818R Interior finishing - Dead Pedal and coolant covers

[SixStar]

What is everyone doing with the massive gap left by using the S interior panels on the R chassis?

FFR didn't send me the one triangle piece for each side, but I did get the dead pedal and the coolant cover. Since the R frame is 90 degrees from the floor and doesn't come in at an angle like the S they really don't fit.

Pictures:

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[FFRSpec72]

If you call FFR they will say "this is a race car, you don't need them, they just add weight".

My plan is to use the side aluminum panels that are on the outside on the inside (since I added anti-intrusion panels on the outside), so that will cover the side and then just make a piece to cover the gap from the coolant cover to the side aluminum and pop rivet it on.

[SixStar]

A dead pedal on the drivers side is a must for me. My main concern is there's room for your foot to go up and into the dash/door area without it finished.

I'm not liking the whole build something from scratch for EVERYTHING on the R so much anymore.

[longislandwrx]

I made a template, let me see if I can get it cut tomorrow (hasn't been a high priority)

I can test fit and send out measurements if it works.

[FFRSpec72]

A dead pedal on the drivers side is a must for me. My main concern is there's room for your foot to go up and into the dash/door area without it finished.

I'm not liking the whole build something from scratch for EVERYTHING on the R so much anymore.

Agree scratch issue. I guess that I'm just used to driving the challenge car and there is no room in the foot box and no dead pedal and so that will not bother me if I can't figure that out.

[D Clary]

I just made a piece out of the door pieces that were shipped with the car.( check my thread) There is enough material in both of them to make the panels that should have came with it.

[SixStar]

I made a template, let me see if I can get it cut tomorrow (hasn't been a high priority)

I can test fit and send out measurements if it works.

If you could that would help me out a TON! I have a month to finish the car but every little hang up like this adds time I don't have.

Would it be possible to send out a template? Just trace it onto some construction paper, roll it up and mail it to the shop?

[Rasmus]

I'm not liking the whole build something from scratch for EVERYTHING on the R so much anymore.

Hear, hear! I'll go grab a torch and my pitchfork. Meet you in front of Dave Smith's house.

Here's what I did:

http://i.imgur.com/Tdot0iH.jpg
Here's the panel I made.


http://i.imgur.com/3Glor4G.jpg
Final install. Link to the relevant part of my thread.
(http://thefactoryfiveforum.com/showthread.php?12631-818Rasmus-X-Prepared&p=170752&viewfull=1#post170752)

[D Clary]

I cut off the flange that is on that weird angle and bent the side piece to go under it and extended it to the firewall to seal the corner.

[SixStar]

So make something is pretty much my option. Bummer. I have easy 600 hours into this car with another 400 to go, adding another 2 days making **** from scratch doesn't sound exciting.

[FFRSpec72]

So make something is pretty much my option. Bummer. I have easy 600 hours into this car with another 400 to go, adding another 2 days making **** from scratch doesn't sound exciting.

Its a race car, it's supposed to be kluged together and look ugly

[longislandwrx]

If you could that would help me out a TON! I have a month to finish the car but every little hang up like this adds time I don't have.

Would it be possible to send out a template? Just trace it onto some construction paper, roll it up and mail it to the shop?

Yeah let me get it right this weekend.

I don't think i'll need to mail it out, i'll just draw it up in sketchup and post it here. I started with corrugated cardboard, and transferred to thick cardboard.

here's the original shot and gives you an idea of the shape. just so you don't get your hopes up.

http://thefactoryfiveforum.com/showthread.php?10668-longislandwrx-Insert-Cool-Nickname-Here-Build-Thread&p=122755&viewfull=1#post122755

I forgot to bring it to the metal guy at work today so I just grabbed some scrap to bring home. i'll cut it with a cutoof wheel so it wont be as pretty but it should do the trick and get you close.

Stay tuned.

[C.Plavan]

The combination of my aluminum side intrusion plate and aluminum coolant tubes fixed the driver side. The passenger side is open, but I'm not too worried about it. I may fabricate something like you guys did on the passenger side.

The 3D printer has been invaluable in making parts for my 818R. Wait till I post pictures of the door mounts/hole filler.

[SixStar]

I guess moving forward I can at least mount the four panels that were included and move on to something else.

[longislandwrx]

just don't drill your pieces to the floor yet. I'm going to do some work on it tonight.

[char]

The 3D printer has been invaluable in making parts for my 818R.
I was wondering about that, actually, how useful 3d printing would be for putting one of these kits together, especially with companies like doing bronze infused steel parts...

[SixStar]

just don't drill your pieces to the floor yet. I'm going to do some work on it tonight.

You got it. The plan is to see how far we can get tonight and then use what you have to finish it off. It's going to be a duct tape and construction paper kinda night!

[longislandwrx]

I am almost there. I worked on it Friday for an hour or two.

The weather was absolutely gorgeous on Saturday so I couldn't pass up the opportunity to take the WRX out for a cruise.

My cousin did the Tunnel to Towers run yesterday so I spent the day with him and His wife.

http://newyork.cbslocal.com/2014/09/28/13th-annual-tunnel-to-towers-set-to-run-through-brooklyn-battery-tunnel/

I just need to trim a little more and drill and cleco for final fitment but I'm happy about how it looks. Then I can flatten it back out trace and get some measurements.

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[SixStar]

That looks NICE!

[longislandwrx]

ok this should be close for the "triangle" I measured off my cardboard template. I am trying to get to my buddies to cut on his shear but he hasn't called me back yet. worst case I will cut it at work tomorrow.

sorry overall length is 22.25 but I ended up trimming the back down about .375

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measuring the bendy piece now.

[longislandwrx]

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it's party time.

[longislandwrx]

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im happy, although I just broke a 1/8 drill bit off in the frame so that was frustrating, heading to the hardware store to get a few more, then some rivets.

riveted and all cleaned up. pm me if you guys want a traced template sent out to you.

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[D Clary]

I don't have a brake so complicated bends don't work for me so my solution was simpler but maybe not as cosmetic34418 pleasing

[longislandwrx]

In hindsight, that probably would have been easier, although I just bent mine by hand. I wanted to use as much of the FFR supplied parts as I could.

[D Clary]

I used the FFR parts, the extra piece is made from the side panels that the car was shipped with. I am not sure wht purpose they served except material for stuff they didn't include.

[SixStar]

Got the template in the mail today! Thanks again!!

Hurt my brain a little, tracing the two big ones now.

[longislandwrx]

Sorry I was low on cardboard, I figured if you can build a car from scratch you could figure out the template.

LOL.