pay for the assistance and would prefer to just get it done in a day with some professional help. Any suggestions on where to find someone... call a Subie shop or post on NASOIC?

24921

24922

[rori]

Anyone know where I can source just this washer? :confused:


Subaru: 20560AA011

[wleehendrick]

Subaru: 20560AA011

Thanks!

[flynntuna]

Looking good Lee. :cool:

[Brando]

I have my EJ right now at OutFront Motorsports (http://www.outfrontmotorsports.com/). They are in Buena Park about an hour north from you just off the 5 freeway. I found them on NASIOC and am more than impressed with how they have handled me so far. I'm going there on Monday to give them my intake manifold, they are doing the TGV deletes and fuel rails that Outfront manufactures and the work well with. Also killer B baffle and pickup along with new oil pan (mine was dented, they threw it on for free). Good group of guys. Ask for John, he is the owner and has a very well rounded knowledge set.

[wleehendrick]

Hi Brandon, thanks for the info. Ideally I'd prefer not to haul the motor. Dru referred me to a guy that's helping with his EJ, so I'll see if he'll travel to SD North County.

Lee

[07FIREBLADE]

I'm trying to prep for my kit arrival next month. For the life of me I can't remember what the cam bolts even look like does anyone have a picture or part number. I'm going through my suspension boxes and can't find them.

[wleehendrick]

Looking good Lee. :cool:

Thanks, George.

[wallace18]

Looking good!

[Brando]

Lee, you know i have a full sized truck and a motor lift. I don't mind coming by and helping you haul the motor both ways. Let me know if you wish to do that...

[wleehendrick]

Lee, you know i have a full sized truck and a motor lift. I don't mind coming by and helping you haul the motor both ways. Let me know if you wish to do that...

Thanks for the offer, I'll let you know if I decide to take it somewhere. Hopefully I get it all sorted out in the garage and the next time the motor leaves, it'll be under its own power!

[wleehendrick]

Last weekend Ray came bay and helped my run the brake and clutch lines. He drove his roadster over and took me for a spin:

http://thefactoryfiveforum.com/attachment.php?attachmentid=25356&d=1390197133

Rather than try to produce a work of art, we kept it simple, minimizing the number of junctions and bends and attached to 'T' directly to the BPV. Here's the front:

http://thefactoryfiveforum.com/attachment.php?attachmentid=25355&d=1390197131

I also installed Stoptech braided stainless steel lines front and rear. My friend Ted did the grunt work of grinding off the brackets from the rear lateral links to keep the suspension looking clean. Also, the swaybar now fits with the new Prothane brackets and bushings.

http://thefactoryfiveforum.com/attachment.php?attachmentid=25357&d=1390197470

http://thefactoryfiveforum.com/attachment.php?attachmentid=25358&d=1390197475

I took the rear firewall to a metal shop of a friend of a friend. We bent the panel a further 16 degrees on a press break; this let me move it back 2.5", tucked up nicely against the Boyd tank. I still have some more rivnuts (threaded inserts) to set to secure it.

http://thefactoryfiveforum.com/attachment.php?attachmentid=25352&d=1390197126

I'm picking up my NRG steering wheel and hub adapter from Erik tomorrow and then will get to work on the steering column and rack and work on mounting the seats. (the motor install will wait a few more weeks until it's sorted)

I have a couple business trips coming up, so progress will slow while I'm out of town (not that I'm the fastest builder, LOL).

BTW, I took the day off from the 818 and my wife and I put the top down on the 135i and drove up the coast to San Clemente. Had to enjoy the beautiful 'winter' day:

http://thefactoryfiveforum.com/attachment.php?attachmentid=25359&d=1390197843


25352253552535625359

[wleehendrick]

I haven't updated my build thread in a while since I've been jumping around a lot and was waiting until I get it to a glider to post progress. That won't be long, but I had to share today's happenings...

The Santa Ana winds have the temperature at 100F with 2% humidity at the coast. I knew it would be a bad day... around 11AM, my wife called and said a wildfire broke out in Carlsbad. This is about a mile from our office; we voluntarily evacuated and I headed home, having to divert around the fire.

http://thefactoryfiveforum.com/attachment.php?attachmentid=29113&d=1400111278

I have many friends who have had to evacuate, or are preparing to, but so far everone's safe. And just now... a fire broke out in San Marcos and is currently out of control. Cal State Univ San Marcos and the surrounding area are being evacuated; this is just across the street from the storage unit where my body panels are, and just a few miles from my friend's place where my build is. He's rushing home to take care of the dogs. Nothing to do but keep my fingers crossed...



29113

[Frank818]

Jesus. :( I hope nothing will happen to your relatives and friends, and you.

2% humidity, how can it be so low, wow...

[wleehendrick]

Thanks, Frank. Santa Ana wind are brutal... the high pressure inland pushes the desert air over the mountains towards the coast... as it falls, it heats up and drys out, like one massive heat gun.

[wleehendrick]

Here's the San Marcos fire, seen from my buddy Ted's (where my 818 is):

http://thefactoryfiveforum.com/attachment.php?attachmentid=29128&d=1400168014

Even though the fire is 0% contained, I'm not too worried. His place is near the high school, which is an evacuation center, and my storage unit is on the closer side of the university (the buildings in the distance), which although evacuated, will be a major priority to save, I'm sure.

29128

[68GT500MAN]

California is very dry everywhere (maybe not near the Oregon border) the humidity here in Fresno yesterday was 8%. No fires here but eight crews headed South to help out.
Doug

[matteo92065]

Good luck with the fires! I'm in Ramona (just east of San Diego) and we have had our share of fires.

Also, I am building an 818 in Ramona. I finished prepping donor parts, and should have my kit next month.
I am also building an 818 in Mira Mesa with my boss. He gets his car next week!

[Mechie3]

I haven't been to California in 1 year, 3 1/2 months. It's good and bad. It's nice not traveling for work all the time, but it was fun to experience california living for a week at a time. Glad I don't have to worry about things like fires.

[MrDude_1]

Completely off topic, but I really wish they would allow controlled burns out there like they do here on the east coast... thats one of the reasons why we dont have the huge loss of property/life from sudden fires like this...

[RM1SepEx]

you have to control the underbrush...

[flynntuna]

I've lived here in San Diego all my life, you get used to the shakin & bakin. Six months from now when the rains come the news will covering the mudslides on the bare hillsides. Tornados and hurricanes, now that's scary stuff!

[MrDude_1]

I've lived here in San Diego all my life, you get used to the shakin & bakin. Six months from now when the rains come the news will covering the mudslides on the bare hillsides. Tornados and hurricanes, now that's scary stuff!

Tornados, Yes. They come out of nowhere and distroy everything.
Hurricanes? no big deal, you get over a weeks advance notice, and as long as you dont have your house in a stupid place, its not a big deal.

[wleehendrick]

Completely off topic, but I really wish they would allow controlled burns out there like they do here on the east coast... thats one of the reasons why we dont have the huge loss of property/life from sudden fires like this...

You don't have Santa Ana winds (i.e. 'devil winds') like we do out out here after months and months of no rain. Completely different environment. Controlled burns can manage forest fires by regulating the undergrowth, but these are not forest fires (that are the result of decades of over-suppresion); they're wildfires in the dry chaparral. This stuff grows back in a few years, and would be impossible to manage all the open areas here with controlled burns. The forests up at higher elevations in CA are often managed with controlled burns, and fire is a required part of the Sequoia life-cycle, so even the national park has fires let burn intentionally now.

EDIT: from wikipedia:

Chaparral stand age does not have a significant correlation to its tendency to burn.[13] Low humidity, low fuel moisture, and high winds appear to be the primary factors in determining when, where, and how large a chaparral fire burns.

i.e. CA chaparral wildfires are a pretty much inevitable when the Santa Anas blow.

[wleehendrick]

Good luck with the fires! I'm in Ramona (just east of San Diego) and we have had our share of fires.

Also, I am building an 818 in Ramona. I finished prepping donor parts, and should have my kit next month.
I am also building an 818 in Mira Mesa with my boss. He gets his car next week!

Thanks, finally some more 818s in San Diego!

[wleehendrick]

I've lived here in San Diego all my life, you get used to the shakin & bakin. Six months from now when the rains come the news will covering the mudslides on the bare hillsides. Tornados and hurricanes, now that's scary stuff!


Tornados, Yes. They come out of nowhere and distroy everything.
Hurricanes? no big deal, you get over a weeks advance notice, and as long as you dont have your house in a stupid place, its not a big deal.

I've been in SoCal over half my life now, and like George, you learn to deal with it and prepare for it. I moved out for graduate school from the northeast after the ice storm of '91.

Everyplace has natural disasters and they aren't always where you expect; the moment you get complacent, Mother Nature will put you in your place... Ice storm in Atlanta, Hurricane in NYC, Earthquake in Virginia, all in the last few years.

[wleehendrick]

:eek:

http://thefactoryfiveforum.com/attachment.php?attachmentid=29179&d=1400256737

Ted's place where my 818 is, seems safe. My storage unit is in an evacuation zone, but I'm not too concerned.

The Carlsbad fire is contained. Our friends who evacuated there are OK, but a home three doors down from them burned.


29179

[RM1SepEx]

No natural disasters here in Maine... big snow and Ice storms, plenty of prep time, if no power the food is fine in the cold, backup wood for heat and a 10,000 watt generator, floods in spring, don't build in a flood plane.

Now I do have to plow the white stuff between 3 and 14 times a year. (29 years, same house, experience) I do have backups for all equipment, plow truck, J Deere tractor with 47" blower, manual 24" blower, plenty of shovel, DC sump backup, propane heater backups, extra tanks, 60 gallons of gas on hand at all times etc...

[Brando]

That picture is insane Lee. Did you shoot that?
The sky is a dark orange in Newport today. It's raining small pieces of ash.

[STiPWRD]

Yea dude, that's a pretty epic photo, hope everyone will be ok


:eek:

http://thefactoryfiveforum.com/attachment.php?attachmentid=29179&d=1400256737

Ted's place where my 818 is, seems safe. My storage unit is in an evacuation zone, but I'm not too concerned.

The Carlsbad fire is contained. Our friends who evacuated there are OK, but a home three doors down from them burned.


29179

[wleehendrick]

That picture is insane Lee. Did you shoot that?

No, a friend texted it to me; that was taken 5 miles from Ted's.


The sky is a dark orange in Newport today. It's raining small pieces of ash.

Yeah, I had left my rear fascia out on our back patio working on the tail lights, etc... it's now covered with ash!

The one benefit is that the sunsets will be gorgeous for a few days, and the moon-rise last night was spooky through the smoke.

[wleehendrick]

No natural disasters here in Maine... big snow and Ice storms, plenty of prep time, if no power the food is fine in the cold, backup wood for heat and a 10,000 watt generator, floods in spring, don't build in a flood plane.


I went to camp in Maine as a kid... in the summers!

[Tamra]

Wow, that last photo is crazy! I just moved to CT from OR last fall. We had terrible fires in OR too (forest fires), and the smoke stuck around for months due to the mountain valleys, creating hazardous air conditions. I was spared any hurricane experiences last fall in CT, but I'm definitely dreading the day. People keep telling me they aren't a big deal.

I hope you, your family, your friends, and your 818 all make it out okay.

[wleehendrick]

Thanks, Tamra; it's looking good (for us, at least).

I grew up in south-east coastal Connecticut (Groton/Noank/Mystic area) and remember several hurricanes. They feed off warm water and lose most of their strength by the time they get that far north; Sandy was an exception and 'perfect storm' of circumstances.

I get up to OR for business and fun pretty often; really like it there.

[Xusia]

Do you ever make it down to Eugene Lee? I'd love to grab some lunch, or a beer, or something. :)

[wleehendrick]

Do you ever make it down to Eugene Lee? I'd love to grab some lunch, or a beer, or something. :)

Not usually... I get to Wilsonville for business pretty often. When I have the opportunity to have my wife tag along, well get around a bit more. Ill let you know next time Im up there.

Things seem to have settled down with the fires... the weather really changed last night, with the wind shifting from the ocean, evacuations around here have been lifted, and everyone I know made it through unscathed, luckily.

[wleehendrick]

Wow, hadn't realized I haven't updated my thread in a while. With getting up early to exercise, typically working long hours, I just don't have much time/energy to get much work done during the week and have had a lot of home projects on the weekends. I need to get this car built!

I did build a rear firewall, gave the motor a maintenance overhaul and bolt-on mods (timing belt, H2O pump, plugs, silicone hoses, TGV and air pump delete, etc...) and I just got Group N mounts, so it's ready to drop in. Once that's done, I'll almost be ready to bring it home from my friend's garage. Although I have much less space than he does, it'll be much easier to get time in on it when it's home; wiring, body and interior should be manageable in our tight 2-car.

I have prepped most of my body panels, polished the white gel-coat, and undercoated the raw side. I'll go 'naked' for a while until I commit to painting, wrapping or dipping it. I did, however, want to paint the speed humps, so these are Subaru Black Obsidian Pearl (Duplicolor). After sanding, priming, sanding, spraying, sanding, polishing and waxing, I now know why Wayne doesn't sand! It's not perfect, but I think acceptable for rattle cans in the back yard:

33239

I also brought my instrument cluster in to work to disassemble it, and install of on Larry's EEPROMs to reset the odometer to zero:

33240

I decided on an exhaust layout and ordered parts; I got a Kinugawa Turbo bellmouth, some 3" SS tubing, and a short FlowMaster. Polished up the end of the straight pipe and think it'll look good exiting the rear mesh with no tip.

33237

I need to fit it and cut/weld the pipes, but this will be copy of Brett's exhaust (http://thefactoryfiveforum.com/showthread.php?12244-Oregon-818S-build-maybe-the-first&p=158391&viewfull=1#post158391).

Finally, been waiting for wheel to be in stock for a while. I got XXR 530's in Chromium Black, same size and finish that GRM went with (https://grassrootsmotorsports.com/project-cars/2013-factory-five-818/hot-wheels-818/), but different style. They came yesterday (thanks, Wayne!). The first thing my wife said is that they'd look good on her car (in the back):

33238

[Brando]

33239

Nice. I'm doing the exact same thing. I am still on the fence of gloss or flat black.

[wleehendrick]

Nice. I'm doing the exact same thing. I am still on the fence of gloss or flat black.

I like contrast between both color and finish. Since I'm planning on eventually going to a matte or satin wrap or dip, I painted/cleared and polished these glossy. If you plan to keep the white gel-coat as is (just polished out and waxed glossy) then I'd go flat/matte on the humps for that extra contrast that makes it pop.


Also, I was going to mention that on Tuesday, Ted (whose garage I'm building in, and some of you guys have met) got rear-ended and his car totaled. He was waiting at a red light and two kids not paying attention slam into the stopped traffic at full speed. He's still sore, but OK; luckily he had just dropped his daughter off at school and she wasn't in the car. Anyway, ironically we both have (had) Le Mans Sunset Z's. Since my plan was always to sell my Z when I get close to finishing the 818 (no need for 2 2-seaters since my wife and I have 2 other vehicles). Well, not long after he told me about his accident, he's asking to buy my Z... At least I won't have to deal with the crazies on Craigslist!

[Brando]

I did a CF wrap but realized it's somewhat cheezy. I decided to go with a satin black wrap just as you had mentioned.

33244
33245

[ehansen007]

Doesn't look too terrible. I dipped mine and it's already peeling around the front where I handle it a lot. No big deal since I plan on painting too. Funny story, I had asked Tony Zullo if they had those CF covers left over from the white car and they had just thrown them in the trash the day before. DoH!

[wleehendrick]

So my new wheels come with nice centercaps and an XXR logo disc, but I don't want an aftermarket look, I want something that looks factory... Factory Five!

I got vinyl decals printed with the FFR logo, but since the XXR centercaps have a hole in the middle, I closed it off with some plugs I 3D printed at work. You can see the below:

http://thefactoryfiveforum.com/attachment.php?attachmentid=33486&d=1410566034

I trimmed and put the decals in, all that's left is to apply a clear encapsulant over them for protection and a nice finish, them pop em in the rims.

http://thefactoryfiveforum.com/attachment.php?attachmentid=33487&d=1410566036

3348633487

[Mifune]

Hi, it has been awhile. I’m one of the “strangers” that came on your kit delivery day and helped you muscle your car into your friend’s garage.

Looks like you need some optically clear, non-yellowing encapsulate that won’t react with your vinyl decals (may want to test one out first)

Have you started to mount body panels? It sounds like a two person job. If you need help let me know.

[wleehendrick]

Hi Gary, good to hear from you!

Thanks for the offer for help. Most of my body panels are roughly prepped (holes cut, trim mounted, gel coat buffed, back side coated with a rubberized undercoat, etc..) however, I'm a little ways off from mounting them yet. But If you're up for giving me a hand with some other work some time, there's still plenty to do... I'm going to have to travel for work a fair bit the next couple weeks, but should be home on the weekends; I'd appreciate any help!

I've had quite a bit going on lately, so haven't done much on the 818. I recently got summoned to Federal District Court Jury Duty, so was driving downtown for that, which really made me really appreciate living and working in North County, not having to deal with any traffic. It was an interesting trial though... a convicted felon was suing 6 correctional officers claiming they violated his 1st amendment right to free speech by retaliating against him, putting him in administrative segregation (i.e. solitary) for filing grievances. On it's face, that may seem to have some merit, but this guy is in for life without parole for kidnapping, rape and murder, spends all his time filing grievances and working the legal system, and was representing himself (not very well). I was the foreperson, and it took about half an hour to find for the defense.

Also, last weekend was my birthday and my wife and I went up to the Santa Barbara wine country for the harvest festival. We stayed in Solvang, the party was at the Mission, and that night Toad the Wet Sprocket performed (a Santa Barbara band that got popular in the 90's and recently reunited). Great weekend; I was hoping to have the 818 ready for the road-trip... there's always next year! We did take her 135i convertible, and we realized it was the first time it had been further away from home than OC. I usually do most of the driving, but she was having too much fun and didn't let me drive :( we took a few back roads and she wrung it out well.

For the centercaps, I used a acrylic casting agent to encapsulate the logo; no reaction with the decal, but the top surface came out a little wavy as it cured, so I'm in the process of sanding/polishing them flat; they should look good when done. Good point on yellowing; a UV blocker would be a great idea. I think I have some leftover from a headlight restoration kit.

Later,

Lee

[wleehendrick]

Build a car they said...

The wiring won't be bad they said...

http://thefactoryfiveforum.com/attachment.php?attachmentid=36064&d=1417130600

It's actually not too bad. Just a few hours in to the harness; I'm still stripping off sheathing and ID'ing connectors. Since I didn't part out my donor, few of the connectors are labeled and it took me a while to wrap my head around it all. But I'm almost ready to start stripping out un-needed circuits.

I can't really complain... sitting on the patio in 80F weather while most of the country digs out of a blizzard...

Happy Thanksgiving!



36064

[Frank818]

Just a couple hours? Wow that's frickin quick! OEM harness or you intend to add/mod something?

[wleehendrick]

I've only spent a few hours so far, but I've just gotten started... It'll take a lot more time! It's the donor harness, and my plan is to remove as much excess as possible... Something like what Larry did (savage build)

My build will be simple, only adding a stereo, seat heaters and a 12V power jack.

[NBinSD]

Looks like good progress. I'm interested to see how the dieting goes for you. I'm still deciding what to do with my harness.

[07FIREBLADE]

Looks good. I gave up on my wife diet. After I got my car running I turned around and hit up Brian from iWire. Hey is currently knocking out my harness. Adding ac and a few other goodies so I really needed the room and security that my harness wouldn't be a weak point in my build.

[wleehendrick]

Thanks, the most involved prior automotive electrical experience I have is installing a car stereo. I'll post progress (although I cant promise how quick :p) . I did talk to Brian a little while ago; he's not too far from me, so I figure if I muck it up, I can bring it to him!

[nkw8181]

Any updates? I read in another forum that you got the spyder headlights. Any pics installed?

[wleehendrick]

Any updates? I read in another forum that you got the spyder headlights. Any pics installed?

I opened the box :p

36558

Seriously, though... I think Brian got the same ones you can see on his build here (http://thefactoryfiveforum.com/showthread.php?16503-brians-818s-build&p=181436&viewfull=1#post181436):

36559

I've been travelling for work and my build is slow due to being in a friends garage and me being time constrained. As far as where my build is at... I started on my harness and worked on it the last few weekends... stripped off all the sheathing, labeled all connectors, removed the unneeded circuits (ABS, airbags, AC, etc...) and realized it's still a rat's nest and will be a lot of work to get it the way I want it (one run down the center tunnel, cleaner fuse/relay boxes...). So I just gave Brian (iWire) a deposit to get my place in his queue.

I should be trailering the 818 home soon and hope progress will pick up from there. It's pretty much a glider, but a lot of things are 90% complete. I hope to get it all buttoned up (and maybe even start on body work and interior) by the time Brian finishes my harness, so I'll be ready to go-cart right away.

[07FIREBLADE]

Good call on giving Brian a shot at your harness. You will be very pleased with his work and it's really worth it.

[wleehendrick]

Good call on giving Brian a shot at your harness. You will be very pleased with his work and it's really worth it.

I'm sure I will be. He's been very helpful with planning, and all the reports on his product have been extremely positive.

Thanks,

Lee

[wleehendrick]

I hit a milestone today.... I dropped the motor in, installed the axles, finished the rear suspension, bolted the wheels on and trailered her home! I had been building in a friend's garage, but being half an hour away really limited build times to when I could devote a good chunk of time. Now that it's mostly in one piece, it's manageable to work on on my smaller garage. I'm hoping progress will really pick up, since I'm off til Jan 5th, and after that I'll have much more opportunity to work on it an hour or two at a time.

The motor install went surprisingly easy. I have the smallest (1 ton) Harbor Freight hoist. I read recently that it wasn't up to the task, but it actually had just enough reach at max extension. I recently put Group N motor mounts on, and must have got it right, since everything lined up perfectly. I removed the exhaust manifold, as well as the dipstick, and half way through pulled the oil filter off. What really helped was tilting the chassis backward (with the front on jackstands all the way up, and the rear wheels on the floor) and using a balance bar with a sling under the tranny. Didn't have to muscle it in at all, just took our time. Started with it pitched forward, and as it got close, went back and forth dropping it an inch, tilting back, moving forward, etc...

http://thefactoryfiveforum.com/attachment.php?attachmentid=36886&d=1419740089

It was also a pleasant surprise how manageable it was to roll it up on the flat bed with just two people. When we got home, my wife 'drove' as we pushed it in the garage and she had no trouble turning the wheel at a standstill. Power steering? Hah!

She's now safe at home, next to my wife's baby (Le Mans Blue 135i). After working on it up on jackstands for so long, it's shocking just how low the 818 actually is.

http://thefactoryfiveforum.com/attachment.php?attachmentid=36887&d=1419740090

It was, however, a bittersweet day... to make room (and finance the 818) I sold my Z :( . It was the plan all along, but I'll miss her. Here we are snagged by the Mulholland photog:

http://thefactoryfiveforum.com/attachment.php?attachmentid=36888&d=1380824722

36886
36887
36888

[Frank818]

So you finally brought her back home in your garage? That's a good move! :)

[wleehendrick]

Yeah, feels good! I pulled the tail of the tranny off and removed the center diff and transfer gears today. However the locking collar wasn't where I thought it was. I spent an hour looking before finding it. Grrr... I really need to get reorganized now that its all in one place. (Well my body panels are still in storage)

[Tamra]

On the ground and in the garage, congrats! It is crazy how much it suddenly grows when you put wheels and tires on it.

[jayguy]

Nice milestone, congrats.

I see your wife shops at Lululemon, too. Great reusable bags. :)

[billjr212]

After working on it up on jackstands for so long, it's shocking just how low the 818 actually is.



I had the exact same reaction just last week when I set mine down on the tires. Next to my wife's Grand Cherokee in the garage, it looks like a glorified go-kart! Congrats on the milestone!

[wleehendrick]

On the ground and in the garage, congrats!


Nice milestone, congrats.


Congrats on the milestone!

Thanks, everyone!


I see your wife shops at Lululemon, too. Great reusable bags. :)

How do you know I'm not the one shopping there? I could be the one with a closet full of yoga tights! :eek:

[jayguy]

How do you know I'm not the one shopping there? I could be the one with a closet full of yoga tights! :eek:

Well they do make mens wear also, I have pants, shorts, and a cap from them, but it was all purchased by my fiance. We have half a dozen of those bags, at least, around the house.

Yoga helps with getting in and out of low cars, by the way. :)

Jay

[wleehendrick]

Yoga helps with getting in and out of low cars, by the way. :)

Jay

I had no trouble getting into/out of the 818 at Huntington Beach withe to soft top on, but some of the "bigger" guys had trouble!

My wife does yoga regularly, and occaisionally drags me along, but I have a decent home gym and prefer my own routine of weights, cardio, core and flexibility... I do incorporate some pilates and yoga moves which help with functionality. The extra strength and flexibility comes in handy in the build, especially with things like the trans drain plug I removed yesterday... I hammered on it with an impact, but it simply wouldnt budge, so I used both hands on a breaker bar with one foot braced on the frame to break it loose, kinda like a sideways deadlift. Guestimating it took at least several hundred ft-lbs, more than my buddies impact could put out!

[Harley818]

Hows your wiring coming along? Was hoping you were going to be about the same time as me so we could compare notes.

I finally reached the a-ha moment last week and saw the light at the end of the tunnel. I didn't think it was going to fit, but after dieting and pre-organizing, it slipped right in.
Had to lengthen the front lights and rad fan wiring, the brake and clutch pedal wires, but the engine harness and fuseboxes all fit right in eventually (all at the front of the tunnel).
Had to lengthen the 10 Ga wires to the relay panel to the alternator, as well as smaller alternator connections.
I'll post more pics on my thread in the next couple days.

[wleehendrick]

Hows your wiring coming along? Was hoping you were going to be about the same time as me so we could compare notes.

After dieting the unneeded circuits and realizing a lot needed to be done to get it the way I wanted (particularly the fuse/relay boxes) I got back in touch with Brian (iWire) and will have him finish it. His work is so nice that he now has a backlog, but I gave him a deposit to get my place in line. By the time he gets to my harness, in a month or so, I'll be ready to plug in and go-cart.

[wleehendrick]

So starting on the cooling lines I noticed that my donor's radiator has a broken nipple (the coolant return). This would blocked off anyway, but I'm not confident in a repair to the plastic end-cap, as these OEM radiators do have a tendency to crack. I was going to just use the old rad, despite it being the ugliest thing on the car, but now I have the perfect excuse to upgrade to an all Aluminum one. I'm thinking Mishimoto MMRAD-WRX-01. Koyo also seems popular. Any opinions or fitment issues on the 818?

[Wayne Presley]

Fits fine. I sell them You could have it soon as they are in stock in the wet coast warehouse

[wleehendrick]

Discussion moved from longislandwrx's Build Thread:


Tell me about it... Whenever anyone ask how the car's coming, my response is "if you want to finish a car project, don't buy a house". Roof, paint, landscaping, flooring, and building a small wine cellar. All while the poor 818 sits neglected in the garage.


Wine cellar for her, man cave for you.

Ironically, the wine cellar was more my idea and project; we both enjoy wine, but I'm more of the wine geek/snob! After buying our small place in Encinitas last year, we removed a wall and obsolete built-in entertainment center to open up the downstairs and I thought this was a much better use of the awkward space available between our dining and family room. I went a little overboard with it: actively cooled, redwood racks, reclaimed wine barrels for flooring and broken down wooden wine boxes for decoration, LED lighting, etc... I'm proud of it:

http://thefactoryfiveforum.com/attachment.php?attachmentid=58355&d=1473356751http://thefactoryfiveforum.com/attachment.php?attachmentid=58356&d=1473356752http://thefactoryfiveforum.com/attachment.php?attachmentid=58357&d=1473356753

She's actually the one who insisted on the epoxy floor and organization in the garage (which we just completed, and I now appreciate). It's small, but a much nicer workplace now:

http://thefactoryfiveforum.com/attachment.php?attachmentid=58358&d=1473357092

Now I have no excuses, and just need to focus my attention back on the 818 so I can update this thread with some real progress!

58355583565835758358

[UnhipPopano]

From the first photo that included your wife, you should think about adding a keg cooler and Tap.

[longislandwrx]

yeah I was going to say the same. clickbait headline reads: man builds beautiful wine cellar, wife switches to beer.

[Frank818]

Nice wine cellar, but she's drinking a beer. What gives? lolll

[wleehendrick]

From the first photo that included your wife, you should think about adding a keg cooler and Tap.


yeah I was going to say the same. clickbait headline reads: man builds beautiful wine cellar, wife switches to beer.


Nice wine cellar, but she's drinking a beer. What gives? lolll

Thanks, yeah everyone comments on that photo. A winemaker once told me "It takes a lot of beer to make good wine"... and yes, it took a lot of beer to build a wine cellar!

[Harley818]

Lee,
I'm in the same program..... house....car.... house.....vacation.....car
I haven't updated much lately but I've gotten back at it again after a couple projects building decks, a small workout gym in the backyard......
Good luck getting back into it. it takes a while to figure out where you left off, but I find as long as I get something done, I use the time to think about what else needs to be done and then it all comes back.....

[Mechie3]

That first pic says to me

Lee (in head): "well...that didn't go as planned"
wife (in head): "I still don't think he knows what he is doing"

[wleehendrick]

Hi all,

Long time no chat. It's been a long time, and the 818 has been collecting dust as life has taken priority. I've finally acknowledged that its time to part with the kit.
I'm putting together a post for it, but would appreciate any advice on selling an unfinished kit. Specifically:
Where are the best venues? (Here, auction it on BAT...)
I realize I wont come near to getting my money back, but any idea on value?
Any other advice?

Will be putting it up as soon.

Thanks!

Lee

[lpmagruder]

Post here and the several 818 Facebook groups for the most informed buyers. I've seen some completed cars go up on BaT but I'm not sure that I've seen an unfinished one there.

[wleehendrick]

Thanks for the info! I'll post it here and then try an auction site if it doesn't sell.

[driveslikejehu]

There seems to be some interest in folks looking for uncompleted kits in the Facebook groups. Might be better to stress that there's interesting stuff left to do, not that its mostly done? With it being discontinued, lower your expectation of what it's worth.