818s Build Tri-cities, WA

[Sean.keehn@gmail.com]

Hey,
So this thread is a little late, ive already got the donor car torn apart and the kit should be delivered this week. Im going to try and hold of to the ABS, do a custom interior and the HVAC system. Here are the pics ive taken so far. Please comment with any questions of helpful hints.

[lsxsean]

good luck with build.

[Kurk818]

Awesome. Glad to see more kits in Washington.

[FFRSpec72]

Sean, Looks like you have a head start on things with the donor. Looking good, hope your delivery goes well and you don't have a long list of back ordered items. Stop by if you are every in the Seattle area.

[Sean.keehn@gmail.com]

So i got the kit delivered, finished the inventory, and got the frame powder coated. I picked up the frame yesterday. Last night i got the front and rear suspension installed and got the engine in. the engine was a pain, mostly because the factory exhaust had a heat shield around it that i had to remove with the engine hanging half way in the car. Today I got the foot box and interior side walls installed. Also a pain, im a little disappointed with the fitment of these parts, and the fact that the installation manual uses an old design foot box. But either way its done now.

Ok, so when i went to assemble the CV drive shafts the tri lope assembly doesn't fit on the shaft provided by factory five. I think the shafts that were in my donor car were aftermarket. Does anyone know where i can get factory tri lobes? I would really like to avoid buying the entire assembly from the dealer. Also what have you guys done to attach the sway bar on the front suspension. The mounting brackets are flat but the bushing brackets for mine are tapered, and it doesn't like like i could bend them to fit.

Ill post pictures later.

[wleehendrick]

Also what have you guys done to attach the sway bar on the front suspension. The mounting brackets are flat but the bushing brackets for mine are tapered, and it doesn't like like i could bend them to fit.

I got Prothane 17mm universal Type A bushings from Amazon, work perfect:

http://www.amazon.com/gp/product/B003870QGU/ref=oh_details_o06_s01_i00?ie=UTF8&psc=1

[Sean.keehn@gmail.com]

ok, so here are some of the pics from the build so far.

[Sean.keehn@gmail.com]

here are some more, i can only upload ones that are less than 2MB and even then its really inconsistent. But everything is going pretty well with the build.

One point of note. when running the flexible coolant lines, make sure you use one of the 2 sections for each side. I used one of the sections to cut both of the rear pieces that attach to the engine and now i don't have enough to run both the front pieces.

[STiPWRD]

sweet textured powder coat job on the frame

[Sean.keehn@gmail.com]

yea, it really helps hide any of the left over weld splatter from the factory, And all the dents, dings and scratches that i tried to put in it.

[Sean.keehn@gmail.com]

So yesterday i picked up some of the aluminum i sent of for powder coating and got the front fire wall installed. Today i got the front flexible brake lines in and managed to install the clutch line. i figured out that it was going to take more that 2 full length lines to run the clutch, so i started one from the front and one form the back, figured id have to run a loop in one of the shorter lines to get the length right. But as luck would have it one of the 18 in lines joined the 2 perfectly. Most of the Pics my camera takes are too big to upload so there only a couple this time.

[Sean.keehn@gmail.com]

Ok, kinda got lost in what I had talked about last and i have moved into a new house. So after a couple weeks of packing, and unpacking Im finally back at the 818. Got the fuel tank in the mail last week, so i got that installed. Somehow i managed to lose the factory filter, so i just installed an inline holley filter. Also got all the brake lines run. they tuned out pretty good. New steering wheels also in the mix. got that installed, looks great. Went with the quick release to make it a little easier to get out of the car. Now im onto the wiring harness, maybe the most difficult part. so ive got the battery in and the harness laid out, i started cutting away some of the loom, mostly the electrical tape and plastic sheathing. That way i can get everything to where it needs to go. I got the FFR battery cable run to the starter, the yellow 10ga factory wire that was apart of the brake master cylinder loom, i just cut the loom away and ran it to the starter. Also spliced in the 36in of 10ga to get power to the main fuse box. Also ran the ground strap for the engine and grounded the battery. I thought i did a pretty good job labeling everything when i took it off the can, but i missed the fuel harness.

Question #1
for the fuel harness which of the 4 plugs goes to the fuel pump and sending unit? I took a pic but im not sure its going to let me upload it so ill try a describe it a best possible. 2 white plugs, one 6 wire and on 2 wire, then 4 black plugs. i think the black ones are for the vapor canister and the white ones are the ones i need. And if the 6 wire plug is for the fuel pump, which ones actually wire in, the FFR pump only has 2 wires.

Question #2
The manual has me splice in 62in of 10 ga wire to the start wire and looks like its running over to the same place as the battery cable and main fuse box power. Where does this wire come from, does it connect with a ring terminal or just a slide together one? All this would be much easier to explain if i had pics.

Question #3
With everything ive described should the engine turn over, granted i dont have oil, fuel in the tank, or coolant. Im just trying to figure out at what point i should be worried that i messed something up. Also when i Actually connect the battery to ground(the frame) the one of the relays in the main fuse box actuates about every 2 seconds, and there something going on with the air flow sensor between the inter cooler and the intake manifold.

[Sean.keehn@gmail.com]

Ok, i think i figured out how to shrink the photo size and get them up here. these pics are related to the questions i just posted about.
3658, just a pic of the rats nest im dealing with right now. Not as bad as it looks.
3662, the battery ground
3657 and 3656, I think this might be the wire the manual is talking about, its a yellow wire the travels from the ignition(blue plug) to the fuse panel.
3652, what i currently have wired to the starter.
3653, you can see in this pic the yellow starter wire goes to the ecu, (this is a factory wire), the splice i did to get power to the main fuse panel and the battery power wire.
3654, just a pic of my new steering wheel

[Sean.keehn@gmail.com]

Ok, this is a post just to get all the pics that i didnt get before cause they were too big. this is everything ive got on my car so far. Now i think im going to finish running the radiator lines.30332303273032930330303333032630325303243032 330328

[Sean.keehn@gmail.com]

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[Kurk818]

What date was your kit delivered?

[Sean.keehn@gmail.com]

April 30th i think.

[Kurk818]

Awesome progress. We're going to have to meet up once we're both done :)

[Sean.keehn@gmail.com]

OK,
not sure exactly where i left off, I kinda took the summer off from the car and have just been getting back into it. When i left the car i had just started with the wiring harness. I had a little trouble getting the car to turn over with the key, turned out that the clutch switch needed to be adjusted. Then the car wouldn't start. I had narrowed it down to something with the immobilizer module. Ended up being the plug between the steering wheel and the immobilizer wasn't connected. I felt kinda dumb, but at the same time I'm glad it was something easy.

[FFRSpec72]

Sean, good to hear that the engine kicked over, does this mean the rest of the wiring is done ? Now tat we are into the rainy, dull grey time of year you should be able to make great progress !

[Sean.keehn@gmail.com]

That last post was actually like an interim post. I’ve been making great progress the last couple of weeks. I finished the wiring harness, well, I’m sure there’s plenty of wire that could either be shortened or cut out altogether but I’m done with it. Next I got the transmission tunnel installed, and the upper firewall. At that point I was in full go cart mode, took it up the street and back a couple times. It’s awesome.

[Sean.keehn@gmail.com]

Next I started with the body. Got the side pods and the rear bumper mounted, with the rear tail lights and reverse lights wired in. All that was pretty easy.

[Sean.keehn@gmail.com]

Up next was the front bumper and the headlights, this I really struggled with. The manual doesn’t really show you how the head lights need to be aligned in their buckets and where the need to be in the bumper to have the front fenders line up right with the hood. So after I have put it all together and taken it apart 3 or 4 time to try different things, I got to a place where I’m ok with the amount of bondo filling I’m going to have to do later, not perfect but pretty good. I also got the head lights all wired in. Not sure what I’m going to do with the fog lights, the Subaru was wired for them so maybe ill get some cool lights later.

[Sean.keehn@gmail.com]

Got a couple race seats for cheap online, I think $390 for the pair shipped, they seem pretty good. I have to fab up some mounts for them, I just used all thread and some ¼ angle steel to make them and I will weld together something a little stronger when I pill the seats out next. I still haven’t installed the aluminum under the seats so I’ll do those at the same time.

[Sean.keehn@gmail.com]

Got 5 1/4” pioneer speakers for the car, turns out they fit in the door perfectly, sound really good too. I am a little worried about rattle when it’s all together so I might put in some Dina-mate. I used some of the left over cardboard to make a stencil for a rear speaker mount/arm rest for between the seats. Also got a dual din pioneer radio, Appradio 3 is the one I got, But it’s is wider that the center console, so that’s going to take some custom work also.

[Sean.keehn@gmail.com]

Right now I’m working on the doors, and my windshield should be installed in its frame the next couple days. So ill have that to install. Also just got a call from the tire place, maybe my wheels and tires are in.

[Sean.keehn@gmail.com]

Not necessarily in order but here's more pics.

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[Kurk818]

Wow, great progress.

Im getting ready to start mounting my body here shortly. Looks like we'll both be ready for Spring.

Im sensing a meet up on near Mount Rainier in the future. :D

[FFRSpec72]

Looking good, keep posting progress

[Sean.keehn@gmail.com]

Just an update, I finished assembling the passenger door, its installed but a couple screws on the bottom scrape a little. Started on the driver door, its much easier after having already done one. There is something a little hinky about the latch, it is really hard to close all the way. It captures easy but then wont latch, so i ordered another one on ebay. Also got the new wheels and tire in, I like em'. And i mostly finished the center speaker? arm rest i was working on. I have the cardboardtemplate i use if anyone wants it.

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[Sean.keehn@gmail.com]

#1
Is this the same shift boot everyone else got with the kit.seems like one of those square peg and round hole things.

#2
Does anyone know where this piece of aluminum goes? I asked the factory and they referenced me to the aluminum placement guide in the manual, which is only really useful from one angle and if you know the part number.

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[mjazzka]

Wish I could help with the questions, but I'm just here to find out where you got your seats! :)

[Bob_n_Cincy]

#1
Is this the same shift boot everyone else got with the kit.seems like one of those square peg and round hole things.

#2
Does anyone know where this piece of aluminum goes? I asked the factory and they referenced me to the aluminum placement guide in the manual, which is only really useful from one angle and if you know the part number.

3591035911

That piece of aluminum is the engine belly pan. That was my first thought. Now I'm not sure.
Bob

[Mechie3]

It looks like the undernose piece, but it doesn't have the louver cutouts.

[RM1SepEx]

Nope, you ordered the CF rear diffuser, that is the under engine piece to close off under the car. It needs to be trimmed for oil pan clearance. It needs to be removed to access oil filter etc...

Easy to ID for me, it was the last of my B/O parts to arrive, 372 days after I picked up the kit. There was no PN listed with the diffuser and I didn't realize that I didn't get one until a full year after picking up my kit! LOL

[Sean.keehn@gmail.com]

The seats are cipher auto brand, I got them online, $390 for the pair shipped. I think there great so far. That makes a lot more sense, thanks.

[Sean.keehn@gmail.com]

So I got the driver door rough fit, both of them closed and latch but rub doing it. I think im going to have to trim the hinge mounts to get the doors to move forward more. Also started working on the dash, got it almost done actually and got it mocked up into place, still need to run wires for the back up camera, the rear speakers and a couple other things. The next step will be to pull the seats out. I still haven't installed the under seat aluminum so ill get all that done at once. But Headed to Billings for the holiday, so ill be away from it for a while.

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[Boog]

The radio install is very slick. All it needs is a little vinyl or leather to finish up the clean look.

[Sean.keehn@gmail.com]

Finally finished the interior, and while i had the windshield off again, worked on the door alignment. the drivers fits pretty good, but the passengers still scraped just a little, couldn't be more that a couple thousandths. So, the only things i have left are the license plates(which includes the state inspection), the splash guards, the trunk and hood. i think i got most of the front wiring wrapped and riveted in place, I still have to clean up the back though, might wait till i pull the engine out next winter, kinda want to get the car on the road and have some fun before I lock her in the garage again. I tried to use a couple rubberized spray paints on the splash guards but they didn't turn out, so I'm having them powder coated, them Ill paint on an epoxy bed liner. Also have to get an exhaust, I imagine that ill borrow a trailer from a coworker and do the state inspection right after i have the exhaust done. Ive also already fit up the rear defuser, just waiting for the fins to get back from the powder coater.

You can see in one of these pics that my hood is a little crooked in the front, Sucks, I think im going to end up with Bondo all over this car before its ready for paint/vinyl.

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[Harley818]

Hey Sean,
Nice job.
Thanks for posting interior pics. Not many that I've seen so far.
Also, I like the speaker in the door. Did it end up working out well. I see you also have tweeters on the dash and two more speakers between the seats. Sound good?
What do you have for amplification?
I've got my chassis pretty much done and in go-kart mode. Now I start the body and interior.
I may have to call you up on my next trip down to Washington.

[Sean.keehn@gmail.com]

Yea, the clearace for the speaker in the door is perfect, just barley misses the door frame. I'm not running any amp, and it sounds great right now. I Think I'm going to have to fade bias the speakers toward the front, which is easy. I haven't been paying attention to the music in the short time I've had it up and down my street, so I'm not sure what's its going to sound like at 70.

[Sean.keehn@gmail.com]

Just some more pics of the progress lately. Got both the rear trunks mounted, had some trimming on the front of the two and for the rear i had to die cut the threads so the pin would serve its purpose. Bought a show 'n go front license plate holder, works pretty good. A finally got the hardware necessary to get the p hose clamps secured.

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[FFRSpec72]

#1
Is this the same shift boot everyone else got with the kit.seems like one of those square peg and round hole things.

35910

Looks like the one I got so did it fit ? if so why is it so strangely shaped ?

[Sean.keehn@gmail.com]

I don't know if I'd say it fits, looks ok but not great.

[Sean.keehn@gmail.com]

Got the rear license plate mount on, the side carbon rockers and the street spoiler.


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[Sean.keehn@gmail.com]

All i have left are the hood pins. Here are some updated photos of my progress. Also got the rear diffuser installed, with the fins. Finally discovered the location of the last couple pieces of aluminum. A little irritating that these pieces are almost entirely excluded from the manual. Im planning on installing them when i get the body colored, at a later date.

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[Kurk818]

Looks great! When do you plan on registering it? Anything completed in the cockpit?

[Sean.keehn@gmail.com]

My state inspection is apr 3rd. The **** pit is done as far as the kit is concerned, I'm going to do a leather interior at a later date.

[Sean.keehn@gmail.com]

Haha, cockpit*

[Sean.keehn@gmail.com]

Yup, I have completed the kit. Still plan of getting her some color, doing the interior, and rebuilding the engine next winter. But now it time to have some fun with her.

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[AZPete]

Sean, congrats on the build! I like your decision to have fun with it during the warm months, then details during the long winter months. I'm also planning on a double-din unit in the console so seeing yours helps a lot. Thanks for all the pictures.

[Sean.keehn@gmail.com]

Got the exhaust installed along with some carbon fiber exhaust flanges. Also took her out to the local auto cross track last weekend, just to shake the bolts loose. Had some trouble with her overheating but after some venting shes running great now. Read more about it here if you like. http://thefactoryfiveforum.com/showthread.php?13682-Help-with-engine-cooling-burping My car inspection for the state is tomorrow, wish me luck.

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[FFRSpec72]

My car inspection for the state is tomorrow, wish me luck.



Keep us posted on the inspection and results, I hope all goes well !

[STiPWRD]

Sean, your exhaust is exactly what I've been planning on going. Can you share where you got your components and I can't tell from the pic but is it stainless or regular mild steel?

[Tamra]

Good luck! Any videos from the autocross?

[Harley818]

Hi Sean,
Is that the Camaro muffler? I've been looking at that as one of the options so I can do dual exhaust, but I'm trying first to keep it all lower down so I can exit lower down and also have a trunk. Yours is my back-up plan if that doesn't work out.
Can you post a video with sound?

[bbjones121]

Got the exhaust installed along with some carbon fiber exhaust flanges. Also took her out to the local auto cross track last weekend, just to shake the bolts loose. Had some trouble with her overheating but after some venting shes running great now. Read more about it here if you like. http://thefactoryfiveforum.com/showthread.php?13682-Help-with-engine-cooling-burping My car inspection for the state is tomorrow, wish me luck.

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Finally a dual exhaust!!

[Sean.keehn@gmail.com]

i bought all the parts off summit racing and had s local guy do the weldibg. All the components are mild steel but I'm looking at maybe having the coated. A local place has this high temp powder coating made for exhausts.

FLO-842583 Muffler
MPE-59955 Cat
PTE-H7059 180degree mandrel bend
SUM-670176 2 90degree mandrel bends

I think I am going to have the same guy build me a straight pipe system after my inspection is done. Right now the exhaust note is super mild. Not any louder than a showroom sti I imagine. I've got a video from the auto cross but it's not from in the car. I'll post that one and one of the exhaust sound when I get a chance.

[Sean.keehn@gmail.com]

Good News is that my inspection went well. I dont know what the factory was thinking when they pu the serial number for the car on the front cross member, right where the lower windshield surround goes. even if the surround wasnt there you still wouldnt be able to see the number with out taking the dash apart. Either way I had the state assign me a VIN. Had to take the car over to get weighed, moment of truth for me. She came in at 2080lb. Not super happy about that but i also have some aftermarket stuff that the demo car didn't have. Now for the bad news, On the way back from the CAT scales one of the nipples on the turbo degas tank broke off and blew coolant all over, not to mention stranding me on the highway. Yesterday i got the new tank in and should be good to go from now on. I went with a moroso tank that i ordered off fastwrx.com. Also included some pictures of the method i used to bleed the coolant system.

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[Tamra]

So are you road registered now? Congratulations!!!!

[Kurk818]

Good News is that my inspection went well. I dont know what the factory was thinking when they pu the serial number for the car on the front cross member, right where the lower windshield surround goes. even if the surround wasnt there you still wouldnt be able to see the number with out taking the dash apart. Either way I had the state assign me a VIN. Had to take the car over to get weighed, moment of truth for me. She came in at 2080lb. Not super happy about that but i also have some aftermarket stuff that the demo car didn't have. Now for the bad news, On the way back from the CAT scales one of the nipples on the turbo degas tank broke off and blew coolant all over, not to mention stranding me on the highway. Yesterday i got the new tank in and should be good to go from now on. I went with a moroso tank that i ordered off fastwrx.com. Also included some pictures of the method i used to bleed the coolant system.

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Did they have any issues with you not having wipers or a wash tank? I have my inspection scheduled for the 6th.

[Mechie3]

Did the nipple break off from hitting the frame? Stock motor mounts?

[Sean.keehn@gmail.com]

I have plates for my car. The inspection was weird, the guy didn't use the check list and didn't look for wipers, center light or reflectors. He didn't even test the lights, turn signals. About the tank, i don't know how it would have hit the frame, and the new one seems to be working. Don't know why it matters but i do have the stock motor mounts.

Video of the exhaust.
https://www.youtube.com/watch?v=pJTrFObO8kg&feature=youtu.be

[Kurk818]

Thats awesome. I hope i get someone who flys me right through the inspection process as well. Congrats!

[Mechie3]

Stock motor mounts are soft and allow enough motion for the tank to hit the frame member. So.done else had that same problem.

[Sean.keehn@gmail.com]

Got these sweet exhaust tips welded on.


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[Kurk818]

I like it :) Finishes it off nicely.

I think youre going to hate cleaning up the sooty condensation off of the bumper tho.

[Hiryu]

I have plates for my car. The inspection was weird, the guy didn't use the check list and didn't look for wipers, center light or reflectors. He didn't even test the lights, turn signals. About the tank, i don't know how it would have hit the frame, and the new one seems to be working. Don't know why it matters but i do have the stock motor mounts.


When I got my homemade car registered here in WA, they didn't care about the safety devices, lights, etc. She wasn't too crazy about it not having an airbag or door handles, but she only spoke to those things. The only thing they really cared about was that all the components had papers so she could certify that nothing was stolen.

[STiPWRD]

The exhaust sounds great!

[Kurk818]

When I got my homemade car registered here in WA, they didn't care about the safety devices, lights, etc. She wasn't too crazy about it not having an airbag or door handles, but she only spoke to those things. The only thing they really cared about was that all the components had papers so she could certify that nothing was stolen.

Which location and when did you have your inspection?

[Hiryu]

Which location and when did you have your inspection?

I ended up doing it at the Bellevue Washington State Patrol location. I wanted to do it in my hometown of Walla Walla, but I think they had just discontinued the service there? Besides, the guy didn't sound that nice over the phone...

It was July or August of 2013, I believe.

[suttonb3]

Looks and sounds great. Did you get those cf flanges from summit as well? That's a great finishing touch.

[Kurk818]

When I got my homemade car registered here in WA, they didn't care about the safety devices, lights, etc. She wasn't too crazy about it not having an airbag or door handles, but she only spoke to those things. The only thing they really cared about was that all the components had papers so she could certify that nothing was stolen.

I went in for my inspection today. The VIN officer didnt even want to look at anything else after noticing that it didnt have an airbag. Said off-road only. Was not willing to be helpful or explain things.

I have another date scheduled for the Bellevue location at the end of the month. Ill see how that goes.

May have to go to Tri-cities if thats what it takes lol

Stanley

[Sean.keehn@gmail.com]

That really sucks, especially since it's not required.

[Jaime]

Kurk, here's the official checklist for homemade vehicles in WA: WA Homemade Vehicle Checklist (http://www.wsp.wa.gov/traveler/docs/checklists/homemade_motor_vehicle.pdf)

Unfortunately, air bag is the first thing on the list. I hope your next inspector is good to you, but it's always a good idea to know what the rules are.

[Kurk818]

Kurk, here's the official checklist for homemade vehicles in WA: WA Homemade Vehicle Checklist (http://www.wsp.wa.gov/traveler/docs/checklists/homemade_motor_vehicle.pdf)

Unfortunately, air bag is the first thing on the list. I hope your next inspector is good to you, but it's always a good idea to know what the rules are.

This checklist is more applicable and has no mention of Airbags

http://www.wsp.wa.gov/traveler/docs/checklists/kit_vehicle.pdf

[Jaime]

Ahhh... New York classifies kit cars as homemade, so I didn't even think to look for the other list.

[Tamra]

How could they fail you if airbags are specifically not on the list for a kit car? Did you have the list with you to show them? What did they say?

[Kurk818]

How could they fail you if airbags are specifically not on the list for a kit car? Did you have the list with you to show them? What did they say?

I did not have the list to show them. My mistake. I assumed i was dealing with professionals who knew what they were doing.

The kit car list doesnt even mention wipers directly.

[Tamra]

I assumed i was dealing with professionals who knew what they were doing.



LOL. It's a great warning for the rest of us to be prepared!!!

I've emailed with our inspections department a few times regarding a few things (our dash is in KPH for example), and I plan on printing out the emails where they said it was fine... just to have as proof on the day of inspection. Hopefully we won't have any surprises like you did, and hopefully your next appointment will go better!

[Harley818]

Kurk, thanks for posting this info. I'm going to double check requirements here in BC..... and bring my list with me.....

[Hiryu]

I went in for my inspection today. The VIN officer didnt even want to look at anything else after noticing that it didnt have an airbag. Said off-road only. Was not willing to be helpful or explain things.

I have another date scheduled for the Bellevue location at the end of the month. Ill see how that goes.

May have to go to Tri-cities if thats what it takes lol

Stanley


Sorry to hear. Sorry if I missed where you said it, but was this first inspection at the Bellevue location?



This checklist is more applicable and has no mention of Airbags

http://www.wsp.wa.gov/traveler/docs/checklists/kit_vehicle.pdf

That's a great list--hopefully the next inspection will go better with this list in hand.

[Kurk818]

Sorry to hear. Sorry if I missed where you said it, but was this first inspection at the Bellevue location?




That's a great list--hopefully the next inspection will go better with this list in hand.

First inspection was in Tacoma.