EODTech87's 818S Build Thread

[EODTech87]

Kit Arrival
February 16th, 2014
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Finally Home.

[AZPete]

Congrats on the arrival! It's like a kid at Christmas, eh? Now you are required to sit in it and make a "Vroom, vroom" video before you start the inventory.
Where are you? And what chassis number? It's stamped in the frame just above the driver's left knee.
The fun begins!!

[EODTech87]

Already did it but forgot to grab a video.

I'm located in Copperas Cove, Texas and my chassis number is #112.

[Frank818]

Congrats!

It says 01/25 on the paper, was the 20 days due to Stewart delivery or your kit was delayed at FFR?

[EODTech87]

My kit was completed on time at Factory Five but because of truck issues it took Stewart a while to get it to me.

[EODTech87]

Front Firewall Prep
February 24th - February 26th
Stage Build Time: 7 Hours, 9 Minutes
Total Build Time: 7 Hours, 9 Minutes
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[EODTech87]

Cockpit Sides Prep
March 3rd, March 11th
Stage Build Time: 4 Hours, 22 Minutes
Total Build Time: 11 Hours, 31 Minutes
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[Outwest]

Great Progress so far!!

[Rasmus]

Cleco's! Neat for me to see detailed photo's of the panel install progress. I havn't seen it before. I'm sure I'm not looking hard enough.



http://i1301.photobucket.com/albums/ag108/EODTech87/Factory%20Five%20818S/IMG_0424_zpsbdac7cda.jpg

That is a sad, sad, lawn. Get on that man. Weed and feed once a month. Ironite every week!

[EODTech87]

I'm trying to be moderatly detailed in order to help other people further on down the road. It sucks trying to search through pages of forum post just to find that one picture to clear up a set of instructions.

Yeah I kinda forgot about the lawn when I started working on tearing down the WRX and now building the kit. But if you drive around my neighborhood every lawn pretty much looks like mine so meh.

[Rasmus]

Have the lawn others covet! Having the best lawn in the neighborhood is like having the biggest rack in High School. Everyone envy's what you have and talk about how good they look. Most want a touch to see if it's real.

[AZPete]

Nice work, Jason. You spaced the rivets well and got the tabs of the piece at the bottom of the dead pedal tucked inside. Some say nobody will notice because carpet will cover, but you'll know. Aaaaaah, did I just hear Rasmus say he had the biggest rack in high school?

[Frank818]

Aaaaaah, did I just hear Rasmus say he had the biggest rack in high school?

Thank god he's not a girl for saying this.

[EODTech87]

I'm actually not planning on using carpet. I kind of like the metal/frame look.

[EODTech87]

Front Firewall & Cockpit Sides Install
April 6th - April 9th
Stage Build Time: 7 Hours, 5 Minutes
Total Build Time: 18 Hours, 36 Minutes
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[nkw8181]

Dang dude rockin and rolling

[EODTech87]

Suspension, Steering Rack, and Engine Install
June 18th - June 19th
Stage Build Time: 10 Hours, 2 Minutes
Total Build Time: 28 Hours, 37 Minutes
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[EODTech87]

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[Quiny]

Just curious, why are you using the red shocks and not the yellow?

[Rasmus]

Are the rebound and compression settings the same on the Red Koni's that we can mount them inverted?

[EODTech87]

Just curious, why are you using the red shocks and not the yellow?
I'm going to be running all of the 818R Aerodynamic parts so wanted to use the same shocks/springs to match up with the extra downforce. Only reason I didn't get the 818R instead was the wife is entirely to short to be crawling over the doors.

Are the rebound and compression settings the same on the Red Koni's that we can mount them inverted?
I'm not 100% sure on that yet but the same shock is used on other Factory Five cars and they actually are ran inverted so I don't think it will cause any issues.

[Frank818]

I'm not 100% sure on that yet but the same shock is used on other Factory Five cars and they actually are ran inverted so I don't think it will cause any issues.

Koni or FFR or someone reputable on this forum mentioned that the reds are designed to be mounted either way. The yellows are not at all.

[chucky797]

From a EOD tech to another, i enjoy the abundance of ammo cans you have around doing misc tasks.

[EODTech87]

Yeah. They seem to appear from no where. I think they're multiplying.

[Rasmus]

So refreshing to see the American flag displayed correctly when vertical.

[nkw8181]

I'm thinking you will be done well before me. I might need to make a trip down :-)

[nkw8181]

What color blue are you using? I'm using Ford dark blue. Easy to come by.

[EODTech87]

It's just called Ford Blue.

[EODTech87]

Pedals, Fuel Tank and Cooling Install
August 11th, August 13th, August 16th
Stage Build Time: 9 Hours, 7 Minutes
Total Build Time: 37 Hours, 45 Minutes
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[EODTech87]

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[nkw8181]

Man looking good!

[EODTech87]

2 1/2 years with no update. Damn that's a long time. Haven't gotten a lot done but have changed the plan 1000 times. Unfortunately deployment plus going from no kids to 2 kids leaves very little time but I'm finally getting back into the swing of things.

I ended up buying a sleeved closed deck EJ22 that was paired with a set of Stage 4 EJ205 heads. I also purchased a PPG Straight Cut 1-4 5 speed transmission and a set of blast plates just in case. Completing the package is a ball bearing FP Black with some 1650cc injectors, surge tank, custom boyd tank, long running big plenum SOHC intake manifold, and dry sump.

Here is some info on the long block I purchased.

http://www.xcceleration.com/imp-gallery-03-wrx.blue.gt35r.htm

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[EODTech87]

Managed to fit the dry sump even with the blast plates installed which was a huge relief. The long bolt actually was one removed in order to install the blast plates so that saved me the trouble of having to purhcase one.
The Zero DB AWIC had to be moved back a bolt on the transmission because the new intake manifold sits further back than the stock one so there wasn't going to be any room for the throttle body.
Speaking of which what's everyone's opinion on a larger throttle body vs the stock WRX one?

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[Shawn818c]

Welcome back after a long hiatus!

[ben1272]

Looking good. The Zero dB AWIC support bracket installed in reverse makes the lettering appear like a different language, neat in a weird sort of way. My powertrain is entirely stock and I give all sorts of credit to you guys who dig in and modify and share it all. When I am ready to tweak my own engine there is so much knowledge in this forum!

[EODTech87]

Looking good. The Zero dB AWIC support bracket installed in reverse makes the lettering appear like a different language, neat in a weird sort of way. My powertrain is entirely stock and I give all sorts of credit to you guys who dig in and modify and share it all. When I am ready to tweak my own engine there is so much knowledge in this forum!

The original plan was for the non-clocked turbo. But with the clocked setup and the SOHC intake manifold I need to move it further back and flip it around.

[EODTech87]

Go the intake manifold mostly shave. Just need to weld up a few holes and off to powder coating.

https://imgur.com/FBnlJXy.jpg

[EODTech87]

After almost 4 years my 818S is actually running/idling. Before my last deployment I managed to get it started but it idled at 4k RPM's and had several leaks. I pulled everything apart and ended up drastically changing my plans and finally got back to where I was over 2 years ago.

[EODTech87]

https://www.youtube.com/watch?v=SJmCjXh6Hs8

[Hindsight]

Congrats!

[Kurk818]

Nice! Keep up the progress.

[EODTech87]

As y'all might have seen earlier I decided to switch to a 2.5i big plenum long runner intake manifold. The bolt pattern is slightly different so It wouldn't work with my Boomba 75mm throttle body so I had to do some modification. I ended up cutting a 5" x 5" hole and had a solid 5" x 5" x 1" piece of aluminum welded in to allow the throttle body to mount directly to the intake manifold.

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I also decided to upgrade to the solid coolant pipes.

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Today, I managed to shave the steering column and weld up a custom bracket with some spare steel laying around.

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Because of the extended intake manifold/throttle body combo I unfortunately had to get rid of the beautiful Zero Decibel AWIC brackets.
I'm pretty happy with how the engine bay is cleaning up. The countless hours rerouting everything and the money spend cleaning up the wiring harness are starting to be worth it.

https://imgur.com/XPg8jSr.jpg

[Frank818]

Woah, that's a lot of switches on your center console, mind telling what they control?

Nice NRG wheel too, 350mm I guess?

[EODTech87]

Woah, that's a lot of switches on your center console, mind telling what they control?

Nice NRG wheel too, 350mm I guess?
The steering wheel is a 320mm.

As for what the switches control my answer is, Yes!

They control everything in the car, battery, ECU, fuel pump, headlights, turn signals, fans, pumps, etc.

[Frank818]

320? Nice! I'll keep NRG on my list if ever my current cheap eBay wheel wears off too quickly.

That's awesome on the switches! I love that! I love having full control over everything. Interesting the TS are switches on the console, though. One for left and one for right?
I'd like to see those switches in action some day, if you ever have the ability to record a video of them in action.

[EODTech87]

It’s going to be weird and unnatural but I wanted the steering column completely shaved. Plan right now is just a single on-off-on momentary switch that will have a turn signal timer to turn them off after so many seconds. I’ll probably move the switch down near the shifter to make it easier to access while driving around town.

[EODTech87]

So the switch location ended up being a no go. With the Boyd tank and the seat all the way back I can't reach them while strapped into the seat. So the switches will be moved to the console between the seats. I'm having the panel machined so I'll have pictures in the near future.

Been a busy last couple of days. I managed to get the wing mount finished which required me to adjust the the AWIC brackets for a 3rd time. I also got the dry sump tank mounted to the wing mounte K-Tuned shifter positioned and "installed". https://imgur.com/2dcHtzD.jpg
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[EODTech87]

Got the switch panel cut and installed. All the switches are wires up just have to wire in all the “stuff”

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[mistasherm]

Jason
That is a nice set up. I like the multiple switch concept that you are going with for your build - nice work!
Ty

BTW - Retired Marine ground combat officer here with some SpecOps time...I thank you and all your EOD brethren for getting me and the men out of sticky situations back in the day!

[EODTech87]

Thank you for the kind words. The switches have been a absolute pain to get working and wired up but in the end I think it will be worth it. I like how much control they'll give me over the car vs letting everything be fully automated. I also really enjoy wiring, electronics, and circuitry so that helps.

[EODTech87]

95% finished with the cockpit wiring. Should be able to finish up tomorrow and get back to getting the car driveable.

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[RetroRacing]

We just got that same relay-fuse panel for out Kmiata project! Nice piece, can't wait to wire it. Wish I would have used it in our R!!!

[EODTech87]

For the first time in 4 years the 818 has left the garage and has moved under it's own power.

As you can tell there is also bad news. The turbo is leaking oil and will need a rebuild.

https://i.imgur.com/yrE0Rtc.jpg

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[Sgt.Gator]

Updates?