Michael's and Bob's Second 818 build (red frame)

[Bob_n_Cincy]

Michael's and Bob's Second 818 build (red frame)
Today, Michael and I started the build of our second 818s.
We learned a lot on our first build, so hope
to make even better improvement on this car.

This are some pictures of our first day on the car:

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No labeling parts or connectors this time.
The first car was Michael's , This on is mine.
We expect the build time to be 1/4 the first car.
Bob

[svanlare]

Every time I complete a section of the car, the little voice in my head keeps saying this is going to so much easier the next time. Looking forward to seeing this one come together.

[Jeff Kleiner]

I'll be watching!

Happy New Year guys :)

Jeff

[Mechie3]

I'm still trying to finish my first one.

[Hindsight]

Mechie, we all appreciate you making all these parts, but I think it's about time you get your 818 done bro. I wanna see you enjoying it and driving it this spring.

That was posted in 2014 Craig... :o

[john g]

Best of luck with #2!

[RM1SepEx]

I'm still trying to finish my first one.

"mega dittos" :rolleyes: Life happens Craig

[Mechie3]

That was posted in 2014 Craig... :o


sshhhhhhhhhhh. :D

[Hindsight]

;) I feel the same way though. My obsession to try to make everything perfect is dragging this project along very, very slowly. This June, I will have hit the two year mark and I have yet to go-kart. I think I'm pretty close though.

Bob, looking forward to watching this second build!

[flynntuna]

Also looking foward to this build, this one's electric right?

[Bob_n_Cincy]

Also looking foward to this build, this one's electric right?
Nope, The electric power train might go into the third chassis.
Bob

[Pearldrummer7]

Nope, The electric power train might go into the third chassis.
Bob


:eek: one is enough for me.

[AZPete]

Bob, will Michael's be the same as yours? How different? I'm also looking forward to watching this build.

[Bob_n_Cincy]

Bob, will Michael's be the same as yours? How different? I'm also looking forward to watching this build.

Michaels is the running blue frame 818S.
This will be mine. Red frame 818S.
Mostly the same. His donor is an o4 FXT, This one is an 05 FXT.
One or both will probably be converted to an 818R some day.
Bob

[Bob_n_Cincy]

Build day 2, removal rear suspension



http://thefactoryfiveforum.com/attachment.php?attachmentid=49433&d=1451961997&thumb=1
First donor was from Detroit, needed 6' cheater bar.
This donor from SC only need 3' Cheater bar.
Bob

[Pearldrummer7]

Build day 2, removal rear suspension

http://thefactoryfiveforum.com/attachment.php?attachmentid=49433&d=1451961997

First donor was from Detroit, needed 6' cheater bar.
This donor from SC only need 3' Cheater bar.
Bob

My NY donor didn't even need a cheater bar. Just an angle grinder :)

[Hindsight]

Looks very rust-free!

[Bob_n_Cincy]

My NY donor didn't even need a cheater bar. Just an angle grinder :)
the outer lateral links seem to be the worst. I will tackle them tomorrow.
Bob

[Bob_n_Cincy]

Finished clean out everything under the hood.
No tagging any connectors this time.

49467

About 1/2 way done stripping the inside.

49468

Hope to tow it to the shredder today (Thursday)

Bob

[Frank818]

Red frame, how about the body color on this one? I mean final color, not the gel coat which is certainly red.

[Bob_n_Cincy]

Red frame, how about the body color on this one? I mean final color, not the gel coat which is certainly red.
Gelcoat is white, this is cahssis# 21 (all three of ours are white)
Bob

http://thefactoryfiveforum.com/attachment.php?attachmentid=49477&d=1365475343

[STiPWRD]

^ America!

[Frank818]

Oh damn! Sorry I thought you just bought a new chassis.

Plz make it look exactly as on the pic!

[Bob_n_Cincy]

No actual work got done on the 818 today. But we did pick up the chassis from the powder coater.
I do highly recommend "Tri State Fab" for anyone near Cincinnati. The have done and excellent job on both my 818s.

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BOB

Frank, The color matches the picture.
The color is RAL3020 Traffic Red
But it looks more orange to me.

[Frank818]

Looks like a salmon color on the pix (camera always changes a little), but it looks great! Certainly stands out from black.

[Wayne Presley]

No actual work got done on the 818 today. But we did pick up the chassis from the powder coater.
I do highly recommend "Tri State Fab" for anyone near Cincinnati. The have done and excellent job on both my 818s.

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BOB

Frank, The color matches the picture.
The color is RAL3020 Traffic Red
But it looks more orange to me.

Nothing wrong with orange... :cool:

[Mitch Wright]

Bob, the chassis color looks great.

[Samiam1017]

3? I thought you only had 2.

[Bob_n_Cincy]

3? I thought you only had 2.
Picked up a damaged frame for a good price.
Bob

[Tamra]

Looks great!!

[svanlare]

I love the render, that is a good looking car design! I assume Hot Rod Fantasy disappeared, but it produced great results.

[Bob_n_Cincy]

We will just call this first picture the Blue Deuce Coupe.
This is off of FFR face book page.

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[129st]

We will just call this first picture the Blue Deuce Coupe.
This is off of FFR face book page.

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A Blue Deuce Coupe with a 2.3 Ecoboost!

[Mitch Wright]

Nice looking hot rod.

[Bob_n_Cincy]

Didn't work hard today as the garage was 25f.
Just spent 2 hours removing the rest of the dash wiring harness. Goes a lot faster when you don't label anything.
Bob

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[Bob_n_Cincy]

Here is a quick video on my real job.
My boss wants this 818 to be electric.


https://youtu.be/gmC2HCc5IzE

[Tamra]

Those bikes are awesome! I miss Andrew's old Brammo Empulse. The electric ones are so much more interesting to me than gas bikes.

[Bob_n_Cincy]

Those bikes are awesome! I miss Andrew's old Brammo Empulse. The electric ones are so much more interesting to me than gas bikes.
Here is a picture of Michael and I at Laguna Seca in 2012. Do you know the guys in the background.

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Bob

[xxguitarist]

Yep! All coworkers at Brammo, and that yellow wheel at left of the frame looks suspiciously familiar too. Tamra and I were there for the GP in 2013!

[Bob_n_Cincy]

Yep! All coworkers at Brammo, and that yellow wheel at left of the frame looks suspiciously familiar too. Tamra and I were there for the GP in 2013!
Hey, congratulations on that win.
Bob

[Mechie3]

Here is a quick video on my real job.
My boss wants this 818 to be electric.


https://youtu.be/gmC2HCc5IzE

Do what Matteo is doing. His boss wanted an 818 so part of his day job ended up.being building his boss an 818.

[Bob_n_Cincy]

Michael and I went to the Detroit Auto Show.
Mike took some pictures. about 100
Take a look at the link below. (low resolution)
If you want one of the pictures in high resolution, let me know and I well email it to you.
Bob

http://s1313.photobucket.com/user/bobgru/library/2016%20NAIAS%20%20Detroit%20auto%20show

[Frank818]

According to the car on the above link, Photobucket is down for maintenance. But we'll be back, we'll be back. :)

[Mitch Wright]

Hey Bob, I see you and Michael are entered in our Trackcross event, I look forward to meeting both of you.

[Bob_n_Cincy]

Hey Bob, I see you and Michael are entered in our Trackcross event, I look forward to meeting both of you.

Thanks Mitch, We are looking forward to meeting you also.
Maybe we can get Mechie3 to show up. (36 days Craig)
We will only have one car as the weather, job and school has slowed progress on the second 818.
It would be great if you could take our car out for a couple runs to give us some handling advice. (how tall are you?)
Hoping for a warm day so we can put our r-compound tires back on.
Looks like the average temperature at the end of February stays above freezing.
Bob & Mike

[Bob_n_Cincy]

Started on my wire Dissection tonight. Same method as I used on first car. About 4 hours.
Here is how I got started.

Covered pool table with a couple of HF moving blankets
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Spread out the body and front harness (46lbs).
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My tools of choice.
Most important is the seam ripper to cut the electrical tape lengthwise.
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Starting with the 2 main engine connectors F60 & F61. I cleaned all the covering on the harness.
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I pigtailed and labeled each wire in connector F60. Most of the labels are the pin number of the ECU that it goes to.
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This is what I ended up with. Most of these wires will end up spliced to the 4 connectors that come out of the ECU.
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I suspect about 30 hours of harness work.
Bob

[Pearldrummer7]

Nice work, Bob. This was pretty much how I did it. Much easier the second time around, isn't it?

[Bob_n_Cincy]

I'm about half way done dissecting the parts of the harness that I will re-use.
The small piles in the foreground is what I cut out.
Maybe one more day of dissection before I move onto assembly.
Bob

http://thefactoryfiveforum.com/attachment.php?attachmentid=50117&d=1454020267

[Hindsight]

Gahhh!!!!! That just gave me flashbacks to my multi-month long wiring harness job. Looking forward to seeing how you get it done.

[Bob_n_Cincy]

Finished the wire dissection phase of my wiring.
First picture is all the parts that I dissected out of the harness that I will use. Second picture is what's left.
It was a little more complex this time with the extra wiring for the automatic transmission and the immobilizer.
Bob

http://thefactoryfiveforum.com/attachment.php?attachmentid=50304&d=1454605605


http://thefactoryfiveforum.com/attachment.php?attachmentid=50305&d=1454605608

[Tamra]

... automatic transmission?? I'm assuming you're doing whatever wiring swap is necessary to convert to manual?

[Bob_n_Cincy]

... automatic transmission?? I'm assuming you're doing whatever wiring swap is necessary to convert to manual?

Yes, manual transmission and no immobilizer.
Bob

[Bob_n_Cincy]

I label each wire with three lines.
Number that typically matches the ECU pin.
The color abbreviation
The function.
As I cut and splice, I will install new tags.
Bob

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[Mitch Wright]

Hey Bob, you and Michael going to make it down for the Trackcross Saturday? The weather is looking pretty nice.

[Bob_n_Cincy]

Hey Bob, you and Michael going to make it down for the Trackcross Saturday? The weather is looking pretty nice.

Yes we are, Even if I have to stay up all night putting the car back together after a totally redesigned cooling system.

I'm bring my R888 so I have some traction. I expect you to show me what it can do on the track. Or at least what I need to do to make it handle better. See you Saturday morning.
Bob

[Mitch Wright]

I will be busy in the morning getting the show going but will make sure to track you down and offer you guys assistance.

[Bob_n_Cincy]

Work has slowed to a crawl on the red 818 for a couple of reasons.

1. Prepping the blue frame 818 for this season.

2. Working on a couple of time consuming project for my real job.


https://youtu.be/gmC2HCc5IzE

Life is good. Wish there were more hours in a day.
Bob

[Frank818]

Glad you're never stressed, Bob. You're cool.

[Bob_n_Cincy]

This would be a great idea.

http://blog.caranddriver.com/gettin-jiggy-in-tochigi-subaru-testing-mid-engine-sports-coupe/

A mid engine Subaru.
Bob

[Bob_n_Cincy]

After spending time racing the blue frame 818 we had some repairs and upgrades to make. Today we finally got back on the red frame 818. We installed the front firewall. The only special thing we did, was to cover the inside with black carbon fiber wrap. Came out looking good IMHO. I will continue this theme on all the interior aluminum panels.
Bob

http://thefactoryfiveforum.com/attachment.php?attachmentid=52160&d=1459296944

[Samiam1017]

Are you using your squared up brake setup on this car also. Do you have a write up or pics of how you did it? What brake pads did you use did you need to mill them for the rotor size? Thx. Sam

[Bob_n_Cincy]

Sam
I doing the same on the second red car. I have the Prop. valve in the rear wheel. They are working great.
Rotors: DBA-DBA2657S from summit $131.97 each from summit.
Calipers: POWER STOP S2682 Red Powder Coated w/Brackets from rockauto 67.79 for pair.

http://thefactoryfiveforum.com/showthread.php?12534-MRG-MotorSports-818S-Build&p=218828&viewfull=1#post218828

http://thefactoryfiveforum.com/showthread.php?12534-MRG-MotorSports-818S-Build&p=173658&viewfull=1#post173658

I had the inner hub of the rotor turned down to fit the bracket.
I had to add a new hole to the backing plate to fit the larger bracket.
I also had to grind on a few areas of the bracket to make it fit.

52494

First car used these pads. https://www.rockauto.com/en/moreinfo.php?pk=2022418&cc=1428780

They are great but I'm going with these pads on the second car.
https://www.rockauto.com/en/moreinfo.php?pk=6096294&cc=1428780

bob

[svanlare]

Nice day joy, enjoyed the video! The Red and carbon look great btw

[Samiam1017]

Sam
I doing the same on the second red car. I have the Prop. valve in the rear wheel. They are working great.
Rotors: DBA-DBA2657S from summit $131.97 each from summit.
Calipers: POWER STOP S2682 Red Powder Coated w/Brackets from rockauto 67.79 for pair.

http://thefactoryfiveforum.com/showthread.php?12534-MRG-MotorSports-818S-Build&p=218828&viewfull=1#post218828

http://thefactoryfiveforum.com/showthread.php?12534-MRG-MotorSports-818S-Build&p=173658&viewfull=1#post173658

I had the inner hub of the rotor turned down to fit the bracket.
I had to add a new hole to the backing plate to fit the larger bracket.
I also had to grind on a few areas of the bracket to make it fit.

52494

First car used these pads. https://www.rockauto.com/en/moreinfo.php?pk=2022418&cc=1428780

They are great but I'm going with these pads on the second car.
https://www.rockauto.com/en/moreinfo.php?pk=6096294&cc=1428780

bob

Bob. You using same pads front and rear

[Bob_n_Cincy]

Bob. You using same pads front and rear
Yes same pads,

We are leaving today for 2 days of Track time at NCM. A total of 12 twenty minute sessions (4 hours total)
Should be a good test for the 818. Temperature will be in the 30s to 50s.
Data logger and video is all ready to go.

Should get a chance to see Mitch Wright's build.
Bob

[Bob_n_Cincy]

First tip.
Loosen axle hub nuts when the hub is still on the donor. We removed the hub and axle assembly from the donor and set them aside.
Today we went to remove the nuts.
Tried impact gun with no success.
Tried breaker bar with another bar wedged between lug stud. no success.
Lastly mounted hub back to a wheel and the strapped it to a pole to hold wheel. took 600+ foot-lbs to break it loose.
See picture below.

64674

[Hobby Racer]

64674

Oh, now that's using your head. Great use of leverage and friction to your advantage!

[Frank818]

So many ideas and tips on this forum... you leave for 2 weeks and you'll miss how to save yourself 50hours and 1000 bucks. (general talking here)

[Frank818]

Ok that's not funny Bob, I went up to page 7 and couldn't find your blue frame build thread...

Anyway my question was which build is the one you built like a boat? I think it's the blue.

Then what did you do to prevent water from dripping down from the windshield and into the sides at the front of the doors? There is a small triangle right on the sides of the windshield and underneath is the start of the cockpit. My water drops there and I was trying to find a solution to prevent water from dropping on the sides inside the frame, and as much as possible preventing it from dropping over the battery too.

[Bob_n_Cincy]

It finally looks like We're going to get some time to work on our second 818.
Michael and I have done a lot of prep work (cleaning ) to our shop.
http://thefactoryfiveforum.com/attachment.php?attachmentid=67388&d=1494045274

Some of the tool acquired as a result of our first build. 20 ton press, full size drill press, MIG welder, Plasma cutter, cold cut chop saw, power bleeder, holes saws, drum sander, and a half a dozen rechargeable power tools.

As this is our second build, I don't think we will need and assembly manual.
So I just made up this one page task list.

http://thefactoryfiveforum.com/attachment.php?attachmentid=67389&d=1494045403

Bob

[flynntuna]

That's exactly what my friend who built a MK4 told me to convince me that I should build a car. Just break the build down managagable sections, one system at a time.

[Frank818]

Michael and I have done a lot of prep work (cleaning ) to our shop.

I give it 10mins to stay that clean. :)
Good thing you took pix of it so we can all remember how clean it once was. :)

[Speedy G]

All's so prrrty when you begin ...

Well, from what I've seen one system at a time isn't always the best bet. For example here's some things that are related:

1) Install pedal box (wilwood) - It's better if you wait for the seat to be in so you know where you need the pedals. There IS some adjustment that can be done.
2) Brake lines. It's actuall better to install the final brake lines after you've installed the wheel wells and the fiber glass.

There's so many dependencies... I have like 4 different systems that aren't finished because if I finish them I'll probably have to tear them apart later and fix. For Bob it may work since he's got another car he can look, measure, make sure, then pray and install... not so much if you only have the manual with all the wrong pictures.

Speedy G

[Bob_n_Cincy]

All's so prrrty when you begin ...
Well, from what I've seen one system at a time isn't always the best bet. For example here's some things that are related:
1) Install pedal box (wilwood) - It's better if you wait for the seat to be in so you know where you need the pedals. There IS some adjustment that can be done.
2) Brake lines. It's actuall better to install the final brake lines after you've installed the wheel wells and the fiber glass.
There's so many dependencies... I have like 4 different systems that aren't finished because if I finish them I'll probably have to tear them apart later and fix. For Bob it may work since he's got another car he can look, measure, make sure, then pray and install... not so much if you only have the manual with all the wrong pictures.
Speedy G

Speedy,
I like when you say:
I have like 4 different systems that aren't finished because if I finish them I'll probably have to tear them apart later and fix

Here is a list of some of the major mods we did, a lot of them took more than one try.

Twice cooling system design, both different than FFR
Wiper system different than FFR, I bough at least 3 junk yard wiper motors.
MR2 shifter, At least 3 version.
Side shift transmission, 2 versions.
Twice major suspension configurations.
intensive harness dissection.
Two intercooler systems (now awic)
Two oiling systems (now dry sump)
Two roll bars
Front gas tank
Two rear brake revisions.
Added front and rear bumpers
Two intake systems

So I can relate to your comment above.

Right now I'm very happy with state of our 818S.
Oh, did I mention, we are changing it to an R.

The way I came up with the list above, was by thinking about what would be the easiest way to dissemble the car.
Then I flipped the list. Read the left column from bottom to top and see if it makes sense.
Bob

[Bob_n_Cincy]

We just put the LS in the Ford pick-up to transport it.
My possible son-in-law is doing a 6.2L 6-speed out of a 2013 Camaro into an RX7.

68007 68008

This motor is a beast compared to working on the little Subaru engines
Bob

[Canadian818]

My possible son-in-law is doing a 6.2L 6-speed out of a 2013 Camaro into an RX7.


:(:(:(

[Mitch Wright]

Fun, now you guys will have a good excuse to come down to LS Fest.