bbjones121 - Denver build

[bbjones121]

My descriptions will be pretty short, I am going to try keeping it mostly to pictures if i can.

My donor is a 2006 WRX sedan bought on salvage auction, shipped from Seattle. It was hit in front and timing had skipped a couple teeth on the belt, so I tore down the engine to look for any damage. Thankfully there was none.

So after lots of thinking, I decided to keep my chassis bare until i completely build the car. There are some things i will most likely be welding along the way. I want it all powdercoated, including all my rivnuts.

I plan to start stock WRX 180ish whp for my vin registration and inspection. When i take it all apart for powdercoating, I have parts to build my motor up and run e85 close to 380whp.

Enough typing, here we go...

Oh yeah, the most important thing to say and I almost forgot. I want to thank everyone who has gone before me and documented your work, it has been extremely valuable. I can't truly express my full appreciation and gratitude for everyone's time and energy.

[bbjones121]

The donor.
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[bbjones121]

Garage remodel. Took way to long, but a 240v electric heater will warm the garage from freezing to comfortable in about 20mins now.

Before.
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During.
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Finishing.
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Cleanup.
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[bbjones121]

Chassis stand.
Wood and Harbor freight dollies.

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[bbjones121]

Front suspension.
Pieces blasted and powder coated silver vein. Lower A arms drilled and tapped. jbweld below shock mount to fill any gaps

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[bbjones121]

Steering rack depowering.
All ports cut off and welded. Pinion welded. Steel and aluminum polished and clear coated.

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[Mechie3]

Looking good. Car and garage. What heater are you using?

[bil1024]

Awesome, looking good!

[bbjones121]

Looking good. Car and garage. What heater are you using?

Thanks. It is the Dr Heater 988. Little red box.

[AZPete]

You do nice work. Keep the photos coming please.

[Frank818]

Really good to see your build thread for progress and follow-ups!

[bbjones121]

Brake caliper powdercoating.
I knew those huge seat boxes would come in handy.
Two coat chrome and candy orange.
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[bbjones121]

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I dont know if this pops as much as i would like. What do you all think?

[Mechie3]

Looks copperish in the photo. Not sure if it's the lighting or the actual part. I like the FFR logo though. It feels more OEM than "818" on the calipers.

[billjr212]

nice progress and I like the calipers and logos. Agree that they look copper.

Curious, where are you hosting your photos? Most (including my own) don't show up for me at work since I'm behind a firewall (imgur and photobucket are blocked).

Keep the pictures coming!

[flynntuna]

Anything is better than "Bronco" orange. :p lol
Seriously though, that color gives it a sophisticated look, I like it.

[bbjones121]

Yeah, the lighting is bad in the photo. They are lighter. I will try to get some better photos with them on the car this weekend.

I am using google+ for photo location. If you right click a photo, you can copy the url. I just past that url in here.

[bbjones121]

Final brake color:
Illusion orange plus clear vision topcoat from prismaticpowders
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[bbjones121]

Final Steering rack.
Polished and ports ground off and welded shut
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[bbjones121]

Steering and pedals.
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[coloskydiver]

Looking good. Moving along nicely.

[bbjones121]

Final pedal location.
Welded and supported the gas pedal mount.
The bracket flexes a lot and the manual calls for rivnut mounting to the chassis, even worse. The whole gas pedal assembly flexes over an inch when you push it down. I bet you would bend the bracket if you were racing.

https://lh3.googleusercontent.com/-Om2neCbt_Nw/VRi3zxk1VgI/AAAAAAAAZU8/xslktHxb5l0/w621-h413-no/DSC04465.JPG



I flattened the upper section which sit perfectly on the back side of the clutch shaft tube in the donor pedal box. I cut the top and welded it to the tube. There was still flex, so I used the top piece and made a support.

https://lh3.googleusercontent.com/-adNDsbiL7Go/VRi30cnGaCI/AAAAAAAAZVE/W0KBw41nSFo/w621-h413-no/DSC04466.JPG

https://lh3.googleusercontent.com/-d3b1dUlXAz0/VRi31DEqtDI/AAAAAAAAZVM/at27Y-aujPw/w621-h413-no/DSC04471.JPG

https://lh3.googleusercontent.com/-cNGOzRE8StU/VRi32Z0qfrI/AAAAAAAAZVU/o8T3VoDUEsc/w621-h413-no/DSC04473.JPG

https://lh3.googleusercontent.com/-VijO1Iy3yfs/VRi34o7_koI/AAAAAAAAZVw/tVfphwWFJNE/w621-h413-no/DSC04477.JPG

[TouchStone]

Does your clutch pedal still work after the welding?

[Frank818]

Does your clutch pedal still work after the welding?

Yeah I second that, the tube its welded on turns when you press on the clutch.

[bbjones121]

Does your clutch pedal still work after the welding?

Haha. Yeah it does. Come on...give me a little credit that i wouldn't do that ;). I tried to keep my weld from bonding to the inner tube. As far as i can tell there is no added friction.
Trust me though...i have done plenty of stupid things. Especially with the rear bearings, abs ring, seals when i powdercoated the rear uprights.

I think it would be easy for FFR to add an extra tab that you could rivet to the pedal box where i welded the back brace (not the tube part).

[bbjones121]

Factory five gunmetal wheels with Federal 595rsr 255/35-18 in rear and 210/40-17 in front.
https://lh6.googleusercontent.com/-mfWyH9qSMAo/VURFj7taP_I/AAAAAAAAZyU/2RT1CDY9_lI/w832-h553-no/DSC04478.JPG

https://lh6.googleusercontent.com/-pYFutK9rkpk/VURHMU_2kPI/AAAAAAAAZ1c/IUy3SEeSRAg/w622-h350-no/0403151327.jpg

https://lh6.googleusercontent.com/-GnwnSwS2f7w/VURJTkbZfmI/AAAAAAAAZ3A/Z_HDHvinKI0/w622-h350-no/0403151326.jpg

https://lh4.googleusercontent.com/-4H9nk0UbjtA/VURJatfZ2-I/AAAAAAAAZ30/ImakZ7ccLys/w622-h350-no/0407151917a.jpg

https://lh3.googleusercontent.com/-5dbtgLl5qaA/VURJZdf3_vI/AAAAAAAAZ3Y/TdzudN5zuYA/w621-h413-no/DSC04492.JPG

https://lh3.googleusercontent.com/-bIorR3SrtVA/VT2s78LE8VI/AAAAAAAAZps/Lfn3y0aoJAk/w621-h413-no/DSC04484.JPG

https://lh6.googleusercontent.com/-nNW86SN0E_o/VURFmz3j3oI/AAAAAAAAZ3I/kFmAYcPr-jM/w622-h350-no/0407151916.jpg

[bbjones121]

Finally mounting the seats. Sparco sliders angled up to allow seats to go up over the angled square tube a bit.
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[chedda]

Fantastic progress! I can't wait to see the final product.

[bbjones121]

Thanks chedda. How is yours coming along?

[chedda]

5 steps forward, 3 steps back but this time for the better. My build is sitting at ZFABmotorsports for the exhaust mockup and build but then the motor started leaking...

[bbjones121]

5 steps forward, 3 steps back but this time for the better. My build is sitting at ZFABmotorsports for the exhaust mockup and build but then the motor started leaking...

Bummer, sorry to hear, hopefully it is an easy fix.

[chedda]

The heads went to the machine shop. My thread shows all the pictures and what not. It happens when building motors right? lol

[bbjones121]

The heads went to the machine shop. My thread shows all the pictures and what not. It happens when building motors right? lol

I just saw the pics. Yeah, I will be crossing my fingers when I start mine up. Good luck.

[chedda]

If you ever want to come by and check it out, you are welcome to do so ;)

[bbjones121]

If you ever want to come by and check it out, you are welcome to do so ;)

Would like to. Are you around this weekend?

[bbjones121]

Seats mounted and done. Making the sliding rails work is a pain!
https://lh4.googleusercontent.com/-RDvIW-bXBEQ/VT2terZVpbI/AAAAAAAAZtc/LK4uShJF7J0/w346-h230-no/DSC04548.JPG
https://lh4.googleusercontent.com/-mIaCCe8jBcg/VT2tf3JL4OI/AAAAAAAAZtk/Wu7vY6OxL3s/w346-h230-no/DSC04549.JPG
https://lh4.googleusercontent.com/-84zt97xAtdc/VT2tg43fgVI/AAAAAAAAZtw/RdsrUeDhyMM/w346-h230-no/DSC04551.JPG
https://lh4.googleusercontent.com/-bikmdTa7pTA/VT2tiBO-8qI/AAAAAAAAZt0/bT-l0ehfD5M/w346-h230-no/DSC04552.JPG
https://lh4.googleusercontent.com/-9Q-mx6EAduI/VTR5nufa_II/AAAAAAAAZlc/kP4BENArkW4/w346-h230-no/DSC04523.JPG
https://lh4.googleusercontent.com/-p4Y2IpLlRlE/VT2tdFFxfGI/AAAAAAAAZtU/Ge5GXKXb-P8/w346-h230-no/DSC04530.JPG

[bbjones121]

Radiator mounted and complete. Mechies brackets work and look great! I welded my own supports to the chassis so they can be powder coated later.

https://lh4.googleusercontent.com/-zL3K6N6oUDM/VT2tRwWC6JI/AAAAAAAAZtE/Z7EpVttrv2A/w346-h230-no/DSC04571.JPG
https://lh4.googleusercontent.com/-lFRTgFc-iuQ/VT2tRcoFTgI/AAAAAAAAZtA/4Gg1rF6qJgc/w346-h230-no/DSC04569.JPG
https://lh4.googleusercontent.com/-p3BTv6rVgv0/VT2tIkB25yI/AAAAAAAAZro/bUk8BnwFxA0/w346-h230-no/DSC04533.JPG
https://lh4.googleusercontent.com/-bphHV2fOSKg/VT2tJ3PbUKI/AAAAAAAAZr4/IuMdgb6-6Vo/w346-h230-no/DSC04537.JPG
https://lh4.googleusercontent.com/-pOdHfbASzYY/VT2tKkshhEI/AAAAAAAAZr8/GejerYwSJmA/w346-h230-no/DSC04545.JPG
https://lh4.googleusercontent.com/-nIHYrki20Z4/VT2tPVdU8qI/AAAAAAAAZss/WmLUYFk-2YM/w346-h230-no/DSC04563.JPG
https://lh4.googleusercontent.com/-2EKmCW1mGeo/VT2tMaFLuVI/AAAAAAAAZsM/7ih0OFsjwOI/w346-h230-no/DSC04556.JPG

[Kurk818]

Quality work. Keep on with the progress. One milestone at a time.

[bbjones121]

Quality work. Keep on with the progress. One milestone at a time.

Thanks. Yup, slowly but surely.

[coloskydiver]

I would agree with the quality work and I am sure that the finished product with reflect that. I wish I could weld and fabricate like that. I fell like is tend to stumble through it and spend more time fixing the problems I created. Can't wait to see it in person. Keep up the good work.

[bbjones121]

I am trying to keep my interior rivet free, so i will be welding my firewall to one piece. I welded tabs to the backside to attach.
https://lh6.googleusercontent.com/-SDxtmzsJy4c/VURAtHZuKfI/AAAAAAAAZwI/9sYvI-2xeeY/w832-h553-no/DSC04584.JPG

https://lh6.googleusercontent.com/-V8bcLXv-ZYQ/VURAufzoNNI/AAAAAAAAZwQ/-SB6dNFE1h8/w832-h553-no/DSC04585.JPG

https://lh6.googleusercontent.com/-BHLesvk_P_8/VURAvm7JeVI/AAAAAAAAZwY/FE2CR0UPBT8/w832-h553-no/DSC04586.JPG

https://lh6.googleusercontent.com/-fOGszNoNK-Q/VURAwkiJiXI/AAAAAAAAZwg/5UpOC7lmmlg/w832-h553-no/DSC04590.JPG

https://lh6.googleusercontent.com/-tG-EQFvVKbE/VURAyexGNRI/AAAAAAAAZwo/zzKIEbYTeVk/w832-h553-no/DSC04591.JPG

https://lh6.googleusercontent.com/-XQM30LjaWks/VURA0W5nYNI/AAAAAAAAZw4/H5oroai7tRU/w832-h553-no/DSC04595.JPG

[bbjones121]

https://lh6.googleusercontent.com/-H0x9N-jet58/VURA3zZMkxI/AAAAAAAAZxY/go_FagEbcpU/w832-h553-no/DSC04599.JPG

https://lh6.googleusercontent.com/-wI978C0b3oM/VURA45mlvCI/AAAAAAAAZxs/vIxPZiewW6s/w832-h553-no/DSC04605.JPG
Going to brush all the aluminum, I tested a spot.

[bbjones121]

Started the rear brake lines. Since I will be powder-coating the chassis later, I purchased a bunch of small rivnuts, 6-32. Let me just tell you that this size is a pain in the ..... The tool bit has broken on me twice already, you really can't squeeze too hard. I just have some bolts that I weld on the tip.
https://lh3.googleusercontent.com/-dM07-W7N7kY/VUQ_Rithj8I/AAAAAAAAZv4/yGs5FjvnRLk/w621-h413-no/DSC04583.JPG

Welded the tabs on the chassis.
https://lh3.googleusercontent.com/-cb5JKV9KJ3Q/VURM2CdyYLI/AAAAAAAAZ4g/TEZCOGB0KD4/w621-h413-no/DSC04577.JPG

https://lh3.googleusercontent.com/-5SEqwOLkvVA/VURM2ojge6I/AAAAAAAAZ40/m92V_Wj68_0/w621-h413-no/DSC04578.JPG


Thankfully I saved the original hardware for the ABS line. It bolts right into the rear trailing arm.
https://lh4.googleusercontent.com/-5q7BoxbZ2aE/VURM1uwKqtI/AAAAAAAAZ4c/Hex6G3dzq3k/w556-h837-no/DSC04575.JPG

[FFRSpec72]

Build is looking real nice, I like what you have done with rear firewall, I don't like rivets/rivnuts either. Whast kind of welder do you have for the aluminum ?

[bbjones121]

Build is looking real nice, I like what you have done with rear firewall, I don't like rivets/rivnuts either. Whast kind of welder do you have for the aluminum ?
Thanks.

It is an Everlast 200dv. If you talk to them, they can work with you on price. I think for about 1400 I got the dual voltage model, upgraded pedal, upgraded gas regulator, upgraded tig torch, plus the another tig torch with the thumb current adjuster,I love it. Used an old Lincoln a bit back in the day and i wouldn't give this Everlast up. The functionality is insane. It has great warranty, pretty nice Siemens IGBTs I think.

For aluminum you can adjust everything and you can use a sharp point on your electrode. You can weld the bottoms of pop cans difficultly. The next model up can do it easily.

Does it sounds like I researched a bit?

[bbjones121]

Finished welding it as one piece. By the way...this was a PITA. I do not recommend trying to weld it together unless the two pieces line up perfect. I had to beat the thing back flat as it warped like crazy.
Underside welds:
https://lh4.googleusercontent.com/-BMf1SsVgz2U/VU7vhOdu3nI/AAAAAAAAZ6E/pOUirR-FMeo/w556-h837-no/DSC04622.JPG
https://lh4.googleusercontent.com/-3nc9dLwJAj0/VU7vjJvmR0I/AAAAAAAAZ6c/aSannmgLL5k/w556-h837-no/DSC04627.JPG

Topside Welds and brushing look:
https://lh3.googleusercontent.com/-LrLCl9YjTV0/VU7vjmvrhUI/AAAAAAAAZ6g/SfnfwKJnFbc/w621-h413-no/DSC04629.JPG
https://lh3.googleusercontent.com/-8fXVmjKr6gA/VU7vlZEMUFI/AAAAAAAAZ6w/gURlsQhEUV8/w621-h413-no/DSC04632.JPG
https://lh3.googleusercontent.com/-KH4RlxoRAWc/VU7vq0d9dbI/AAAAAAAAZ7U/Fk0xBkNxyR8/w621-h413-no/DSC04636.JPG
https://lh3.googleusercontent.com/-yY3oKxXXXuQ/VU7vrQKRaDI/AAAAAAAAZ7Y/ogtk1wMSaHs/w621-h413-no/DSC04637.JPG
https://lh3.googleusercontent.com/-2ZtUvEJqS3E/VU7vswqZR6I/AAAAAAAAZ7o/uK0CR0J4Lro/w621-h413-no/DSC04639.JPG

[AZPete]

Beautiful work, especially since we didn't see you beating it back into shape.

[bbjones121]

Beautiful work, especially since we didn't see you beating it back into shape.

Thanks, haha. Yeah, the fixups from the f...ups are better done in secret. Plus I don't really feel too inclined to grab the camera for those events; I feel more like throwing it and that wouldn't be good.

[bbjones121]

Using OEM line snap holders, proportion valves within reach of driver. I reused the metric threaded connections from the donor and re-flared all connections.
https://lh6.googleusercontent.com/-izAtA987_zk/VX-Nf7tc9iI/AAAAAAAAaE0/PZgtriBGVXE/w832-h553-no/DSC04776.JPG
https://lh6.googleusercontent.com/--hol1axiYB4/VX-Ng1BhgZI/AAAAAAAAaE8/G1dyJOqPLiE/w832-h553-no/DSC04777.JPG
https://lh6.googleusercontent.com/-fs9XG8_X594/VX-Nr5jRuWI/AAAAAAAAaFk/C4P6oRWJcVY/w832-h553-no/DSC04782.JPG
https://lh3.googleusercontent.com/-G9PmHqBJbq8/VX-NwbpihpI/AAAAAAAAaF0/AJ7lXL0LMYE/w983-h553-no/0615150702a.jpg
https://lh3.googleusercontent.com/-o059sHNMP4s/VX-NyZhDZlI/AAAAAAAAaF8/X2uvXKxmLDE/w983-h553-no/0615150702b.jpg

[Bob_n_Cincy]

Using OEM line snap holders, proportion valves within reach of driver. I reused the metric threaded connections from the donor and re-flared all connections.


Great job on the brake lines. It takes a lot of time and patients.
Your proportioning valve will not be within reach of the driver unless you have super long arms or are not wearing seat belts.
Bob

[bbjones121]

Thanks. Yeah, these took forever. Plus relandscaping our front yard didn't help.

Sorry, that is what I meant. Taking seatbelt off, then reaching up there. I just wanted them to be reachable inside the windshield.

[bbjones121]

Since I haven't powder coated chassis yet, I am also trying to make every brake line easy to remove.

I still wish I were further along.The summer will be over before I know it :(

[Bob_n_Cincy]

I also just noticed that your passenger side lower control arm bushings is in upside down. This will reduce the tire-firewall clearance.
Bob

[bbjones121]

I also just noticed that your passenger side lower control arm bushings is in upside down. This will reduce the tire-firewall clearance.
Bob

Is it really? Crap. I did flip bolts so flange head would be against aluminum?

[Hindsight]

Very clean brake line routing!

[AZPete]

Very nice work. The projects that take much longer than I think they should are also the projects I'm most proud of. I'll bet you've come back to admire your brake lines.

[bbjones121]

Thanks guys!

Good point on looking back.

[bbjones121]

Are my control arm bushings backwards? I thought I was following everything correctly.

[JeromeS13]

Are my control arm bushings backwards? I thought I was following everything correctly.

It looks like your driver side is correct (straight portion on top), but your passenger side upside down (it has the fillet on top).

[bbjones121]

Wow, Thank you guys for pointing this out. I would never have caught it.

[Frank818]

Those are great brake lines!!! I wish you'd do mines. :)

[bbjones121]

It has been awhile and I have lots of photos to add. Where to start...
How about engine?
Putting it back together.
https://lh3.googleusercontent.com/-g1sZ77oo80A/ViXBmmTRc5I/AAAAAAAAabw/asnS9ZyBW20/s800-Ic42/0801151648.jpg
https://lh3.googleusercontent.com/-hSikE1R5iaA/ViXBrLG39PI/AAAAAAAAacA/SpiGitakXVU/s800-Ic42/0801151649.jpg

Powder coated the head covers in two part. Prismatic colors orange and then a clear coat.
https://lh3.googleusercontent.com/-6YK6-uhKEto/ViXBs9EGyII/AAAAAAAAacI/dUY1snY_tHI/s800-Ic42/0803151844.jpg
https://lh3.googleusercontent.com/-Y7Yb-rcj4do/ViXBvJiIPhI/AAAAAAAAacQ/JybqMGP3-lI/s800-Ic42/0803151845.jpg

[bbjones121]

I figured it would be a good time to color match my brake calipers and engine heads with some other pieces. Even though you can't really see this, the black color of my Perrin lightweight crank was boring.

Taped off the letters so I would keep the Perrin words. Here is it just after powdercoating the orange, but before the clear coat.
https://lh3.googleusercontent.com/-ZZmwRzP_4wI/ViXC64be3jI/AAAAAAAAafU/3rZis_tl320/s800-Ic42/0906152154.jpg

With tape removed
https://lh3.googleusercontent.com/-tBf1aYVA2yE/ViXC9L2ubLI/AAAAAAAAafc/-UfTLYkPCIM/s800-Ic42/0906152230.jpg
https://lh3.googleusercontent.com/-Rwt-53NMSmA/ViXDF_vebqI/AAAAAAAAaf4/mFQWyuBFNgA/s800-Ic42/0906152230c.jpg

[bbjones121]

I kept going back and forth on this on, but ultimately decided to weld up an extrusion and drill down through it. I was thinking about just getting an aluminum barb fitting, but whatever...this worked. I didn't want any obstruction down inside the coolant passage. kinda ugly weld, but hard to build up an aluminum weld pretty.

https://lh3.googleusercontent.com/-T9aKw6e2tQQ/ViXCt6d-API/AAAAAAAAae4/tC-oql6crY0/s800-Ic42/0905151449a.jpg
https://lh3.googleusercontent.com/-0yvDOXPnwRg/ViXCwHBWXjI/AAAAAAAAafA/bKJwk9we04g/s800-Ic42/0905151449b.jpg
https://lh3.googleusercontent.com/-PAISiPpjr30/ViXCn8pZtqI/AAAAAAAAaeg/1KxEH6moY4Q/s800-Ic42/0905151448.jpg
https://lh3.googleusercontent.com/-2Z6an6PrGHA/ViXCpWYoC9I/AAAAAAAAaeo/Zoatu4ou--0/s800-Ic42/0905151448a.jpg

[bbjones121]

So out of the entire WRX of parts in the basement, I have only sold one part to this date, the power steering pump. Guess what was part of that pump I did not remove before shipping it off... the alternator tensioner!!!

I went ahead and made a simple one. I plan to powdercoat or spray paint it black.

https://lh3.googleusercontent.com/-M-658xPAzZs/ViXCZQcnAhI/AAAAAAAAaeE/HJC2sUAqPZg/s800-Ic42/0925151649.jpg
https://lh3.googleusercontent.com/-Rup5au6uoBM/ViXCei51ocI/AAAAAAAAaeY/BGRzEIrTcjk/s800-Ic42/0925151649b.jpg

[bbjones121]

Again, I thought the black Perrin color was boring, so I taped off the existing Perrin sticker (thankfully this is a high temp sticker) and powdercoated away.

https://lh3.googleusercontent.com/-_r2WXd5i_I8/ViXDlmKKSeI/AAAAAAAAags/6t_vAGhnNU4/s800-Ic42/0906152144.jpg
https://lh3.googleusercontent.com/-Dz3wzNeG3BM/ViXD6OKLtPI/AAAAAAAAahY/J_S75JmQ8Zk/s800-Ic42/1010151021.jpg
https://lh3.googleusercontent.com/-wpcrvBN21TQ/ViXCAKUdYgI/AAAAAAAAadE/OG1G8OP2oSk/s800-Ic42/0906152301a.jpg

I couldn't find a good place to put the fuel pressure regulator, so I actually drilled and tapped one of the air intake manifold tabs.

https://lh3.googleusercontent.com/-fvBlBKfnjKU/ViXD-20wXOI/AAAAAAAAaho/jWlkvm2y2-s/s800-Ic42/1010151021b.jpg

https://lh3.googleusercontent.com/-OdDgO6ETRmw/ViXDzH4JuoI/AAAAAAAAahI/Rg5TYabVsNM/s800-Ic42/0925151650a.jpg

[bbjones121]

The Cobb air intake filter and neck put the intake in a perfect spot. I plan to shield off the engine from this later.

https://lh3.googleusercontent.com/-9TshtggGcms/ViWxnB77bfI/AAAAAAAAaWo/XQ0idSCLcp8/s800-Ic42/DSC05121.JPG
https://lh3.googleusercontent.com/-_CjU_2CmYa4/ViWxlSsoYuI/AAAAAAAAaWg/PV0G-JZ1eqI/s800-Ic42/DSC05120.JPG

[bbjones121]

I actually took pictures of the entire process with the CV shaft powder coating. It is amazing how the colors change. The orange is very dull when it is first cured, but when the clear coat cures, it almost sparkles. The white powder is the clear coat before it is baked.

CV housings sandblasted first.

https://lh3.googleusercontent.com/-4SsYCAWb7A4/ViXCL7iH_BI/AAAAAAAAadQ/wtgAK4dyCw0/s800-Ic42/DSC05061.JPG
https://lh3.googleusercontent.com/-qsmPRijMnfs/ViXCMX4UcEI/AAAAAAAAadY/mVT4hkNMDpk/s800-Ic42/DSC05062.JPG
https://lh3.googleusercontent.com/-SAMnAdJShCs/ViXCM982NmI/AAAAAAAAadk/sLw2FTpSZU4/s800-Ic42/DSC05063.JPG
https://lh3.googleusercontent.com/-PutJyFXhXJ0/ViXCNqSsstI/AAAAAAAAado/gzG05FBdEPo/s800-Ic42/DSC05066.JPG
https://lh3.googleusercontent.com/-eA86KdtsZig/ViXCQ9Up4lI/AAAAAAAAad8/d0EICJIWCCM/s800-Ic42/DSC05068.JPG

[bbjones121]

I wish I had photos of my transmission, what a pain in the a... I had to take it apart 3 times after adjusting the backlash and sealing. Beware, the 02 and 03 wrx cv stubs have an internal c clip. This is not the c clip that you just tug on really hard and it eventually pops out, this is a real c clip that you have to use a c clip pliers to remove. Unfortunately mine was clipped inside my Cusco LSD, so I had to take that apart along with the tranny to get to the clips.

[AZPete]

Very nice work. I appreciate the detail you took in properly cleaning and powder coating many of the parts, like pulley and CV housings, that most of us just installed. Nice.

[bbjones121]

Very nice work. I appreciate the detail you took in properly cleaning and powder coating many of the parts, like pulley and CV housings, that most of us just installed. Nice.

Thanks Pete. Any testing of the stock ac compressor yet?

[Mechie3]

I like all the color added to the normally boring colored parts (like CV's).

[Bob_n_Cincy]

Michael And I set up an oven and bought the equipment to do powder coating.
After a month or so of using it, we determined that it takes a lot of time to disassemble, clean, prep, coat, reassemble and clean the equipment after each part.
It was really slowing down our build. So we went to cheap, easy, and quick rattle cans. "because racecar"

BBjones, Your stuff looks awesome.
Bob

[bbjones121]

Michael And I set up an oven and bought the equipment to do powder coating.
After a month or so of using it, we determined that it takes a lot of time to disassemble, clean, prep, coat, reassemble and clean the equipment after each part.
It was really slowing down our build. So we went to cheap, easy, and quick rattle cans. "because racecar"

BBjones, Your stuff looks awesome.
Bob

Thanks. Yeah, the prep work sucks. I have almost given up so many times. The brake calipers were one of the worst. I finished them up and the clear coat started spider web cracking. I was completely upset and settled on having to reblast them and start over. I actually just charged them up and sprayed one more coat of clear on them and thankfully the powder only stuck inside the cracks. I was able to bake and they turned out perfect.

[bbjones121]

I feel like this is one of my most rewarding steps. I feel like second to style, among brakes and headlights, comes the exhaust of a sports car. The look of the exhaust is very important to me, it says if a car has some beefy guts or if it is all for looks. I feel like the kit really lacks in the headlight and exhaust department, but that is where customization comes in play. Every major sports car out there typically has dual exhaust. Among the high hitters are quad exhaust systems. Most WRX's you see on the road are quad exhaust, so I figured why not...

After months of studying every known exhaust system and setup in a 2.5l WRX I finally settled on one setup, that is a Nameless exhaust. I have a subaru legacy gt with a Borla exhaust. I love the way it sounds for my legacy, but I just didn't feel that the deep rumble would be suited for a small little sports car. In fact, when you start looking, almost every exhaust system you get for a subaru makes it very deep and rumbly. Another big issue is the amount of space we have in the 818. Most systems wouldn't fit. I believe the Nameless exhaust system sounds perfect. It has a little burble to it, but it gets pretty loud and poppy like a racecar should. The biggest advantage are the tiny mufflers they have.

I had been talking with Nameless about just purchasing the tips and muffler with a stub out, but hadn't heard back from them. I started looking for used and found a very good price on some. This system has the 5" diameter mufflers, the rolled lip 3.5" tips, and staggered/angled configuration.

https://lh3.googleusercontent.com/-6U0bacM0vkk/Vixjtak0WcI/AAAAAAAAanI/xp4OoBOkCro/s800-Ic42/download_20151024_225731.jpg
https://lh3.googleusercontent.com/--T01J6A1FJs/VixjthYv0DI/AAAAAAAAang/U88c0qSGB8o/s800-Ic42/download_20151019_112314.jpg

[bbjones121]

I am still learning how to weld up stainless. I can't believe how low of current you weld, I set my tig to 50 amps and am only about half-3/4 pressing down on the footpedal.

https://lh3.googleusercontent.com/-hsN3bkAVxeM/ViXAO2EzZII/AAAAAAAAaYg/p1pcLaLeovQ/s800-Ic42/DSC05151.JPG
https://lh3.googleusercontent.com/-B-00rMaXbxM/ViXASyOFuUI/AAAAAAAAaYw/RBTfJa-EZUQ/s800-Ic42/DSC05154.JPG
https://lh3.googleusercontent.com/-Lpznw6DEsEw/ViXAUxLsCMI/AAAAAAAAaY4/7y6EDpRg2zc/s800-Ic42/DSC05157.JPG
https://lh3.googleusercontent.com/-2EoYAuLDI6c/ViXAaVmRNeI/AAAAAAAAaig/7abksQoAqcM/s800-Ic42/1019151902.jpg
https://lh3.googleusercontent.com/-KH39tPM1gy0/VixjSMCgb4I/AAAAAAAAalk/CsHuu45Nm4Y/s800-Ic42/1024151905a.jpg
https://lh3.googleusercontent.com/-6fsDNT3-Y70/VixjiKseQHI/AAAAAAAAamc/_zP6j2G8Gjo/s800-Ic42/1024152155c.jpg
https://lh3.googleusercontent.com/-wK4p9j5L_eQ/Vixjgc4H3bI/AAAAAAAAaoE/gHFZ7ris9Q4/s800-Ic42/1024152155b.jpg

[bbjones121]

https://lh3.googleusercontent.com/-QDOqbKBWe8Y/ViXAHJwBtZI/AAAAAAAAaYA/N3r4fSQY4Y8/s800-Ic42/DSC05143.JPG
https://lh3.googleusercontent.com/-Nimf4swMJvo/ViXAc14rjUI/AAAAAAAAaZQ/Yk4eWkJ3etc/s800-Ic42/1019151858.jpg
https://lh3.googleusercontent.com/-ZJtG72h6xXs/Vixjq50nw1I/AAAAAAAAam0/dZeQ4y55c7Y/s800-Ic42/1024152156b.jpg

[Hindsight]

Woah, very nice! It never occurred to me to 180 the main pipe to get more space and alignment for the mufflers and tips. Those are really nice looking tips too, and I like the low and wide placement. It has an effect of widening the look of the car. Looking forward to seeing it finished.

[mikeb75]

Superb work there! Looking forward to seeing & hearing the finished product.

[Canadian818]

Great work!

[STiPWRD]

Very nice, that's going to look great! I wish I had a tig welder for stainless but I'm stuck with mild steel for now.


I feel like second to style, among brakes and headlights, comes the exhaust of a sports car. The look of the exhaust is very important to me, it says if a car has some beefy guts or if it is all for looks. I feel like the kit really lacks in the headlight and exhaust department, but that is where customization comes in play.
Definitely have to agree with this.

[bbjones121]

I still have some fab work inside, then I will weld up a support for a hanger on each side.

https://lh3.googleusercontent.com/-FdojW8BjQZE/Vi2Z5jOJt_I/AAAAAAAAap8/W7gMLhA_bQ4/s800-Ic42/1025151757c.jpg
https://lh3.googleusercontent.com/-puXBTrVvUUY/Vi2Z38F6PqI/AAAAAAAAapw/6SdpKzD8Va4/s800-Ic42/1025151757b.jpg
https://lh3.googleusercontent.com/-u9pyfjZwsxM/Vi2aJYtUu3I/AAAAAAAAarQ/VRHYulSwYUw/s800-Ic42/1025151809.jpg
https://lh3.googleusercontent.com/-g8Z6jrnuZ4U/Vi2Z_DYcP8I/AAAAAAAAaqI/XthfRnn0xDA/s800-Ic42/1025151758.jpg
https://lh3.googleusercontent.com/-EIEtW-jAeGk/Vi2aBefvowI/AAAAAAAAaqQ/R_18F8-8_g4/s800-Ic42/1025151758a.jpg
https://lh3.googleusercontent.com/-G8Ney9_J7AI/Vi2aHieSujI/AAAAAAAAaq4/Q0eZPj88agY/s800-Ic42/1025151801.jpg

[Canadian818]

Can't wait to hear it. Great fab work, nicest setup I've seen yet.

[Frank818]

Kick *ss setup! It really is going to be a Ferrari, with that red and 4 tips.

Nice welds, learning myself how to weld SS, I have some issues on the continuity of the bead, it's actually very stop and go (can't do a continuous bead), I don't understand why yet.

[Rasmus]

That's a nice way to do it. Good work there.

[Mechie3]

Any plans on trim rings for the exhaust? ;)

[bbjones121]

Any plans on trim rings for the exhaust? ;)

I do need some ;) I was thinking aluminum powder coated matte gunmetal like my wheels and chassis would be great or mold carbon fiber. I was trying to figure out how I could get an inside lip to protect the fiberglass with aluminum.
Any ideas?

[blkstig]

Beautiful. Great job

[Mechie3]

Molding CF would be an easy way to get a lip. It might be possible with thin enough aluminum to make a form and slowly hammer it over the form to get a lip.

[bbjones121]

So it has been a little while... and now I have this...

https://youtu.be/gFjxyG2e13U

Videos just can't do an exhaust sound true justice, but it sounds awesome in person. I love the Nameless exhaust.

[bbjones121]

Here is a drive by. You can hear the exhaust pretty well when it is a block away.

https://youtu.be/f9ge65ye_vk

[Kurk818]

Sounds awesome. :)

Nice, clean, quality work. Cant wait to see the final finished product.

[bbjones121]

Sounds awesome. :)

Nice, clean, quality work. Cant wait to see the final finished product.

Thanks. Here are some exhaust fab pictures. The tips still need to be welded, but that is the last part. I have to put the bumper back on to line them up just perfect. This all took way longer than anticipated...but hey, everything seems to take longer with this project.

Lined tips up in bumper, then temporarily welded them to the chassis.

https://lh3.googleusercontent.com/-Xe4jfxGDDKY/VldssvNXhwI/AAAAAAAAats/Ggz5X8Oo3rY/s800-Ic42/1101151726.jpg

https://lh3.googleusercontent.com/-JuzWqsa1TE0/Vlds2t8ktrI/AAAAAAAAauE/kLhdYyFutlI/s800-Ic42/1108151547.jpg

https://lh3.googleusercontent.com/-8CgdRqv95To/VldtIaydURI/AAAAAAAAaus/cZiprt-5lcI/s800-Ic42/1108151913b.jpg


Being way too particular, i had to create a diverter that would help make sure that the majority of exhaust was not just going out the left side due to the 180 degree angled into the "Y".

https://lh3.googleusercontent.com/-ffs57cPBXCw/VldtLsHedoI/AAAAAAAAau0/nVbZMA1Wxjk/s800-Ic42/1108151943.jpg

https://lh3.googleusercontent.com/-jZB-1exZmZY/VldtOcYyFKI/AAAAAAAAau8/8fVJvOTCMfc/s800-Ic42/1108151953.jpg

https://lh3.googleusercontent.com/-HUfTxyVopfE/VldtXVxfnzI/AAAAAAAAavc/4e7J1sDgBBM/s800-Ic42/1108152020b.jpg

[bbjones121]

https://lh3.googleusercontent.com/-L6lG0OljIKQ/VldtvErdxGI/AAAAAAAAawE/ThY7-KJrmGQ/s800-Ic42/1108152056.jpg

https://lh3.googleusercontent.com/-4AWyMsGj3J8/VldtxG4ZuMI/AAAAAAAAawM/_H5iG8imODY/s800-Ic42/1111151019.jpg

https://lh3.googleusercontent.com/-GX2z3fHEs10/VldtzMl64DI/AAAAAAAAawU/vJHSM_-hxUo/s800-Ic42/1111151019a.jpg


Internal purging as I go.

https://lh3.googleusercontent.com/-dgxyY_2A8SY/Vldt-yLz9XI/AAAAAAAAaxE/cPUXKvs5Fiw/s800-Ic42/1111151126.jpg

https://lh3.googleusercontent.com/-_PDm2OU8qAI/VlduAphfLXI/AAAAAAAAaxM/LsDFB-bSZ8A/s800-Ic42/1111151131_HDR.jpg

[Hindsight]

Looking like a work of art with all those nice welds. Excellent looking and sounding. I am itching to start on mine.

[Kurk818]

Wow. Professionally done. Plans to ceramic coat or wrap the pipes to keep heat down?

[bbjones121]

Wow. Professionally done. Plans to ceramic coat or wrap the pipes to keep heat down?

Yeah, i have been debating which to do. Wrap or ceramic. I believe wrapping would keep it the coolest, unless I got over a 1/4" of ceramic. Even at an 1" of ceramic in my green egg it is still hot to touch when I am smoking meat.

[bbjones121]

https://lh3.googleusercontent.com/-zBuhEyIzBf8/VleSzUXsc9I/AAAAAAAAazo/_wiJWKro0Kc/s800-Ic42/1122152044.jpg

[Aero STI]

Looks great. I'm happy seeing that you're back purging all that stainless pipe. A flex coupler or two would be useful if you're going to be rigidly mounting anything to the frame.

[metros]

Great work! That exhaust looks top notch. Very nice.

[Frank818]

One heck of an exhaust, a gem!
Plz make it scream soon!

[bbjones121]

Looks great. I'm happy seeing that you're back purging all that stainless pipe. A flex coupler or two would be useful if you're going to be rigidly mounting anything to the frame.

Thanks. I have some stiff rubber mounts I was going to use. 4 total. Hopefully they work. I will video record the tips to make sure they aren't hitting the bumper. If they do, I will rigid weld the tips and use flex couplers.

[bbjones121]

One heck of an exhaust, a gem!
Plz make it scream soon!

Here you go:

https://youtu.be/gFjxyG2e13U

https://youtu.be/f9ge65ye_vk

https://youtu.be/LY8cZ-2KCHM

[lennyspecv]

Yeah, i have been debating which to do. Wrap or ceramic. I believe wrapping would keep it the coolest, unless I got over a 1/4" of ceramic. Even at an 1" of ceramic in my green egg it is still hot to touch when I am smoking meat.

Could you do both? Have it ceramic-coated AND wrap it?

I have no experience with either

[bbjones121]

Could you do both? Have it ceramic-coated AND wrap it?

I have no experience with either

Probably could do both, that would be best.

[lennyspecv]

Probably could do both, that would be best.

After all the reads I've read about heat control issues, I've been wondering about coating and wrapping any part that can be. I wonder if it's realistic to coat the block?

And also running a larger oil pan with a cooler.

[Frank818]

Nice sound man!
There's snow already at your place, I guess it's Denver.

I've heard that protecting exhaust parts too much from heat is not very good. I can't recall why, I think it overheats the pipes.

[bbjones121]

Baby daughter shifted my project list around for a bit...ok, for a long time. I am finally taking my kit apart to get the chassis over to powder coat. I am hoping that I can get it back and put together before she starts crawling. Wish me luck!

My daily time-lapse:

https://youtu.be/f4khI_I34D4

One last photo of the exhaust before it gets wrapped.
https://lh3.googleusercontent.com/3xMuu5IvXrxpOQFH0Seoo22WD_91obBRQs5P7Ac5F8wzHGAKho YU4D9Dkj7HP3Qi1BEfnDmcVzVSQcA=w1920-h1080-rw-no


Finishing the last welding jobs as I remove stuff: HVAC - Vintage Air Heat/AC
https://lh3.googleusercontent.com/Rg0hOxisRD00N5EkmJ_PZEgIjbLpE681a_PGbYjYxBwcYaKxP1 uO_58O6_0eEQk9dw7E5mqGJKnXn8c=w1920-h1080-rw-no

https://lh3.googleusercontent.com/kLbNQPOJLF38aC0xsxGul_Tr7E8uyxRwNfbbHXliHkGH-VTeFoLEkSOh7B-aL_v9RIaJSVWAfX_LYQA=w1920-h1080-rw-no

https://lh3.googleusercontent.com/aW-NpZ3amUzyQBA9Fas18qNodmJayXB_pG3xfxMzdrY1TGkEL4cJ2 Sn_pPa2FVd71CmrrccTct2Vb3I=w1920-h1080-rw-no

[Hillermi]

cant wait to see that exhaust wrapped! :o :o

[bbjones121]

After opting out of the powder coat, my project has taken at least an extra year. This was not all due to the extra work, it was very hard to stay motivated to work on it knowing everything was coming off. So my biggest recommendation to anyone, Get the chassis powder coated from Factory Five!! Even if you are going to do modifications, most of them are hidden from view. If you want a custom color roll bar, just paint it.


https://lh3.googleusercontent.com/Z6SOUKbb9KEhoGRiOMyKVAAoeV5H9XRuUwhk8VAc0GdNAxOKLm CVJ491kJ9QWNn_N8KJh2E4DWf_Iqbod8tvy8mH9W3YRMkk2m-9DIIFEMhqrwjZWVhSXeiFUt-H7ZEZ9FGbQmZwMgWJRhSq95ymAQSwKhksjp0YsKwJokBum8Tms kRLZ00PVIBiQnlLeFOTduNXtJOHldMf6grLO-KXyUzBxdfLyrvr7kr8mq3jRa3QY0jnqkf0bxClPwCAJ6LgZff-51GBMfp_5ODXt20a9BooAXdUcTJEXl6sGC_oI-hhn7MrHqfue8TGY2Nw93yDUKXgzm9BsodxTGgzANRpeDFgDld4 Y39szZtNicdI-r28Eui7yKLGFXYZVPtnCBkoteLe_bwJYHwLKhbcb_cyFCeg3sK h4QUDZSZNZv3RRye88MIyKGSy7Ia2o0bmX-6p0o1jDLZlE-Yck1zWO7V7v5ZQGl5xnlFLJ9C405t-YZexdlZwV2ridtstizsZkO1dPA1gTU27W0lqPF_sC_p2MahrvA UQykdceyyUL97IieGYCWKMzqXZVoXNwF7RvmIjCaQ8tNka7Pg5 oySXW99dLY7okQwD4bCkp0CkOlyYyXqXobnMWA=w1225-h919-no

[bbjones121]

First, for the biggest update and the reason I have been delayed in finishing my car...she is definitely worth it.

https://lh3.googleusercontent.com/ogcLW9SMFgLYTyiFxgG4plbEy4O9OuNhoirnE6Lo2qz96xP38Z YpWKHMrpDNClG3gXh4ODcSVfDyohWotNWHxc_Snv_h9JYHGbkL 1ipNlVU7XXdEfFviLMNZ8uVqLqrVEEwFuyXXOqRYMLhC37ADHY ZJ7Vv0Xxi2XiL_qlVpZhrYqQkUWy8Z_RRmwhq88XblG920nfgT YC9jbEYoRdzQBKrTCewvnXUMh9bdhOSqs5DE3ilywkz7HjhSlP lPU32KecnAYjM2Q_98fUM-2xu1bmhahlxZgwqpNVE24EJn5JxDGJwgmix2RU_M9G0a9MIRWB hr5jm0rEyheL8wgFwL87XSYC5JJK0eVklZCGxYAwfHWnWPGTf3 jazs6nLgEMw4wlGZt0U5kCeRQJ6FP1jY41FUJBEV5kR1mPzQdm NEGeG4nnvdQtY3B3C5EdSeRuVeOJc9n0FWNayJZutRw07XLlsz JHzqTs6Jl78tTbUkOUr71HOlntg1qAim1Elf_ydEmyckkPyYU3 Jnnf3UnN7lJKLR-aNpIKGPJ4GDxkejWMHpOcoyP7ab5kbm-sEI-DaZdbNtSC2WGMvLhw36TDvHnqnpvu1vYMtt6QGkNVsuzIz6Kjc IzvReAA=w1268-h950-no

[Mechie3]

You got that add on too? I think they're all show and no go when it comes to performance. ;)

[bbjones121]

Before:

https://lh3.googleusercontent.com/lM64mTql4bd4U1IhIhkVW_x6YOV1f-zsbTDGYrVZGdE8414Wc6zC6DVko7CNiiB6H6V90VWJSQGa4zLY oGVmMs380Bq-oxyA3BE89WW5n-9MnH-2w0QbPAOPfeyyU5EhjkbT6VHfb8n8fg3Y2x8MauphC2YrM1Ld5 SVRP3OEIMDAZRTIbFvhtgh9bzjU1M6AuAOmF2a5Tg64FmDuKCz 6jMrbFBXNMCr1KobskKo02mdnYxC6F5Z3xON_Xqjz0yc3_Hc1d QW8x5Ax5YN4Rl0Aa_LLadhkiRc2JXF7HW0u5TBI3wt7KXZ46q0 9fEDQ0GBklJyKUHemU-ekG_PA0qy7ekNZEk7viRBYkcR52Tt4XDPVYCyNi3IL7V9zyG3E gd6JeLM_z1zylSsoQ2N9p1XfHAEyE3-2QwoTVo65hspChYRD8OFT2rrSdk8zNgXwzG7kvp03ThWltyTGM 7QX-MCkN8ATJ9ddXESvh6jWPMpiY4r0Rb-PIJDOM2E99uxl0_p1v1gmM1rXHW1poXx8xzaSjx_Q6IMFq6hrh HIrPphVZFlyPtBYtwVVo25H5z466QOTAjoBmlgJzHQGokikh8_ A6c_Mk2jvMsQzxfjnAM8m-UbO-n71lWW8yw=w1268-h950-no

After gunmetal powder:

https://lh3.googleusercontent.com/LStyXBt48HmKHm-7rui6QTGfPOnW4-sDfP0LgJdzUYheFuzUk0vnfSU6k86pOgfw7Fha4U25F91S2dDt T0JV9G8AVsw9bh8ZGUpAALSPxAa5pbkD1TshZnn6wWq9qeulYs kdm4Qe4327vpCiTomjxlaRXaH1Nfq9sAhzT8d6NoYchQ8pCzt5 hBm4V9UsZ01YIylbxaVltPMnslUg3dQZ6ltNOHI8y_mHT6PG8Q 2r0k3nTgCCBK6TOkP3eszetGnPpveNui44TMx3JT1zNnxOCMaS K7iSrm1IFiHSu1ftra2imBnn757EwV2kLjUbW4Wq0Sbw7UZ5UO jOXKIShrOPkqJ9V49jgFwPOZEWQnmmmynZeXwsJVCOmxZrvf8b bvBIQP1atzOzw704_BMolJoILsbj0b-_mJC83-vN-8_b7Z0p283E_Hyypmqaon6NtB8XeSArzK02qIOxsv9Pqz8_4oe 18jT2f7FaefNay6jtMGxbBiSfvRU26DLatsm7EpVzjNpWpyDos _ax6wxZBqYj8QtSK77qzjY9DOeYiexvjNGcvu5GSIXFqYjbo3x Vusf4EmjXwYVmwDeUGv2DeIYNY8ercV41MmMLJnMpN8Z7erTeU HkgR848Bg=w713-h950-no

https://lh3.googleusercontent.com/PoaCNVpU2N9rnG6QKjY3DFmLY_7OeCOsRTfWAGd257EBe-xhmp-gSQjfovkhNfJl3c5WqU3SI3_6emlVwmCD6kQdrZJEFkf2t-KJ9dDQFdPLbT6vJadNceZuVyNoHbXcxC1Q-84H51JS-yynhGsXq1rnNAl8YW542tmPFUY2UXZX1aLLXKYU88qWM5SGu5j X-LB4yMlbqzhElAtvRt6QAn-rf-3oxZt2jIRoC4yrqopezfa3X87Ixtkk_uZr0m-6Y6Jq-P42Vp0Q_3UYSpbyP_iKDdycxoBIJ6HNcT2f9OZPX95KH906UTP szqxpK5upK7X13kYI4yq1KkUTj5VgQLXSCp9qk1taSRdeeZdZp CeoccdziK8X7f0WC_691bO95BG1CZFQ5b7hT1nOW47zK9VFi2P Rn8Ix5RnFFZEC4lXOc5tIxskm_PK1FdC3Ml_4FJVs6hoe0Uhfy Z9k_p3XUbVw4uqRj1zIp_SI_XV7QSxoqvPmSjjHRWYoNaawP7a I_d-e6HiGqaqeO-odA_tbveFLshdAZmFGqwDzcYLidfI0uDC0PNTew6kvcqoDL2TY TqKCnY0teju4881owCUJkd2003dlX80nufCflEOBOfvcTBGOLV 4auQ=w1268-h950-no

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[bbjones121]

Every aluminum piece is getting Noico Liner 157 Mil on the backside. It works very well and makes the pieces sound like they are solid steel. It is lightweight, sticky as hell, and it is chemical resistant too.
https://www.amazon.com/gp/product/B00URV8MFC/ref=oh_aui_search_detailpage?ie=UTF8&psc=1.

The floor boards inside the car and the side wells where the coolant passes through got CSI 25070 Heat Shield Insulation lined on the back of the aluminum. One side is reflective, the other is a fiber material. It is not adhesive, so I had to spray 3M adhesive. https://www.amazon.com/gp/product/B000RPG0DO/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

Inside all the triangles of the chassis, I decided the lightest and most efficient material would be Rmax Thermasheath-3 1 in.. It is extremely light for it's insulation ability. It is not exposed to any direct heat from the engine. I cut it to size, then black caulked it in place. http://www.homedepot.com/p/Thermasheath-Rmax-Thermasheath-3-1-in-x-4-ft-x-8-ft-R-6-Polyisocyanurate-Rigid-Foam-Insulation-Board-787264/100549260

The front "fake firewall" and the real firewall in the rear are lined with DEI 050503 Floor And Tunnel Shield. It is aluminum on one side and fiber on the other. Fiber side is sticky. It is was very hard to get in place in some locations, so I had to cut into more manageable sizes and use reflective tape on the seams. https://www.amazon.com/gp/product/B000CEO5W8/ref=oh_aui_search_detailpage?ie=UTF8&psc=1


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[bbjones121]

You got that add on too? I think they're all show and no go when it comes to performance. ;)

Lol, yeah. I just need to cut out the floor and she can help Flintstone style.

[bbjones121]

I definitely recommend waiting on putting any bed liner on the bottom of the car until after the side body panels are installed. It makes the side panels sit a little lower and I had to scrap it off to get the rivnuts I opted to use instead of rivets to sit flush.

https://lh3.googleusercontent.com/Yl6bsLdA98I3NPn6EJu7rmQcWG7uL3mxMTto7awX0gQMFsFNT1 gA5DEYk4hIV3fnxKsOPnwRFPyO-tml2tQN9FYSyHsmYhffOqHjV-UuUlxtf9DB7v-M5tL5rnjJQFUrVkVKdpXKrWbk3sgJN3O0rt2U-EIs7k3R_0OAK0RnZS_rjtz5ol7fNQWVDuB7j9GbtKOlGK1YpDD 0BjisTeilzv7wrU3K1_qRItA-L9GZMZvmpHE4294qjIBpj_rTwQC5S3ZFca8nXp8ZcWg9o2K0sk p5Ub1V9AmFjDPGod9RFGwJuL_iyvD1EBCHnTxcW6fdUteOGxz-jMDep6EN-FLMQaozy07Ii9zASLthcsiBDT6_pMiLvJh8VYSnFyaLrDvh8zG tzkqfF832jrQbptHLbIiEeNm6hVOl5xxVbYMJMtF-hiQ0cvuyVHYt222iPGRB5uPGroWRUnZzvcw4Kcx6oIYXbiBndq VabtJ8X5ecqO2DHe7SNWSSYnS1Ndmz1qN5CXH4DFwQDtEZsc_D 1guy63KjjgaS1l1bocIf5ehD6B1mbHFY7RgCy3jB6S5Go96eFC LQ-NGnPddMSrgySRUXty7BGNCdJ2-fElQVXo9vSAj18JgY4XI-Pg=w1268-h950-no

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[bbjones121]

This is factory fives extra carpet kit. I haven't finished the center console yet, but their kit does not cover the whole thing. The middle center section up to the dash and the e-brake section are not covered.

https://lh3.googleusercontent.com/FEDeJdE-9tdILucVJSdps0idY5laTjvazFJNFU4wq-zr_GTbx_sODBINSFS01qQm6ucix6sjFpkv9fAEeP1yL88d3alG 46Gwd3CGa4Z-DI7INCJLel9lE_8yNa7hFnL_XlOET7Ip7l73MsOuughx7WJirX 3Dj1f1zssc3y4vShQkdMD45Oed_h2qOJVNsFjWeLtr7orTIYkF 8k3mkLS4OvLQDK-NKVzr-jus4wkqA-Xyd-XiZfmkrEsh5i8TOEQuS7WwWH6qQ1U_ar_6VEcjkYqNZGqV8JkO LVIKjCn1vZ4NyZ_kBZ1EPOAcUzHTB7sda-JCcRGRXC6kssu7_BuAnqyC77EEUs1um20dr94ZVBMn1I7RV-xD1JWT-0MfsWMNxd_athsNg5nmqADHQ2pP99s0Gmu6rQRkFjsxv_ncy-Z4syv83bsaZH9eGy75-0k7L5BUz8rini3ud83-OtkL2tLXkZEdXpyB28Hfd1cI9Wl2_H5JeF9MTq1g8OVVQTYok0 nxCYi9R6gt47U0DV-PFyHz1evtfCXnGm4TtBBYUBYalAZEwktLQTrC1PQnLpzAHU7_A aLqg1DA_tP2Q5OMwWiTUb-PSMaTDzMm0Vh2w_M7Ch8WMw__sA=w1268-h950-no

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[bbjones121]

I had to have a stereo...

I purchased these to waterproof the backside and provide some better sound isolation. DEI 050321 Boom Mat 5.25" Round Slim Speaker Baffle https://www.amazon.com/gp/product/B0039YWT62/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

I had a hard time picking my speakers for some reason, but I settled on Kenwood KFC-1395PS 5.25" 320 Watt 3-Way Car Audio Coaxial Speakers for the rear. Anything bigger would not fit where I put them on the sides. https://www.amazon.com/gp/product/B00HZR8QKC/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

I got the component versions for the front so I could mount a tweeter in the door or in the dash. Kenwood Kfc-P509Ps 5.25-Inch Performance Series Component Speaker System. https://www.amazon.com/gp/product/B003WQ9S6G/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

And I was going to make a custom sub box, but figured I should focus my time elsewhere. I got this little Kenwood KSC-SW11 Compact Powered Enclosed Subwoofer. https://www.amazon.com/gp/product/B00BO8O9XQ/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

https://lh3.googleusercontent.com/UqKTyr8ub1gOWI_F7xKLXBlvIgpGKB9cB742uA-iu4p0MSw9wMKjoc0R7gtf9FQCkR7u8Z41c7h1BrHLq3HM92qsu wIDNR_6NaUq3TnDfb0v9wWKxzT0ASuRQYuYqfDZwBB8K_gxe0V 9z6E6VlBvYGqaMlFGocyQvK5d1c1Zc6VGx77v-RQIerUcsY86y7w66S6dd8X1V1LI9YSF_2D_CorMUIgDO-GBcWYWsHXEXo__2wRuivoyFw6PA3_rVob8knpB4WUK_NrM4tTb 2yyVsYcTjjlcC0vAAgEQJcreCTZx6UfAT4tSmLBVZ8XKT1hao6 8m5GpceFDSdioyNAi-UfpnH4xDp7lO8FpZ8EbyjUy9HATThiAr5BOm0-F9xoclrfJjkxrIwU3LTEE8_fMId4WB5V61CERsTtIjQhQwz17k prHrqnRsfM1YVNExAlzVNItCblVIbwE4v2gq4ixk8vlxfssPEz eDvIyZK_Pz9SxmXOmXLWM6CEb8th-gUZLon4B_6x4yrQHHsL6JwpOU3vqY6ReMCmrorXAjHD-OlwXhHEH-ICLwDTLvQBqyLheRzFUZJ5ymwEPkF9ppeb84GYWhxmSDj-w4b5wvqDt5-9oGX1-436W2vA=w1268-h950-no

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https://lh3.googleusercontent.com/g8SxAqCAJiKTwSTA6OAm5YZ_qIGGXrdfnqxJKtoQJBqTGjE7jp 6LCASTBk4aOZblv69BUFsK0PVtveSX4BPsgEOY0M7DmYdm9oOt YFXRQQM0X3wxVtCvw2KM54CcBvUGDOOWPTfdtpopJfmIfFdALS bO2k7Ovw-hAqiRaNQKlEVzR28sNNVvXVP_sWxyD9IyQ2rb7OF2WT9M3ZG3f D0MObd8gLdgSxSukbIbF0nRrLsO_oHMoxpWNQhy1qWYuv0yzpP gKcO0sk0J5rk8luOB0DIfx7rfhboBGcz74r1v0HwZ_i5MQmrN1 Z0U5PITD1VBCyfFtbvImsoNeSCRGHGfy8HYEqcDBjHqsvAd2ha 8C2GnNezpBdbmnMojBKwR0EeqRYH09EfzG7tauWbte-sgYThdeX1Mj3CQHdFZvMkIv8RMz11Zc0yG6skKc7ZiYJvLjZk8 3UceULi_vJDfMBAGtBeh28AegbWb5L4y1vd9TusYBbv_an2Xqc 2vsUGZ1bU1Q1FGp3yePXfV712veF3SZ1iLkFyVGt0I7exKhygc Sl-RsClBZMYcPApL7PqJpUyGLgzpejCihFF12Wb-YU5KurFLGI9EQa4VTbYyk3JqKh_6kOEQ4aWQCA=w1268-h950-no

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https://lh3.googleusercontent.com/NzaAqmDZhCgUYg4QY75OJ9_XaXIbdwMNED8tAw0UrEBzYcGh47 JFXrq5dIeJvFKYHO2YrQyllfxAj6gaeg_2tK0o4gXYZS_ZTM6_ q0kBE-RmSG1FV0MGrwTc_Fws6apex5Cug8vVxrSpvZfaYzlUW7xf5Fto xe9GbiJ8uwOJyHkWr2xkqWSfRNMG463LQXT3I0lC3C05ui4238 B6nnV_pFrd8uylsfTG7Mmjxv-d9-GI5M-RLX1Y3mCm-6pkykMYOwyo_e5unoQYf2UYoZTi6VgBm0Ov9WDOzDyXXk88osU ziZGBO6Vs67vwgWtdpjhfRnskFpsmma4_wl-jNW_7sMyhlZxwhJe83nYr14QoPk4fHfjx2ywoyb4ZvWjrC_YiB 7GVAw1Mezux0R7n8BkzAESdkPwR1qrg75CZXFiNVe6MBh00xur 3x6vt46jWtZSEQlvLBPJ_sG62JYGv2uaXlaa0r8i7C00HuRlVo nmVz-u6t7Il32OEoAXJpY_ERfK_vWnKls2PxdRF9ekMej-QSAtTyYa4XHS9XqpJsd_9gXr6rW4weOSKWFPmK43bhfwVBAeX6 zpne_b_PEsRIBCENPnHuKqfQJ17zL6RP8TGyVMh8Tw8ugktIA= w1268-h950-no

[bbjones121]

More to come tomorrow...i am going to watch a movie then go to bed.

[Hindsight]

Coming along really well! Nice to see a fully carpeted interior.

[Canadian818]

Great progress! I bet it's motivating knowing everything is now a final assembly.

[bbjones121]

Coming along really well! Nice to see a fully carpeted interior.

Thanks! Yeah, i had to order some more from FFR to cover everything.

[bbjones121]

Great progress! I bet it's motivating knowing everything is now a final assembly.

Thanks! Yes definitely, the mid assembly was very very de-motivating. I probably could have had everything done last year if I didn't know I had to take it all apart again during the first build process.

[bbjones121]

I decided to build a different way for the parking brake cables to be held instead of the aluminum piece that FFR has you attach the cable retainer to. I just ran a metal strip from the chassis bar behind the gas tank. It holds the gas tank down also.

https://lh3.googleusercontent.com/Y4yrcLpVZ-sYT9GZCGvD4YXt_Omalga0xX8VLI-mfddLPtKA8_y9SRqG_ughtpQBnPZJGSbfAqCvSMPjxyeAva37q g3wgbNkGA3GrK2YnDjl9M9PYuHD3mVxQJNhwxpnYwQ3p8NIEoF vYFeLqqwXIoYTPWbu8HtPg_c0__hpXGpQPgl_MSrpxRzcbaxEv-cnk47VKtsrYx8lQoExQiMVMT5uVrqCpcl9fAz1b-s9rok1XTWL0lnt3xWKCH85R9a5ptZGIyMXI1ruwUkwbGHgxGiF 4laRZBxWK-UKQ2Qeo0gkU_k9h3tcsmAnJmZWQpbv_Z4i6pnQuGpli44n8NPP E7cs7QEEtxfKW94fijWVtUt8e-CFJzKsI_YOij5MfI5hwCUUqWwkjVp91ciKyhlGpaCusyA4k0nO QKBjTYc9GYuYDfF7m33JoS1kxexZ4Dmo6iaeWD2i0h-s4H_3A1AF8NeiRVYAsiMGfUuZJ5ttb2Myyf6j0ITLFbZmYRlq9 1Yj-24uJtCE7iijXWJ3ZB2SWs819-8_9kFswnwIzRbO8J0UIRa_gce5XdWcTsla0I3Fmzb1hWkKUJTj F4m5__GkN7UWLbEZatiiNRSROtvysnX_3C8SfEiyNA=w1425-h950-no


Here is the original Subaru parking brake.

https://lh3.googleusercontent.com/tbwByZRJznnPfjcMq882yunD0VZ63c6XlAdYaQevoVM7YIc3fc KLiOpXR3QxHXpUIxnHKMGubAbIIm1evHXSKD29Ep2T3GieLH4J ohIouverk2E9ekO-MGXJpmL4qJ8b77qCZAq17R40lDivhfweSxcLjYMpDaBMh27aUQ G0-5tvYQFpMuNzde-PlNl4TeWZw24txsPokkwJS_IZbv7cKdAt9WEkEwqYJBojRCza8 JO9ELb7w9ILnj7FvGQmblthBPETk6tvvX6x9wjKL_37f-J4KVeTOpyHEHnlT-cDO11YS6S6p275qga7EOM01ygMSas8txsat-DvMad2Zj4NWBREje2wQ1Lh5NTE4iuq63ur9pTTluilxYLybn7j iZU_lrdBzUg_CXRApXh-Q_cw0ReFllK7uIz5_a2JHLI4BleDYgdDIpb91fVD5j6qX3YpPb ZsiZLZnNMyEr74dclTSdeJIGtMAtaX4CHkZTGXEy_aXivI0Iuz 6zFF3dXytZNzufMqg4GIDI1qKL7j50gW7GiA23_Q2vn9sPtDXV mfjDrPI6KfS5hvWd4Cphf5U89l40HaN86efhFv1p3TD35ZWaZ0 kcrgGTmE2VkjLD8F0qKy2tE3PQHWug=w1268-h950-no


Here is the smaller Lokar EHB-7000F Floor Mount Emergency Hand Brake. I modified it to attach back further so I could have two cup holders. The factory OEM parking brake button/electrical contact could be removed from the original parking brake and attached to this model fairly easy. https://www.amazon.com/gp/product/B000COMNKY/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

https://lh3.googleusercontent.com/o_ZVC6ImK4dJzvTj1rQ34hkKZrksQ8viP95PuG9veuReaTxq7-ZDMhkzXi9-wPJseJjGTQy1hrHMk7GAONq5md1FU0N6Z5--W3OEgQTQK6yv8SLgGuh1y2j1k9KRlhh6Ktlr7m6xLCzFudPm1U fRKUTyifR0IUhtoUU9sH5NPG0_vgX0hqz8D8vNzL2qu9Yqnkg2 001kJqXUiPK1zUDGHrztFvRk6bG6OdkfCtFHVKBeYgw-SoNJ1dYFq3I6EDuSGisPsKN_4fuM-hXsd2HJMff745QSookTntveAdHewifA_QkY5732tCu_B_8OcGV-I99O-5AdpsEpwi8xZkceN5kOIl0I3Z2nrX1SHvHNlljcHAq8RMbqe1C Gvec4MjC0bjA29Cc3hXi30TbEolz5G8x_OJ-ZsBXrqq7HEz86DJVwjwKQiCxX3Jzbgga8Z_10zhiNo2yYzJaCA 0yPxRBrFpnI6Pii4MP-TeFne85GHOd5aAtHGlbHA3z_jTkK7xDcG2tvOio0fZBime-p_8_ExFs5_EOjhEozIegtecMXSJya1PqyDqXceVNs1w09No7cg-qU_JQotmZBn3MQAmet_kUIxFx79TmaH63tz2g0eva3J5CJzuCe BA=w1268-h950-no

https://lh3.googleusercontent.com/r8jIPlygifsQpDhvtY0D1YHCR9Rhb7XlU0wlM9QblvJelC5Zck driZ7dhYCEpBOXLy_PHZPJOSC77lsOtO2IKNqXIuaaBUi0Y45B HWnr3s8iTeDlNd3R5wUlzyjlVj4aawsk3RbqmxZdtyDh4RWICa 71vUO6D4LuWzC3ZxiqhPPOTzyiyZ6mnZJQnKUrmwoaWtsxdSQa 2DMbnyJ86qXZflw6M2rJp_bCOkxPB7i08klqOAuFZBEC3KAsX7 xCOlz5bkhQ0P4U1DMPhu6iP9v8-m7QeXNC0vOrqAZCcjEP_Ffl-ODK2YOBxwyFD0kGXLPttBUB2OiKqCIB39eglHPfnfL_-S9UksII-WFaVCZacEc14y8j_OvdK9esUA8QItU-zZ4gldAwgjjmo03LpkRtkPJ6oZRoK1MP4WYiQNsmmwekfngHJD WNT6bKPNzxOVE_6c9Q1uTyD5Dv0LGsoXbKNPICG0ddybEy8mxA ntyihrUApgFTvxytOKnAUP7cRPxtI5RBqoJhsa2srDC-6Sr9vH9dsPSZOlWSMchP8K8qBmgl0ht9iVFebzjF32EuvxrYVC rcNb6dYumqtVksTzWO-xbdAvpwXJI8Sn7xXnYeYe04-a49aIMG2Q=w1268-h950-no

https://lh3.googleusercontent.com/cJURtBkPXxb70gNdQkVJ-yyLP16xX4kzELOOT7lKORvSC1cZsTgk7QotKZeHWAWB1UAmJrd 732EhPXlqRdCUNk-Ed5dPjh6xi_Fr75hmk_UpzTGS7JC-YpcqdUe2wCgbW5LpUKx3rEKNH8nEr7149j5KM1IjwbdISJibrc WITD_Jlf0pAM7bgqoaUkD_U2CAdW4KSwkVNT8JKJObDMD8gkDh sB4jAXq4m9THByyr-uTxB_avP6ie-alIM1gwvdvcZ12yV4kCqGcMyjdglDhIG237ln3A2U6NZYXb2d0 glBeIK17_ySx9W8wa-Ru6Y-H3pgpVWCElnog6l1v90EIc3GsBn_uTFOmDsR5VL9Q6Bz3Ba4fv 6amG6sx54l1JdrSRKOP_JfDDX0O3H-oGlQXCDu__o_MOjeXkiQIAtcI59tqM-YkUnsGtqNQa_JB5E40Ncd4RLU0icMKAuiOd8B_0HzoHQ_1N7dc 4FPWQBhmKZSL8Rv_B4JyYs8hSLSuC3AeuBw6enwnzVSHfIaQcT A09Mf53QvlwxIiU25VS8sDBVP_-G15BFHXMkKch1y1r7Par5Hgu-VGxo34wzhI2H3p2kBfwHgJLzqtCXp_BN5Vzbe9cu4VrO9S9oA= w1268-h950-no



Then I sandblasted and powder coated the handle gunmetal and left the button on the end chrome.
https://lh3.googleusercontent.com/229hgWqXmJ9zaiJUPPlGrzKvEMnCAPixilNSxVfpmSW_4dptr0 3OBeE9lU4YIvQ9fYiqY-7R8eLf_i0fW97sXn09BCUS5mbtlw63VCeUoGb2olwUkD6O7kKb EF64cSSY1RW48EgQC8genS8XQ0F_Xs0KmlQOLxOTCjN4Ix_O15 0xxOL_NPLk8VMPRp5KszzRdC-WFq0mPzP4nsx32_dV3ih7TJZgJrTXwO-UBWza5N0_bz9CBuX2n5WDFkDJokUWW6XOGlNIV4f99liXg7DCf _K_-2GZ8vGTQ5RY6DjWg1At8ITij54Cb4wKMaKTyyWYK4N9cGPhN4O qIjynQYTePe4odxeoYRB8evebK8MaLj4JXDdLbCgkX80G1gjTm 7F96w61CdBnrCLZCj52p_ebgnsWotnEv0zVzswNHRVXssj4-4G9h377UcEIa1ZZMT0ZQVlefQ_V7iJ9XX0dcc6xnfoY403XZqN g28ca5YAhwbCOJuqAsqJEwayQm_hjfBft2nZYXczW4EAOCwu1c 2qHD-9eeWkkX3F25X31XjPfrYcKuxnvQShoktuJNV6v3ULLY3-gnRtNKdXrpMoO8FtjDs32XphfafVvIDkl7pXGexJP_w4sOHJh_ g=w1268-h950-no

[bbjones121]

I probably got a little carried away with gauges, but whatever...
I settled on:

Oil Pressure
Oil Temperature
Coolant Temperature
Turbo Boost
Air temp in and out of intercooler
Wideband O2


To get all these cables back to the dash I bought a multi-conductor cable so that I wouldn't have to run every single sensor individually. I also got an 8 pin waterproof connector so that I could disconnect easily.
https://www.amazon.com/gp/product/B00NQB9XJ4/ref=oh_aui_search_detailpage?ie=UTF8&psc=1
https://www.amazon.com/gp/product/B002ODEZ1G/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

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To locate the gauges, I sat in the car and tried to angle them to match the curvature of the steering wheel so that I could see these four main ones while driving. The other two gauges will go down on the center console bridge.
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[bbjones121]

Almost forgot one of my experimental systems. I am using the Vintage Air 66005-VUZ-A Gen II Mini System for my A/C and heating. https://www.amazon.com/gp/product/B002VW7FVC/ref=oh_aui_search_detailpage?ie=UTF8&psc=1. The problem with this system, as you may have read elsewhere, is that it comes with a valve that is either open or closed. The Subaru coolant system must continue to run a loop to the coil that is inside the car. So typically others have replaced the 2 way valve with a 3 way or run tubing configurations to make this work.

I have a theory that the loop tubing that FFR has you put in the top engine coolant manifold to the smaller suction on the water pump causes a drop in coolant efficiency. If you own a subaru, you know that hot air is typically always coming out the side vents. This is because the coil inside the car is continuously dispersing heat. In the FFR, there is nothing to do this.

To fix this issue, in my car, the smallest diameter tubing for coolant is right off the engine. I used the supplied FFR corrugated stainless tubes right off the engine down to hose fittings, then into aluminum 90 degree bends that I welded to the side tubes factory five provides. From there to the radiator, the inside diameter is larger. So I welded barb fittings into these 90 degree bends back at the engine. Rather than installing FFR's U bend tubing for the coolant, I route the manifold connection down to the new barb fitting in the 90 degree bend going to the front radiator on the right side of the car. The suction of the water pump is connected to a barb fitting in the return 90 degree on the left side of the car. This means that even before the thermostat opens, there is a continuous slow flow of coolant up to the radiator. It may take my car longer to warm up now, but I am hopeful that my engine is getting as much cooling as possible.

For the vintage air HVAC system, I am relying solely on the small pressure differential across the radiator to pull a little coolant through the coil. I welded another barb fitting in the right side coolant line just below the HVAC system and installed another barb fitting in the left side coolant line running back to the engine. The Vintage Air valve is installed in this circuit to close and open as needed. If I can't get enough flow, then I will buy a little pump and replace the valve with a pump that the Vintage air system will turn off and on as needed.

Please don't judge me on these welds. I was in a hurry and did not properly clean the aluminum the first time.

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[bbjones121]

After thinking that my stock headers where cracked, I purchased some STI P&Pned headers. In this picture you can see my original 2006 WRX headers below with the UpPipe attached still and the 04 STI headers above them. The geometry is slightly different. This is to accommodate different size oil pans. Thankfully, the STI headers clear my WRX oil pan. I do not believe that the WRX headers clear the STI oil pan.

https://lh3.googleusercontent.com/XWSWtHMCAypDL6EkaG4UpOcmiIsZgWiIZAltzEkjpMzJV7Tuyw GeCKcdiyoMx9GfGkAAgIjlgSgUDLidOA3GMtbM5RiUbKgil7hk CJEyWyCHEI-i4V7nBu0le0uHo4oTVHjfcNlm4SUf6r237KCcFoz3HZuCK8bAr _MxsaZ0yaB14iT8-_j2FH0gNoqiso-9bTLvlJdHHPy-1swy_TNZtOUI0_4V3EiHXTVaJ6iyETn3BIQ6DPdTiEnD4L1hQq Jh9bs3j3_fW0UHyRO3JpEDQU0bxeu_YAjTcs5tDVkGljyl4EIO bpZLDCYJefBO0m9nk_y_cQOwGgHJaYW3ePclkAeLIaPhlXCcd3 tOOEx-mPeNPFxIxC_llkLxJHyPglHSXcUD64vLWxAFAktKLxEHa2-k9pYvva9ICVvq7MKl7qRSdHYGtsey3gmosFxuQ-6Kz8_vUW8t9OwqAEbA2XB__sGOfCjyv1lUpjBpInANkZo-J6QpsiXq_gpwQku6SoPFTKInoqolpE6kIwvtA9FASApInf3v6d kkLPhx2WVkuKxv9CTVrffD1efFCaDDya0LJJ6aXBFTt44SXElh xc8rX1E4qUv4XeshEdF-S8C_sVHEvHUY22bU8g=w1268-h950-no


I decided to get rid of the stock heat shields and wrap the headers. So I ground off all the tabs.

https://lh3.googleusercontent.com/HCSwTmnVNuPgLJ1gUvffsy-55ukh_-NnFomzvdpI3-d9ibdcJF0Hgm5uQzwNbGb112BYQOTXRLviFgEbI5QjBKmdWzv3 tImCmuygwjCFmP_KyAA-UxcHwFNJesJX3Bru1_8MUF-aw1BHaANMvt_B4YvcvFymz1KrDx8-3-mpZK4x6QcHnX_ENRffH3PqGHoyD4t03iLchkzTfI-9L7TagJMci702qTDT2KuOYCSHo5WUBO_7cMxXXQ74ThFAasVYo z5h_ybG6e_0nRs0t8318B4sBmkj06-pZWwY-YDjpSa2Ug_W4Hazti1_-RRN7XsDD8daFsiHwGxYCBBttTVU3n8RmbqIBceeiZfSsY-wyFSZvZEIMGow-MTZlshAj2O23amMZ6s900Yg672if01s-EVn8RWG4H979i3nxxooe-UO_kSRWmVxJf1rmyRgUDdLoO1VfPwXP0R3jBBy5jqp_0dBMe4f dpMB2c4svEUxL438VG-Fs2WWbyMQ9BEIGjClEQUHC03Hs0vXXEn0GMwqBRSgoWNo_y5_J 8zRtlCj0CJdLIK0a9b_APEg8DiggahT2hzTAJhACcnsBn_zF__ i1h-CTpdRAkc5h2YMlAJzaLFvMIHhrKdZCA=w1268-h950-no

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[bbjones121]

Since the registration process takes so long for a kit, I decided to store my hardtop until next fall. Plus I wan't to get it painted before I install windows on it and I need a windshield for the inspection. I purchased a jeep roof pulley system. It was expensive, but saved me the time of finding all the individual pieces. https://www.amazon.com/gp/product/B005AUH8OG/ref=oh_aui_search_detailpage?ie=UTF8&psc=1 I should be able to back my car in and lower on top.

I also had to modify my garage door support to allow the hardtop to sit perfectly between my lights. Eventually I hope to get a screw type garage door opener and a high lift track system.

https://lh3.googleusercontent.com/e6i8c5HT_g9EYSwlds_DHNO-h7Cw0Y0ulIpzrocnjy1ShKmQwqfUNxmVZODPHMYy5lF3SOYJ3_ zvPDX7zKdaxFYWok8VGr3Z8jWGM0VUZuXskxhzVlkqn4mUB9UP DAZYxL9BWLTgUaN0_WXPdVPNbn1ic9UubbxqBoUDufhrHQHUBe CigEmo-u7pmJH78zWZgQQ9BXDnvfybYf_Mvt4b5M5vU6L5pF2syZ_Y1Wm oQ5w6WK5iFS62h8-_qw49_aYR4XAejfT417OijyUdWfVLOZSCt8FGv6h2rj3oP5O3i 7_TVW3xPMofI_CrvG5E_xBbwFcfokP_ssAIE3-kVjJfpbs7QEioPolsa2TRvXP-bjkC_0GUBTk3WRPYyKmcOtTHdoXn-EkQ6fMsfZDGtRe84yhxSTyBZHVjknw-kMT-vcWdU7ZIB0AXl0ilJs-UfdUnawBay99sZ8ol_KfiCfABpfBhUI6LXR6aqJXTfBtO3yUao 4yQBm8PYuB0xCdtuaTDENQbEhyjipyrnKmCtrAcnU7831g3kit hUffUwzq0_czq3_RlvPMuDSACcrZmcOu9aHsvc6yv6Zk-czpUL_sBBLOgmkLEB8UUkgMO50tCwG3s4L2KTPs9ag=w1268-h950-no

https://lh3.googleusercontent.com/W5Lxppb2KsYFQdnhcfnqTzsl3IfjGARevZTTIe4qy6tMpseRfB WaTi1kUsH2WCZzPbQvrDu-IeHrjNsw0lM8ITvY4H7IUzP05SgUVk5b7ke0uH4bMQd0bfq6UY 4QZNTpIY3FGaTOshZDHnlqQxIneHDakZuhD2A-KKUKw5sZpa1ICWMtMkwcpfU6j1netGiCBKiHSCKRAtKSfSLyOR 4xKxc3ZMQH_kURoVLp4gpy5pZavqeDjXroCQIAB1xJc29htNgW nFw-ALIqtJeLD2hhUPdimN880di-jqrDVm2lijTy6_n1DT7b89X3CU2nPDbMitpup4Ods4GqqqHLOH 5HU102KblpDMRQtKmQbHYmiEaS_ytN2KCM1Atf2ZLclI_Antwv V1SQfj8O8KVwJ74Pg2BWiTHK97Es_mCckjR5Q8zZK5JpymD7Bp SjKnJ4sKaH8_nVM7txUgNiSpVEEFvInutp8O2vwawEimnD-hovQRXLYtj2t339ZeFigi160XkxKVFFAsG-zBdHOv3bgyWI1T2gWXNrFDAyeOpO5zfP3-ZpNjhbDy8yVlasFZsGZwqJgbbIvBWfj6kfvPvpbMTAAH5_EuUl 1IdlVcOTBwXuPsSp2I7--aY5Rg=w1268-h950-no

[bbjones121]

I had a hard time trying to figure out where exactly these should go. I wish that factory five would have provided some guidance on where they weld them currently. I clamped them on and test fit everything and this seemed to be a good location.

https://lh3.googleusercontent.com/Sd0Pyqycli74avZlr8zM6DD_53xlTs5rIqv-hJYu2IWRtPq216tSYqeHAHhl9TU1oeqSRSWxvOwIyh76o7h7hc s-To6X1hwMf34kkPhckJYErhnYpbkIpoXrRAvCWrf-bx-OlSbECUTW7ocDiXtD0gxqCR9dp1sqYmZNICJt4eE32Lmsn6_cg P12X16YkIx9lSOuRklkW9epWaDDA7GsHN9ovGAD1OFNO3HirFx SHMf2i1qwuNEDeQk76gKMDG9gH1VZ1MhlUCRlpcOam2NxQoIyx qjenXRrwBsHvAImM3VSmKUfgM_KGG9V64-1Hb875f80YTLWbgO-i9_fBFCOLxsg9LhtUwMZ8FVwvEMmMpoVImzh8sFob65vC8G-PvdOFbVh8GifUYVv8Vy8T0CjnTee7KzMfY4G7JJG_Vp9oROOIO OGm3qFcEpPXiTMzY1MZOVJ0PU8W8RD2OnYuG9n6uN7i478clj5 6PR63avuMmIBbgMvqkEynHqh8UmL4pGgiKkFKHCfG0zFTlZKCV y98izFjTPRj6rhCXc2wjcy_zx4ku-BALuMkKJ_VPqGdF8O17cp5gmB8Xw0hXqh8z-d-GCF7QtsrUdwmvF10zeinpsnlpWG7Aa_vQ=w1268-h950-no

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https://lh3.googleusercontent.com/2n5DqfC9k3f6rnThxeqZBLnnJ2gXF9ZmRtxFy03LkgYHYx0B0w aD0ounT3wpDmmJ9MjV2wBJ5S4Em73fYjI_qNKd4n6K8TOJjZmE EglrzP9jzbvikgDNoTby3dGqHuCCSdJqztfh58ZpkawAqxVj46 PRm09j6UbS8xVuQPgTeNDZJULIu8P2PIc8bOz-yZE8D_w1LHz8-aDHRRoL0zrksfNCbOx1yBwGv2SNmXgLHfljzElCaTc_eW56bAE u0CM8Xowfw92o4Qb-KpiJ1GZ3pk1uySnbOPIRQD542iVW_1O67M5M8nn-1mrg3ht32WwE0r0Cu69Kg4oVvJpo0TOSy77i22vx9JWQZ1K9FH ppda_qPaR63eGGaf1qimagRHO5x6E8TQfObwCFbpWy6Vr_Q31W x6NeEi3jSAUFS1aVxt0Sz41p8S2ClWGALJeSUu3usPXCnIy5NF 1yPwcBA4LO1_7TdY-aOtZXo24bzSkzW600MaV-piGWQTs7TvFjiFa55cJxmd3m8Ldb4NmKApFqdWMuibnas_bpB8 nzpDdM0RtkB-C1BzNaCwwdUcll3_SU-h5iPW2FEaRNQbuszgSRF0tGkMee62zxttVABT4qh8xik1mCZ5e WJA=w1268-h950-no

[bbjones121]

I painted a black line around my lenses. Don't mess these up, they cost 90 a piece to replace. I highly recommend that you test fit these to the body first. They are not the exact shape. Sand the edge to fit evenly and use a heat gun to get them in the correct shape. Use something to press down on them to shape them properly before painting the line on the lenses. I used these suction cup clamps and they seemed to work very well: https://www.amazon.com/gp/product/B000MQX4T6/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

I ran a tape line all the way around the outside of the lens. This marked my line, then I ran another on the inside and removed the outside tape to leave me a consistent width line around the perimeter.

https://lh3.googleusercontent.com/oueI0UFyrntFP9u8zB9uTg6ObAaZb521wGPOk0BANNmnMTXLNK 89GJAhIjKBPuGKjRwCLSgDR6cPFugqsbvkf3Cn_bXHV7kqxA7A ZEo-SPBOLNkwbQN7o17XCD7t3FeCaQMv9xOWuBP8TsQ8onZ2bp3YDE hmbaMwkcByBQpBfizE0mOD4j3TUDcjthtIg6Fg9oaEQEdeMhA3 HE3-iTVtrtxjBULHYqHK0lxJ3lhgC8mhxeJET1DvonVvyF948g9jYn gmjUbGDojX6ceGEy6i8NGohk6jmcY3_RhYVqKLOhQeMOS7Q1Su jq7vGhSjmnxoyYqfQEs7KdcYPUum12t93Bg2XV8jw5ylUiLdcs WH3W0TfiqdoM8TZcw-EwTpcM5xtHESTAnygz6z_DAoLjXrNPPgY-oF4tzUGHqROm6ZN54dhhtJ-YVNUvJf5_p90H2SibYjoXwnf4J9I9FhGutFaoHNPjcmGmB_wnM 5JbcAxKwLsKPpQ9eM2kShIlW1b5tEzBVtYNr0rv2ZblYGYlhEt V2PpBvJfI4kHiEks9d6q3Wo5OIOIJsXJlsT2pcdYIdyDI1Hp5h VQPDH8Mdit_zpSY8iCKX4Y5Q-PPegjJ5Cdv4F10Xgq1xyMQ=w713-h950-no

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I wanted to make my headlights serviceable, so I recessed 8 screws around the outside of the lens. These were kept loose. I purchased high strength double sided tape to install the lens so that it can be removed later. I will add non permanent caulk all around the lenses soon to water-seal them.
https://lh3.googleusercontent.com/1wr4RuApu9SOIxwhxiQua6RV1UTRwCL6BdUOOFEJeozt9Fl9I9 AA12u08aNZLg_ttzvym2ZGTmgC7k-kjuLe2yOEvt5OztHYZY1cHMuXCY5ifpMgrVkIuEqX0IJKhSSnA l15MVaBzN-XccLvfcePJgSG-dNiG5DbW6cDuGUkC0uvAz3Whj8uZQb5x0255CGP9cTg1nx9i__ orsrjqQrYM9_2MZd8way1knNKOmTDVNpgBVWnXCZylltr8Cz4M CFbS3mwg1HfJS1eegY5b957MeYYEnXpNa0gQlhMEpyQtXUClTj sTpnT-6BrvvUiAiaC6SmVksBpgg3RdrENcoMsXjYFWHpbWZnLtdICMed 3KKzQkc3sOQIahedLOS8y9IKF91-1_2SC-dN6hbnOgvU3WZjMpomBgTBYrjk2Mr4I--OemgqjyTUZBxj8ma6B1Nawy6NUYUTSSunNcH4o-0oXJltYh4a0cOCl86tpRFPhN9Xy79tkLjGBQJZMhf3YbJySxdt wJBFtQGIyqHlSQgNHH8CoomL75lFscjiTlapJpo4lyRgSoXZy0 JHXC3i0Nj9nFbFpwiCzbeiQBHybyPuRklGmJ8GU8z_ShEEeods PuCDOOpua8QmJbA=w1268-h950-no


I purchased Eagle Eye LEDs on amazon. I was extremely impressed by the quality. I had to pick through the bunch of them to find the best. If you tug on the cord, it will move the little LED panel inside the lenses. I also purchased these little connectors so that I could remove the LEDS easily later if needed. The connectors are small enough that they fit through the LED drilled holes.
https://www.amazon.com/gp/product/B018IAZLZC/ref=oh_aui_search_detailpage?ie=UTF8&psc=1 https://www.amazon.com/gp/product/B018IAZK1W/ref=oh_aui_search_detailpage?ie=UTF8&psc=1 https://www.amazon.com/gp/product/B015A6ZOA4/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

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https://lh3.googleusercontent.com/1Rww8yCnsRRtFOwBarRqSxaEnoOQo1b8gPmxEcw3fZtn7DbBO-JSBQzK8O7UqmxNh8-Sx25dDsTOVP0YxlyiItGDUcdQlybGRu8TkXmgZ9yNSjlPDhzbB Lk1ooOpgei8EOMN-v9Et_tDrECrAGkmX5uVpiv7D10DHj0Tr3gbybuLo5WgMsbbqoo giX1WQ_wX_pMY4fgkrAtSlgN_gIQTJYN9-pKSe_A8rv8n32TdXW2JUhpCpUiKeTJdy7UVjmCgSWSuipiAEV9 UH1Scyv7sa86Py7yznk6gnHLFJefr2MoFuf3-sLeM2MFiiUcnRP_BAzRTVRhyVHG42fw6uqbPy0vyCAVJuPP0Ay qtPP9Q3tyfvxPDMkl_fqm9wwngB89IgssADgJqFstw8UeA6J2f qxyAbW3mab59dMjhvXcOueS6hBnvEhrjuJchojvBca3luvlBXb 4u8iWj5NZBhCs6pdlo2nz1R150ktOqfxgdL88QHvv20ecYKTdd LwE2hMVt8AYOabclv77tqpBIsO3dXGrQexBIHocB6QCnkJX7xb 8nFdoyPXXbmptbMRLHsVSyqrRZ0M24wwWY6dgqDBtdG5BRKNFu wkFuAvt_Fbe_QSy9EJJ0JuEaKg=w1268-h950-no

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[bbjones121]

Even though Factory Five spent a lot of time creating these headlights, the rotation of the projector cutoff line is way off!!! I do not believe that you can adjust the cutoff angle later. Before gluing the projector into the housing, get a dremel cutout bit and make the three projector mounting holes oblong. I bolted my housings on the car and held the projectors in the housing while on. I could then rotate the housing to adjust the angle of the light cutoff. I used hot glue and coated each of the three projector mounting clips and held it in place while the hot glue dried. I then took the entire assembly with the projectors temporarily held in place off the car. I used plastic epoxy and coated the 3 clips. I had to remove a little hot glue from one clip at a time to get good epoxy contact with the clips.

[bbjones121]

I also used windshield super fast dry urethane to fill the gaps between the rear projector mount and the housing. It can fill large voids, you just build it up pass by pass.

https://lh3.googleusercontent.com/FxXLPT2cddxTJE_AVDtfpu_cnOyeKdQDPqUp0qOh5JImoiz-WdiHxtkLy9ZLC4K0tM8Ud8595KG-SHytJnjLtXMnQmnvHhfK7to5SOVQoMf9lqENhVAQDgyL9HeUd8 n_7vq8ogfex_DdLhXYX3wC2W87b1ATcL3idqNFm0lGOt0YVDCV A_S65_DVNiaJPy1uIcV5kLHbVgPlG3-BwYadNzGbCF92vToIk1YEimPRAIwNQb_PUTzPqxq-ggG1DFhRiUhHtsjY-JOkjrVO7ZY2XXkUPfvdu2aUpLX6ibf_XN1VK49moSw1zTvQ2Ui-xlr6blxxNoYXqiv6pUiZSQaQGxj1twM3Jtmu1KtF0b5puuHJLT vfPjz-pXkl54HX22mMdq3_AqvCkrFJAd7OcBzntAxGL7UXqqXr4q6Za7 eGbhq6HSB-E-qivVhQHSGaazn-5dSdVxujLML0fXExcMiDIJhyvyp8Nl484wI6ANX8GerCWzS3bP 431U-BnVzM8VHJgwsBLWhTayCrpRvGP9X_RVNkSSQdeKkfwR0DDD53_ w6QxUiefnYGynVgjVauoU3coYQ13eM9P9X5sEIz9wK0q44hKo_ MhhikEB-UAeviTfW0UexSLlxOGQ=w1268-h950-no

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[bbjones121]

Geico offers insurance for kit cars! You will probably need to talk with several different people, some will send you to home owners insurance group, others will tell you that Geico does not offer insurance for these cars. To save you the trouble I went through, ask to get transferred to the classic cars group. They know exactly what this car is. The coverage is an agreed value with mileage restriction. I got 25k with 6k miles a year estimate for less than 400 a year. It sounds like they third party it out to American Classic insurance. I don't really care as long as I have one servicing company for all our vehicles.

The unfortunate part is that they will do not have temporary coverage for a non-VIN vehicle. If they did, I could have gone to the DMV and gotten two day temp tags to drive the kit car to the state patrol. Instead, I had to rent a U-Haul car trailer. FYI the 818 is a PITA to get on one of these!!! I had to cut up several 2x4s and keep placing them in various places under the tires to get the car loaded. Anyways, I finally got it and made it to the State Patrol just in time.

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One look around the car and I now have sign-off by the state patrol to apply for a VIN!!!! Now I just have to wait another 6 wks for the VIN plate to get created and mailed.... :(

[bbjones121]

I now have a little time to get the body ready for paint. My color scheme will be Subaru World Rally Blue body, Gloss black (including carbon fiber bits) accents, Matte Gunmetal metal components, and a touch of bare aluminum here and there.

https://lh3.googleusercontent.com/2RMq8cVCgmIYvt2C_86sLqz4l31ufwCtuFHh0ro5kumhreml_4 bco82h8r2KL3iAaaZHa1O-GvzXNbLMrtAhGpuOf52OFwwqzysnSmWoqbcrfc1Yk6hrq_1Usj CSnYCic9l0QdQPB7hTU93cti1o2-FW6d3bnQvyM0ilmwfti5eNCxObqCELqjCd9XNL3-ZpSZzVnRGrOyJ-ntXxUgLc2ScJHU_tldHnmGhfk83fMnuRx4CJ39jOIS2yy0KMmM 4Na5Brp2Y7U5DjT_kb7I12d9gRVG90AzCamSTEs1B3WikbQ6iX BrqRk61unDTh7DMV9n6BDbBPOJ8hJol1AZVEol49I2d0yD0qtf UweG74xX7V6kC4u6lbt73G40kG40UaEPl-TB6SEf41WHWgq0FVgZkM-jnmLnpeu7NJKG-zFT6mSrVJua9fuCcCfGruBKYm9F_1gCMEuHhxjfCof5LniC7Qp jnXKo-2aG5wqcA0vwr3wbGbGS-pW2FF9CpiAIq9Z6ipjKgvHCz1W31haKclHVF5xrGFH2WG2ax8D UXD5DG3ijkbVFzPKV8UqE0tjXJccXDE5clB2b0A0_h_POTSMFA bY4fhux9efY6IeGl6Fs2bSW4Mnj_HMA=w1268-h950-no

[AZPete]

Your update has included several creative mods that will help me and others. Though I've completed my shifter, E-brake, and HVAC coolant lines, I admire your work. I also found that it's necessary to paint the headlight lenses - carefully - and just ordered a set of the "Suck & Clamp" clamps for other projects. Thanks for spending my money! :) My only problem with your post is the empty parking lot at the DMV. I'm jealous because my DMV had a line of 12 people at 7 AM all waiting for inspections by one slow-moving, grouchy agent. Very nice work and great descriptions.

[bbjones121]

Your update has included several creative mods that will help me and others. Though I've completed my shifter, E-brake, and HVAC coolant lines, I admire your work. I also found that it's necessary to paint the headlight lenses - carefully - and just ordered a set of the "Suck & Clamp" clamps for other projects. Thanks for spending my money! :) My only problem with your post is the empty parking lot at the DMV. I'm jealous because my DMV had a line of 12 people at 7 AM all waiting for inspections by one slow-moving, grouchy agent. Very nice work and great descriptions.

Thanks Pete! I wouldn't have known where to begin with some of my build and especially the HVAC if it wasn't for your extremely helpful thread and guide. I have gotten some great ideas from your build as well and will continue to since I am not complete yet. I was extremely thankful that there was no line at the inspection, I would have had to reschedule if there was since I was running late. I believe that the county office will be a different story when I go there next.

[turbomacncheese]

Oh man, what a great build thread!! Thanks for the detail!

[Frank818]

Really looks like a Ferrari (rear end, color, style and 4 tips)! :)

[STiPWRD]

Excellent attention to detail and great tips on the head lights!

[Mechie3]

Headlight screws were kept loose? Why did you do that? How did the bucket get held on then? I'll probably end up doing something like you. I don't like the permanence to several of FFR's solutions for things that will likely require servicing (like, an LED dying). What tape are you using?

Thanks.

[bbjones121]

Headlight screws were kept loose? Why did you do that? How did the bucket get held on then? I'll probably end up doing something like you. I don't like the permanence to several of FFR's solutions for things that will likely require servicing (like, an LED dying). What tape are you using?

Thanks.

You could probably epoxy or fiberglass the screws in place like some others have done, but it makes getting the nut off the back very difficult. The screws on the outside of the headlight buckets are not perpendicular to the body, so it prevents you from pulling the bucket straight back to remove. Without significant modifications to the back rim of headlight bucket to make a nut sit flush on a surface, I think it would be nearly impossible to pull the bucket straight off the body with 8 permanent studs.

3m VHB 1/2 wide mounting tape is what I used. It fits the mounting lip edge perfectly.

If I need to remove my lenses, I just run a razor blade along outside of lens to cut a thin bead of black silicone caulk, then just pull the double sided tape off. I can then still use a screw driver topside instead of trying to get at a tiny nut on the back side.

Just FYI. If you need to do minor touch up or replace LED lights, you can remove the projector easily from the back and get a small hand to reach in.

[Mitch Wright]

Nice build and the car looks great, just in time to enjoy it this spring.

[bbjones121]

Thanks everyone. I actually got a VIN rejection letter Thursday last week, the DMV forgot to include a copy of my $3.50 fee receipt and the form from the Colorado State Patrol was missing a comment in the notes section stating that there is no VIN found. Thankfully I didn't have to go back to the DMV, I just directly mailed it to the state office. I just hope it didn't put me in the back of the pile again.

[bbjones121]

I was upset at first about the deficiencies they rejected it for, but considering that nobody at the DMV knew what to do for a kit, I should feel lucky...

[Mechie3]

Ahh, loose meaning not epoxied in place. I thought you meant not tightened and couldn't figure out how that worked. Thanks. I think this is the route I'll take.

[Shawn818c]

Awesome build thus far!

Just one thing I noticed. Wrapping cast iron manifolds is not recommended as it makes them more prone to cracking.

[bbjones121]

Awesome build thus far!

Just one thing I noticed. Wrapping cast iron manifolds is not recommended as it makes them more prone to cracking.

Thanks. I am hoping it has heat cycled slot. The crossover pipe is stainless ceramic coated I think. I will keep the spare I have just in case.

[bbjones121]

Ahh, loose meaning not epoxied in place. I thought you meant not tightened and couldn't figure out how that worked. Thanks. I think this is the route I'll take.

Yeah sorry that is what I meant, not epoxied or fiberglass in place. Way easy to unscrew. You have to work a little on the countersinking. Some are angled.

[bbjones121]

Been awhile, my car is tuned and I am having a blast with it!
I have lots of photos to upload. Hopefully I can get them done this weekend.

I decided to go ahead and attach my rear louvers before i plastidip the car. It isn't going to be that hard to tape them off. I powder coated the louvers gunmetal to match my chassis and wheel color.

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[bbjones121]

I decided to make the hood louvers removable since they come up next to the fiberglass recess. Without them being removed, it might be hard to get a good paint spray. I used small rivnuts flipped over and fiberglassed them into place. The washers are to allow some gap, so once the fiberglass hardened and I screw the louvers back on, I can make them tight.

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[bbjones121]

These fit perfectly. You just rotate them until they cover the entire headlight and then mark the edges with a permanent marker. Then it is easier to line them up. See photos.

https://www.amazon.com/gp/product/B002BHSA8O/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

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[bbjones121]

So the factory center console does not work with the upgraded shifter. Plus, i wanted to give if a better look with a cup holder or radio. So I cut the aluminum into three pieces. On mine, the aluminum piece was wider than the chassis steel. If I would have bolted it from the sides, it would have bent.

I cut the top off the supplied aluminum piece with a little of the rounded edge still attached, then I vinyl wrapped it with carbon fiber. It looks real, especially with the edge that bends down on the sides.

For the sides, I made them longer to go all the way up to the front firewall and riveted them in place and made the top removable so I could access everything inside easily.

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[bbjones121]

I decided not to take the center console all the way to the dash. Gives it a more open feeling and helps my HVAC system disperse better. I may end up putting a lock box or something down there for insurance and registration.

I used various extra aluminum pieces for this...

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[Jim Haar]

Really nice work and great build posts !
How do you like the SPARCO seats? I am considering
the same.

[bbjones121]

Really nice work and great build posts !
How do you like the SPARCO seats? I am considering
the same.

I like them alot. They can slide forward and recline. I made the rails so they tilt up going forward allowing the cushion to go over top of chassis bar if needed. The recline lever is tight, but fits. It is nice to be able to tilt them forward to access behind the seats.

[Jim Haar]

Sounds good , did you use the Sparco sliders ?

[bbjones121]

Sounds good , did you use the Sparco sliders ?

Yep

[bbjones121]

I purchased this 3d plastic mesh on Amazon: https://www.amazon.com/gp/product/B01BR0OEOE/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

I routed out a groove in the back side so that it would protrude out past the back side of the cutout to give it more of a factory look. I sprayed black rubber paint inside once I was done.

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[bbjones121]

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[aquillen]

BB - re the grill material from Amazon - I was looking at that for the same purpose a while back but had not decided yet. Looks good but wondering now that you have seen it in person - do you recommend it? Thanks!

[bbjones121]

BB - re the grill material from Amazon - I was looking at that for the same purpose a while back but had not decided yet. Looks good but wondering now that you have seen it in person - do you recommend it? Thanks!

Hey, Yeah definitely. It looks great on person and it can be shaped a little