Andrew's 818S - LYTW8

[Frank818]

Self clinching studs! Great idea, I'll try that! Those are freaking cheap too.

Great idea again on blocking the front of the rad at the top. Will copy as well. lolll

[Hindsight]

Nice ducting work! I need to do the same this winter. I'm going to start from scratch as well since the FFR panels just wouldn't fit on my setup. I predict a lot of cardboard in my future. I'm looking forward to seeing that hood done.

[mikeb75]

Can't wait to see the hood results! Very cool idea to try bending the vent cutouts down.

[Aero STI]

Some progress was made on the hood

http://i.imgur.com/tKkDrChh.jpg

Foam mold

http://i.imgur.com/DRqlVrsh.jpg

First continuous layer of perimeter glass

http://i.imgur.com/MPZvuUHh.jpg

http://i.imgur.com/wF8Feajh.jpg

[Scargo]

I like it. Nice design. A lot of work to seal all that off and maximize the flow, but I'm sure it will be worth it!

[Aero STI]

Thanks! I don't have an enormous amount of time into it. The finishing work to make things look symmetrical and smooth is going to be fun.

Here you can see the beginning of the center rib.

http://i.imgur.com/V7tdlfTh.jpg

Also, I ordered the Kia Soul fascia so I can do the Rori style rear bumper. I want to get maximum airflow out of the back of the car.

http://i.imgur.com/TZucnpvh.jpg

[Scargo]

What I am thinking about.
62513

[Mitch Wright]

Nice work.

[Aero STI]

I wanted to make sure the openings are symmetrical. I made a template of each lower opening and they were almost identical, but one corner was tighter. I took the larger template, copied it to two pieces of foam and made some relief cuts to get the corner back in shape.

http://i.imgur.com/pKOL5HYh.jpg

http://i.imgur.com/qARuuCoh.jpg

http://i.imgur.com/qiPzyQgh.jpg

Added some more fiberglass

http://i.imgur.com/bCX78gCh.jpg

[Hindsight]

Looking great.... I can't wait to see the finished hood. I may copy what you did. Better cooling and better down-force if you route ALL the radiator air through the hood like you are doing.

[bbjones121]

Love the hood vents. I really wanted to do something like this also. It looks much more exotic and less kit-car if openings have a dynamic look instead of flat with cut openings.

[Bob_n_Cincy]

Like your hood vents.
I'm going to try and do something like this gt40.
Bob

63058

[Frank818]

I wish I had thought of that to precisely cut my hood vents (flipping over a template), in the end I managed to do it precise but it certainly took way more time than using a template for both sides. Good tip.

[Aero STI]

Thanks for the compliments. The thought crossed my mind to make the vents look very similar to the GT40 style. However, it would be a major re-sculpting.

[Aero STI]

I installed the S2K mirrors tonight. I really like how they seem to match the body lines. I also put a thin layer of 3M vinylester filler on the hood, added some additional reinforcement to the driver door panel mounting, and started in on the passenger door and door panel modification.

http://i.imgur.com/IP4rl9nh.jpg

http://i.imgur.com/FJFs2kTh.jpg

http://i.imgur.com/d8rqloNh.jpg

http://i.imgur.com/27tp8gch.jpg

[bbjones121]

They look good.

[Canadian818]

Great work on the hood!

[BC Huselton]

Great work all around. I know the commitment it takes to cut into things to create a unique look. Back end and interior really a lot of work with major non-kit car impact IMO. How are you finishing off the front of the door panels where the dash intrudes?

Foam and Glass can really make some fun shapes.
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632766327763278

[Aero STI]

Great work all around. I know the commitment it takes to cut into things to create a unique look. Back end and interior really a lot of work with major non-kit car impact IMO. How are you finishing off the front of the door panels where the dash intrudes?

Foam and Glass can really make some fun shapes.


Wow! Incredible customization.

I actually cut the dash so the door panel intrudes into it. I don't think I have a picture. I plan to make a conforming fiberglass end-cap for each side and then cover it with some matching vinyl.

[flynntuna]

Lovin it! You have some great skills and a great vision too. Can't wait to see the final product. :cool:

[BC Huselton]

I messed up a dash trying to do that...cut the dash vs the Door. Could not get the glove box to work and the driver side lower panel to fit very well. So made an indent in the Door Panel. I guess this is the trade off for a more OEM looking dash. Still a good move IMO.
63287

[Bob_n_Cincy]

I messed up a dash trying to do that...cut the dash vs the Door. Could not get the glove box to work and the driver side lower panel to fit very well. So made an indent in the Door Panel. I guess this is the trade off for a more OEM looking dash. Still a good move IMO.

BC
All great looking mods.
I be on island with our 818 in June. Can't wait to see it in person.
Bob

[Frank818]

I admit that hood looks awesome. Too bad FFR didn't have it as an option...

[Aero STI]

Passenger side door panel is mounted. I probably have 5 hours into it. That's half the time of the driver side to get to this point.

http://i.imgur.com/koNQx09h.jpg

http://i.imgur.com/pkRzjV1h.jpg

[Frank818]

That is really impressive! Makes the interior, uhm, more "cozy". What is that door panel from again? Subaru?

[Aero STI]

It does make it a bit more cozy. The armrest piece is actually very useful. These are out of a Subaru BRZ.

[Aero STI]

I test fitted the front street spoiler. Is anyone running it with the new nose, or did you switch to the race spoiler? I don't love the rear gap before the wheel well.

http://i.imgur.com/gK3rHVGh.jpg

[Scargo]

Looks rather puny, but I guess OK for a street car.
Was thinking of you when I was at Daytona.
63596One version (not shown) does not have Gurney flaps in front.
63598

[Hindsight]

Andrew, even the race spoiler doesn't go all the way to the wheel well opening if you stick it out 3" on the front side. But yes, it does seem the R version is deeper, but only by maybe 3-4". I have some pics up of mine and you can see a gap between the wheel well opening and the back of the splitter but it's not as pronounces as your pic with the S splitter.

[Aero STI]

Looks rather puny, but I guess OK for a street car.
Was thinking of you when I was at Daytona.
63596One version (not shown) does not have Gurney flaps in front.
63598

Definitely an aesthetic piece more than anything. I recall Factory Five saying you need the race splitter with the new nose and I wasn't sure if that was just to fix the issue of the gap near the wheel well or what.

[Aero STI]

Andrew, even the race spoiler doesn't go all the way to the wheel well opening if you stick it out 3" on the front side. But yes, it does seem the R version is deeper, but only by maybe 3-4". I have some pics up of mine and you can see a gap between the wheel well opening and the back of the splitter but it's not as pronounces as your pic with the S splitter.

I'll look more closely at your pictures. I would love to have an S spoiler overlaid on an R so I could determine where exactly the length differences are.

With the current part it would not be terribly difficult to make a mold and modify it for better fit on the new nose.

[Hindsight]

The R splitter is 22" from middle front to middle back.

[Frank818]

Andrew, considering you're probably not sticking out 3", the race splitter would be pretty flush with the fenders. But at 3" no. If you stick out what FFR recommands, on the race splitter it sits flush with fenders.

[frankc5r]

Looks rather puny, but I guess OK for a street car.
Was thinking of you when I was at Daytona.
63596One version (not shown) does not have Gurney flaps in front.
63598

I love the Intrepid. I designed an built all of the cars electrical systems.
Interesting note. It had 5000 pounds of downforce at about 100 mph and broke its tail lights in a few laps. Leds were just coming out and I had to custom build led lights-nowhere to buy in 1990.

[Aero STI]

Andrew, considering you're probably not sticking out 3", the race splitter would be pretty flush with the fenders. But at 3" no. If you stick out what FFR recommands, on the race splitter it sits flush with fenders.

Frank, do you have a picture of this in your thread? I don't recall seeing it.

[Aero STI]

I love the Intrepid. I designed an built all of the cars electrical systems.
Interesting note. It had 5000 pounds of downforce at about 100 mph and broke its tail lights in a few laps. Leds were just coming out and I had to custom build led lights-nowhere to buy in 1990.

Do you work at Pratt & Miller?

[Aero STI]

The R splitter is 22" from middle front to middle back.

Sweet. I'll compare to the S and then I can see how it all lands. It seems a little silly to buy an R, but it may be necessary. My S is the absolute junk see-through single layer of carbon with fiberglass backing anyway.

[frankc5r]

Do you work at Pratt & Miller?
Worked for P&M before it was P&M. Gary PRATT started in company in late
70's and it was called Protofab. Became P&M in 1989. C5r vettes started in 1999 with first race
in 2000. Particularly remember working with Dale Sr and Jr in 2001 at Daytona 24 hr. 63603

Picture from 2017 Roar test.

[Frank818]

Frank, do you have a picture of this in your thread? I don't recall seeing it.

Yeah. Oh wait, you mean a pic of the race splitter flush with fenders? That I did not cuz I didn't fit it like that. But I can fake fitting it like that tomorrow and take a pic. My whole front end is on.

[Aero STI]

Yeah. Oh wait, you mean a pic of the race splitter flush with fenders? That I did not cuz I didn't fit it like that. But I can fake fitting it like that tomorrow and take a pic. My whole front end is on.

That would be much appreciated. Thanks!

[Frank818]

Here you go, man!


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Just one thing, I had to support the splitter with 2 boxes and it's short 1" from touching the body, the boxes where not tall enough. You can see it's flush with fenders on the wheel section, it can be better than that if you spent a few mins more to make it 100% flush, it was difficult for me with the boxes and 1" underneath the body as well.

The splitter was 1" or 1.25" sticking out. Any more than that and it will NOT be flush with fenders.

[Aero STI]

That's very helpful Frank!

I purchased Craig's hood hinges and had them powder coated black. I hope to install them this week and keep making progress with body work. This winter has been so unseasonably warm in Michigan. It's making me very anxious to get the car done.

http://i.imgur.com/Wv5JlUYh.jpg

[Canadian818]

I hear you on the unusually warm weather, same up here, very motivating.

[Aero STI]

My Tillet seats arrived today. They're super light and very comfortable. The carbon fiber is flawless. Stark contrast to the FFR stuff. I'm excited to ditch the fabric Corbeau seats. After only two Michigan summers of limited sun exposure they're very faded.

http://i.imgur.com/C82xW2yh.jpg

http://i.imgur.com/1sKc4G8h.jpg

http://i.imgur.com/PiuQHvMh.jpg

http://i.imgur.com/0kJPRlkh.jpg

[Canadian818]

Wow! Wild looking seats!

[07FIREBLADE]

Andrew could you post some better photos of your door panel/dash interface. Did you have to cut out the frs door panels in the front to get them to line up well with the wrx dash?

Nvm found the pics I was looking for

[Aero STI]

Andrew could you post some better photos of your door panel/dash interface. Did you have to cut out the frs door panels in the front to get them to line up well with the wrx dash?

Nvm found the pics I was looking for

I carved into the dash rather than the door. There is a small lip removed at the bottom of the door, and then the end near the latch is shaped to match the door contour. Let me know if you still need additional pictures.

[Aero STI]

Photo storage full

[Mechie3]

I've missed some good stuff the past few pages. How did the pems work out on the headlight? Bwalker had to orient his screws in all the same direcrion. Did you have to do that?

[Aero STI]

Photo storage full

[Hindsight]

Slick! You'll be really glad you have those hood hinges, with the tank being up front.

[Scargo]

Front tank design is off to Boyd Welding for quoting. It's easy to back seat drive... but why not gain more volume with it squarer on the right and use a bottom baffle detail much like a surge tank around the pickup area? Back in the day, we used simple hinges to act as trap doors for surge.

[Aero STI]

It's easy to back seat drive... but why not gain more volume with it squarer on the right and use a bottom baffle detail much like a surge tank around the pickup area? Back in the day, we used simple hinges to act as trap doors for surge.

Nothing has been built yet. I'll gladly take criticism and refine the design. I'm not following the squaring up on the right. The areas in the back of the tank are for the brake and clutch master cylinders. The bottom baffle might be cool. I can't believe my fuel level would be very accurate though. I'm going to be utilizing the Holley hydramat that I bought previously and I figured the angled design will naturally keep the fuel low in the tank during sweeping corners that starve a flat tank. The hydramat is a rectangle that nearly exactly matches the bottom of my design.

http://i.imgur.com/w13XR4qh.jpg

The thing I'm most excited about is freeing up the space behind the seat so I can stick my turbo in front of the engine. With the dry sump I'll be able to plumb the turbo drain directly to the pan.

[Aero STI]

Slick! You'll be really glad you have those hood hinges, with the tank being up front.

I know!

[Scargo]

In red is my proposed change. Dashed gold is optional angled floor of tank. Cutout is to clear the steering. Vertical red is baffles on each side of the Hydromat. In the bottom of each vertical baffle you would have small notches to let the fuel in probably equivalent to some factor of what the pump can move and perhaps accounting for 30% more for E85. The Hydramat should do the trick without flaps being necessary. With the V shape you are losing near half of potential volume.
64657
You might want to give some thought to clearance of the tank to the frame, vibration isolation mounts and/or flexible mounts that can absorb some frame movement in case of front-end damage. In other words, don't fit it too tight or too solidly with hard mounting and stay off the tank seams and have crushable mounts. I'm not a big fan of squarish welded tanks because the seams might rupture. Might be something to ask Boyd about.
There are aftermarket "vertical" sending units for the gas level that don't use a conventional swing-arm float.

[Aero STI]

In red is my proposed change. Dashed gold is optional angled floor of tank. Cutout is to clear the steering. Vertical red is baffles on each side of the Hydromat. In the bottom of each vertical baffle you would have small notches to let the fuel in probably equivalent to some factor of what the pump can move and perhaps accounting for 30% more for E85. The Hydramat should do the trick without flaps being necessary. With the V shape you are losing near half of potential volume.
64657
You might want to give some thought to clearance of the tank to the frame, vibration isolation mounts and/or flexible mounts that can absorb some frame movement in case of front-end damage. In other words, don't fit it too tight or too solidly with hard mounting and stay off the tank seams and have crushable mounts. I'm not a big fan of squarish welded tanks because the seams might rupture. Might be something to ask Boyd about.
There are aftermarket "vertical" sending units for the gas level that don't use a conventional swing-arm float.

I think I follow you. I would need to do some major frame mods to get that to fit in the front. I'm basically taking Lance's design and fitting it to the stock subaru master cylinders. There should be 1/4"-3/8" space between the tubes of the frame and I have some nice 3M isolating rubber that I'm planning to use.

Here's lance's completed tank for reference: http://thefactoryfiveforum.com/showthread.php?19228-First-818-COUPE-build&p=222041&viewfull=1#post222041

[Scargo]

Someone here removed the under-frame and bolted it back in place once the tank was in.

[Mechie3]

BobnCincy did that I believe. BillWalker also is doing a front tank and cut out some parts (or is planning to).

[Aero STI]

I started widening the rear ducts. You can see the slit I cut on the upper and lower portion of the vent. I determined how much I could open them up without too much stress then created two identical foam templates so both sides will be the same size. I did some sectioning on the upper to get the shape closer. I fiberglassed the upper with two layers of 3 oz mat. Once dry I'll do a few more layers and also take care of the lower.

http://i.imgur.com/Ai0r0hbh.jpg

http://i.imgur.com/dkjmYz4h.jpg

http://i.imgur.com/5NQDBOkh.jpg

http://i.imgur.com/734ugvnh.jpg

http://i.imgur.com/3ISmHCth.jpg

[Canadian818]

Once you start modifying the fibreglass you just can't stop. The larger scoops look good, my drivers side is filled with intercooler but once I widened the passenger side I really like the bigger scoop, suits the car. Good work!

[Scargo]

Yes, good work! I have thought that, when I get to it, I would slit from the vertical, inner, upper and lower corners and push the "released" inside panel in and fill that in. You started in the middle, which may make more sense.

[Aero STI]

Once you start modifying the fibreglass you just can't stop. The larger scoops look good, my drivers side is filled with intercooler but once I widened the passenger side I really like the bigger scoop, suits the car. Good work!

So true! I've got some work on the back end to do then I should be done with the major fiberglass work.

[Aero STI]

Yes, good work! I have thought that, when I get to it, I would slit from the vertical, inner, upper and lower corners and push the "released" inside panel in and fill that in. You started in the middle, which may make more sense.

Many ways to skin this cat. I could see the corner slit method working pretty well too.

[Aero STI]

I applied 3 more layers on the upper and 5 layers in one go on the lower. I laid up the fiberglass for the lower on wax paper then pressed it into place and had some foam pieces keep it pressed in place. I put down a coating of the 3M vinyl ester high strength filler too. The rough work is done.

http://i.imgur.com/D6ZFEyGh.jpg

http://i.imgur.com/f0A4w3Eh.jpg

http://i.imgur.com/fnITMMgh.jpg

[Scargo]

Many ways to skin this cat. I could see the corner slit method working pretty well too.
Do you feel that the opening was all the flex you could get out of the fiberglass, did you run into frame behind it or was it just what you wanted? How wide is the opening at the top?
I could see scoring the backside to get it to bend more if needed or desired.

[TomV]

That was fun to read, nice work!

[Aero STI]

Do you feel that the opening was all the flex you could get out of the fiberglass, did you run into frame behind it or was it just what you wanted? How wide is the opening at the top?
I could see scoring the backside to get it to bend more if needed or desired.

Glen, I could have flexed it further. This is what I thought looked good and was reasonable flex. I tried the scoring method on the hood and it didn't work as well as I expected. Certainly nothing like plywood. The only real limitation I see would be interference with the fuel fill, but that's going away on mine anyways. My opening is around 4.5" at the top.

http://i.imgur.com/hVqHegOh.jpg

[Aero STI]

Photo storage full

[Lumpyguy]

that is exactly how I opened my vent up as well, makes it look more aggressive

[lance corsi]

Very nice build, but I have 2 questions: where did you source your seats from? Is that a seat cover on pass seat or a different style Tillett seat?

[lance corsi]

I did the same thing on my side vent openings, only I cut paint sticks to the length I needed to hold the glass in place while it was curing. I used KTM motorcycle radiators on each side, through which I will circulate coolant to the oil cooler via a small electric pump.

[Aero STI]

Very nice build, but I have 2 questions: where did you source your seats from? Is that a seat cover on pass seat or a different style Tillett seat?

Thanks, Lance. I should have my custom boyd tank that mimics yours in 6-10 business days.

I sourced the seats through Allan Uzwiak. Youtube username is Zakari3030. I can PM his e-mail if you want. He's regularly building Superlite cars and uses the Tillett B5 in most of his builds. The passenger seat in one shot is just the old fabric corbeau still in place. They're both Tillett B6 carbon. No cushions at this point, but may have some custom cushions made.

[Aero STI]

More rear bumper progress...

This was my new inspiration

http://i.imgur.com/I003cVCh.jpg

http://i.imgur.com/yltfT8Oh.jpg

http://i.imgur.com/fxtEu3Lh.jpg

[Hindsight]

Wow, that thing is going to look MEAN!

[Aero STI]

Wow, that thing is going to look MEAN!

Thanks! I'm hoping the whole car is pretty aggressive looking. I'll be ditching the rear duck bill and adding a nice wide wing from Mallen Alley. I have an idea for a fairly clean chassis mount. Then extending the front splitter 3-4" off the front like you did.

[Aero STI]

Some self-explanatory updates.

http://i.imgur.com/7yixNBoh.jpg

http://i.imgur.com/5o8E64hh.jpg

http://i.imgur.com/xIStgALh.jpg

Mocking up a wing mount...

http://i.imgur.com/PiuweqKh.jpg

[turbomacncheese]

Nice!

[RetroRacing]

Exactly!! We used 1/4" plywood, drilled all of the mounting/adjustment holes and sent them to a water jet cutter. 100 bucks later, done!
65686

[RetroRacing]

Oh, and depending on the wing you use, that area of the frame will actually bend! we were only running 5 degrees with tension rods from the mid trunk pin mounts to the wing, and were bending it! Ended up installing two more vertical tension braces and moving the wing to 0 degrees to solve the problem. the plane of our wing is 2" above the top of the roll bar to get out of it's turbulent shadow, and because our wing is effectively behind the car, the leverage is pretty significant, so don't need much wing angle to be effective.

[Aero STI]

Exactly!! We used 1/4" plywood, drilled all of the mounting/adjustment holes and sent them to a water jet cutter. 100 bucks later, done!
65686

Your mount was my inspiration. I was planning on 3/16" aluminum. That's impressive that you're bending the frame. I'll keep an eye on that.

[Aero STI]

The body prep work continues. I rolled the car outside for the first time in many months and did an initial sand of most of the gelcoat. It helps give some perspective on the widened side scoops and the rear end modifications.

http://i.imgur.com/DYd7SSgh.jpg

[Hindsight]

Looks awesome Andrew!

[Sector]

Very impressive, can't wait to see the finished product.

[Canadian818]

Looking really good! I love what you're doing with the back end. If I didn't already have a plan for my bumper then I'd probably copy you, which I'm sure someone will do. What are you going to use for lights?

[Aero STI]

Thanks guys!


Looking really good! I love what you're doing with the back end. If I didn't already have a plan for my bumper then I'd probably copy you, which I'm sure someone will do. What are you going to use for lights?

I've got a few ideas I'm floating around. Probably something totally custom. I entertained using the later model year LED ring Toyota FJ Cruiser tail lights. The area is going to have some hex patterned plastic grille material left and right of the wing uprights. I could see the first revision where I install the provided red tail lights "floating" in that material.

[Sector]

I can't seem to picture FJ cruiser taillights. Aren't they to big too fit in that space?

[Aero STI]

The cruiser tail lights would take some creativity to make them work. I can't find a great picture.

[Aero STI]

My Mallen Alley wing showed up today. I'm very happy with the quality. This looks tall to me, but it measures only 2 inches above the roll bar.

http://i.imgur.com/EQLNrGh.jpg?1

http://i.imgur.com/HsVJ9Zl.jpg?1

[Hindsight]

Very nice - I think that is a good height. When I finally get around to getting one, that's exactly where I will be putting it. Looks be-damned. It's about function. Higher the better.

[Canadian818]

How high off the rear deck are you? My plan is to put it way up there too, function over form.

[Bob_n_Cincy]

Very nice - I think that is a good height. When I finally get around to getting one, that's exactly where I will be putting it. Looks be-damned. It's about function. Higher the better.

Remember, the higher the wing the more lift on front end.
Bob

[Scargo]

Just out of curiosity I looked for roadster wind tunnel tests and found FFR's video of their wind tunnel tests along with notes (http://www.factoryfive.com/whats-new/wind-tunnel-testing-the-new-factory-five-818/). I wonder if having the wing that low will maximize the value of the wing? Then there is the real need for a lot of front-end aero for a car that already ploughs.
I did a search for wing roadster "wind tunnel". I think the Miata image is interesting.
66112

[Hindsight]

Hah, Glyn I found the exact same Miata image the other day when I was searching for the same thing. I was surprised at how much airflow there was over the trunk. I expected it to be more disturbed up higher. That is good though... I think putting the wing just a little higher than the windshield will probably result in pretty good function. It would, of course, be better if you ran without the street windshield but I still think you'd get some good benefit.

[Aero STI]

Good dialogue guys. I'm open to any input. I plan to have the front spoiler 3" to 4" off the front of the nose and probably will add adjustable sections to extend portions of the front spoiler even further as necessary. I talked to the aerodynamic guru at work. This guy knows his stuff. Was the primary designer of racecar bodies for a formidable team in the 80's-90's and still does a ton of aero development with his laydown Yamaha kart. He suggested around 2" to 3" above the windshield/rollbar. With a level I found the windshield to be around 1" above the rollbar. He also suggested adding a teardrop profile to the rollbar, think formula 1 aero bars.

I'll try to grab a measurement off the deck lid when I get a chance.

Here is 3" above the rollbar. 71.5" wide. I sent these over to Kevin Allen (www.mallenalley.com where I got the wing from) for his opinion.

http://i.imgur.com/GZoycOnh.jpg

http://i.imgur.com/ibpihJkh.jpg

http://i.imgur.com/ahkarvVh.jpg

[Aero STI]

Photo storage full

[axelthrasher]

That seriously is one good lookin' tank! Makes me kind of want to go with their behind-the-seat option for the 818...

[RetroRacing]

2" above the roll bar should keep it out of the shadow of roll bar depending on how far back you are from it. You need the cleanest air possible to maximize it's efficiency or you will start cranking in more angle, which equals more drag, which means more hp which means more money....

Perfect world, no windshield, but I would suggest at least one inch above the windshield to start with. We used the stock mounts to template the top of our supports, and left enough room to cut them down an inch if we felt we were too high.

[Hindsight]

Nice tank! I love the wing mounts - that is exactly how I'm going to do mine: out the back instead of through the deck lid. Much easier to remove and replace that way.

[Aero STI]

Good info and thanks! I'm pretty heavy in the horsepower department at the moment, so a little drag won't kill me, but I get your point. The ends of the wing should be in some pretty clean air. The shadow of the windshield near the top is only half the wing width. The roll bar is around 1/3.

I'm starting to get pretty comfortable with using 3/16" 6061 material. This is modeled using 2225 N (500lbs) of downforce 750 N (168lbs) of drag, both applied at the extremes of this single upright. I don't expect to be generating 1000 lbs of downforce or over 300lbs of drag from this wing. There is negligible displacement from the downforce, 0.3mm or so. The drag is creating around 2.8mm of the displacement.

http://i.imgur.com/Fy5KmNNh.png

http://i.imgur.com/H5ydhlMh.png

[07FIREBLADE]

Did you do that analysis in solidworks?

[Aero STI]

Did you do that analysis in solidworks?

Yes. I used the simulation package. http://www.solidworks.com/sw/products/simulation/whats-new.htm

[07FIREBLADE]

It was just very coincidental that I was learning this stuff like this week in class and was thinking there's gotta be any easier way to calculate this stuff. Solidworks for the win. But I wasn't the student that was like when will we see this in real life. Lol

[07FIREBLADE]

It was just very coincidental that I was learning this stuff like this week in class and was thinking there's gotta be any easier way to calculate this stuff. Solidworks for the win. But I wasn't the student that was like when will we see this in real life. Lol

[Aero STI]

I did a little more FEA and made some changes. I shipped these off to my friend's machine shop this afternoon. I tested with very high forces from multiple angles. I even looked at resonant frequencies to determine stiffness. I think they'll do the job quite well. Here is an animation of stress changes while loading up to 4500 N of downforce.

http://i.imgur.com/YXqMWlq.gif

The overall design

http://i.imgur.com/LQJAezb.png

[Aero STI]

Also, I noticed some stress cracks from flexing in the larger engine cover. This is more than likely from taking it on and off not so carefully. Two layers of directional carbon fiber and it's crazy stiff. I'm glad I caught this before I finished the paint work.

http://i.imgur.com/RGIa0t0h.jpg

http://i.imgur.com/cQSEc3Lh.jpg

[Mechie3]

Wing Design: Are those top round bars just there to simulate the structure of the wing for the FEA? I wouldn't imagine they're needed in real life as the wing will provide enough lateral rigidity at the top. For the middle bars, if you didn't want something quite so large you could just just some parts like this. They act in pure tension if you put heims on the end so don't need to be very beefy.

http://i297.photobucket.com/albums/mm227/thaidiep/s2k%20wing/IMG_4293.jpg (http://s297.photobucket.com/user/thaidiep/media/s2k%20wing/IMG_4293.jpg.html)

[Aero STI]

Wing Design: Are those top round bars just there to simulate the structure of the wing for the FEA? I wouldn't imagine they're needed in real life as the wing will provide enough lateral rigidity at the top. For the middle bars, if you didn't want something quite so large you could just just some parts like this. They act in pure tension if you put heims on the end so don't need to be very beefy.


Craig, yes the bars up top are just replicating what structure the wing will provide for simulation. I plan to experiment with what is really required to stabilize the side to side motion. Thanks for the suggestion.

[Frank818]

Also, I noticed some stress cracks from flexing in the larger engine cover. This is more than likely from taking it on and off not so carefully. Two layers of directional carbon fiber and it's crazy stiff. I'm glad I caught this before I finished the paint work.

http://i.imgur.com/RGIa0t0h.jpg

http://i.imgur.com/cQSEc3Lh.jpg


I had that same problem! But cannot add FG or CF where you did, cuz I use Craig's louvers. I had to add FG just on the top corner where the crack happened.

[metros]

Great looking build. Really enjoying seeing this come together.

[axelthrasher]

I had that same problem! But cannot add FG or CF where you did, cuz I use Craig's louvers. I had to add FG just on the top corner where the crack happened.

I have the exact same stress crack as well... I am yet to address it though... :-/

[RetroRacing]

We used 3/16" material and you should have no issues, but side to side movement was a bit too much, so we added a vertical shear plate behind the car (as our struts go to the trans mounts)
You may need to add a cable X or round stock X brace

[Aero STI]

I love it when all of my measurements are correct and things fit as they should.

http://i.imgur.com/ggHRcZEh.jpg

[turbomacncheese]

So NICE!

[Canadian818]

Sweet! How much does it hold?

[Shawn818c]

Boyd tank looks great

[Aero STI]

Sweet! How much does it hold?

I believe CAD said 13.5-14 gallons.

[Aero STI]

First layers of primer are on. Still lots of sanding to do and some remaining body mods.

http://i.imgur.com/Z6olMdSh.jpg

http://i.imgur.com/6Ik6y3vh.jpg

http://i.imgur.com/zEzNKFah.jpg

[Canadian818]

Oh man, really coming together now! Looks great

[Frank818]

Oh man, really coming together now! Looks great

Nice competitor against you, isn't it? :)

[Canadian818]

Nice competitor against you, isn't it? :)

I love it, I want to see more guys thinking outside the box and changing things to suit their tastes. Part of me wishes I had just finished the car and went back to modify it like Andrew instead of changing everything first.

[Aero STI]

There is no right path with these cars. I enjoyed driving it around, but it bugged me that it wasn't more finished. I'm still messing with the rear bumper. Nowhere near complete.


http://i.imgur.com/ckXTmeNh.jpg

[Aero STI]

Started the day like this...

http://i.imgur.com/t6ALZ4Nh.jpg

http://i.imgur.com/YaiGUqvh.jpg

Ended like this...



http://i.imgur.com/igskW5vh.jpg

http://i.imgur.com/3mDkFOlh.jpg

I need to paint the front fascia and mirrors black.

[bbjones121]

Looking good

[Aero STI]

Temporary assembly

http://i.imgur.com/4ICMfrHh.jpg

http://i.imgur.com/93YTfMjh.jpg

http://i.imgur.com/g5gKbn6h.jpg

http://i.imgur.com/HHlpCyRh.jpg

[Hindsight]

Very nice Andrew! The vent mods came out really nice. Can't wait to see this all buttoned up.

[Aero STI]

I received a few requests to compare the regular design to my modifications. I focused on better airflow. Improved exit in the hood, more air into the scoops, non-parachute rear bumper. We'll see how it all works. I'll probably do this compairson again once the car is all put together.

http://i.imgur.com/JyChzZAh.jpg

http://i.imgur.com/zXiNhcRh.jpg

http://i.imgur.com/X4nPkUth.jpg

http://i.imgur.com/Y1m4ORAh.jpg

http://i.imgur.com/d4QSZZIh.jpg

[Wayne Presley]

Very nice!!!

[Aero STI]

Thanks, Wayne!

Wing uprights are back from fab. I'm still waiting on the machined mounts. I'll weld the cross braces in and then send them off to powder coat. I'm planning on black.

http://i.imgur.com/fujj9Irh.jpg

http://i.imgur.com/Ut1Iqb9h.jpg

http://i.imgur.com/dtHD75sh.jpg

http://i.imgur.com/Jx4SNiGh.jpg

[Hindsight]

Great wing mount. Did you design them in CAD?

[RetroRacing]

perfect!

[Hobby Racer]

Great wing mount. Did you design them in CAD?

Why yes he did!

http://thefactoryfiveforum.com/showthread.php?18770-Andrew-s-818S-LYTW8&p=275746&viewfull=1#post275746

[Canadian818]

Looks great Andrew! Really digging that rear bumper, if only I could come up with a design of my own.

[Frank818]

Very nice body work.

Are you sure those "embedded" strikers stick out enough? Mines are just tall enough to reach the doors and I can even space them out further (towards door).

[Aero STI]

Thanks guys. Adam, I'm looking forward to seeing your widebody 818 in paint.

Frank, the strikers work where they're at.

[Aero STI]

Painted the black parts black...
http://i.imgur.com/CJbjRKbh.jpg

Also got my machined parts for the wing uprights.
http://i.imgur.com/yviSmNbh.jpg

http://i.imgur.com/JKBl9Glh.jpg

[Frank818]

That is one solid mount!

[Aero STI]

Letting the parts cure in the sun. There is a small amount of blue metallic in this black. It was Honda Accord black.

http://i.imgur.com/jXqVX7ch.jpg

http://i.imgur.com/stCh0kHh.jpg

Here's a shot out of direct sunlight

http://i.imgur.com/dfvVqEfh.jpg

[Hindsight]

Looks great Andrew! Sorry I keep calling you Adam. I dunno WTF my issue is!

[Aero STI]

No worries on the name switch. I've been called worse!

Put 30 miles on it today. Still have plenty of work to do, but she's back to driving. Still stinks of exhaust every now and then, even with all of the venting out the back and huge side scoops. I have two small areas, where the door latch brackets are located, to seal up. Otherwise there should be no easy path, unless it's just coming over the top of the panels. Exhaust relocation is in my future, but I was hoping to go center mounted with the wing. I'm going to reconsider.

http://i.imgur.com/SRM9i7Yh.jpg

[autostang]

Car looks great! It's interesting to me that so many people are getting exhaust smell in the cabin. My exhaust exits next to the transmission (roughly the same spot as yours) and after 300ish miles I have never smelled any exhaust....some burning oil that got on the headers, but no exhaust.

[Hindsight]

Wow that looks incredible!!!

RE exhaust in cabin, you may recall my struggles with this, and the three different exhaust setups I tried to find the one that worked. With no hard-top, I found that the only place you can have the exhaust exit and not pull fumes into the cabin is behind the tire. Next to the transmission didn't work, nor did having it dump inside and slightly behind the tire. From my experience, the fumes aren't seeping into the cabin from the engine bay, they are getting pulled upwards over the rear bumper then forward over the trunk lid and engine cover and into the cabin.

[Aero STI]

The exhaust coming over the engine/trunk lid seems like the most obvious conclusion at this point. I remember behind your tire was the best location for you. That's what I'm going to aim for.

[Frank818]

huge side scoops.

I must be missing something. Your side scoops are OEM FFR, you call them big? It's relative I know, just curious to know what's a "huge" side scoop for you.

That hood... that hood... yeah THAT HOOD!!!!! lolll
Drool!


you may recall my struggles with this

F yeah!!!! loll


The exhaust coming over the engine/trunk lid seems like the most obvious conclusion at this point. I remember behind your tire was the best location for you. That's what I'm going to aim for.

How about trying a plexiglass covering all the rollbar area? No one has tried that (or aluminum but plexi makes you see through) yet AFAIK and I'm very very interested to know how it turns out.
Never thought of becoming a pioneer in that area as well? :) You could test it with simple cardboard first as a mock-up or any other easy and quick material.

[Aero STI]

Frank, my scoops are much larger than standard.

The plexiglass seems like it would be worth a try.

[flynntuna]

A lot if not all of the newer convertibles use some sort of "wind blocker". A lot of different materials are used too. https://www.google.com/search?q=convertible+wind+blocker&ie=UTF-8&oe=UTF-8&hl=en-us&client=safari

[Frank818]

Frank, my scoops are much larger than standard.

Then the picture doesn't give justice, I'd swear your side scoops are standard FFR...


The plexiglass seems like it would be worth a try.

Yeah that's what I have in mind for the future, that and/or a deflector wing at the top of windshield like the Porsche 918.

[Aero STI]

Photo storage full

[Hindsight]

Looking awesome Andrew. Those exhaust exits should work very well from a fumes standpoint. You won't get any fumes in the cabin.

[Aero STI]

Thanks! I would say it nearly eliminated the smell. Still get a wiff very rarely. I need to try the plexiglass.

This was with the cutout closed.


http://www.youtube.com/watch?v=SYPazUKkJlk

[Harley818]

Check my thread. I added the lexan covering the roll bar area and eliminated almost all of the exhaust fumes.
I have pics there

[Aero STI]

Wing is on.

http://i.imgur.com/U8ura9l.jpg

[Hindsight]

Looks good. I'm interested to see how effective it is with the full windshield in place. If it works well, I'd strongly consider adding one to my car for the track days. I'd been thinking about adding one, but modifying my dash and windshield so that I could quickly and easily remove my windshield at the track to get better aero and make the wing receive more flow.

[Frank818]

That's a big wing. :)
I want the hood.

[Aero STI]

It seems to be working, but I have only noticed on straight line acceleration at this point. There is a lot of surface area that should be in clean air.

[RetroRacing]

Looks great, love the bracing! we should have done something similar, but lack the imagination for that.

[Aero STI]

Thanks!

Installed a simple 2x50W bluetooth amp from Parts Express to power 6.5" speakers in my BRZ door panels. I'm a little unimpressed, but the speakers installed easily with some plastic epoxy.

http://i.imgur.com/ASogLfmh.jpg

I installed a 1/4-20 bolt in each door hinge. This gives an adjustable limit to how far the door swings open. On the driver side I fit a nut to each bolt to lock it down. The passenger side clearance was tight, so I used loctite. If it backs out I'll sand down a couple nuts to make it thinner.

http://i.imgur.com/aM4vZswh.jpg

[Frank818]

I installed a 1/4-20 bolt in each door hinge. This gives an adjustable limit to how far the door swings open. On the driver side I fit a nut to each bolt to lock it down. The passenger side clearance was tight, so I used loctite. If it backs out I'll sand down a couple nuts to make it thinner.

http://i.imgur.com/aM4vZswh.jpg

CRAP! Why I didn't do that in the 1st place! So much more wise! Ah man that's a pain once everything is installed and completed to remove and re-start.

Everyone, DO AS ANDREW!! Don't use FFR's non-adjustable stoppers.

[Aero STI]

Adjustable is definitely the way to go.

I tested out the Holley Hydramat on accident today. My new fuel sender shows 1/8th tank when in fact the tank is bone dry. The hydramat worked perfectly, sucking up every single last drop of fuel. I was getting after it and the car showed no sign of fuel starvation until it was absolutely empty.

[longislandwrx]

I know it's a little more money but get this guy. It cranks, will take a little water np and is actually really small. the remote does basic controls perfect for the 818 no head unit required.

https://www.sonicelectronix.com/item_93348_Kenwood-KAC-M1824BT.html

run it bridged and your speakers will sing.

bonus usb charging port.


on amazon.

https://www.amazon.com/Kenwood-Compact-Automotive-Marine-Amplifier/dp/B00UTXQL74/ref=sr_1_1?s=electronics&ie=UTF8&qid=1504104573&sr=1-1&keywords=Kenwood+kacm1824bt

[Aero STI]

I might upgrade to that amplifier. Thanks for the recommendation.

The car was a huge hit at the Grand Rapids, MI Cars and Coffee today. In the presence of true exotics it still always had a huge crowd. There should be some good pictures pretty soon from the professional photographers. My wife snapped these when it was time to leave.

https://i.imgur.com/kqETO1mh.jpg

https://i.imgur.com/lREYim8h.jpg

[07FIREBLADE]

CRAP! Why I didn't do that in the 1st place! So much more wise! Ah man that's a pain once everything is installed and completed to remove and re-start.

Everyone, DO AS ANDREW!! Don't use FFR's non-adjustable stoppers.

Posted those up on the Facebook group a few months ago. Seriously easy to do but a real pain if you have to take your doors off to do.

[longislandwrx]

tail lights look awesome dude. great job on everything.

[Aero STI]

Thanks!

I made an acrylic wind deflector. It seemed to make the cabin air way more turbulent. It's possible that it would cut down on exhaust, but that is virtually gone with my new setup. I took it off. Maybe mesh material like some convertibles have would be better.

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

[Frank818]

You fitted it on the rollbar? It's weird cuz Harley tried the same and said it reduced air flow in the cabin.

[Aero STI]

Yes, right behind the roll bar. I couldn't wear a hat above 50 MPH and my wife's hair was going crazy.

Here are my rear tow hooks I decided on. They're just set in place for the pictures because I need longer fasteners.

http://i.imgur.com/pwVyIwOh.jpg

https://i.imgur.com/peoqy5th.jpg

[Hindsight2.0]

Wow very surprised about the windscreen! I'm glad you shared that because it will save me some time from going down that road. Wish I could find a good solution because there are times I don't commute places in my car because my hair will be to flock-of-seagulls by the time I arrive.

Where are you getting all your blingy aluminum parts cut??

[Frank818]

I wish Harley will read that, I'd like to hear about the comparison.

[RetroRacing]

What the H$ll is wrong with Flock of Seagulls?

[Harley818]

You fitted it on the rollbar? It's weird cuz Harley tried the same and said it reduced air flow in the cabin.

Actually, for me the flow in the cabin was about the same. The major difference is that the lexan changed the flow so the exhaust didn't come up into the cabin.

Whats wrong with a little wind in the hair?..... just cut it shorter.
Actually, my wife's not complaining either and she has shoulder length hair.
Whenever I get worried about my hair I just push harder on my right foot....seems to work!

[longislandwrx]

Cool hooks... now you just need an octagonal bump bar to slide between them and some set screws.

https://www.rockwestcomposites.com/shaped-tubing/octagonal-tubing

I've got a lot of CMMG stickers too!

[Frank818]

Whenever I get worried about my hair I just push harder on my right foot....seems to work!

I like that!!

[Aero STI]

Where are you getting all your blingy aluminum parts cut??

I've got a few friends/acquaintances with CNC capabilities, also at work. The tow points were cut on a water jet and then cleaned up with a belt sander.

[Aero STI]

Cool hooks... now you just need an octagonal bump bar to slide between them and some set screws.

https://www.rockwestcomposites.com/shaped-tubing/octagonal-tubing

I've got a lot of CMMG stickers too!

That would be an interesting look! Keen eye on the sticker. I've done two complete builds from 80% LRs. One to .223, the other to .300 blackout. All of the part suppliers want to give you a sticker.

[Aero STI]

Full photo storage

[Aero STI]

https://i.imgur.com/ws5L1uNh.jpg

[Hindsight]

Holy cow that is bad-***!

[Scargo]

Your gas tank is in front, correct? This is what I have designed for mine except mine is a single-seater R.
I plan on exiting the exhaust in front of the rear wheel on the passenger side.
Could we see more pictures of the turbo installation? I'm not that far along on mine so I'd like to see how it fit into the gas tank area. I am contemplating a Garrett as they make the reversed housing versions.

[aquillen]

Love your exhaust work. I know what it takes to do that...

[redbudrr]

Wow! Your headers look great!! You have some skills!!

[Aero STI]

Full photo storage

[Mitch Wright]

Nice work on the exhaust and header.

[lance corsi]

I agree with Mitch! You may have missed your calling!

[Aero STI]

Full photo storage

[Scargo]

I was going to use that exact spot for an identical oil cooler until I got some GTR intercoolers to use in both sides. I will enlarge the opening as some have done.
I bought and modified these $13 pliers from Amazon. I've found that you only need a few spots to keep the clamp from slipping on the intercooler tubing.
83371

[flynntuna]

Nice work on the exhaust, that's next on my to do list. I also bought the jobber do tool though I've yet to use it. ( I'm so far behind were I thought I'd be at this point) I think it will work great for I'll need it for.

[melnjoel]

Just came across your thread. Amazing job!! I wish I had half the talent of some of you guys. I am looking at Corbeau seats as well. Are yours the FX1 Pro seats? And did you use the Corbeau mounts? I have read that people have used their universal mounts, but I haven’t found which height of their three mounts that people have found successful.

[idf]

Just came across your thread. Amazing job!! I wish I had half the talent of some of you guys. I am looking at Corbeau seats as well. Are yours the FX1 Pro seats? And did you use the Corbeau mounts? I have read that people have used their universal mounts, but I haven’t found which height of their three mounts that people have found successful.

I have the Corbeau FX1 Pro seats in my 818s. Used their universal flat mount (says Porsche on it). I added some 1 1/2 inch spacers at the front between the seat and the mount to get some rearward tilt.

[Aero STI]

I had seat mounts fabricated for the Corbeau seats. I'm pretty sure I showed them earlier in this thread. Sort of a z shape that was around 1.5" in the front and tapered to flat in the back. The Corbeau seats were fine, but they faded to purple after little sun exposure. I'm in Michigan, so not exactly the highest UV levels. I ended up ditching those seats in favor of full carbon Tillett seats.

[Frank818]

I don't think you can get any fresher air on that intake and oil cooler! :) Nice job!

[Aero STI]

Full photo storage

[Scargo]

Nice stuff! One day I will have a DS.
I helped buddy install a GReddy block like that by making his mounting bracket for him and I just put one in my '07 STi. Stuffed it in front of a smaller battery, so I redid the in and out for 1/2" NPT to save fitting space, as I needed to turn them down at 45° and 90°. Too bad they don't make a version with the inlet/outlet on the other side!
Called GReddy and they do not make angled ORB fittings. That and theirs seem to be unique and non-standard. I ordered the tapered reamer for prepping the holes for tapping as I didn't want to stress out the somewhat thin casting!
BTW, his first filter block with thermostatic bypass valve did not work properly (stuck open) and oil was not getting up to temp. They sent him a new one. I checked mine and it opened/closed properly. On the STi track car I used the Canton block and Mocal OT2 parts so you get into more fittings and hoses with that approach.

[Aero STI]

Nice stuff! One day I will have a DS.
I helped buddy install a GReddy block like that by making his mounting bracket for him and I just put one in my '07 STi. Stuffed it in front of a smaller battery, so I redid the in and out for 1/2" NPT to save fitting space, as I needed to turn them down at 45° and 90°. Too bad they don't make a version with the inlet/outlet on the other side!
Called GReddy and they do not make angled ORB fittings. That and theirs seem to be unique and non-standard. I ordered the tapered reamer for prepping the holes for tapping as I didn't want to stress out the somewhat thin casting!
BTW, his first filter block with thermostatic bypass valve did not work properly (stuck open) and oil was not getting up to temp. They sent him a new one. I checked mine and it opened/closed properly. On the STi track car I used the Canton block and Mocal OT2 parts so you get into more fittings and hoses with that approach.

That's good info on the thermostat being stuck open. I think monitoring oil temp is very important with a dry sump setup. The added capacity increases the time to reach proper operating temps. Having a stuck thermostat would make it impossible. Also, considering the overheating issues that Chad Plavan had with his DS setup, temps need to be carefully monitored.

[Aero STI]

Full photo storage

[longislandwrx]

looking good, i have that same iwg75 real nice part.

[Aero STI]

Full photo storage

[Hindsight]

Looking awesome Andrew! You might consider not having the exhaust point straight back, but instead kind of at a 45 degree angle. It helps with the exhaust smell in the cabin.

[NetWRX]

Andrew, I sent you a PM. Your low mount header setup is awesome BTW

Thanks for being an inspiration to us,

Josh

[Aero STI]

Looking awesome Andrew! You might consider not having the exhaust point straight back, but instead kind of at a 45 degree angle. It helps with the exhaust smell in the cabin.

Yeah, I'm going to try the rear exit again. I didn't love the look of the side exit setup I had before.

[Aero STI]

Andrew, I sent you a PM. Your low mount header setup is awesome BTW

Thanks for being an inspiration to us,

Josh

I appreciate all the compliments. Thanks guys!

[Aero STI]

Full photo storage

[BN]

Thumbs up

[Hobby Racer]

Nice... I have a tig welder, I have to learn how to weld aluminum. :rolleyes:

[Aero STI]

Full photo storage

[lance corsi]

Looks good Andrew but help me understand why one side is muffled and the driver side is straight thru?

[Scargo]

Pretty sure it's a cutout. (https://www.summitracing.com/parts/sum-670150-2/overview/)
84092

Looks good Andrew but help me understand why one side is muffled and the driver side is straight thru?

[Aero STI]

Lance, Scargo nailed it. I wanted to have twin tips and this is a simple way of achieving that. The electric cutout can be a little childish, but sometimes you just need to let the engine scream. It usually amounts to 5-10 hp increase too.

[lance corsi]

I should've known that! Looks great!

[Frank818]

There's a lot of work on all this, pretty impressive!

Did you get to hear it yet?

[Aero STI]

I haven't fired it up with the new low mount turbo kit yet. Hopefully in a few weeks.

Also, if anyone needs a Boyd aluminum gas tank, please send me a PM.

[ben1272]

so you either have single tip with muffler (cutout closed), or dual tips with one being a straight pass-thru and the other being thru muffler? Is this how it is 'normally' done? Nice looking work.

[Aero STI]

so you either have single tip with muffler (cutout closed), or dual tips with one being a straight pass-thru and the other being thru muffler? Is this how it is 'normally' done? Nice looking work.

That's the basic gist. However, you can adjust the angle that the cutout is open. It's like a volume knob for your exhaust.

[Aero STI]

Full photo storage

[lance corsi]

Is that another 6 spd trans? Nice work Andrew!

[Aero STI]

That's the same 6 speed as before, just repaired.

[Aero STI]

I learned how to powder coat today. Some really nice guys in town with a walk-in oven and really good spray equipment let me try my hand at it. Most parts got sprayed satin black, but the intercooler, intercooler pipes, and intake pipe got a "high temp" coating which has a little bit more texture.

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

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

[Aero STI]

Back on the road. I really like the way the new black parts blend in. Still needs some real shakedown miles. The turbo seems insanely responsive and power builds faster than ever. No lag on a 60lb/min turbo. Feels like no turbo Subaru motor I've ever driven.

https://i.imgur.com/F11TkCfh.jpg

[Canadian818]

Looks awesome!

[Wayne Presley]

Back on the road. I really like the way the new black parts blend in. Still needs some real shakedown miles. The turbo seems insanely responsive and power builds faster than ever. No lag on a 60lb/min turbo. Feels like no turbo Subaru motor I've ever driven.

https://i.imgur.com/F11TkCfh.jpg

I drove an 818R with the 7163 twin scroll and it was awesome!

[Aero STI]

I had a little accident today. Long story long, someone ran a red turn arrow, but that's not who hit me. I along with everyone else with a green light waited for the first car to run the red turn arrow to clear the intersection. Once cleared 6 lanes of traffic in both directions started to go. An older gentleman waiting in a turn lane got confused by the inactivity in the large intersection and decided it was a good idea to take a left turn, even though he had a red light, with three lanes of oncoming traffic headed his way. Rather than stop once he saw traffic was coming, he sped up and ran right into me. He was cited for failure to yield. I was able to move the car about 10 feet to get out of the intersection, but the driver side wheel was stuffed. The car is at my toy barn. I'll start rebuilding as soon as the insurance check clears.

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

https://i.imgur.com/Ulf84CCh.jpg

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

I'd love your input for a parts list. I think the frame is OK. I can take more pictures if that would help.

Right now I have:
Windshield
2006 WRX Left Lower Control Arm - 20202FE671
Koni Yellow Shock Assembly
Driver side lower control arm shock mount
Carbon Front Splitter - 80718
Carbon Front Fascia - 81149
Driver Front Fender
Driver Headlight Assembly
Driver Side Nose Support Brackets
Black Enkei TY-5 18x8 Wheel

[Hobby Racer]

Looks like you may also need the following:


Hood
Power steering rack?
Possibly driver side spidle?
Body and paint work
Lots of labor.



Don't let the insurance company short you on the labor!

[Hindsight]

Oh man, so sorry to hear this Andrew! I hope the frame isn't damaged and that insurance treats you fairly.

[Aero STI]

Thanks for additional items Hobby Racer! I think you're probably right on all of those. I'm not sure what is customary for labor and body work when you're going to do it all yourself. Insurance is through NCM, so I suspect they have experience with all of this. I bill out up to $10k per week for my job. I doubt they'll accept $250/hr hourly rate.

I also hope the frame is OK. It was low speed, 20-30 MPH combined.

[turbomacncheese]

holy ouch, batman. glad you weren't hurt.

[Canadian818]

That sucks, but it seems like it hasn’t got you down. Good luck hitting 600whp!

[longislandwrx]

check your tire for bulges, and file a road hazard claim if you can.

also check the upper knuckle mount, upper a arm, front undertray aluminum,

also check your radiator, a lesser accident cracked mine in a few places

[Frank818]

Oh crap, I was so sad to read that. :( I hope it's not too major to repair.

[Aero STI]

My 818 is up and running again. Right now I'm waiting on Factory Five to sort out shipping of the replacement body components.


http://www.youtube.com/watch?v=Cjd5plAljnk

[Hindsight]

Nice! Glad you got it fixed.

[turbomacncheese]

Great. Now I want to build a rotary engine.

[Frank818]

Great. Now I want to build a rotary engine.

Oops, I posted on the wrong thread!!! I soiled your build thread, I'm so sorry. I'll delete it.

[Aero STI]

New low mount turbo kit work has begun. This time with a single scroll EFR 7163 and external wastegate.

https://i.imgur.com/Ewr1UeZh.jpg

https://i.imgur.com/5cONvqHh.jpg

https://i.imgur.com/T9ypoXNh.jpg

[Hobby Racer]

Looking good. I was linking of mounting small twin turbos on my H6 in a similar location one on each bank! Where are you sourcing the tubing and turbo flange?

[lsfourwheeler]

What's the reason for low mounting the turbo? Shorter exhaust plumbing before the turbo to reduce lag?

[Scargo]

Interesting. My plan for a low-mount is to put it in front since I'll have a fuel cell.

[Aero STI]

Looking good. I was linking of mounting small twin turbos on my H6 in a similar location one on each bank! Where are you sourcing the tubing and turbo flange?

I've sourced flanges from all over the place. 1/2" 304 stainless machined to accept 1.5" schedule 10. One example:
https://www.pandlmotorsports.com/shop/pandl-products/pandl-cnc-products/p-l-motorsports-cnc-d-wrx-sti-brz-exhaust-head-flange/

Your choices for the H6 may be limited:
https://www.racemufflers.com/Subaru-EG33-H6-Stainless-Header-Flange-p/rm-80047-shf.htm

Sch 10 tubing can be found all over the place. Amazon, aceraceparts.com, Vibrant, etc.

[Aero STI]

What's the reason for low mounting the turbo? Shorter exhaust plumbing before the turbo to reduce lag?

Pretty much.

[Aero STI]

Interesting. My plan for a low-mount is to put it in front since I'll have a fuel cell.

That was last year's setup. Been there, done that.

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

Packaging is not particularly fun. I had to move a frame cross brace. In the end you've got a heat source right by the low pressure passenger area. The low pressure sucks in heat from all sources. Even with exhaust wrap, extra aluminum heat shield, and turbo blanket the additional turbo heat was noticeable.

[Aero STI]

The manifold mock-up is almost complete. I need to tack up the turbo inlet pipe and v-band. Also need to weld in the wastegate. So close...

The car has been running an equal length twin scroll setup since 2016. I think this being so uneven should bring back the boxer rumble.

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

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

https://i.imgur.com/maMe8eKh.jpg

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

[UnhipPopano]

How does your design take into account different thermal expansion related to different materials and different temperatures between the engine and the headers?

https://www.engineeringtoolbox.com/linear-expansion-coefficients-d_95.html

[Aero STI]

How does your design take into account different thermal expansion related to different materials and different temperatures between the engine and the headers?

https://www.engineeringtoolbox.com/linear-expansion-coefficients-d_95.html

I was just talking with lance corsi about this. The flanges have enlarged holes. Slip joints or flex joints could be added. However, if you look at most sch 10 manifolds for Subarus, nothing more than enlarged holes are used.

[Aero STI]

Design is complete. The oil feed line will be re-routed so it is between the manifold and the engine. Now it's time to weld everything up.

https://i.imgur.com/j1JMD4Nh.jpg

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

https://i.imgur.com/fqvuCJ6h.jpg

[Mitch Wright]

Looks awesome and excited to hear the report on performance. It sure has to clean up the engine bay up top.

[Hindsight]

So much craftsmanship on this build! Really makes me miss my garage!

[Aero STI]

Thanks guys! It's getting close to roadster weather in Michigan. I need to keep cranking.

At least the other cold weather project is back together. My EFR7163TS + AWIC setup in the Saabaru.

https://i.imgur.com/Jlb7QXah.jpg

https://i.imgur.com/SLIlf5ph.jpg

https://i.imgur.com/z00qSvqh.jpg

https://i.imgur.com/PvNX6JIh.jpg

https://i.imgur.com/jV6sHk5h.jpg

[Aero STI]

https://i.imgur.com/T1PYtW7h.jpg

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

[Aero STI]

My 818 had its first start today on the new turbo. A few loose ends to button up and it'll be ready for tuning.


http://www.youtube.com/watch?v=f8_wgRsiVWw

The headlight modification is moving along too. The passenger side is ready for fiberglass.

https://i.imgur.com/cM3HPx8h.jpg

https://i.imgur.com/F7xVvs2h.jpg

[Ajzride]

I looked back a few pages and didn’t see any mention, which headlight are you going with? I’m headed down that path now with the old nose, and I gotta say it looks way easier when the headlight is contained within one panel instead of where 3 meet. Definitely making me consider a clamshell.

[Aero STI]

I looked back a few pages and didn’t see any mention, which headlight are you going with? I’m headed down that path now with the old nose, and I gotta say it looks way easier when the headlight is contained within one panel instead of where 3 meet. Definitely making me consider a clamshell.

2007-2008 Yamaha R1 Headlights.

[Aero STI]

Rethinking my headlight choice...

https://i.imgur.com/BWQvnx9h.jpg

https://i.imgur.com/C1huvAgh.jpg

https://i.imgur.com/Qp0oQrfh.jpg

Let me know what you think compared to the R1 headlights.

[Lrauka]

I like it! What headlight is this one?