Andrew's 818S - LYTW8

[Aero STI]

I never started a build thread, so this is more of a recap.

Current State:
http://i.imgur.com/8jWxdQr.jpg

http://i.imgur.com/Ju6feZW.jpg

http://i.imgur.com/skb2P2Y.jpg

http://i.imgur.com/8YGJ7tj.jpg

http://i.imgur.com/3CTR6Rh.jpg

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

http://i.imgur.com/wIqESy4.jpg

[Aero STI]

More Pictures Taken Recently:

http://i.imgur.com/K1dqMRf.jpg

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

http://i.imgur.com/0N8EH3U.jpg

http://i.imgur.com/X9B0J7g.jpg

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

http://i.imgur.com/922Da4h.jpg

[Aero STI]

Various Pictures:


http://i.imgur.com/9jGwUpU.jpg

[Aero STI]

Some Videos: (these were the stock turbo setup)

http://www.youtube.com/watch?v=U7IN2W9JZyc

[Aero STI]

http://www.youtube.com/watch?v=uw35pFe8bZI

[Aero STI]

http://www.youtube.com/watch?v=D2mKwG02YiQ

[Aero STI]

Reprogramming my Gauge Cluster:

http://i13.photobucket.com/albums/a300/eqlized_aero/bitbanging.jpg

http://i13.photobucket.com/albums/a300/eqlized_aero/ponyprog.jpg

http://i13.photobucket.com/albums/a300/eqlized_aero/clusterreprogram.jpeg

Early Progress:

http://i13.photobucket.com/albums/a300/eqlized_aero/photo1.jpg

http://i13.photobucket.com/albums/a300/eqlized_aero/bodyfitting.jpg

[matteo92065]

I remember seeing a lot of these pictures over the past 14? Months. I really liked your build and followed many of the same things you did. Thanks for putting this up.

[Hindsight]

Very nice! Thanks for posting. Looking forward to seeing the refinements.

Hard to tell from the pics but looks like you went with an IWG? Did you have to modify the up-pipe at all to get it to work in the 818? Any cross-brace modification needed?

When I upgrade my turbo I was planning on trying to fab my own up pipe in hopes of locating the turbo where I wouldn't have to modify the cross brace, so am curious to see what you did.

I take it you are running E85?

You say your fuel pump is hard-wired.... what does that mean?

[Aero STI]

Exhaust Fabrication Work:

[Aero STI]

Manifold Work:

The 2.5i intake manifold is really ugly to start with.

http://i.imgur.com/kpPK8Oj.jpg

http://i.imgur.com/Mua7M57.jpg

[Aero STI]

Very nice! Thanks for posting. Looking forward to seeing the refinements.

Hard to tell from the pics but looks like you went with an IWG? Did you have to modify the up-pipe at all to get it to work in the 818? Any cross-brace modification needed?

When I upgrade my turbo I was planning on trying to fab my own up pipe in hopes of locating the turbo where I wouldn't have to modify the cross brace, so am curious to see what you did.

I take it you are running E85?

You say your fuel pump is hard-wired.... what does that mean?

Yes, I'm using a Turbosmart dual port IWG actuator. See the latest pictures I added.

E85 is the only fuel this car is tuned for. Ethanol or nothing at all. The fuel pump is run off its own relay (well it's shared with the AWIC pump) that bypasses the factory fuel pump regulator circuit. This ensures the pump is running at its full potential.

[Aero STI]

I haven't completely finished the doors, but rather than have door handles on the inside or the outside I went with electric actuators and I have a keyless remote. It works great and is a bit of added security from people easily entering the car.


http://www.youtube.com/watch?v=ReHZ_MR0vpM

http://i.imgur.com/Y2AIssf.jpg

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

[Aero STI]

Boyd Tank Fuel Filler:

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

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

http://i.imgur.com/2hajRSb.jpg

http://i.imgur.com/LjL7ZBa.jpg

[Bob_n_Cincy]

Great Job AeroSTI,
I love your build.
Bob

[Hindsight]

Love the up-pipe fabrication and using the PVC as a template.

For the very small slivers of bends you had to slice out of a larger mandrel section, what did you use to make the cut? I have an abrasive metal chop saw and it works good for straight pipes but doesn't work so well for cutting bent pipe or for making cuts in very short pieces. Wish I had a band saw.

[apexanimal]

excellent!

it was great to meet you andrew - you've got an awesome car going

[Frank818]

Very very nice stuff!!!

Can you elaborate a little more on the LCA spacers? How thick are they and what did you gain/lose?
What specs bolts you used for?

[Aero STI]

Love the up-pipe fabrication and using the PVC as a template.

For the very small slivers of bends you had to slice out of a larger mandrel section, what did you use to make the cut? I have an abrasive metal chop saw and it works good for straight pipes but doesn't work so well for cutting bent pipe or for making cuts in very short pieces. Wish I had a band saw.

The nice thing about schedule pipe is that it's the same OD, so schedule 40 PVC is a perfect substitute and much cheaper than the 304SS. I used a horizontal bandsaw for some of the smaller slivers of pipe. You can get a lot of those slivers out of a single 90 degree bend.

[Aero STI]

Very very nice stuff!!!

Can you elaborate a little more on the LCA spacers? How thick are they and what did you gain/lose?
What specs bolts you used for?

This is the "more caster mod (http://forums.nasioc.com/forums/showthread.php?t=1900666)". I think I used 10 to 12 mm thick aluminum. Longer 10.9 metric bolts are needed.

[Aero STI]

The opening in the boyd tank for the fuel pump is quite small. This turned out to be a problem with the large bottom Walbro 450 fuel pump. I didn't feel like welding anything tonight so a quick angled cut gave barely enough clearance to get the assembly back in the tank. Also, the aeromotive stealth had a rubber isolater wrapping the pump and it was loud. This walbro is direct metal on metal contact and way quieter.

http://i.imgur.com/p9WQbze.jpg

[Aero STI]

Insurance Guy was asking about seat brackets. I designed these up and had them formed by my friend's fab company. They go almost flat to the tubing in the back and provide 1.5" of lift in the front.

http://i.imgur.com/38YODFQl.jpg

[Hindsight]

Those look nice. I used some momo aluminum brackets. They weren't cheap ($50 I think) but they do allow for a lot of adjustment and I can basically get the seat right down to the bars as well. Still have weld some tabs to the frame bars to have something to bolt them too though as they aren't as long as yours.

[Aero STI]

I'm having major traction issues, but this is still a fun road dyno.

http://i.imgur.com/PVsDk0L.png

[Hindsight]

Have you thought about getting a traction control system? Do you have a limited slip?

[Aero STI]

No LSD at the moment. I'm going to source a 6 speed with a factory front LSD. I can't justify spending $1,000 to $1,500 on installing a quaife unit in the 5 speed, when a 6 speed can be had for $2,000. Traction control would be awesome, but I completely deleted the ABS system.

[Aero STI]

Photo account full...

[Hindsight]

That's a meaty flange! Did you have it CNC to your specs or was it something you found online?

In your turbo research, did you find conclusively that the twin scroll EFR 7163 spools faster than the non-twin scroll version on a Subaru engine? A tuner I've been talking with a lot says they don't really see any spool difference between twin and single scrolls on Subarus on the dyno and ever since that comment, I've been looking for data to support or refute that claim. It's just rare to find someone with the exact same year and setup who has tested both, which is the only fair comparison. The fact that the 08+ cars or dual AVCS and so many people are now running 08 and newer cars makes it even harder to find an applicable comparison to the earlier years.

The Quaife you'd need ca be had for ~$800. I like the 6-speeds for durability but I'm not sure how the factory LSD compares to the Quaife, the 6 speed adds a lot of weight, and I think 6 short gears might be slower in 0-60 and 1/8 mile times on a light turbo charged car like the 818. Certainly a lot more shifting, though you could skip gears when driving around town. Just my two cents.

[Aero STI]

I designed the flange myself. I had an elaborate design, but it required 3 setups in a 5 axis CNC, this takes 2 setups in a 3 axis CNC and certain sections could be laser cut to significantly reduce machining costs. I would change it slightly so there is more space between the two pipes to facilitate welding, but otherwise it works great.

I can't say conclusively that boost onset is faster than a single scroll. Transient response is insane and I have to imagine it's faster than the SS. I chose the twin scroll because theoretically it should be better and I've had a couple of TS EJ207 setups that I loved.

The price of the quaife alone is not bad, but if I'm in the tranny I'm going to swap a few other components, thus the $1k to $1.5K I said. Also, without expensive gears the 5 speed is not suitable for my power levels. There were at least two options for front LSD, A.P. suretrac and Helical, in the 6 speed. I can't recall which one is the best, but holding the power is the primary concern, LSD the second, gear ratios probably the third.

[Hindsight]

Yeah the 5-speed strength is a concern. 6 speed should hold up to anything you could throw at it. There are, of course, the PPG gears for the 5 speed but at like $4500 for the complete set.... that gets expensive quick. I will probably go to a six speed if I blow up my 5 but I really don't want the added weight and extra short/close gears. I think it would also require changing the clutch setup and driveshafts I have which would add to the conversion expense.

[wleehendrick]

I'm having major traction issues, but this is still a fun road dyno.

http://i.imgur.com/PVsDk0L.png

I would think so! You realize you're around the same power/weight ratio as a $3M Koenigsegg One:1?

[Rasmus]

That flange is hot, Hot, HOT! I'm virtually sold on getting the EFR 7163 for my build.

What header system did you use? Do you like it?

[Aero STI]

I would think so! You realize you're around the same power/weight ratio as a $3M Koenigsegg One:1?

That plot is total bull****. The road dyno software is just watching changes in RPM, since the tires broke loose the change was extremely exaggerated.

[Aero STI]

That flange is hot, Hot, HOT! I'm virtually sold on getting the EFR 7163 for my build.

What header system did you use? Do you like it?

This turbo is amazing. VF-39 like spool, twice the horsepower. I bought the exhaust manifold off of eBay. The seller claimed it was a Full Race, but there are no markings.

[wleehendrick]

That plot is total bull****. The road dyno software is just watching changes in RPM, since the tires broke loose the change was extremely exaggerated.

Ah got it... what looks like a steep, late rise is exagerated by wheelspin. Still impressive!

[Evan78]

Traction control would be awesome, but I completely deleted the ABS system.I'm guessing you already know this, but I think all you need are the wheel speed sensors and the Racelogic traction control system.

[Hindsight]

You can even get aftermarket wheel speed sensors and run them off the driveshaft or off the stock signal wheel.

RaceLogic decided to stop offering their traction control system LAST WEEK, so if you think you may want it, I'd suggest calling them ASAP and placing an order. They have a few left and they will support them forever but their other products make up 99% of their business so they felt it just didn't make business sense to keep offering the traction control system. It's a real shame because I know of no other comparable system for around the same price-point. I have been told by Cobb Tuning that they are planning on adding traction control to the AccessPort but admittedly that is probably going to be at least a couple years down the road, if at all. If they roll it out, they'll start with the newer vehicles first and then go down from there. I'm sure it will work great if they release it but I wouldn't bank on it happening for sure. I ordered my RaceLogic unit on Monday of this week and just received it today.

[Aero STI]

Good stuff. Hindsight, you have a PM from me.

I weighed the car today at the local milk distributor. It only goes in 20 lb. increments. The car came in at 2,000 lbs. with a full tank of gas. I weigh 170, so my 2170 guess I've been using for road dynos is pretty accurate.

[Aero STI]

Here's a good power comparison.

2008 Yamaha R6 with minor mods vs 818. I was making around 430 WHP with this run. The most I've seen was 510-515 WHP.


http://www.youtube.com/watch?v=vcch2sW4_aU

[Rasmus]

Damn, Son! That thing is quick. I think the Yamaha even got a slight jump on your 818.

[Hindsight]

Looked like you may have been pulling on him right before he let off... hard to tell. Those bikes run low 11's in the quarter stock. With the HP you have, I would expect you to be in the 10-second range, but there are a lot of factors like how you start and whether you get traction or not.

[Aero STI]

He was doing the horn so got the jump and I spun for a bit. Yes you can see it in the video and it was very apparent from my perspective, I was reeling him back in once I had traction. Speeds were about to exceed the legal limit so I chose to shut it down. ;)

My Race Logic traction control arrives today. I'm hoping I can carve out some time this weekend to get it installed and tested. I'm very excited for that.

[Hindsight]

I'm looking forward to a review from you of that traction control unit. I'm wiring mine in over the next couple weeks as part of my overall wiring harness work. It will be months before it's on the road though.

[Frank818]

430whp?
Oh ****, it means I need more power then. :)

Nice vid though! Too short but we understand its purpose. :)

[Aero STI]

The unit is here.

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

The wiring on this is dead simple. Outlined is how things hookup on an '06 WRX wiring harness.

Red wire with fuse - 12 V
Black twisted pair with ring terminal - Ground
Black/White - RPM Signal connects to Blue Green wire at connector C pin #5 on cluster

There is a 6 wire group for injector inputs:
Red on TC harness connects to Pink wire at connector D pin #8 on ECU
Orange on TC harness connects to Pink Blue wire at connector D pin #9 on ECU
Grey on TC harness connects to Pink Black wire at connector D pin #10 on ECU
Green on TC harness connects to Pink Green wire at connector D pin #11 on ECU

There is a 6 wire group for injector outputs:
Red Black on TC harness connects to Pink wire that goes to injector #1
Orange Black on TC harness connects to Pink Blue wire that goes to injector #2
Grey Black on TC harness connects to Pink Black wire that goes to injector #3
Green Black on TC harness connects to Pink Green wire that goes to injector #4

There is a 4 wire shielded cable for speed sensor inputs:
Red on TC harness goes to Front Left wheels speed sensor
Blue on TC harness goes to Front Right wheels speed sensor
Yellow on TC harness goes to Rear Left wheels speed sensor
Green on TC harness goes to Rear Right wheels speed sensor

There is a three wire group that connects to the dial controller:
Red to Red
Blue to Blue
Green to Green

That's it

[Aero STI]

The software that comes with the Racelogic traction control unit won't natively install on Windows 7 64 bit. It will install if you use compatibility mode and choose Windows XP SP3, it will also run in this mode, but it doesn't look like it will work because all of the main tabs are missing. It installed fine on my XP laptop and the tabs loaded up. Be prepared to bust out some old hardware if you want to connect to the unit with your PC. I haven't contacted tech support about this.

Fake XP
http://i.imgur.com/lD6Gaya.png

Real XP
http://i.imgur.com/thm1Lai.png

[Hindsight]

I've had that issue with some VW service manuals that only work in XP. I just installed VirtualBox and put XP on that. Keeps you from having to have two laptops.

Glad the install was easy, hoping to see the behind the wheel report shortly :)

[Evan78]

Yeah, I hope it'll run inside VMware, etc.

[Aero STI]

I got the Racelogic Traction Control up and running today.

For those doing the install, I counted the front and rear tone rings based on pictures I could find online. Both came out to 44 teeth. Based on the speeds I'm logging this appears to be correct. The subie ABS sensors were noisy for me until I got up to around 35 kph in the software.

My initial impressions are that this system works awesome. The launch control works very well, builds boost and keeps traction off the line. The traction control feels a bit surreal. It doesn't kill power like every other factory system. It feels like the engine is lightly breaking up or missing, but still accelerates hard. I felt the rear end get a little loose each time, but then it came back in check and accelerated. Usually in 3rd it's unnerving when the tires let loose above 60 MPH. This keeps the car collected. I'll get videos soon. I'm very happy with this purchase so far.

[Hindsight]

Awesome! So glad to hear it works so well. Now call that R6 for a re-match.

I should be wiring mine up as part of my harness install over the next few weeks.

[matteo92065]

Good update.

I have a kit on the way. I will be using your wiring work since I have the same year and model as you.

Keep posting your updates on details, experiences, and races!

[Aero STI]

Unfortunately I have no more observations to give about the Racelogic traction control. I blew up my 5 speed today. I lost 3rd gear around peak torque during a pull for tuning. The TC was not engaged because I planned to get one pull without and one with. I never got to the pull with.

I was able to jam the shifter into second, slip the clutch to get going, and roll through stop signs the whole way home. Oops.

My plan is to get a 6 speed with the AP suretrac LSD front differential.

[Aero STI]

http://www.youtube.com/watch?v=YU4E-sm3Fes

That's the sound of a broken transmission.

[Frank818]

Oh god, another one broken. :(

[Hindsight]

Doh! Well in the 5-speeds defense, you were pushing ~500 ft/lbs of torque and something tells me you weren't gentle :D

Guess I better move that set of PPG gears higher up in my priority list. Good luck with the six speed.... I will be very interested to see your take on having to shift more. But at least you'll never have to worry about it breaking. I read of guys running 700+ HP on drag slicks with zero issues on the 6-speed.

[matteo92065]

What do you do now?
Look for a 6 speed on ebay and/or craigslist? How will you hook up the speedometer? Conversion to two wheel drive parts come from FFR?

I received my Racelogic traction control kits today! I quickly opened them up to find out that they sent me the Digital Adjuster.!? I was expecting the same exact kit as yours. Now I need to find time to install it.

[Aero STI]

I didn't abuse the 5 speed while it was in my possession. Of course I have no idea what its life was like before me. This happened after the clutch was fully engaged, just winding it out from 2000 RPM up to redline. It blew up around peak torque.

I haven't torn it apart but I'm guessing the teeth of 3rd gear sheared off.

Yeah, eBay, craigs, wherever. I have a contact in Canada that has sold me multiple EJ207s, transmissions, brembos, etc. over the years. The JDM V7-V9 and USDM 04-07 6 speeds have the proper vehicle speed sensor. That wasn't eliminated until 2008. I believe the factory five center differential piece is designed for earlier 6 speed transmissions, which should be fine because that's what I'm shooting for.

[Mechie3]

My 5 speed blew up in my wrx at peak torque. Shifter, clutch out, accelerate......bam! It did make 450tq at the crank so not terribly surprised.

[Frank818]

450Awtq?

[Frank818]

I have a contact in Canada that has sold me multiple EJ207s, transmissions, brembos, etc. over the years. The JDM V7-V9 and USDM 04-07 6 speeds have the proper vehicle speed sensor.

No way! How's that possible, we've got f**k all in Canada! lolll

[Mechie3]

450Awtq?

No, 450 at the crank. It dyno'd 351 at the wheels on the stock turbo. Super peaky though. Back calculate a 22% loss and you end up with 450tq.

[longislandwrx]

No way! How's that possible, we've got f**k all in Canada! lolll

what? Robert at JDMracingmotors can get you anything if you have a little time. give him a call.

[Hindsight]

Any progress on the transmission replacement? Still on the hunt for a six speed?

[Aero STI]

Any progress on the transmission replacement? Still on the hunt for a six speed?

Nothing new in the transmission department. I parked the car for the winter in my basement garage last weekend. Now I have until April or May to get a new transmission installed.

[Hindsight]

Well, 7 to 8 months sounds like plenty of time. Good luck and keep us posted with what you end up going with.

[Frank818]

what? Robert at JDMracingmotors can get you anything if you have a little time. give him a call.

That's true, there are a lot of JDMs in Montreal.
My statement was more of a generic sarcastic joke, as 99.9% of my parts are all ordered from USA or China. :)

[Aero STI]

I think it is time for an update.

I bought a replacement 5 speed out of a 2011 WRX about a month ago. It has a bad center differential, which is obviously no biggy, but it's lacking a speed sensor which is minor. I got busy with other things and my opportunity for a quick fix evaporated.

http://i.imgur.com/4BXyy4Ih.jpg

The car is packed deep in to my basement garage behind other projects and summer toys.

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

In the mean time I've been looking for 6 speed deals and stumbled upon a great one. The transmission should be shipping out early next week. It's going to take some fabrication, but I'm excited to have a stout drivetrain.

[Bob_n_Cincy]

I think it is time for an update.

I bought a replacement 5 speed out of a 2011 WRX about a month ago. It has a bad center differential, which is obviously no biggy, but it's lacking a speed sensor which is minor.

Aero
I just bought a 2013 5mt to replace my tranny the ate itself earlier this week.
How were you going to fix the speed sensor issue?
Bob

[Hindsight]

Looking forward to your 6 speed conversion notes and driving thoughts once it's on the road.

RE speed sensor, you can always get one of those devices that uses ABS sensor signal to run the speedo. That is, if the 6 speed sensor is not plug and play for your current cluster.

[Aero STI]

Bob, I was going to use a front wheel speed sensor or gps to generate a signal to match what the cluster/ecu is expecting. I would run it through a SoC micro. This is the one I've been using lately: https://www.sparkfun.com/products/13229

The 6 speed I'm purchasing has the proper speed sensor built in. The biggest complication will be locking the center diff, because f5r only has a piece that fits the 06-07 DCCD and mine is from 2004.

[Bob_n_Cincy]

Bob, I was going to use a front wheel speed sensor or gps to generate a signal to match what the cluster/ecu is expecting. I would run it through a SoC micro. This is the one I've been using lately: https://www.sparkfun.com/products/13229

The 6 speed I'm purchasing has the proper speed sensor built in. The biggest complication will be locking the center diff, because f5r only has a piece that fits the 06-07 DCCD and mine is from 2004.

Hi Aero
I've been doing a lot of stuff on mega2560 but would go with something much simpler for this.
Do you know the pulse per mile or per tire rotation of the transmission.
Bob

[Aero STI]

Hi Aero
I've been doing a lot of stuff on mega2560 but would go with something much simpler for this.
Do you know the pulse per mile or per tire rotation of the transmission.
Bob

The mega is a good micro. I just likely the flexibility of a micro and fabric. Combined I can make almost any circuit that I would need in software.

Everything I read said that Subaru uses 4104 pulses per mile.

[Bob_n_Cincy]

The mega is a good micro. I just likely the flexibility of a micro and fabric. Combined I can make almost any circuit that I would need in software.

Everything I read said that Subaru uses 4104 pulses per mile.
Thanks Aero
Bob

[Aero STI]

Photo storage full

[Hindsight]

Nice.... looking forward to install pics.

[Aero STI]

Photo storage full

[Hindsight]

Nice! Eagle one etching wheel cleaner FTW.

[Aero STI]

Nice! Eagle one etching wheel cleaner FTW.

Yeah! The picture doesn't even do it justice. Since the etching wheel cleaner dulls the finish I used the wire wheel to help add back a little bit of shine. It's a night and day difference.

I'm going to pull apart the tail section of the transmission on Friday to begin the process of welding up the center diff and cutting down the rear output.

[Kurk818]

A tip for cutting the tail section; use the back of the back of the tail shaft bearing seat as your cutting point. Freeze plug will then fit securely into the bearing seat. You will end up with an additional hole to the right that served as an oiling port. I plugged this with epoxy putty after cleaning.

[Aero STI]

A tip for cutting the tail section; use the back of the back of the tail shaft bearing seat as your cutting point. Freeze plug will then fit securely into the bearing seat. You will end up with an additional hole to the right that served as an oiling port. I plugged this with epoxy putty after cleaning.

Thanks, Kurk. I'll use that as my reference. I'll probably weld a plate into the rear driveshaft output hole and blend it smooth. Same goes for the oiling port. I plan to take pictures.

[Kurk818]

Thanks, Kurk. I'll use that as my reference. I'll probably weld a plate into the rear driveshaft output hole and blend it smooth. Same goes for the oiling port. I plan to take pictures.

If you have the ability to weld it, its definitely the way to go. Please post photos when you get to it in the 6speed install thread.

[Aero STI]

Well my plans to mill the rear output shaft off the transmission and weld the hole were ruined yesterday morning. I pulled off the rear case and to my dismay the transmission was missing the center differential. From the damage to the case, clearly the diff grenaded. Parts from the diff spread everywhere. It's pretty messed up. The seller isn't accepting responsibility and won't give me a refund, but I suspect the Paypal dispute I started and fraud charges I file on Monday with the Virginia AG (his state) will get him in line.

Now some pictures...

http://i.imgur.com/DX7lFMR.jpg

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

http://i.imgur.com/SPr13kE.jpg

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

http://i.imgur.com/EE1UsqH.jpg

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

http://i.imgur.com/MrZ4cL3.jpg

[Aero STI]

http://i.imgur.com/w4ga6n1.jpg

http://i.imgur.com/tDYw71K.jpg

http://i.imgur.com/Mu5Rfqs.jpg

[Hindsight]

Oh man, what a bummer. Where did you find the seller (eBay, NASIOC, CL, etc)? Good thing for PayPal though; I'm sure you'll get it sorted out just fine, and you still have a long winter to locate a good 6 speed and get started on it.

[Aero STI]

Oh man, what a bummer. Where did you find the seller (eBay, NASIOC, CL, etc)? Good thing for PayPal though; I'm sure you'll get it sorted out just fine, and you still have a long winter to locate a good 6 speed and get started on it.

I bought it off of a guy on NASIOC. The seller was incorrigible. He wouldn't accept that there was something wrong with the transmission not having a center differential and blamed it on the "guy" he got the transmission from. I could hardly believe it. I can only imagine what someone would have done if they had installed this transmission into a Subaru, found out that it couldn't move the car, then removed it to discover what I had found. I have around 10 hours into cleaning and dissecting the transmission to understand exactly what was wrong with it.

Everything will work out between PayPal and my credit card. I had a little hope to get the car back on the road for one drive before the snow set in for the winter. I've got my eye on another transmission already. They're pretty abundant. Once I get my money back I'll pull the trigger on something else.

[Tamra]

Wow, that's horrible. Can't believe someone would do that!

[Mechie3]

My biggest beef with the car scene are dead beat sellers.

[RM1SepEx]

Basic statistics, large sample, for every honest Abe there is a crook, for every car savant there's an idiot. Our entire society has low moral fiber, reinforced by our continued pounding by marketing that is best described as propaganda. You just have to protect yourself as best you can.

[Aero STI]

Photo storage full

[Hindsight]

Wow, that clutch disc. I had that happen to me in a 1983 Rabbit GTI that I swapped a Corrado G60 engine into back in the late 90's. But it didn't fail due to the transmission. A piece just came off from the torque and started rattling around inside the bell housing. I could hear something but wasn't quite sure what it was. Then one day as it fluttered around in there, it got caught between the bell-housing and the flywheel and was rammed right through the transmission case into the transmission resulting in all the oil leaking out.

I'll be interested to see how that clutch feels after you have broken it in. Keep us posted. Love that up-pipe! Which header is that?

[Aero STI]

The header is a full race knockoff.

http://www.ebay.com/itm/SUBARU-IMPREZA-WRX-STI-Equal-Length-Full-Race-Turbo-Manifold-Up-pipe-1-5-Scroll-/271267573373

[Hindsight]

Interesting.... how is the quality?

[Aero STI]

Interesting.... how is the quality?

The flanges needed some surfacing to get them real flat. No cracks yet. The stainless is high quality, probably 16 gauge. Overall I would recommend these for the price. The header wrap may be the death of them.

The seller I bought mine from claimed that they were genuine full race. I knew the price was too good to be true so I didn't believe it going in to the purchase. There are other good twin scroll headers out there.

[Aero STI]

I got my center console from Wayne. I'm very excited to make the interior look so much more like that of a production car.

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

[Hindsight]

Wow, that's going to look slick! Can't wait to see the finished product. I got rid of my console, though I do still have my dash. I think my shifter is probably placed at a position that wouldn't line up with the console though. Same for e-brake I'm sure, when I finally install it.

[Kurk818]

I have the center console and the head unit trim installed with the factory ABS dash panel. I will be attempting to install the factory dash panel as well at some point. My two three items of concern are the steering column alignment with the the recess, height of the head unit trim and the side to side fitment of the center console as it relates to the dash and the steering column. Im interested in seeing how this all plays out for you and hopefully get some lessons learned from you :)

Have you already mounted the ebrake and shifter?

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

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

[Aero STI]

I have the center console and the head unit trim installed with the factory ABS dash panel. I will be attempting to install the factory dash panel as well at some point. My two three items of concern are the steering column alignment with the the recess, height of the head unit trim and the side to side fitment of the center console as it relates to the dash and the steering column. Im interested in seeing how this all plays out for you and hopefully get some lessons learned from you :)

Have you already mounted the ebrake and shifter?


Kurk, yeah your center console was part of my inspiration. It looks awesome. The shifter and ebrake were previously mounted so I could drive the car last year. I suspect they will need to move a little, but it looks pretty close so far.

The console will have to be slightly off center left-right, cutting more into one door than the other, and then the steering wheel will also still be slightly off center because it would look weird to go the full distance needed.

[Aero STI]

Photo storage full

[Aero STI]

http://i.imgur.com/hAF0cX6h.jpg

http://www.lambocars.com/images/prototypes/sesto29.jpg

[Hindsight]

Damn, it really makes the back look like a Lambo

Guessing that initial welding of the disk might have been a challenge.... always tough when welding a big thick aluminum piece to a thin small piece.

[Mechie3]

Hah! I was just showing the marketing guy at work the sesto elemento. I told him "don't hide it, make it a focal point on purpose!"

[Bob_n_Cincy]

Hah! I was just showing the marketing guy at work the sesto elemento. I told him "don't hide it, make it a focal point on purpose!"
The focal point was way to the left.

[Aero STI]

Damn, it really makes the back look like a Lambo

Guessing that initial welding of the disk might have been a challenge.... always tough when welding a big thick aluminum piece to a thin small piece.

There wasn't much drama. I cut the 2" round rod to about 1/4" thick, not exactly thin. I thought I might be able to get enough penetration that I could finish the case perfectly flat with no weld showing. No dice without a serious bevel added and I didn't have time for that.


Hah! I was just showing the marketing guy at work the sesto elemento. I told him "don't hide it, make it a focal point on purpose!"

Your taillight post inspired me. I considered having it sent off to be anodized, but I decided that I didn't want to pull the reverse lockout mechanism and shift rod bearing/seal.

[longislandwrx]

66. When behind another Subie, you habitually recognize the Subie rear differential... like dogs sniffing each other's balls.

[Hindsight]

How goes the progress?

[Harley818]

I like what you did with your dash. What year is that, and did you have to cut the sides?
I got my inspiration from Kirk originally and am working on more of a production look as well, but I was planning on using the FFR dash till now...... maybe I need to source a new dash.

[Aero STI]

Nothing major to report at the moment.

The dash isn't fully mounted, but the doors will likely be carved out to accommodate.

[Aero STI]

Photo storage full

[Hindsight]

Nice progress. Spring is right around the corner.

[Kurk818]

That tranny and cover look amazing. I may have to copy you and do a contrasting color :) nice work

[Aero STI]

Photo storage full

[longislandwrx]

Great a pioneer! let me know how your solid mounts feel, I really want to do msi mounts but concerned it may be too much vibration for the frame.

[Hindsight]

Wow those mounts are slick looking! Are they a little higher to help level off the trans? They appear to be a bit higher than stock anyway. I too am curious about vibration. Let us know how it feels.

[STiPWRD]

Great a pioneer! let me know how your solid mounts feel, I really want to do msi mounts but concerned it may be too much vibration for the frame.
++ 1

[Aero STI]

I welded my stock engine mounts solid and didn't notice any major difference in NVH. I did end up cracking them though. My welds held strong but the material I used (1/8") was too thin.

THe MSI mounts look good.

Everything is OEM height according to the manufacturer.
https://www.aluminati.us/collections/solid-mounts/products/aluminati-solid-motor-mounts

[Aero STI]

Photo storage full

[Hindsight]

Good stuff, bet you can't wait to test it out. Very interested in seeing what you think of it.

[longislandwrx]

good stuff man, looking forward to the 6 speed putting the power down.

[Aero STI]

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

[Hindsight]

Awesome, congrats on getting it all wrapped up!! Just in time for spring too. Has to be a good feeling.

[Aero STI]

I'm wrapping up the design on my 6 speed shifter. I haven't gone through detailing everything yet. It should be a vast improvement over my current prototype.

http://i.imgur.com/61zwcKph.jpg

[Aero STI]

The shifter mechanism was finalized and sent off to be CNC'd. I'm just putting miles on the car and e-tuning at the moment. It still needs the new dash and center console installed and I'm patiently waiting for my new nose so I can do some body work.

[Loring]

Andrew,

How well does your wheel/tire setup hold with TCS off in 3rd when you take it all the way up?

[Hindsight]

Wow, that's a great demonstration! I'm excited to get mine hooked up and working this weekend!

[Aero STI]

Andrew,

How well does your wheel/tire setup hold with TCS off in 3rd when you take it all the way up?

I'm not sure what you mean by take it all the way up? Without TC In third, doing a standard pull starting at 2500 RPM, the car always breaks loose before peak torque. Same holds true for 4th. The car pretty much spins the tires on command below 80. Above that it's hit or miss.

[Aero STI]

Wow, that's a great demonstration! I'm excited to get mine hooked up and working this weekend!

You're very likely to see misfires after using it. I think I'm going to have the DTCs shut off for that. The launch control is so epic. I plan to get a video of that too.

[Hindsight]

It will be interesting to see how the axles hold up to launch control launches.

What size and type of tires are you running?

[Aero STI]

It will be interesting to see how the axles hold up to launch control launches.

What size and type of tires are you running?

With LC it's a pretty smooth takeoff. Tires are 255/40r17 Hankook Ventus V12s. They're for my Saabaru and at the end of their life. I need to pull the trigger on some new wheels and tires for the 818.

[Hindsight]

Yeah the new tires should help a lot. What are you thinking about getting?

[Aero STI]

Probably some Hankook R-S3 V2s. I'm contemplating Enkei TY-5 wheels. 18x8 Front 18x9.5 Rear. I haven't fully committed.

53118

[Bob_n_Cincy]

Andrew,
Are you using the front STI axle or the custom ones?
Bob

[Aero STI]

Bob, I'm running my '06 WRX donor axles with the FFR axle shafts. The JDM 6 speeds don't use stub axles, but have the proper diameter axle seal to match WRX male axle ends.

[Hindsight]

18s will look awesome! I think you'd get better traction with 17s and a taller sidewall, but everything is a trade-off. I have 17's in front and 18's in back and the 18's look not just a little better, but like a completely different wheel. You could always be like the street race guys who run 18's up front and 15s in back with super tall drag radials hahaha.

So now that you've driven it a bit, what are your comments on the 5 speed vs the 6 speed? I know you mentioned the limited slip helps a lot, but what about the gear ratios? Are you ok with the amount of shifting and the time spent in each gear? Can you hit 60 in 2nd with the 6 speed?

I'm headed out to the garage to finish re-wiring the traction control, hopefully for the last time.

[Aero STI]

The downside of 18s is that they make the brakes look tiny. I do prefer the tire sizes you can get in 17s for fronts, but I don't care for the looks of many lighter weight 17s that fit 5x100. A lot look dated, as if the manufacturers have abandoned that size for updated styles.

I haven't paid close attention to where I can shift at yet. The gears go by so quickly in either transmission it doesn't really matter ;)

I hogged out the doors to fit the dashboard. It's mounted rigidly, just wrapping up the center console mounting. I didn't have to move the ebrake, but I do have to move the shifter. I'm going to finish it up tomorrow.

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

[Hindsight]

Looks great. Much more OEM look.

[metros]

Agreed, nice finish work.

[Aero STI]

Thanks guys. Unsurprisingly, with the glove box, cup holders, etc. it looks really close to a factory interior. Plus it's way more functional. Even the deeper recess of the gauge cluster is a huge benefit for visibility in a roadster like this. I'm surprised FFR didn't utilize the Subaru dash. Maybe they tried it and didn't like how it would finish out. It's such a close fit and could have easily been designed in.

[Aero STI]

Back to being driveable. Overall I'm very happy with how it turned out. It still needs some finishing touches.

If anyone still has their factory shifter boot and e-brake boot, please let me know. My shifter boot is pretty nasty and I can't locate the e-brake boot.

http://i.imgur.com/Oi5MFbDh.jpg

http://i.imgur.com/Fj5tUmoh.jpg

http://i.imgur.com/X7ZC4y1h.jpg

http://i.imgur.com/e5KpV3uh.jpg

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

[Kurk818]

Looks fantastic. Will be doing the same when time allows. Does the steering column align pretty well the where the Subaru column used to be? Any ideas on what youre going to do to fill the gap in front of the dash?

[Aero STI]

Thanks! The steering column is probably 1 to 1.5 inches off center. I think few will notice.

The plan is to fill the gap to the windshield with the plastic from the FFR supplied dash. It's not much, probably 4" at the furthest point. I'll try to get a picture at some point.

[Kurk818]

FFR has used a off the shelf column in their new coupe, it appears. That may be a way to correct the alignment.

I was thinking the same with regards to filling the gap. Perhaps fusing it to the smaller removable OEM portion of the dash and painting it. How hard was it to find attachment points for the dash?

[Aero STI]

The steering column, Subaru or otherwise, will likely interfere with the pedal box. A steering quickener may be the best option to shift things over. There are examples of them installed on NASIOC. I'm fearful the car would dart too quickly with the quickener.

Yeah, fusing the removable piece would be great.

I fabricated all the mounting brackets. It wasn't difficult, but I wouldn't call it easy. 4 for the dash so far, two for the center console.

[longislandwrx]

nice work man.

are you going to carpet? Once you get those door panels sorted this is going to look amazing.

[Mitch Wright]

Looks great, nice work.

[Aero STI]

I appreciate the compliments. I might try to fit BRZ door panels. I need some measurements and don't have a BRZ or FR-S readily available. There are a few at work, but I don't know the owners.

The floor boards are carpeted. I stole the STI floor panels from Rori. I don't feel that much more carpet is needed. I would like to make some custom kick panels out of fiberglass eventually. I used to do elaborate car audio installs back in the 90's, so I have some experience with custom kicks.

[billjr212]

Really great work. You should be able to take a slice out of the center glove box to make it shallow enough to install. I was able to do this, then riveted some aluminum strips on the outside to fuse it back together.

[BN]

Niiiiiccccce work and where did you get your steering

[07FIREBLADE]

Looking great. I spy the dreaded 4wire trailer wire in your door. This might actually work for the C guys the way you took a cutout of the door panels. Looks to clear the window area but I need a better picture to tell

[Aero STI]

Really great work. You should be able to take a slice out of the center glove box to make it shallow enough to install. I was able to do this, then riveted some aluminum strips on the outside to fuse it back together.

Thanks for reminding me that you did this. I knew I saw that done before, but couldn't remember by who.


Niiiiiccccce work and where did you get your steering

The steering wheel is the FFR optional wheel


Looking great. I spy the dreaded 4wire trailer wire in your door. This might actually work for the C guys the way you took a cutout of the door panels. Looks to clear the window area but I need a better picture to tell

Hah... The ONLY place I used it was to provide power to my door actuators. I dieted my harness, but I'm not happy with the aesthetics of the whole harness so will be redoing everything this winter. I think you're right that it would clear the C windows. I'll try to snag some of the requested pictures tomorrow.

[BC Huselton]

The entire dash is amazing. Do you have any pics of the structure that supports it? I am at a similar stage and have been plotting to us the center section which causes the shifter to be moved 2" forward. I like what you created much better. Any help is appreciated. OR e-mail me @ BChuselton@gmail. Thanks

[Aero STI]

I'll take some additional pictures soon. Hopefully tonight.

I called FFR today and spoke to Courtnie. My new nose is shipping out today sans lens covers. Also, I ordered the bent aluminum coolant tubes so I can get rid of hidden hose clamps.

[Frank818]

So that confirms there are still out of lenses. I wonder who they source it from...

BTW your interior is more than amazing! Who would have thought it would be possible to fit the Subaru's entire dash and console in the 818... Bravo. :)

[Aero STI]

Courtnie didn't elaborate much on the lens issue, just that it was ongoing.

It's a bit shocking how well the interior fit in there.

[Aero STI]

Here are the mounts holding the dash and center console in at this point. Sorry if the images aren't super intuitive. I would have to take things apart a lot more to get better pictures.

http://i.imgur.com/2D9SOeTh.jpg

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

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

http://i.imgur.com/402H1Wih.jpg

[Aero STI]

I got my nose retrofit today. It doesn't look like FFR has done anything with the molds to make them match better at this point. The left fender is still 1/2" too long.

http://i.imgur.com/9yH1Y3Wh.jpg

http://i.imgur.com/js5apMNh.jpg

http://i.imgur.com/H9iAHp2h.jpg

Also, I don't have the best luck when it comes to quality control on my aesthetic pieces. I have an earlier chassis, 73 I think, pre-ordered when "no paint bodywork" and "real carbon fiber" were selling points. All the panels have the bad edges and voids galore in the gel coat that early buyers ended up with. I also upgraded to every aero part and received super shoddy carbon fiber covered fiberglass parts (street splitter, side sails, and rear diffuser are all see through) before they went to the autoclave process. Now with this nose, the QC person must have been on break when one of my fenders was made. I unwrapped it to find a wide open void. The rub is that the gel coat void is right on a hard body line. That'll be fun to get right with body filler. Oh well, body work galore awaits.

http://i.imgur.com/lUE3dCKh.jpg

http://i.imgur.com/Z1k8uvgh.jpg

[Kurk818]

Wow, thats quite the void. Person applying fiberglass shouldve definitely seen that when rolling it out. Ouch.

Hope mine arrive with nothing like that.

[07FIREBLADE]

Sucks to hear. Their car has shorter fenders so I don't expect ffr to change their molds any time soon. Your front splitter will not fit with the new front most likely mine didn't and I'm fond of forking over more cash to ffr for carbon parts at the moment.

[Aero STI]

Sucks to hear. Their car has shorter fenders so I don't expect ffr to change their molds any time soon. Your front splitter will not fit with the new front most likely mine didn't and I'm fond of forking over more cash to ffr for carbon parts at the moment.

That's no good. Did you make FFR aware of this?

[07FIREBLADE]

Yes. I kinda got a shrug and its hand shaped molds so there are slight variations.

[metros]

Op, did you contact ffr about the condition of your fenders upon their arrival? That's pretty poor.

Fireblade - more details? What about the splitter doesn't fit? Too wide?

[Aero STI]

Yes. I kinda got a shrug and its hand shaped molds so there are slight variations.

Seems to be the common theme. That's unfortunate because the splitter isn't exactly something that can be massaged into place.


Op, did you contact ffr about the condition of your fenders upon their arrival? That's pretty poor.

Fireblade - more details? What about the splitter doesn't fit? Too wide?

No, I haven't contacted them yet. I wanted to see how things fit together and see if there are any other significant flaws that I missed. I highly doubt they'll do anything. 3 years of direct interaction and a few years before that lurking and monitoring their activity would suggest customer service is not their strong suit.

[Hindsight]

Darn, sorry to hear about the quality issue Andrew. But I am looking forward to seeing it all put together on your car.

[Aero STI]

I started sanding the seems on the new front fenders and also painted the headlight buckets with gloss black.

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

http://i.imgur.com/Z2wfWhHh.jpg

I took 07FIREBLADE's lead and ordered the Eagle Eye LEDs, except I went with their switchbacks so that I'll have white DRL and then have all four lights as amber for turn signals.

http://www.amazon.com/Everbright-8-Pack-Switchback-Daytime-Running/dp/B00X5NI9HU

All 8 LEDs tested as good so far. I'll give them a good test cycle before I seal up the headlights. That won't happen until FFR figures out the headlight lens issue.

[Aero STI]

In an effort to make the interior look even more like it came from a real car factory, I ordered up some BRZ door panels. They're the perfect height, basically the perfect length, but will need some pretty serious custom work to match the lower door radius. I'm up for the challenge.

http://i.imgur.com/Neu1hfbh.jpg

http://i.imgur.com/UCn8VPXh.jpg

http://i.imgur.com/fK8RUjVh.jpg

[Aero STI]

One more video of the car's ability to create prodigious amounts of tire smoke


http://www.youtube.com/watch?v=63FBqH5kefw

[AZPete]

I'm looking forward to see how make those door panels work because they look good so far. Can you explain what the headlight lens issue is?
(I had to open windows to get the smoke out of my office after watching your vid! ;))

[Scargo]

The video and the numbers are quite impressive. So much so that I had to back-up and read all your posts. You've done so many neat things to the car.
As I get it you are running E85 in a stock EJ255 out of 2006 WRX. What is your boost? I just can't imagine the engine holding together at the numbers you've mentioned, even at 430 WHP.

[Aero STI]

The video and the numbers are quite impressive. So much so that I had to back-up and read all your posts. You've done so many neat things to the car.
As I get it you are running E85 in a stock EJ255 out of 2006 WRX. What is your boost? I just can't imagine the engine holding together at the numbers you've mentioned, even at 430 WHP.

Glyn, the motor is stock. I'm running 27 PSI peak. I'm still working with Phatron on refining the tune. I believe we're around 60 revisions at this point. He's awesome.

I would expect to crack a ringland or bend a rod by now, but over 1000 miles at these power levels and holding strong.

I've been breaking and rebuilding Subarus since 2005 and I've had good luck pushing a handful of stock motors to pretty absurd power levels. I usually like to take a wait and see approach on these things.

[Scargo]

27! I've been a little over 26 (due to sticky wastegate). My mildly modded, stock bottom end motor with CP pistons, ran like a banshee. That was on 100 octane. It was dyno'ed to make 395 @ 24PSI. I got 70 hours out of that motor.
I understand E85 runs cooler, so less of a piston burning issue. I'm surprised that you can get away with 1000 cc injectors.
I like your attitude, though. Sort of throw-away motors.

Thanks for the tip about the mag cleaner/etch. Got me to thinking and looking at metal preps. I have some and often use them though I try to use my blasting cabinet as often as possible and then immediately go to solvents and a final acetone wipe before going to paint. I have spent a lot of time with parts just to make them friendly to handle; not for cosmetic purposes. The Subaru castings can be really nasty, with their casting spikes sticking up and sharp edges. I like the finish on my intake that I coarse blasted and clear-coated.

[Frank818]

Tnx for the LED tip!

[Aero STI]

I'm looking forward to see how make those door panels work because they look good so far. Can you explain what the headlight lens issue is?
(I had to open windows to get the smoke out of my office after watching your vid! ;))

Hey Pete, FFR is having issues with their supplier delivering the piece of acrylic that covers the headlight bucket. I'm not sure if it's simply a slow supply or quality problems. They sent my front end conversion, along with many others', without the lenses.

[Frank818]

Just bought your LED switchbacks, tnx again.

[Aero STI]

New wheels and tires... 225 front 265 rear

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

[Hindsight]

Awesome! I figured you'd be pulling the trigger on tires after that last video. Wheels look great. I bet the new setup has much better traction.

[Kurk818]

Loving the wheel/tire combo. Suites the car nicely.

[longislandwrx]

look at that scenery! car looks great

54346

[Frank818]

Great stuff! Do you have a pic of the rear tire how close to the fender lip it is? Does it stick out a little bit, inside, or flush with lip?

[Aero STI]

Thank you everyone for the compliments on the new wheel/tire combo. I love the "Pure Michigan" addition to the picture. The wheels are Enkei TY-5 in "Painted Black". 18x8 et45 front and 18x9.5 et45 rear. I went with Hankook RS-3 tires 225/40R18 and 265/35R18. They're so much better than the V12s. I actually have a brand new set of RE11s to put on the wheels that the V12s are currently on, but there are a couple more epic burnouts left in the V12s.

Frank, I've been running 1.5" rear spacers on each side. These were purchased to properly space some factory 17" WRX wheels (shown in other pictures of mine). The current wheels and tires stick out a little under an inch. I'm going down to 15mm spacers. I'll take a picture of the "flushness" once the new spacers are installed.

[longislandwrx]

I'll be running a 9.5 +40 in the rear but I am yet undecided on rear tire size. I'd love to run a 275/35R18... i'm looking forward to seeing your setup with no a smaller spacer.

[Aero STI]

I'll get better shots with my SLR when the new spacers are installed.

A few more parts that I will be installing soon. S2000 mirrors like 07FIREBLADE.

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

[Hindsight]

What color are you painting it? I'm still stuck. Leaning toward a non-metallic gloss grey, or a pearl orange. Probably do the grey.

[Aero STI]

What color are you painting it? I'm still stuck. Leaning toward a non-metallic gloss grey, or a pearl orange. Probably do the grey.

I really like the way the car looks with cyber gray metallic (like Lumpyguys'), especially because I have all of the carbon and black accents.

[Aero STI]

I was told to give the car a good thrashing and log it. The RS-3 tires are awesome. It's fun to have traction.

[ben1272]

wow....I think that was 60-120 in about 3 seconds

[ben1272]

I started sanding the seems on the new front fenders and also painted the headlight buckets with gloss black.

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

http://i.imgur.com/Z2wfWhHh.jpg

I took 07FIREBLADE's lead and ordered the Eagle Eye LEDs, except I went with their switchbacks so that I'll have white DRL and then have all four lights as amber for turn signals.

http://www.amazon.com/Everbright-8-Pack-Switchback-Daytime-Running/dp/B00X5NI9HU

All 8 LEDs tested as good so far. I'll give them a good test cycle before I seal up the headlights. That won't happen until FFR figures out the headlight lens issue.

Sorry, what is the headlight lens issue? I have some with my headlight kit, but I have not done anything with them yet. Is there something I should be looking for/aware of?

[Hindsight]

Wow, that's incredible. Makes me want to get a 7163!

[Aero STI]

Sorry, what is the headlight lens issue? I have some with my headlight kit, but I have not done anything with them yet. Is there something I should be looking for/aware of?

FFR is having trouble with the manufacturer of the headlight lenses. I still haven't received mine.

[Aero STI]

Wow, that's incredible. Makes me want to get a 7163!

It's a lot of fun. I still have a lot of headroom for more power if the boost was cranked up more, probably 50-75 more WHP.

[Aero STI]

I started making progress on the BRZ door panel fitment. I'm going to have the top edge of the door panel exposed so it forms a softer edge on the top of the door for someone's arm to rest on. I'll utilize as many factory fasteners as possible.

http://i.imgur.com/zmNM1kIh.jpg

[Hindsight]

Wow that's really going to look awesome when all the trim and handles are in. Very ambitious!!

[Aero STI]

I have to admit, the driver's door is looking awesome. I'm going fill the top edge seem as part of the painting process. It can be pulled in tighter than what is seen in the pictures. However, doing that makes it harder to take off so I didn't go hole hog for the pics. The edge of the door that was cut to shape will also get a U shaped trim piece glassed and filled to mate with the door and the panel. The side of the dash needed some pretty good relief. I plan to make a fiberglass piece to cap the side of the dash. It took a huge amount of work taking it off and on probably 50 times, but the next door should go smoother.

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

http://i.imgur.com/kHeP2yrh.jpg

http://i.imgur.com/dI1iYZhh.jpg

[Hindsight]

WOW that looks incredible! Much, much more OEM looking.

[Frank818]

Impossible... you've made the impossible true. The truth really is out there, Mulder!
You gotta tell FFR about what you did, they will twitter and facebook your pix!

[mikeb75]

Really nice job on the door and your entire interior. Maybe the nicest looking on the forum.

[AZPete]

Great work on the door panel. What's your plan for the switches? Can you repurpose them for interior lights or something?

[Aero STI]

Thanks everyone for the compliments. It wasn't easy so far and there is still plenty left to do, but I think the interior is really coming together.

I'm going to be installing s2000 mirrors and plan to have them powered, so I'll use that switch. Maybe the others can be used for something. I don't have any ideas at the moment.

[07FIREBLADE]

You could just wire up the mirrors to the brz switch. That's what I'm using for my s2000 mirrors. Very bold move on the door panels. People need to keep in mind that this will not work very well with the coupe unfortunately

[Aero STI]

I plan to use the BRZ mirror switch. Glad to hear it's working for you.

I actually think that these door panels could be made to work with the coupe. You would use the factory seal on the door panel to butt up against the window.

[07FIREBLADE]

The problem I'm seeing is that it's not shallow enough to work with the window motor. What latch do you plan on using? The Wrx or the brz? I would love to have these work. But the way ffr designed the new door frames and the way the motor fits inside it doesn't seem feasible. I'm not knocking you at all. I love the look could you lay the drivers door panel in the passenger side and take a sharpie to see how much is trimmed. Also maybe a panel depth measurement. I have to go remeasure but the ffr new ones are half the depth as the original panels.

[Bob_n_Cincy]

The problem I'm seeing is that it's not shallow enough to work with the window motor. What latch do you plan on using? The Wrx or the brz? I would love to have these work. But the way ffr designed the new door frames and the way the motor fits inside it doesn't seem feasible. I'm not knocking you at all. I love the look could you lay the drivers door panel in the passenger side and take a sharpie to see how much is trimmed. Also maybe a panel depth measurement. I have to go remeasure but the ffr new ones are half the depth as the original panels.

Great Job Aero,
There was a guy at Grissom yesterday that saw my car and thought you might be there.

Fireblade,
A agree with you that this probably won't work with the coupe windows. But, for us 818S Roadster guys, this looks great. I talked to Tony at FFR. If I remember correctly he said 818s and 818c sales are 50/50.

Bob

[Aero STI]

I've been too busy enjoying the car and the summer weather to post. Here are a couple of updates.

Broken driver's side axle using launch control on the street
http://i.imgur.com/6VzbAgeh.jpg

[Hindsight]

Nice, was wondering if you feel off the face of the earth. But glad to hear you have been out causing trouble.

Do you have WRX or STI rear spindles? I ask because I think the outer CVs are larger on the STI..... so wondering how you dealt with that during your six speed conversion. After doing a few track days, I've decided the six speed is the way to go so I've been researching to figure out what is involved and what years I can use. How did you handle the speed sensor?

[Frank818]

1000hp? Then mines are certainly good for that much as well, but DSS couldn't guarantee anything over 450-500.
Did you get your hubs broached or you're using OEM splines? I can't believe OEM splines will support 1000hp on RWD but if they do, then I'm good for 1500 at least.

[Aero STI]

The car has been phenomenal this summer. Still fast as hell and holding strong. I very recently did a compression check and saw 152 to 155 PSI across all cylinders.

I have WRX rear spindles. According to DSS the spline going in to the WRX rear hub is the weak link. They rate these axles to 750 HP on a 3,300lb vehicle, so they seemed comfortable with up to 1000 hp on our car. If the spindle to WRX hub lets go I will upgrade to STI hubs and the rating is then 900hp+ on a 3,300lb vehicle.

Jeff, you should be all set with the '04-07 USDM STI transmission having the proper speed sensor. It's not until '08 that it went away. You also lose the oil pump and go to splash lubrication that year. Pay attention to front differential seal diameter differences (05-07 is different and won't take WRX male axle stubs without some changes, JDM switched in '05 as well). Obviously the center differential lockup will need to be addressed. My JDM forester transmission has some of the best 6 speed ratios available, but you're still shifting to 3rd gear for 0-60.

[Hindsight]

Thanks Andrew. So on the 04-07, you are saying they have an oil pump? Could this be used to add an external transmission oil cooler or would I need an electric pump to do that?

Last question, do you know what changes are needed to the 05-07 to accept the male axle stubs from the WRX? Or is there a better way.... like getting custom axles and running STI inner CV joints?

Thanks again.

[Aero STI]

Thanks Andrew. So on the 04-07, you are saying they have an oil pump? Could this be used to add an external transmission oil cooler or would I need an electric pump to do that?

Last question, do you know what changes are needed to the 05-07 to accept the male axle stubs from the WRX? Or is there a better way.... like getting custom axles and running STI inner CV joints?

Thanks again.

Yes, you can run an external cooler. No extra pump is required. I guess the factory unit isn't thermostatic. My Blue Saabaru has a JDM V9 Spec C Type RA. This transmission came with a factory cooler. It was a very small loop with fins in front of the radiator. Oil pump line comparison between no cooler and cooler.

http://i1062.photobucket.com/albums/t486/mg556linked/d5038d1f.jpg

http://i1062.photobucket.com/albums/t486/mg556linked/5ed417fd.jpg

Axle seals are easy to fix.

http://forums.nasioc.com/forums/showthread.php?t=1097352

[Hindsight]

Thanks Andrew - so are you using the inner CVs from a WRX or an STI?

[Wayne Presley]

Thanks Andrew - so are you using the inner CVs from a WRX or an STI?


Doesn't matter, the stub that goes into the 5 and 6 speed transmissions are the same

[Hindsight]

Thanks Wayne. That makes it easy.

[Frank818]

I took 07FIREBLADE's lead and ordered the Eagle Eye LEDs, except I went with their switchbacks so that I'll have white DRL and then have all four lights as amber for turn signals.

http://www.amazon.com/Everbright-8-Pack-Switchback-Daytime-Running/dp/B00X5NI9HU


Well I'm not sure those lights work well, or there's something I don't understand in the word "switchback". I thought that when the white DRLs are on and you then activate the turn signal, the white LEDs would turn off while the amber ones are activated by the turn signal. Doesn't work, both amber and white stay on at the same time. Unless I use a relay. Nothing "switches back", it's just plain on and off for 2 independent circuits.

How are yours working?

[Aero STI]

Well I'm not sure those lights work well, or there's something I don't understand in the word "switchback". I thought that when the white DRLs are on and you then activate the turn signal, the white LEDs would turn off while the amber ones are activated by the turn signal. Doesn't work, both amber and white stay on at the same time. Unless I use a relay. Nothing "switches back", it's just plain on and off for 2 independent circuits.

How are yours working?

There is a "switchback" controller you can buy. https://www.oznium.com/switchback-driver

I created my own with a relay board and microcontroller. Amber is directly wired to flasher, when flasher is detected by microcontroller, DRL power for white is turned off for a set amount of time. Each flash resets the timer. When the flash stops DRL functionality is restored. This is exactly how the OEMs do it.

[Frank818]

Interesting! I'll see what to do. It's just sad though they advertise the Eagle Eyes as switchbacks but they aren't. I thought the driver was included in the lights already. Os well, I've had a lot of surprises on this build anyway. :)

[Aero STI]

A few new videos...

http://www.youtube.com/watch?v=cdEGXM60YcE

[Aero STI]

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

[Aero STI]

http://www.youtube.com/watch?v=sBB6-egX7vc

[Hindsight]

hahaha, I'm sensing a common theme with you :D

[flynntuna]

Did someone say doughnuts?

[Frank818]

Man check out those repairs on the road. lolll

How did you come up with those camera plans? Awesome.

[Aero STI]

hahaha, I'm sensing a common theme with you :D

I had some tires that really needed to die.


Man check out those repairs on the road. lolll

How did you come up with those camera plans? Awesome.

Just some quick scouting things out and it all came together.

[Hindsight]

59288

[Samiam1017]

what drone do you have

[Frank818]

Never thought of a drone! Damn I'm so stupid, or too much focused on building my car.

[Frank818]

There is a "switchback" controller you can buy. https://www.oznium.com/switchback-driver

I created my own with a relay board and microcontroller. Amber is directly wired to flasher, when flasher is detected by microcontroller, DRL power for white is turned off for a set amount of time. Each flash resets the timer. When the flash stops DRL functionality is restored. This is exactly how the OEMs do it.

For those who use Eagle Eyes like the ones on this thread, so far the Oznium driver is not very good. It switches to ground but the Eagle Eyes are positive and have a common ground. Cost me 30 bucks with shipping for 1 driver so I will see if Oznium can do something to help. Otherwise I think finding another solution is better, like your own relay board yeah.

[Aero STI]

what drone do you have

I have a bunch that I've built. 90mm FPV brushed up to 650mm 8s that can hover for over 40 minutes with gimbal and retractable landing gear. This was shot with my DJI Phantom 4. The built ones were fun, but the DJI beats them hands down for functionality and ease of use.

[Aero STI]

For those who use Eagle Eyes like the ones on this thread, so far the Oznium driver is not very good. It switches to ground but the Eagle Eyes are positive and have a common ground. Cost me 30 bucks with shipping for 1 driver so I will see if Oznium can do something to help. Otherwise I think finding another solution is better, like your own relay board yeah.

Sorry to hear that. I didn't look closely at the circuit design of that driver.

[Frank818]

No worries, those LEDs fit great in the bucket but it's good that people know they all don't come with switchback included and that you need positive switchback. In the end it's cheaper to build your own like you did. Some come with an external driver, but it's 1 driver for 10 lights, you need to buy 2 sets, that's 50 bucks and 12 spare lights. lolll Which I have paid already but I made the mistake without looking at the switchback circuit. :)

Have you run with them on the road? Are they good as DRLs?

[Aero STI]

No worries, those LEDs fit great in the bucket but it's good that people know they all don't come with switchback included and that you need positive switchback. In the end it's cheaper to build your own like you did. Some come with an external driver, but it's 1 driver for 10 lights, you need to buy 2 sets, that's 50 bucks and 12 spare lights. lolll Which I have paid already but I made the mistake without looking at the switchback circuit. :)

Have you run with them on the road? Are they good as DRLs?

Nope... I was more interested in driving the car this year, so I put off the front end conversion.

[longislandwrx]

crazy that they tar all these roads that no one drives on. ;)

[axelthrasher]

The BRZ door skins look really good - FYI as a small upgrade you can get the speaker trim panels from a 2017 BRZ, the speaker area has red stitching to match the other pieces on the panel and the speaker surround is silver. Adds a nice touch in my opinion.

59471

Or if blue is more your color - you can get the Hyper Blue Series door card...

59470

[Frank818]

Oh I thought you meant we could upgrade FFR's entire door skins and use the BRZ's, with handles, arm rest, pocket, etc.

Look cool yes!

[Aero STI]

I'll consider those speaker panel pieces.

The car is off the road until spring. I'm hoping to finish the interior, upgrade to the new nose (possibly doing paint), and install this over the winter...

[Bob_n_Cincy]

I'll consider those speaker panel pieces.

The car is off the road until spring. I'm hoping to finish the interior, upgrade to the new nose (possibly doing paint), and install this over the winter...

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

Aero,
Same system I've put in.
We should talk about the work arounds to some of the small issues we had.
Bob

[Aero STI]

Aero,
Same system I've put in.
We should talk about the work arounds to some of the small issues we had.
Bob

Yeah, I mentioned your name to them and told them I wanted the same setup.

Are your issues documented in the dry sump thread?

[Hindsight]

Holy cow, Andrew sighting! Congrats on the dry sump purchase... I'm very jealous. I need to get one at some point but am guessing it may be a while.

How is the car running? Have you had a chance to 1/4 mile it yet?

[Bob_n_Cincy]

Yeah, I mentioned your name to them and told them I wanted the same setup.

Are your issues documented in the dry sump thread?
No, probably not. Just so little hints and fixes.
Bob

[bbjones121]

I don't know how I missed this build. Looks amazing!

[longislandwrx]

What was the price for all the parts? looks nice and simple, no pulley included or just not sized yet?

[Scargo]

Oooh! Pretty parts! This is Element kit?

[Aero STI]

The pulley was back ordered. I have it now. I think around $2700 shipped. Still need the hoses. This is direct from Aviaid.

Started piecing together the new front end today.

http://i.imgur.com/Uv0aLAoh.jpg

[Aero STI]

Holy cow, Andrew sighting! Congrats on the dry sump purchase... I'm very jealous. I need to get one at some point but am guessing it may be a while.

How is the car running? Have you had a chance to 1/4 mile it yet?

The car is still great. I didn't make it to the drag strip or a road course. Things got busy at the end of summer and are just starting to settle down.

[Aero STI]

Happy New Year!

I've been making steady progress over the holidays. I got the new nose mounted. I also started working on the massive void on my passenger side fender. Sanding revealed that it was much bigger than what the small hole in the gelcoat was revealing. I used 3M vinyl ester filler. The stuff gets as hard as fiberglass. The remaining imperfections are small enough for standard filler.

http://i.imgur.com/fwAp8hth.jpg

http://i.imgur.com/ALNOMw9h.jpg

http://i.imgur.com/e3Dy67nh.jpg

[Hindsight]

Wow, sorry you had so many issues with the body. But it is looking good! When spring comes for you in another 10 months or so, you'll be ready ;-)

[Frank818]

Looks like the car is at its acupuncture appointment of the week. lolll Been there done that, keep up the good work.

7 holes per headlight, that's a lot.

[Aero STI]

I will probably do even more to make sure the lights go tight to the body panel. I bought something like 30 M4 blind fasteners. I'm going to install them so the headlights are removable from the back side.

[Aero STI]

Wow, sorry you had so many issues with the body. But it is looking good! When spring comes for you in another 10 months or so, you'll be ready ;-)

It's not too many issues. I've committed to doing some decent body work over the winter and painting it in early spring.

[Wayne Presley]

Car looks great

[Hindsight]

What color?

[Frank818]

30 M4 blind fasteners. I'm going to install them so the headlights are removable from the back side.

I'd like to know more about that. Looking for a solution myself, what are those blind fasteners? Certainly not rivnuts?

[Aero STI]

What color?

I like the cyber metallic from the Corvette that someone else did. I may stick with white and then vinyl wrap if I want a more exotic color


I'd like to know more about that. Looking for a solution myself, what are those blind fasteners? Certainly not rivnuts?

http://www.ebay.com/itm/M4x15mm-Flush-Head-Stainless-Steel-Self-Clinching-Threaded-Studs-Fastener-30pcs-/391344165716?hash=item5b1dee1354:g:K~QAAOSwal5YD5g a

Someone showed some epoxied in fine thread screws. Same idea. These are specifically designed for the job

[Aero STI]

Worked on wrapping up the air ducting to the intercooler today. I was not happy with how many escape routes Factory Five allows for with their design.

Also started on the GT40 style hood. I tried to bend the existing fiberglass to shape, even added some backside cut reliefs like you do when you bend wood. No dice, so I'm going to start over from scratch.

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

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

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