818C Build - John and Lou - The Woodlands, TX

[TX-Lou]

And so it begins.......

We took delivery of our 818C on Friday (2/5/2016). There is nothing like seeing that big beautiful Factory Five truck rolling down your street.

I took a ton of pictures and video of the unload with my phone only to find out later that none of them saved. My son John was going nuts wanting pictures as he couldn't be there for the unload.

We spent most of the rest of the weekend opening boxes and going through the inventory of all of the parts. There were a number of parts that were back ordered and some missing that should have been in the kit. We have just a couple that we couldn't identify so we'll work on that this week. The manual that is shipped is still the 818S manual so the new front end sheet metal part numbers aren't listed in the manual and weren't in the inventory parts list either. We knew where they went as they looked close enough to the 818S versions that we could make an educated guess.

We were able to get all of the body panels off and the hood, dash, splitter and diffuser pulled out of the interior before we called it a day to go watch the superbowl.

Here are some pictures from the weekend.

http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00262_zpsjzvmyrr0.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00262_zpsjzvmyrr0.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_Attach20648_20160205_115824_zpshfywc9er.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/Attach20648_20160205_115824_zpshfywc9er.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00266-2_zpsqlrmgrxh.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00266-2_zpsqlrmgrxh.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00269-2_zpssnr27rws.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00269-2_zpssnr27rws.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00274-2_zps0doxultg.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00274-2_zps0doxultg.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00291_zpsmtwgzjtp.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00291_zpsmtwgzjtp.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00292_zpslaualasb.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00292_zpslaualasb.jpg.html)

- Lou

[Hindsight]

Cool congrats! First time I have seen a delivery in the official FFR truck. Usually it's Stewart Transportation or another carrier. How did you arrange shipping this way, out of curiosity?

[TX-Lou]

Thanks! The delivery was through Stewart. I wasn't expecting the Factory Five trailer but it was nice to see. And our neighbors sure noticed it.

- Lou

[Hindsight]

Very cool - much more pic-worthy than the plain white trailer that most people get. Good advertisement for FFR too.

[redfogo]

I also got a FFR delivery truck, I was extra surprised makes you feel special haha.

[AZPete]

Even better than the FFR truck were the photos of the coupe top like the one I'm hoping to get in March, in white. Congrats on the arrival of your new baby. It will be a wonderful journey!

[THE FURNACE]

Congratulations, the fun begins! I should be picking up my 818 C, during spring break in March. It's approximately a 9 hour journey (one way) from Ontario, Canada. My nephew (Jasl13) and I, are looking forward to a factory tour. I'm currently waiting for paperwork from Transport Canada, before I can bring it past the border. It should take another 2 weeks, if they come good on their 4 - 6 week processing time. Unfortunately, I've dealt with government run departments before. A 4-6 week wait for a building permit took 6 months! I hope TC is more efficient than that, and it all works out.
I'm looking forward to sharing some stories!

Dave

[TX-Lou]

Thanks Guys. Pete, here are two other photos of the Coupe Top that I had. If you want to see anything else just let me know.

The first picture is of the Coupe Top itself sitting on the garage floor. We are going to wrap it in moving blankets, flip it over and hang it from the ceiling of the garage using straps so that it doesn't flex. Right now it is sitting on the steel arms in the front, and on some towels that are propping up the middle of the back. Without the towels the back corners flex with the weight.

The second picture shows where the steel arms are bolted to the chassis.

http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00293_zpsg9pohzvb.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00293_zpsg9pohzvb.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00276_zpsptzb2xe3.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00276_zpsptzb2xe3.jpg.html)

[SnyderJD]

When I hung my top from the ceiling. I laminated 2 2x6's and lagged them in between the frame. ran 2 2x4's to the back and added a sinlge 2x4 so that it looks like a double i-beam. places a couple of i-bolts through the front and rear and hoist using the frame. you wont put any flex on the top at all. If need be let me know and I can take a photo from underneath.

[TX-Lou]

Sure, I'd love to see a picture of it. If that works out better I'll go that route.


When I hung my top from the ceiling. I laminated 2 2x6's and lagged them in between the frame. ran 2 2x4's to the back and added a sinlge 2x4 so that it looks like a double i-beam. places a couple of i-bolts through the front and rear and hoist using the frame. you wont put any flex on the top at all. If need be let me know and I can take a photo from underneath.

[BN]

Sure, I'd love to see a picture of it. If that works out better I'll go that route.

I like to see that as well

[RMB]

Congrats! Where in The Woodlands are you? I have a MkII Roadster and live in Creekside.

Rob

[SnyderJD]

Here you go...

I used pocket holes to screw the front and rear to the two center 2x4's from there I placed an eye bolt at 4 points within the windows so as not to wrap around the body at all. I have it connected using ratchet straps to anchor points in the ceiling. (a couple of short 2x4 strips lagged to the ceiling with an eyebolts

http://i963.photobucket.com/albums/ae119/snyderjasond/818C/CC78322A-7410-4740-A4C8-827667124A32_zpsojdrc3dn.jpg (http://s963.photobucket.com/user/snyderjasond/media/818C/CC78322A-7410-4740-A4C8-827667124A32_zpsojdrc3dn.jpg.html)

http://i963.photobucket.com/albums/ae119/snyderjasond/818C/6276D699-B9B0-43C7-AE6B-57BC210BDB0F_zps2gn4eite.jpg (http://s963.photobucket.com/user/snyderjasond/media/818C/6276D699-B9B0-43C7-AE6B-57BC210BDB0F_zps2gn4eite.jpg.html)

[BN]

Is there 2 2x6 up front to keep it level Ben

[SnyderJD]

Yes, in the front, I used (2) 2x6 so that I could lag through both of the frame holes.I used a dozen deck screws to laminate them together. If you want, I can get a better photos of the 2x6 part. the only thing I would do is maybe lengthen the 2x4 from front to rear if I did it again, but I was building around the eye-bolts I already had in the ceiling which were originally for my jeep hardtop.

Seemed the like the most efficient and cheap way to hang the top without any flexing stress.

[BN]

Thanks ben

[ram_g]

Very nice - congrats!

Have you given some thought to how you are going to register it in Texas? Are you planning an OBD-2 emissions compliant build?

[TX-Lou]

Sorry, I was traveling yesterday.

SnyderJD: Thanks for the pictures. That looks like a great solution. I don't know that I can do that with the area that we have available but I will adapt something similar.

Rob: We are in Grogan's Point. John and I would love to check out your Cobra at some point. I will PM you our address. If want to swing by on a Saturday you know where we will most likely be....:)

Ram_g: We are doing this as a street build so the plan is to build with full emissions compliance and annual inspections. Hopefully that works out.

Thanks,
- Lou

[nkw8181]

Allllllllrightythen! Let the fun begain!

[ram_g]

Ram_g: We are doing this as a street build so the plan is to build with full emissions compliance and annual inspections. Hopefully that works out.

Thanks,
- Lou

i hope it does too! I worry about complications with the VIN number of the donor engine as reported by the OBD2 testing machine vs the VIN of your assembled car...that's why I'm favoring a 33 or a Coupe for my 2nd build because those can be registered as emissions exempt replicas, although I really would prefer an 818.

Will be following your progress with interest...unfortunately we live way on the southwest side just about as far from the Woodlands as you can get in greater Houston, else I'd have invited myself over.

Ram

[TX-Lou]

Ram,

I know there have been issues with registration in the past. There are a few options that we can look at if it proves to be a problem for us. I'll post how things are going on that front when we get to that stage but those issues are a long way away right now.

If you are going to be up in our neck of the woods at some point and want to see the build just PM me.

- Lou

[Frank818]

There is nothing like seeing that big beautiful Factory Five truck rolling down your street.

How about driving your own 818C? :)
Time will come. A lot of time, though. lolll

Welcome and let's see all the tricks you'll come up with during your build! Always facinating to compare each other's solutions and tricks.

[TX-Lou]

Been a busy few weeks. We haven't had as much time to work on the car as we would have liked but we did get started. We completed our inventory, hung the coupe top, built a workbench that folds into the wall and got started on the mounting the first few sheet metal pieces.

The solution that we came up with for hanging the coupe top was similar to what SnyderJD did. We hung the front by the mounts. We also put a 2x4 between the two mount points for stability and to make sure there was no flex or twist. I doubt there will be but better safe then sorry. As for the rear end we are suspending it by a 2x4 that the round sections coming from the coupe top are sitting on. We thought the way we did it was a little safer in terms of supporting the weight.

http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00298_zpsvewjnsll.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00298_zpsvewjnsll.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00297_zpsd1rkzk95.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00297_zpsd1rkzk95.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00296_zpslt92jkxl.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00296_zpslt92jkxl.jpg.html)

Here we are just getting started.

http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00303_zps4gg8qvdv.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00303_zps4gg8qvdv.jpg.html)

We are doing it with rivnuts instead of rivets. There was a bit of learning curve in using rivnuts that cost us some time. We accidentally had the rivnut tool setup so that the screw wasn't all the way through the rivnut before crimping. After having to remove a redo a few we figured it out and then got on a roll.

We are taking a welding class this weekend as it has been 30 years since I've done any welding and John hasn't done any yet. Should be fun.

- Lou

[AZPete]

I am so envious! I had lots of fun building, driving, upgrading and then selling a FFR roadster. Now I'm ready to license an 818S, to be upgraded soon to 818C. All good, but your father/son build will be MUCH more rewarding than either of my builds. I wish I could have built a car with my son but it just didn't work out. Enjoy your journey!!

[TX-Lou]

Thanks Pete!

- Lou

[nkw8181]

looking good!

[TX-Lou]

Not much to report as we are missing parts that we need to move forward.

I did want to take second to thank Wayne and BC for their time and great advice. We were on vacation in Destin, FL last week so we took the opportunity to drive up to Wayne's shop in Enterprise, AL. We had worked it out with Wayne before hand as we were picking up a new radiator and his shifter setup. Wayne and BC showed us BC's 818S that they were working on. They also showed us the orange 818 that Wayne brought to SEMA. That is a beautiful car to see in person.

Thanks again for your time and advice!

- Lou

[TX-Lou]

Sorry to family and friends that have been looking for updates. We did receive the missing "critical path" parts from Factory Five that we need to really get moving forward.

Since then we have:

Mounted the Pedal Box Mount Bracket
Completed the front firewall installation and sealing.
Installed our new STI Aluminum Lower Control Arms
Setup and installed the front Upper Control Arms
Greased all of the fittings in the ball joints and Upper Control Arms
Hooked the Driver's side knuckle into the Upper and Lower Control Arms


This weekend we are hoping to complete the front suspension including the Willwood rotor and brake assemblies.

Here are some pictures from right after we completed the installation of the front firewall. Thank God for our pneumatic riveter!

http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00641_zpsbbd1uyux.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00641_zpsbbd1uyux.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00643_zpsw2aumykx.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00643_zpsw2aumykx.jpg.html)

I'll post more pictures after this weekend.

[TX-Lou]

We decided to go ahead and replace all of the bearings in the knuckles. We had a local shop press out the old ones and install the new bearings and seals.

Last weekend we were able to move ahead and get the front suspension installed. We:

Installed both knuckles
Built and installed the Wilwood Rotors and calipers
Installed the upgrade Koni 3012 shocks


Here are some pictures:

http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00645_zpsyws3j9fa.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00645_zpsyws3j9fa.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00650_zpsmbzjavax.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00650_zpsmbzjavax.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00651_zpsi0zsqhzp.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00651_zpsi0zsqhzp.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00656_zpspyaqsxad.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00656_zpspyaqsxad.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00657_zpspqyg1z8q.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00657_zpspqyg1z8q.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00665_zpshc2e6gac.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00665_zpshc2e6gac.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00662_zps70xxai3g.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00662_zps70xxai3g.jpg.html)

This weekend we hope to get the steering rack and tie rods installed.

Next weekend John and I will be attending the FFR 818 Build School class in Michigan.

- Lou

[07FIREBLADE]

Looking great is that the $2000 upgrade option for the shocks? Attending the build school should be fun wish I was able to do this before building my car. Im currently working on the engine portion of their iWire harness. We are trying to get it done for you class next week. Its going to be a mission but we are up for it.

[TX-Lou]

Thanks Fireblade, we are looking forward to the class and I'm glad they will be using an iWire harness. We are going to go either with the iWire or VCP harness so it will be nice to see how that works out.

As for the upgrades, we went back and forth trying to decide if we should just put the base 818 together with mostly donor parts and then upgrade down the road, or upgrade for the build. In the end we decided to upgrade for the build. It is way more expensive up front but I'm glad we are doing it this way. I can already see that it would be no fun pulling this car apart to try to upgrade stuff later. We are putting a lot into upgrades for the engine, suspension, and other performance aspects of the car.

- Lou

[07FIREBLADE]

I'm bias and would say iWire. You get a true plug and play harness that's made specifically for your build. I'm getting mine redone from the original 1 piece harness to the new modular setup and 3 fuse boxes to accommodate the new front and top conversions. We've only done about 55ish builds to date and have done every combination of build too. If you decide to get it you truly won't be disappointed and tell Brian that you saw it at the build school.

[TX-Lou]

I'm bias and would say iWire. You get a true plug and play harness that's made specifically for your build. I'm getting mine redone from the original 1 piece harness to the new modular setup and 3 fuse boxes to accommodate the new front and top conversions. We've only done about 55ish builds to date and have done every combination of build too. If you decide to get it you truly won't be disappointed and tell Brian that you saw it at the build school.

How long does it take to make an iWire harness? How far in advance do I need to send the donor harness in?

[07FIREBLADE]

We can accommodate but it's 6 weeks but if that doesn't fit your schedule just let Brian know. We are doing the build school and we had to get that out in less than a week. For you guys to use it next weekend.

[TX-Lou]

This past weekend we "completed" the front suspension install. I say "completed" because the passenger side of the steering rack didn't come out the way we wanted it to. We used Mechie's mount bracket but that wasn't the problem.

The problem was the half round, half square bushing on the passenger side. The bottom of that bushing is square and the shape isn't just in the exterior rubber. The bushing is "filled" so that it is square on the bottom throughout. When we mounted the rack it compressed the bushing but not nearly enough. You can see the angle that the rack is sitting at in the picture below. To resolve it we ordered new bushings for both sides. The new ones are polyurethane and look to be the correct shape. They also come with new brackets. The donor bushings and brackets were worn and they were starting to go anyway.

We also installed our new inner and outer tie rods, the sway bar from the rear of the donor, and the FFR links for the sway bar that connect to the lower control arms. John had painted the sway bar red with the black writing of 818C in the middle. Unfortunately it got scratched up pretty good when we put it in. We will have to touch up the paint on it.

Other issues we encountered concerned the donor mounts for the sway bar. I'm guessing we didn't keep the originals because what he had with our donor parts were mounts that weren't flush where the bolts go. They were at an angle. We did have bushings that fit and we were able to bend the mount brackets in a vice to get them to work.

Here are some pictures....

http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00679_zps9pzbsm0w.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00679_zps9pzbsm0w.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00681_zps7wshopw4.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00681_zps7wshopw4.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_DSC00682_zpsgsridgih.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/DSC00682_zpsgsridgih.jpg.html)

- Lou

[nkw8181]

Nice! Keep at it one part at a time

[Mechie3]

Several people have switched to generic (prothane?) bushings and mounts for the swaybar. Fit much better. I think I have a link in my build thread.

I forgot to ask what year steering rack you had. There are some part numbers in the original steering rack group buy thread for the 05+ bushing and clamp.

[nkw8181]

I have yet to put the sway bar in. If you do you're one step ahead of me

[TX-Lou]

Thanks Nolan.

Craig, no problem. The donor was an 04' WRX Sedan. Your mount looks great and is solid.

Here are the bushings I ordered. They arrived yesterday but the brackets were not included.

Whiteline KSR202 (http://www.amazon.com/Whiteline-KSR202-Rack-and-Pinion/dp/B004ZZVM8K/ref=cm_cr_arp_d_product_top?ie=UTF8)

- Lou

[Mechie3]

These are the Subaru parts (newer style bushing and clamp).

06 Style Bushing:
ADAPTER GEAR BOX PIPE
Make: Subaru | Part#: 34115FE020
List Price: $10.43
Your Price: $7.76

06 Style Clamp:
CLAMP GEAR BOX PIPE
Make: Subaru | Part#: 34166FE060
List Price: $6.50
Your Price: $4.84

[TX-Lou]

I can't believe so much time has gone by since I was last able to post. We've continued to move forward on our build but we just haven't had a lot of time due to just being super busy in May, June and the first half of July. When we have had time we've run into roadblocks from missing donor parts, stuff that needed to be replaced and issues with customization we are doing.

Since our last post we have:

De-rusted and painted the rear knuckles
Had new bearings and seals pressed in
Cleaned and rebuilt the Ebrake components
Completed the build out of the rear suspension including the Wilwood rotors and calipers, knuckles, shocks, axles and all control arms and links. We spent a lot of time adjusting and testing the ebrakes on both sides to make sure they worked because once those Wilwood rotors go on for good you really can't get in there to adjust it.
We got our engine and transmission back from Auto Science and installed new fuel injectors (ID 1000's) and the adapters for connecting into the wiring harness.
Had to pick up a new plug for the transmission fork rod. Once we had that we were able to install the new throw-out bearing and fork.
Changed the engine and transmission mounts to new Group N mounts
Mated the engine and transmission, and put them in.
Cleanup of the pedal assembly (clutch and brake) to remove rust and repainted them.


Our new turbo (Blouch 18g XT-R) is in but we haven't installed it yet. We need to clean up some of the rust around the mount first but I really just wanted to get the engine in this past weekend.

Here are a few pictures...

http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_20160622_140721_zps17fivzdr.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/20160622_140721_zps17fivzdr.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_20160622_140647_zpspeufubjx.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/20160622_140647_zpspeufubjx.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_20160622_140633_zpsbzx6q24l.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/20160622_140633_zpsbzx6q24l.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_20160622_140826_zps1bwekizj.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/20160622_140826_zps1bwekizj.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_20160716_131645_zpsob4gvfxl.jpg

(http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/20160716_131645_zpsob4gvfxl.jpg.html)- Lou

[TX-Lou]

I just wanted to post another update showing where we were at. We have been working when possible through the summer and early fall. Since our last post we have:


Put the AC Compressor back on the engine and put on and tensioned the Alternator and Compressor belts
Installed the steering column from the donor. Connected it up to the steering rack. We have the donor steering wheel on temporarily but will replace it with the optional FFR wheel later in the build.
Installed the new FFR fuel tank
Replaced the fuel pump with a Walbro 255 lph fuel pump
Connected the Fuel lines from the tank to the fuel rails
Installed the Blouch 18G XT-R turbo
Installed the fuel filler neck
Installed the Clutch, Brake and Gas pedals
Installed the Brake and Clutch Master Cylinders. We replaced the Brake Master Cylinder with a new one.
Made our brake lines, installed the proportioning valve and connected up all of the lines to our calipers
Bled our brakes
Made our clutch lines and used the Replica Parts flexible clutch relocator kit.
Bled our clutch
Ran the throttle line through the car and connected up the throttle body. Needed to use a Cable Stop kit (set screws) from Autozone to terminate the end of the FFR throttle cable. If anyone needs it the part is Dorman 03336.
Took the fan unit off of the donor radiator and mated it to a Mishimoto 3 row radiator we picked up from Wayne at VCP. Installed the radiator.
Installed the coolant lines and used the 818 Hard Line replacement kit from Mark at Breeze Automotive to replace the corrugated lines that come with the kit.
Started installing the AWIC kit that we got from Wayne at VCP.


We also just sent out our donor wiring harness and related FFR parts to iWire.

Here are some pictures of where things stand:

http://i288.photobucket.com/albums/ll166/TX-Lou1/2004%20Subaru%20Impreza%20WRX%20Tear-down/th_20161002_151623_zpsee1u96vn.jpg (http://s288.photobucket.com/user/TX-Lou1/media/2004%20Subaru%20Impreza%20WRX%20Tear-down/20161002_151623_zpsee1u96vn.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/2004%20Subaru%20Impreza%20WRX%20Tear-down/th_20161002_144847_zpsnpqi6dma.jpg (http://s288.photobucket.com/user/TX-Lou1/media/2004%20Subaru%20Impreza%20WRX%20Tear-down/20161002_144847_zpsnpqi6dma.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/2004%20Subaru%20Impreza%20WRX%20Tear-down/th_20161002_144832_zpszhnga3hk.jpg (http://s288.photobucket.com/user/TX-Lou1/media/2004%20Subaru%20Impreza%20WRX%20Tear-down/20161002_144832_zpszhnga3hk.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/2004%20Subaru%20Impreza%20WRX%20Tear-down/th_20161002_144826_zpszwcitzxa.jpg (http://s288.photobucket.com/user/TX-Lou1/media/2004%20Subaru%20Impreza%20WRX%20Tear-down/20161002_144826_zpszwcitzxa.jpg.html)
http://i288.photobucket.com/albums/ll166/TX-Lou1/2004%20Subaru%20Impreza%20WRX%20Tear-down/th_20161002_144819_zpsrpxqamrg.jpg (http://s288.photobucket.com/user/TX-Lou1/media/2004%20Subaru%20Impreza%20WRX%20Tear-down/20161002_144819_zpsrpxqamrg.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/2004%20Subaru%20Impreza%20WRX%20Tear-down/th_20161002_144811_zps9xodrz6f.jpg (http://s288.photobucket.com/user/TX-Lou1/media/2004%20Subaru%20Impreza%20WRX%20Tear-down/20161002_144811_zps9xodrz6f.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/2004%20Subaru%20Impreza%20WRX%20Tear-down/th_20161002_144752_zpshftojpq1.jpg (http://s288.photobucket.com/user/TX-Lou1/media/2004%20Subaru%20Impreza%20WRX%20Tear-down/20161002_144752_zpshftojpq1.jpg.html)

We have the Mishimoto radiator mounts but we will need to do something with them to get them to attach to the frame. We have one of them sitting on the top drivers side mount but it isn't actually on yet. We also have a temporary setup for the throttle pedal mount. We have some steel cross members that we are going to put on instead of a section of aluminum bracket that is there temporarily. The steel cross members should stiffen up that pedal so there is no flex at all. It is very slight as it is but we would prefer it to be rock solid.

Of course there were a lot of things we had to learn (and sometimes the hard way) to get to where we are today but all in all we are happy with the build so far. We hope to be able to go-cart by Christmas.

- Lou

[ben1272]

Looking good!

[TX-Lou]

Thanks Ben. Just one correction from the last post. We got the replacement hard line coolant hose/tube kit from Breeze Automotive.

- Lou

[frankc5r]

Lou,
When I was at Wayne's picking up my donor for 818C a few weeks ago, I asked him about using the stock a/c compressor with the mini a/c from
Vintage Air.. There is a question about whether it will work since it is a variable displacement unit. He said he was working on problem. Did u talk to Vint Air
about it or have further info. Thanks
frank

[Wayne Presley]

The car looks great Lou

[AZPete]

Lou, I'm running the donor compressor in my 818C and the A/C works perfectly. Long ago, the tech guys at Vintage Air said that the Subaru compressor would not work with the Vintage Air system because it is a variable displacement compressor and the Vintage Air system needs a fixed displacement compressor. My local Vintage Air dealer said it would work just fine, so I researched it. The Subaru factory service manual lists the compressor as “vane rotary, fix volume”, which sounds to me to be fixed displacement. I then confirmed this with the Vintage Air tech guys who confirmed that the Subaru compressor will work well with their system. Now I know for sure that it works fine. If you call Vintage Air, remember that the Subaru compressor is compatible because it is not variable displacement but fixed volume, even if a tech says otherwise.
Pete

[frankc5r]

Lou, I'm running the donor compressor in my 818C and the A/C works perfectly. Long ago, the tech guys at Vintage Air said that the Subaru compressor would not work with the Vintage Air system because it is a variable displacement compressor and the Vintage Air system needs a fixed displacement compressor. My local Vintage Air dealer said it would work just fine, so I researched it. The Subaru factory service manual lists the compressor as “vane rotary, fix volume”, which sounds to me to be fixed displacement. I then confirmed this with the Vintage Air tech guys who confirmed that the Subaru compressor will work well with their system. Now I know for sure that it works fine. If you call Vintage Air, remember that the Subaru compressor is compatible because it is not variable displacement but fixed volume, even if a tech says otherwise.
Pete

Thanks for that info!!

[TX-Lou]

Thanks Wayne, and thanks for the confirmation Pete! I have been following your thread on the AC issue and knew you had it worked out. That was what triggered us to go ahead and put the donor compressor back on. Right now AC is down on my list. After we get a running go-cart we will probably look to get the AC system installed and charged.

- Lou

[Connedale]

Lou, I was considering this kit, but could not figure out a clear path to registration. How are you planning to do that? PM if necessary. I'm in Montgomery BTW!

[TX-Lou]

Connedale,

I was planning to try to register it first as a car manufactured by FFR. From what I've read the paperwork they provide should be acceptable. However, it will require annual inspection and emissions testing just like any other car. From what I've seen trying to go any other route will be much harder. Things have already changed a bit in the last year. But I will know more as we get closer to the point when I will need to get it registered. I will post updates here as that happens.

Thanks,
- Lou

[nkw8181]

Josh and mine are registered if you have any questions.

[TX-Lou]

It has been way too long since I've posted an update. Part of that was the craziness of the holidays and travel. Part of that was wanting to hold off until we got to XXX in the build......we are so close.... We haven't have as much build time as we would have liked but the project is moving forward little by little.

Well, here is our long overdue update and status.

Since our last post we have:

Completed our AWIC install
Ordered our Kirkey High Back seats
Ordered and installed a Saikou Michi Dual Catch Can setup
Installed our 5 point harness bar
Installed the K-Tuned Shifter and knob that we pickup up from Wayne at VCP.
Installed the transmission cables
Connected up the Ebrake handle to the ebrakes lines
Installed Wayne's trailing arms so we could use larger tires on the rear wheels
Ordered Federal 595RS-RR - 255/35-18 (rear) and 595RS-RR - 215/40-17 (front) tires from onlinetires.com. Had them mounted on the FFR wheels we bought at our local FireStone
Installed the tires and did a first blush camber, caster and alignment setup
Mounted the degas tank and connected the hoses including a splitter to bring in Wayne's coolant modification
Ordered and installed the Boig under-car Center Exit Exhaust that we bought from Mark at Breeze Automotive


We were officially at "roller" stage on January 8th. Here are some pictures. The first is of the Catch Cans and the other three are of the car in our driveway on January 8th.

http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_20170102_165943_zps4rbecxv2.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/20170102_165943_zps4rbecxv2.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_20170108_120049_zpscuvqo2ic.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/20170108_120049_zpscuvqo2ic.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_20170108_120059_zpsm8ztskhu.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/20170108_120059_zpsm8ztskhu.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_20170108_120121_zpsbkiw1i47.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/20170108_120121_zpsbkiw1i47.jpg.html)

And here are two pictures from last Sunday (February 12th) after we had installed the exhaust.

http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_20170212_132914_zpsu82u7qep.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/20170212_132914_zpsu82u7qep.jpg.html) http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_20170212_132905_zpsv9pbxdri.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/20170212_132905_zpsv9pbxdri.jpg.html)

The seats are just sitting there at the moment. We haven't mounted them because we wanted to make sure of the position and setup before we did.

We received our iWire harness back from Brian and are hoping to get that all installed this weekend. After that we have a few small things to finalize (coolant overflow, hoses, add fluids, etc) and we will be ready for our first start (hopefully).

Cheers,
- Lou

[TX-Lou]

FIRST START!!!

https://www.dropbox.com/s/hoqkh3l0psyjc2y/firststart.MOV?dl=0

We are in the process of bleeding the coolant system now. Should have that done tomorrow and then we hope to take it out for a drive.

We had some delays including the fact that the donor starter was dead. I had started the donor but that was almost 2 years ago now. In the time since it must have seized up. But we are up and running now. Next steps are to get it tuned and then to start working on the body.

Cheers,
- Lou

[DSR-3]

Very cool - Congrats!

[Wayne Presley]

Make sure you do the cooling system mod!

[BN]

Congrats thumb up

[wirenut]

Looks awesome! I'm finally getting started on my 818s in Houston. (Oak Forest) Would love to come by some weekend and get some tips.

[TX-Lou]

Sorry I missed these replies, I didn't get an email message for them.

Thanks Wayne, yes that was one of the first things we did when we got the engine back from being rebuilt. We ended up doing the coolant via vacuum system. We got tired of trying to bleed the system and we ended up doing the same for the AWIC.

Wirenut, just PM and we can setup a day/time if you want to come see the build.

Thanks,
- Lou

- Lou

[TX-Lou]

So we hit a big milestone event in the build. My son and I took the car up to Fort Worth to get it tuned on Monday. It took 10 hours but everything went great. In the end the car puts out 307 horsepower at the wheels and 301 ft/lbs of torque.

Here is a picture of John standing behind the car with our tuner Dusty in the driver's seat. Dusty rebuilt the engine as well. If anyone is looking for a tuner Dusty is your man. He owns D.A.P. Tuning in Fort Worth.

http://i288.photobucket.com/albums/ll166/TX-Lou1/818C%20Build%20Thread/th_20170605_113312_zps95d41sgd.jpg (http://s288.photobucket.com/user/TX-Lou1/media/818C%20Build%20Thread/20170605_113312_zps95d41sgd.jpg.html)

The video below is to one of the many pulls where Dusty was accelerating full throttle in either 3rd or 4th gear to red line. In this video he is cruising at about 40 mph in 4th gear when he opened up the throttle (at the 33 second mark) and takes it up to about 130 mph before letting off the gas. The roar of the engine was so loud that the phone cuts out and just gives white noise when it can't handle it. The whining noise you hear at the end is the sound the Dyno makes when it is spinning that fast. He has a laptop in the car plugged into the ECU (Engine Control Unit) and another computer on the stand that reads engine sensors and the feed from the Dyno.


https://youtu.be/nJXzp5262aA

We had no issues with overheating. Both the cooling system and the AWIC worked great. The only issue we had was we had a crack in the up-pipe to the turbo right at the weld near the turbo. Clint, the guy who owns the shop, pulled it off and welded it for us. I don't know how Dusty heard the crack but he kept saying he could hear air escaping. John and I couldn't hear it.

Next on the list is getting the AC installed and starting the work on the body.

- Lou

[wirenut]

Man that thing sounds mean! Congrats. Great numbers too!

[TX-Lou]

Man that thing sounds mean! Congrats. Great numbers too!

Thanks!

It was such a satisfying feeling to see something we built perform like it did. It was hard to imagine we would be where we are now when this project started.

- Lou