York's 818s

[alpine227]

Good afternoon.

I picked up my kit on the Sep 1st.

I am using an 02 WRX donor with 209k miles from the north east. Yeah I used alot of pb blaster
18g turbo
Decapped blue injectors
JDM ej205 avcs
MS3X
4/2 pot brakes
OBX front diff (if it's ever back in stock) so far I have completed the bottom and front aluminium, front suspension steering rack and rear suspension.

I am doing the build with my man cub soon to be 5 year old.

[alpine227]

How many 1/8th drill bits does one need? Atleast one more! Just a quick update. Installed the engine trans, pedal box master cylinders steering rack and column and preeping the fuel tank. It's refreshing to bolt new parts onto a new chassis with new hardware. Rivits are starting to get a little old however.

[jcpresto]

For what's it's worth I used Dewalt and have only needed 4 to do every frame hole.

[Mechie3]

The harbor freight air riveter is good. Are you near rm1sepex in Maine?

[alpine227]

I am about an 75 min from freeport. I live a few miles north of Waterville. I will give the DeWalt bits a try. Will give the hf riviter a shot as well. Unfortunately I have a solid entry for the world's loudest air compressor competition atleast a podium finish.

[longislandwrx]

I bought a 8 pack of Milwaukie drill bits, I cut a few down to get into tighter places with my 45 degree drill. Its been plenty to do the whole car so far.

I connected my hose reel to my compressor with a 10 ft rubber line. When I get tired of my compressor I wheel it outside and shut the door.

[RM1SepEx]

a pack of the HF TI double ended bits will do the entire car. Dip the bit into oil before each hole. I also use the HF air riveter. Mine's spent after building an electric reverse trike and the 818. PM me when/if you want to see a completed 818, mine's about 1400 miles from first registration

[alpine227]

Thanks Dan, ti bits and oil trick is working nicely. It's officially a roller. Metric to standard brake line clutch Lin adadapters are pol as is diff lock, so jumping in on the wiring. I am using MS3X for engine management with lc1, egt, gps and 3way accelerometer for data logging. Going to try and use a jbperformance dual vr conditioner board with factory abs sensors to try percent slip traction control as well. I need to take more pictures then figure out how to add them to thread as well.

[alpine227]

Wiring is more fun than I thought it would be. Since I am running stand alone I cut the harness into long pigtails and used Delphi weather pack bulk head connector and separate relay / fuse box in the engine bay. Holds relays for coils, injectors/iacv avcs solenoids, fuel pump and alcohol injection pump. Will do separate box for chassis harness.

[alpine227]

http://i377.photobucket.com/albums/oo219/johnyork1/Mobile%20Uploads/IMG_20160908_142405517_zpsjpwzhde6.jpg

[alpine227]

My favorite photo so far. Man cub helping out.http://i377.photobucket.com/albums/oo219/johnyork1/Mobile%20Uploads/IMG_20160902_083937470_zpsnyvovcst.jpg

[alpine227]

http://i377.photobucket.com/albums/oo219/johnyork1/Mobile%20Uploads/IMG_20160919_105702033_zpsffwu2txw.jpg

Will be putting ecu in a Hammond 1550 watertight enclosure with ampseal connectors.

[alpine227]

First start today, had an awful notice coming from the flywheel, pulled trans and noticed I forgot to torque down the flywheel oops! Back together and took a spin around the yard..... Not a huge fan of the ej205 sound miss my ez30

[alpine227]

So I think the JDM ej205 avcs has a different cam pattern than the usdm as I loss sync when I try to run full sequential spark and sync loss counter goes crazy. I have a pretty clean signal from crank up to 5500 on the crank signal 36-2-2-2 vvt mode. Gets a bit noisy after that.ordered a vr conditioner board to try and clean it up. Appears the cam is out of phase with the decoder.
Lights are in, cluster is getting wired in as well. Used waynes door trick and coolant mod.

[Aero STI]

So I think the JDM ej205 avcs has a different cam pattern than the usdm as I loss sync when I try to run full sequential spark and sync loss counter goes crazy. I have a pretty clean signal from crank up to 5500 on the crank signal 36-2-2-2 vvt mode. Gets a bit noisy after that.ordered a vr conditioner board to try and clean it up. Appears the cam is out of phase with the decoder.
Lights are in, cluster is getting wired in as well. Used waynes door trick and coolant mod.

I'm not terribly familiar with the EJ205 with AVCS, but the EJ207 V7-V9 used an inductive cam sensors, whereas USDM EJ257 used hall effect sensors.

[alpine227]

Yes the sensors are vr, I am going to run them through a vr conditioner board to clean up the noise a bit. Just not sure why it's not sync the cam and crank with the 36-2-2-2 vvt decoder. I will try it on the 36-2-2-2 standard decoder to see if I get sync. It works fine with semi sequential fuel and wasted spark cop with only the crank signal. I suspect the cam signals should be the same as the usdm ej205's as reportedly the work on a usdm ecu just won't run avcs. I need to put the engine back in I had to replace the water pump and try the regular decoder not vvt.

[Shawn818c]

what was the process you used to clean/prep/paint your chassis?

[alpine227]

First I am not a paint expert! An important prep step is to ensure its not raining on pickup day! The weather at home was 80 and sunny but it was raining in MA. Nothing a few cans of wd40 couldnt fix. As for prep I hit a few areas with a flap disc, I used a case of brake cleaner and rags to degrease it. I used metal prep to etch and promote adhesion than let Ethan at it with a roller. I used a gloss epoxy paint on the roll bar. The powder coat looks better to be honest but it was a fun project the boy could help with.

[alpine227]

Thanks Larry, the new EPROM was a snap to put in look forward to not seeing 209k on the odometer.

[alpine227]

I picked up some Delphi weather pack connectors to finish off the engine bay harness from DIYAutoTune. And installed the Mike's brake relocation bracket and alternator kit. The relocation kit came with a template very nice product.

[ben1272]

Would you post a picture of your front top door hinge frame mounting point? (either side)

[K3LAG]

Thanks Larry, the new EPROM was a snap to put in look forward to not seeing 209k on the odometer.

Your welcome.

Larry

[Frank818]

http://i377.photobucket.com/albums/oo219/johnyork1/Mobile%20Uploads/IMG_20160908_142405517_zpsjpwzhde6.jpg

Wow 20 days and the car was already that far? Unbelievable.

I'm interested in your fuel filler neck (pipe), by any chance do you have a picture of the pipe off of the tank or a close up pic of the pipe on the tank?

[alpine227]

http://i377.photobucket.com/albums/oo219/johnyork1/Mobile%20Uploads/IMG_20160908_142418701_zpswej4yyz2.jpg

[alpine227]

http://i377.photobucket.com/albums/oo219/johnyork1/Mobile%20Uploads/IMG_20161103_240419874_zpsfzdhue4l.jpg

Filler neck into tank pic

[alpine227]

I tried but with the doors on its hard to get a shot of it. The side view picture of the rolling chassis is pretty high res so if you zoom in you get a pretty good view of the mounting point.

[Frank818]

Yeah looks pretty good enough. It seems to fit more fwd than mine, not sure if FFR did a change on the pipe or the way it mounts at the bottom of the tank, but yours should fit pretty close to the fuel cap.

[alpine227]

It appears to be a change as it didn't look like the one in the manual. There is approximately a 3/4 gap between the cap and end of the filler tube.

[Frank818]

Great, tnx for that man. I'll mail FFR, maybe if the cost is right I'd prefer to pay to get a part that fit much better, rather than taking who-knows-how-many-hours to make mine fit somehow.

The 3/4 gap is it side-to-side of the pipe or up-down from the pipe to the bottom of the cap? I mean is the pipe already pointing at the cap or slightly off by 3/4? Either way it's a huge improvement over the old style (3-4" or so).

[alpine227]

Its Nearly perfectly lined up just 3/4 of an inch from tube end to cap end.

[Frank818]

Tnx so much for the pix and the info. Curiously the pipe at the bottom seems to extend further than mine but at the top it's more fwd, the angles in between are certainly different.
I'll get a price and see if it's worth it for me.

[alpine227]

Welding aluminum will not be my new day job. I would post pictures but I think the carnage would cause some mental scarring.

[alpine227]

Made some progress with wire managment finishing off the engine harness, I started on the cluster wiring and lights. I broke a lead going off my sub fuel level sender boo. Replaced brake lines with metric Cooper nickel lines and made bracket for waste gate on my 18g clocked 180 degrees and installed side mount intercooler. I need to get a new intake temp sensor bung since my primitive aluminum welding skills destroyed my first attempt. Still having issues getting the cam to sync I need to spend some time with the tooth logger on tuner studio to see what I am missing.

[wirenut]

Hey man, what tires are you running?

[alpine227]

Federal 595, I got them super cheap. I can't give a review yet. People running the factory five option wheels what tire size up front are you running without interference?

[alpine227]

Just powered up the cluster, really like seeing 0 miles on the odometer thanks again.

[alpine227]

https://youtu.be/Kn25nymPgt8

Enjoying the snow, sorry I have no mount for my camera so it sat on my passenger side floor

[Frank818]

It's cool to have fun, isn't it? :)

What's that red disconnected about 1" silicone hose for?

[alpine227]

ha ha me not cleaning up. It's a hose sitting on the firewall "shelf" aka place I put everything I just used and didn't put back in the tool box/parts shelf. It was a breather of PCV hose that I replaced for Air Oil separator.

[alpine227]

It's cool to have fun, isn't it? :)



Just a cop out enjoying donuts!

[Frank818]

Man you really were in a hurry to have fun with it! :)

[alpine227]

It's been a great break from the daily grind, when I can go out to the garage and deal with something that seems to makes sense (and does donuts).

[alpine227]

-14 degrees this morning and it warmed up to a balmy 15 I decided to bring the doors and dash into the basement to work on them as it was painful to pick up tools with bare hands. I have to do a repair of the drivers side sail where the pin for the hump cover goes is cracked, it seems thinner than the passenger side as well. I am not a fiberglass guy but it appears I could put mat on the underside and wet it out (not sure if that's the correct terminology or not) to repair it. Any recommendations on what type and or brand of products to use for a novice to use. Would the curing process make my wife angry if it had to happen in the basement as temps are frigid in the garage?

[alpine227]

Another cold week. I managed to repair the side sail and added a few layers of fiberglass. Pretty easy.... Messy but easy. Installed the touch screen need to get the mega squirt software loaded and the head unit talking to the ECU.
Quickly moving up the to do list as the temps quickly move down towards absolute zero is install an old mobile home furnace I scavenged a few years ago in the garage.

Hopping people enjoyed Thier Christmas.

[flynntuna]

Gotta love spell check😄

[alpine227]

Sure I guess...

[alpine227]

I got to spend some time working on the torque management system. I am using the MS3X for traction control. I wired a front abs sensor though a JB performance condition board to get a clean digital signal for the undriven wheel speed. I need to feed it the driven wheel signal now and calibrate them. I added the knocksense module which has some neat features and wired in a GM boost control solenoid (no more wastegate pressure) now I need to get a big area that doesn't have 2 feet of snow on it to tune it all.

[alpine227]

I managed to get a few hours in today before my hands turned into blocks of ice. I connected the trans vehicle speed sensor into the MS3X and managed to calibrate it to the cluster speedometer. This sensor could be connected directly to the ECU.

[alpine227]

Typical Maine weather today was in the 50s two days ago it was -18.

I wired in my boost, oil pressure and oil temp sender's and gauges. I installed a double din Android head unit and connected it to the MS3X using MSDroid app.

I started the paperwork for getting a VIN assigned. Not sure if having a JDM engine is going to hold it up as I don't have the VIN from the vehicle it came from, fingers crossed.

I am headed to Sears in the morning looking to replace my air compressor with there closing they are supposedly having some crazy sales.

[alpine227]

Sears blowout sale was terrible 10 to 20% off MSRP.... More expensive than Amazon prices.

[turbomacncheese]

Typical Sears distraction. Seems like they've been having "going out of business" sales for the last 10 years wherever I go. Always a disappointment.

[alpine227]

http://i377.photobucket.com/albums/oo219/johnyork1/Mobile%20Uploads/IMG_20170122_134519856_HDR_zpsiwwx4yat.jpg
Headlamp lens's installed. The LEDs are so much brighter at 13.8v vs 12v.

[alpine227]

http://i377.photobucket.com/albums/oo219/johnyork1/Mobile%20Uploads/IMG_20161230_111117556_HDR_zpsayskb8bp.jpg
Kinda digging the new exhaust bezel.

[alpine227]

Thank you Dan for the parts and staying out in the freezing temps to show me your very nicely done car.

[RM1SepEx]

my pleasure, enjoyed swapping parts for Sam Adams too, great talking with you.

[alpine227]

I got my VIN assigned today. No drama easy peasey.

[Canadian818]

Congrats!

[flynntuna]

Alright! Hope the rest of the build goes as well.

[Frank818]

Already? Congrats! Man USA isn't like Canada, hopefully Trump will not add restrictions for plating custom cars. :)
But who cares? You got the VIN before! :)

So what's your next big thing/step on the build?

[alpine227]

I live in a relatively "free state" so the VIN assignment was send In a form that states were the major components came from I supplied my donor title and the certificate of origin. The inspector brought a number plate over a week later. Body work is next on the list. Looking at the voids that surfaced in Dan's car after a short time I plan on spending the next few months sanding and filling them to prep for paint. Seats/interior and try to figure out how to get the avcs to work on mega squirt, alingment are still on the to do list.

[Frank818]

Cool! Live free or Die, as your NH neighbours would say. :) And they're right.

About voids, I did find many me too. Sometimes in places you would least expect and tiny places right in front where rocks would hit a small edge facing front. Those need to be repaired before you hit the road. It does take time to sand, there's always something you missed or that is harder to get right. Add gel coat, sand, doesn't look good again, add gel coat, sand and one day you get it fine.

[alpine227]

Not 818 related but my Ford Interceptor Sedan's AWD decided to quit working in the middle of a blizzard during my shift. The under steer is surprising/terrifying. I guess 10 plus inches of snow on unplowed roads running code was the last straw for this tired old girl.

[Frank818]

Ford had AWD on the Interceptor?
If your tires weren't good in snow you'll understeer terribly.

[alpine227]

Great tires Goodyear ultra grip, they do have a decent AWD system however my exuberant driving in severe conditions over prolonged distance overheat the power transfer unit and the car shut off power to the rear diff. Gave a warning message saying AWD Off went from a slight oversteer to terrible understeer.

[Frank818]

exuberant driving in severe conditions

I like that. :)

[RM1SepEx]

You should have seen my wife's face when his car was sitting in my driveway with the door open... priceless

[alpine227]

Haha I do get a spectrum of reactions!

[alpine227]

Finally figured out the cam sync issue I was having and am officially running coil on plug and sequential Injection. After messing with polarities and trigger edge. Long story short I wasted a lot time read the forums and placed a 2.2k shunt resistor across the cam wires and what do you know sync. These VR sensors are noisey buggers time to invest in some hall sensors. Now to get the avcs feed back sensors to work the JDM ej205 has 4 tooth wheels instead of the 4-1 triggers on the usdm avcs.

[alpine227]

I painted my interior aluminum with liqidamp it's like a paintable sheetrock mud. Dries pretty quick even in the arctic wonderland here.

I am working on an RFID relay using Arduino nano for a starter kill (more starter revive) know RFID tag will close relay on the starter wire the operator will have 15 seconds to start the engine before the relay is open again.

[RM1SepEx]

Arctic Wonderland... I've been working on my old Yamaha 1975 RD350B in the garage with the door open ;) Only 5 more weeks before J-Lo makes her 2017 appearance from hibernation

64314

[alpine227]

How's the heater module working out? I still have a bit of fabrication as Julie bought my seats and harnesses for Valentine's day. As there are no harness anchors incorporated in the chassis.

[flynntuna]

[QUOTE=alpine227;268956]I painted my interior aluminum with liqidamp it's like a paintable sheetrock mud. Dries pretty quick even in the arctic wonderland here.


Curious about the liqi damp, how much did you need to do the interior? Did you do just the floor or did you do the firewalls too?

[alpine227]

I used 1qt did floors interior aluminium and firewalls with some to spare. It's pretty thick and one can see brush strokes in the finished product so I would plan on covering visible areas with carpet or vinyl or lightly sand any areas that are just getting paint after.

[alpine227]

I pulled off the aluminium trim bezels and went the edge guard route, I was skeptical about the aluminium sticking with only silicone, I am not anymore those buggers stuck pretty well.

[alpine227]

So I can get avcs to activate in test mode I can hear the engine tone change however it only occasional registers a change in angle from the sensor. Seems like program should allow me to say how many teeth are on the cam but it doesnt. I wonder if it just uses the first tooth after tdc and skips the others.

[RM1SepEx]

I haven't touched the heater and seat heater hookup yet, I have almost every part. J-Lo is back on the 4 post so I can use the area underneath for the RD work and my snow blower etc...

[alpine227]

Art, thank you for the switchback kits they work fantastic even with my primitive soldering I managed to have a trouble free install. Thanks again.

I also started on a plug for a side scoop for the smic. The windshield gets installed Saturday.

The harnesses and seats got installed and spent some time on interior lots of "carbon fiber" vinyl wrap and marine grade vinly cloth.

[TomV]

Looking great so far, nice work.

[aquillen]

Art, thank you for the switchback kits they work fantastic even with my primitive soldering I managed to have a trouble free install. Thanks again.


Good to hear - enjoy!

[alpine227]

Sometimes you just need to laugh! 3hrs to find a bad crimp on the crank position sensor causing intermittent sync loss. With that fixed I moved on to some fuel tuning after a few runs the turbo coolant line blew glad it happened near the house was able to coast to the driveway.

[alpine227]

Yay windshield is installed thanks America glass top notch job. Body panels have been cleaned and blocked with some work left on the front fenders near the parting seams but getting closer to spraying time. Probably the thing I have the least confidence in doing but yolo!

[alpine227]

I just got a great deal on an 80gal 5hp 2 stage compressor which is getting wired and plumbed in this weekend. The body panels are off and I hope to get the go kart out to the "race track" for some durability/reliability testing and fuel tuning.

[turbomacncheese]

Nice. Cheapest one I could find around here was a little over $800, so I went with a single-stage 3.7 hp.

[alpine227]

Sand, fill, sand, fill, sand, fill.
I feel like a surgeon preeping for surgery as I get my garage ready to paint.

[alpine227]

Things have been a bit slow as it's my kids share nothing but germs and have kept us all sick for a few weeks. But I did manage to shoot some primer and get my side scoop on for the side mount ic.

http://i1284.photobucket.com/albums/a577/alpine2275/Mobile%20Uploads/IMG_20170511_150944475_zpsj4vhcyhe.jpg (http://s1284.photobucket.com/user/alpine2275/media/Mobile%20Uploads/IMG_20170511_150944475_zpsj4vhcyhe.jpg.html)

http://i1284.photobucket.com/albums/a577/alpine2275/Mobile%20Uploads/IMG_20170511_151310047_zpsljmumj8k.jpg (http://s1284.photobucket.com/user/alpine2275/media/Mobile%20Uploads/IMG_20170511_151310047_zpsljmumj8k.jpg.html)
http://i1284.photobucket.com/albums/a577/alpine2275/Mobile%20Uploads/IMG_20170511_151339348_zpsxibivx1m.jpg (http://s1284.photobucket.com/user/alpine2275/media/Mobile%20Uploads/IMG_20170511_151339348_zpsxibivx1m.jpg.html)

[AZPete]

Very nice job on the side scoop. I also like the center-drive race car, but it needs more stickers on the back of the seat.

[turbomacncheese]

Dig the side scoop. I want to make one (well, two, really...).

[alpine227]

5 year olds and stickers! He would probably put them on the tires if left unsupervised.

[alpine227]

Thanks, it took a fair amount of time to make. Its not really hard but it sure is time consuming making the plug. I wish I had spent more time on the plug so I didn't have to spend the time on the back end smoothing out the part but first go at making fiberglass parts I will put it in the win column. Certainly not going to quit my day job for it though...

[RM1SepEx]

That's the same IC that I have but I put both inlet and outlet at the top

nice scoops

[alpine227]

I am running the ffr wheel setup but noticed a pretty big gap between the tire side wall and the edge of the fender. Are people running wheel spacers up front to close up the gap?

[Canadian818]

Can't help you with the wheels, but your side scoop looks great! Very clean lines.

[alpine227]

http://i1284.photobucket.com/albums/a577/alpine2275/IMG_20170527_223942107_zpszt2gqgqq.jpg (http://s1284.photobucket.com/user/alpine2275/media/IMG_20170527_223942107_zpszt2gqgqq.jpg.html)
Head unit and ecu are talking!

[alpine227]

http://i1284.photobucket.com/albums/a577/alpine2275/IMG_20170522_123923359_HDR_zpsvxqlgp03.jpg (http://s1284.photobucket.com/user/alpine2275/media/IMG_20170522_123923359_HDR_zpsvxqlgp03.jpg.html)

http://i1284.photobucket.com/albums/a577/alpine2275/IMG_20170522_123854341_zpsa7wjber2.jpg (http://s1284.photobucket.com/user/alpine2275/media/IMG_20170522_123854341_zpsa7wjber2.jpg.html)

[alpine227]

http://i1284.photobucket.com/albums/a577/alpine2275/2017-05-30_16.07.55_zps1yna2efi.jpg (http://s1284.photobucket.com/user/alpine2275/media/2017-05-30_16.07.55_zps1yna2efi.jpg.html)

Got my plates! 25 miles in today! sounds like I have a bad wheel bearing and my wideband sensor of 10 years is starting to flake out but no major issues.

[mikeb75]

Nice job & congrats.

[alpine227]

Thanks you too on the first re-start. Thanks Adam the scoop was definitely outside the comfort zone and I learned a lot about what not to do when making molds but given enough sandpaper and filler I am pleased with the finished product.

[alpine227]

I found a bosh 17014 is a cheap replacement sensor for an LC-1 wideband $50 in stock at orielys.

I managed to put a few more miles on today. Does it ever stop feeling like driving a ticking time bomb? like when is that bolt I forgot to tighten going to come loose or when is a cold solder joint going to leave me stranded on the side of the road.

[Bob_n_Cincy]

I found a bosh 17014 is a cheap replacement sensor for an LC-1 wideband $50 in stock at orielys.

I managed to put a few more miles on today. Does it ever stop feeling like driving a ticking time bomb? like when is that bolt I forgot to tighten going to come loose or when is a cold solder joint going to leave me stranded on the side of the road.

Congrats on your completion of the "street legal stage".

We've been stranded three times.
Two snapped axles. On at autocross launch and one on the street under normal load.
The third time was at a track day where the to coolant hose on top the engine was pulled off during a 1.2g right turn. I suspect that we did not have enough hose slack for the engine movement.
Bob,

[RM1SepEx]

Me too, 3 times all related to my transaxle sliding pins to keep her in one gear at a time. I did have to repaced a 1/4-20 lock nut on my shifter in a parking lot but she drove home in an hr vs having to go get my trailer!

I started the break in/cruising with short 8-10 loops around the area to make getting home a minor issue.

[CdnCarNut]

I'm still amazed at the speed of the build. My donor car has been sitting out front for 3 months due to other priorities. Soon...

[alpine227]

I'm still amazed at the speed of the build. My donor car has been sitting out front for 3 months due to other priorities. Soon...

I have a unique work schedule that gives me a lot of free time. I also don't sleep much!

[alpine227]

Me too, 3 times all related to my transaxle sliding pins to keep her in one gear at a time. I did have to repaced a 1/4-20 lock nut on my shifter in a parking lot but she drove home in an hr vs having to go get my trailer!

I started the break in/cruising with short 8-10 loops around the area to make getting home a minor issue.
I have been going around the "block" being a country mouse it's about 10 miles around and at the half way point is my buddy with a tow companies garage. Each lap is a bit more confidence 60miles so far

[Bob_n_Cincy]

I have been going around the "block" being a country mouse it's about 10 miles around and at the half way point is my buddy with a tow companies garage. Each lap is a bit more confidence 60miles so far


Our first summer (2015) with the 818 we trailered it to a half dozen autocross events.
Couple of reasons.
1. car was not registered yet.
2. wanted to push the car to the limit to expose any issues.
3. We were never more than a quarter mile from our trailer if something did break.

After registered, we've gone on a few 100 mile trips. At this point I have no qualms going on a long trip other than the no roof issue.
Bob

[alpine227]

Our first summer (2015) with the 818 we trailered it to a half dozen autocross events.
Couple of reasons.
1. car was not registered yet.
2. wanted to push the car to the limit to expose any issues.
3. We were never more than a quarter mile from our trailer if something did break.

After registered, we've gone on a few 100 mile trips. At this point I have no qualms going on a long trip other than the no roof issue.
Bob

Makes sense, I have a "closed course" a few miles from the house. I will trailer it out and give it a good shake down to see what falls apart.

[alpine227]

Lessons learned from painting. Hose management is tricky it seems to want to rub against any freshly painted surface it can find. More pressure is better than not enough. You can't have enough tack cloths. Clean clean clean than for a change clean more. Have a test panel to check flash times. And keep your paint mixing station away from your work area so when you spill something it doesn't end up on the door you just painted the only GD panel that turned out great..... well no plans to quit my day job but excited to reassemble and get ready for a Dyno tune.

[alpine227]

http://i1284.photobucket.com/albums/a577/alpine2275/Mobile%20Uploads/IMG_20170713_224509664_zpsty1u2zml.jpg (http://s1284.photobucket.com/user/alpine2275/media/Mobile%20Uploads/IMG_20170713_224509664_zpsty1u2zml.jpg.html)

http://i1284.photobucket.com/albums/a577/alpine2275/Mobile%20Uploads/IMG_20170713_224444388_zpselw7fsqt.jpg (http://s1284.photobucket.com/user/alpine2275/media/Mobile%20Uploads/IMG_20170713_224444388_zpselw7fsqt.jpg.html)

http://i1284.photobucket.com/albums/a577/alpine2275/Mobile%20Uploads/IMG_20170713_224509664_zpsty1u2zml.jpg (http://s1284.photobucket.com/user/alpine2275/media/Mobile%20Uploads/IMG_20170713_224509664_zpsty1u2zml.jpg.html)

[alpine227]

Some pictures of the new color and a bit of work on the interior. Also installed Mike's remote resivoir kit. The third part (previously purchased alternator and brake cylinder bracket.)I purchased from Mike all have been easy to install with clear instructions and seem to be well thought out improvements.

[Frank818]

That seems to be a nice color, can't wait to see the finished product.

Can you remind me what brand is your S/W?

[alpine227]

Steering wheel is an NRG with a 1 inch spacer. I made a clock spring so he horn works too.

[alpine227]

http://i1284.photobucket.com/albums/a577/alpine2275/Mobile%20Uploads/IMG_20170715_224110088_zpsmvqf59y2.jpg (http://s1284.photobucket.com/user/alpine2275/media/Mobile%20Uploads/IMG_20170715_224110088_zpsmvqf59y2.jpg.html)

http://i1284.photobucket.com/albums/a577/alpine2275/Mobile%20Uploads/IMG_20170715_224226400_zps33pbzut5.jpg (http://s1284.photobucket.com/user/alpine2275/media/Mobile%20Uploads/IMG_20170715_224226400_zps33pbzut5.jpg.html)
http://i1284.photobucket.com/albums/a577/alpine2275/Mobile%20Uploads/IMG_20170715_224152393_zpskznl24ji.jpg (http://s1284.photobucket.com/user/alpine2275/media/Mobile%20Uploads/IMG_20170715_224152393_zpskznl24ji.jpg.html)

[mikeb75]

Wow, that looks really nicely finished!

[alpine227]

thanks, I am pretty happy with the way it came out there are a few spots that need some work dry spots, a few places where the hose hit the wet paint and an area were I didn't mind the flash times and it wrinkled a bit. But you forget about them when you hit the loud pedal and cruise in the car you built yourself.

[Frank818]

I agree, it looks OEM straight out of the dealer.

[flynntuna]

I'm constantly amazed by the talent on this forum.

[alpine227]

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

I did a thing today after a ringland failure in my ej205. A bit of wiring to finish up and 2 injectors plastic end cap broke duing disassembly but should running tuesday

[mikeb75]

H6? sweet.

[alpine227]

Yes it is, I plan to run it NA until winter (kinda itching to put some miles on it) than it's will get boost compliments of a gt35 and dw injectors. If funds will permit rods, pistons and valve springs.

[alpine227]

Wire harness is complete but two injector caps broke when I pulled the fuel rails waiting on replacements to fire it up. The beautiful part of running standalone is just adding some pins to my bulkhead connector and dissecting the engine harness a few drop down changes on the laptop. (I did have to turn two pots and add a jumper on the ecu to account for the hall sensor instead of vr on the cam)

[Hobby Racer]

Welcome to the H6 club! There are only a few of us, but are ranks are growing. I hope to have mine started by the end of the month.

What are you running for exhaust?

[Frank818]

Finally!!! Another 6cyl!! :)

I thought the H6 was "unboostable" due to weird crank or rod angle and lack of aftermarket parts, was that more for the 3.6?
Ok you got H6 3.0 or 3.6?

How much boost and power you could get out of it (boosted)?

[flynntuna]

Both have been turbo'd, on the Haltec website There's a link to an ez36 build.

[alpine227]

The 3.6 has offset rods but has been boosted low pressure the most famous being the mighty car mods Gramps build. Some obstacles are the small rods, 10.7:1 compression and open deck block. Wayne pulled 320ish at 8psi stock block (larger injectors). With rods, pistons, sleeves valves and springs Perrin got 600 around 20psi if I recall. I recall seeing a twin ez with 1400ish but it had closed deck block built heads pistons rods crank and twin snails and a horrid torque curve

[alpine227]

Welcome to the H6 club! There are only a few of us, but are ranks are growing. I hope to have mine started by the end of the month.

What are you running for exhaust?
I am running the 1st gen ez30 single port. I am using a crossover pipe similar to the ej20 had to relocate a few pesky coolant lines still fabricating the rest of it. The uppipe is going to pass near stock turbo location hook down go through hiflow cat, flow through muffler. Winter time will add turbo flange, and ewg plumbing.

[alpine227]

I scored a H6 outback for $300 had a blown transmission sold a few hundred of parts and should get some more from the scrap yard. So I got paid for this engine! Feels weird making money on new parts... May even make enough for the new injectors.

[alpine227]

https://youtu.be/Ow3xa8jpU5c
First start of the H6, I need to adjust idle settings. Also not good for the tinnitus without exhaust on.

[flynntuna]

Congrats on the first start! What are your plans for the exhaust?

[alpine227]

Well my first thought was to use the header I had from my wrx that was h6 swapped but clearance issues with chassis and coolant lines I have moved to to disturbingly tight bends up between the heads and motor mounts to a 2 into 1 cat 2 180 degree bends to a flow through muffler out the back. This is because I have all the pipe on hand and I am currently executing operation get this thing back on the road before the white stuff falls from the sky. The winter I will build a crossover and uppipe similar to Wayne's for the gt35 turbo setup with 321 stainless and someone who welds better than me.

[Frank818]

Awesome 1st start! It looks monstrous when you give it some gas!!

321 stainless? Never heard of that metal type, what's so special about it?

[alpine227]

321 is similar to 304 but with titanium in it. It is more resistant to cracking due to high tempatures than 304.

[Frank818]

Is there enough titanium in it to change the exhaust note?

[alpine227]

I don't know if it changes the tone, however fun lesson learned today don't pick up with bare hands the piece you just finished welding 2 seconds prior, probably shouldn't be in the garage today have a 102 fever not really running on all cylinders. The only things my kids share is brocolli and germs.

[alpine227]

https://youtu.be/8qbavtcQxvs
No more boxer rumble. Ignore my out of date virus protection. Still needs a tune but i don't need hearing protection now!

[Frank818]

How did you change the usual sound like that? Amazing!

[alpine227]

I ran the oem 2:1 cat and a flow through muffler. The induction noise is probably louder than the exhaust ATM.

[alpine227]

https://youtu.be/fqH6twsUJMU
Definitely enjoying the extra two cylinders it does seem to run out of steam in the top end though might need some more manifold pressure ��

[Frank818]

It has some kind of a racing sound in there, love it! Maybe a little Porsche-like or something... Not the big 3.6 Porsches but say the earlier ones.

[alpine227]

The car sounds more like it looks in Comparison to the H4. New issue is the outback cluster is too wide for the guage pod from ffr and ms3 can't scale the tach output for 6cyl on a 4cyl tach it can only double it or half it. Possible solution is make an overlay for the guage face calibrated for the 6cyl my observing needle location at various RPMs confirmed on tuning software. Or use a pic controller to intercept and scale the signal (not sure how much delay this would cause I am guessing it's a square wave output)

[Frank818]

Isn't the RPM signal pulse-based? Like 2 pulses per second, 4, etc... If so, you could convert the 6cyl's output pulses to whatever the tach is expecting, assuming such a conversion is possible.

[longislandwrx]

The car sounds more like it looks in Comparison to the H4. New issue is the outback cluster is too wide for the guage pod from ffr and ms3 can't scale the tach output for 6cyl on a 4cyl tach it can only double it or half it. Possible solution is make an overlay for the guage face calibrated for the 6cyl my observing needle location at various RPMs confirmed on tuning software. Or use a pic controller to intercept and scale the signal (not sure how much delay this would cause I am guessing it's a square wave output)

http://www.dakotadigital.com/index.cfm/page/ptype=product/product_id=127/category_id=287/home_id=59/mode=prod/prd127.htm

[Hobby Racer]

The car sounds more like it looks in Comparison to the H4. New issue is the outback cluster is too wide for the guage pod from ffr and ms3 can't scale the tach output for 6cyl on a 4cyl tach it can only double it or half it. Possible solution is make an overlay for the guage face calibrated for the 6cyl my observing needle location at various RPMs confirmed on tuning software. Or use a pic controller to intercept and scale the signal (not sure how much delay this would cause I am guessing it's a square wave output)

I do not know what firmware version you are using with your MS3 but the latest version does have variable scaling built into the tach output.

Update your firmware and your tach problem is solved for free!

73700

[alpine227]

I do not know what firmware version you are using with your MS3 but the latest version does have variable scaling built into the tach output.

Update your firmware and your tach problem is solved for free!

73700
I am about two behind, thank you for the great news!

[alpine227]

A few mouse clicks and I have an accurate tach thanks again.

[Mitch Wright]

Your H6 sounds great.

[alpine227]

Thank you, I am happy with the way it turned out. My inner teenager is pouting because there is no bov sound though.

[Samiam1017]

I ran the oem 2:1 cat and a flow through muffler. The induction noise is probably louder than the exhaust ATM.

you ran stock stock headers? any pics of the exhaust

[Hindsight]

Sounds great!!! Nice work.

[alpine227]

you ran stock stock headers? any pics of the exhaust
The stock headers, were hacked up and some obsurdidly poor flowing tight turns were made to clear the chassis and suspension. The primarys bolt up to the factory 2:1 cat than into a 3" flow through muffler out the back. I will take some pictures tomorrow and upload them for you. It's honestly quickly done poorly planned exhaust setup with the goal of getting some more miles on it before the snow starts falling. Flanges weld els and bits are on order for this winter project of adding boost.

[longislandwrx]

can you fit the raptor header? i know they make huge gains.

http://raptorsc.com.au/subaru/subaru-libertylegacy-4-gen-ez30-header/

[flynntuna]

The Raptor headers don't fit. I have a pair. I haven't decided whether to cut them or to start from scratch.

[alpine227]

The Raptor headers don't fit. I have a pair. I haven't decided whether to cut them or to start from scratch.

I went the easier route with a first gen single port exhaust. The headers likely interfer with the chassis as the stockers did. My next exhaust will terminate with a t3 flange for a turbo because if it isn't broke I haven't turboed it yet.....

[longislandwrx]

how much boost are you planning on running? a tuned intake long tube header and exhaust might be good for almost 45 hp.

might not be worth the added expense, complication, and weight to go turbo if you don't plan on really boosting it.



The Raptor headers don't fit. I have a pair. I haven't decided whether to cut them or to start from scratch.

good to know. easier to cut the frame or the header?

[flynntuna]

how much boost are you planning on running? a tuned intake long tube header and exhaust might be good for almost 45 hp.

might not be worth the added expense, complication, and weight to go turbo if you don't plan on really boosting it.




good to know. easier to cut the frame or the header?

The header. The raptor headers would have to go thru the part of the frame that the engine mounts to. I'm pretty sure I'm going to route it the way that John (hobby racer) is going to, except that I'll be going out the back instead of through the humps like he is planning.

[alpine227]

Expense is pretty low turbo and ewg is on the shelf. Will turn a npple for oil return and weld to valve cover and have parts for oil feed and coolant lines on hand as well. The only cost will be a t3 flange and materials for manifold and uppipe.

[alpine227]

I was playing around with a spare set of first gen ez30 injectors. They are air assist and have a very unusual pintle caps. They flow around 230cc/min. I removed the cap and noticed they have a similar disk covering the output side as wrx injectors. I decapped the disk reassembled the injectors and did a crude flow test using a graduated cylinder fuel pressure regulator, walbro external pump and a push button to simulate to energize the injector and a tee and fuel line for a make shift rail. I ran the pump to prime the fuel rail and energized the injector to similate 100% duty cycle and ran the test for 30 seconds. I conducted the test on 7 spare injectors I had 6 out of 7 produced between 320 and 330 cc per the 30 seconds and one odd ball ran 290 cc. I checked the odd ball a second time with the same results. Spray pattern was a bit dodgy but the factory pattern wasn't great either.

[alpine227]

https://youtu.be/-jLUemFSWqE
Closed course professional driver.
Are there any oem or after market ring and pinon gears that are a bit longer? Just kinda noise at cruise and have to shift twice for 60mph.

[alpine227]

I replaced the factory oil "cooler" with an external air to oil cooler mounter in the driver's side scoop.i need to make some ducting for it still. The 198k motor is consuming a little bit of coolant so a rebuild is in order this winter before she see some positive pressure.

[longislandwrx]

are you running the 5mt? what final drive do you currently have? there are 4 oem ratios made.

https://www.flatironstuning.com/p-2635-2002-2014-subaru-5mt-front-ring-and-pinion-gear-set.aspx

[alpine227]

Should be 3.9 I found this a few days ago its not a huge change but does get me to just over 60 in second. Added to Christmas list with LSD.

[alpine227]

Had a little flat 6 therapy today before it all gets pulled for a rebuild and boost. Melts the stress away!

[Frank818]

Video, by any chance? :(

[alpine227]

Video, by any chance? :(

I did not bring the camera today kind of kicking myself probably the last drive with fall faoilage as I am sure the 70mph winds and driving rain are ripping the remaining leaves off right now. Wednesday looks like some decent weather I might hold off til than for operation bring the boost for another cruise with video.

[alpine227]

Bit of a crazy storm 2/3 of the state lost power we should be back online by the weekend thankful for the 11k standby generator that has finally earned it's keep after 3 years. I walked out to my car to go to work and found a half dozen shingles In the driveway. So that's fun.

[alpine227]

https://i.imgur.com/bO5P04H.jpg
https://i.imgur.com/sGxcCG0.jpg

Decided on nominal pipe instead of stainless ad I can weld it. Header "collectors down working on crossover pipe.

P.S.
I do not plan to quite my day job to be a welder, I weld like a gorrila who amoung many faults also can't weld.

[alpine227]

https://i.imgur.com/4PxAQ15.jpg
https://i.imgur.com/5guYpkV.jpg
https://i.imgur.com/37nDDiW.jpg
https://i.imgur.com/2R1ozg8.jpg

Getting there!

[alpine227]

https://i.imgur.com/oNtGhQ4.jpg

I need to finish up the dump pipe and cold side plumbing. Than it's time to pull the motor for a rebuild.

[Frank818]

Turbo looks so close to the frame, it won't touch?

[alpine227]

It's not fully tightened down in the picture however there is about 1 inch of clearence. the front timing chain cover will hit the frame tubes long before the turbo does.

[alpine227]

Motor is out and disassembled seriously impressed that with 2 billion bolts holding the timing cover on it still manages to leak oil. To be fair she is a bit high milage. The cost of rebuild is pretty foolish compared to buying a used low miles jdm long block. To justify the cost I should rebuild with upgraded rods and supertech pistons you know justify it by spending more money that makes sense doesn't it?

[Frank818]

So you're on for a JDM?

[alpine227]

No they are cheaper than a rebuild (including cost of machining) but they are a crap shoot. Unknown condition and mileage. A rebuild the major components bushing bearings and seals are new. Just thinking about spending a few extra sheckles on forged rods, supertech 8.5:1 pistons and supertech double valve springs.

[Hobby Racer]

The rods are pricey, but if your going to boost to it you'll need them!

[alpine227]

The rods are so tiny however they should hold up to low pressure 6-8psi with oem pistons and compression ratio. But I don't think there is alot of wiggle room in the tune.

[alpine227]

In hopes of better reliability I painted my block Ford blue. Fingers crossed.

[Frank818]

Probably the most reliable color. loll

Can't wait to see pix of it!

[alpine227]

It's coming together pretty good, the center pistons are a bit tricky and take some paitience to pull and some long needle nose pliers. I got factory pistons for the rebuild due to being married for 13 years and looking to keep that going for some time longer. I am waiting on some replacement timing components (oddly enough the parts store was cheaper than online for these) and it's time to put it back together. Lots of Ford blue paint left over. Replaced the valve seals, cleaned up the valves and seats, decked the block and heads new gaskets water pump, chains and guides, pistons and rings the bores look immaculate. Did I mention Ford blue paint!

[Frank818]

Yup, that sounds pretty much like a list of an engine rebuild! I copy those same parts and more.

[alpine227]

-14F temps, fingers started sticking to tools maybe ts time to hook up the old furnace in the garage.

[Frank818]

You're stuck in that cold too?

Don't tell me you work in your garage at -14F??? That is way too crazy! Anything under 55-60F I find that very uncomfortable, for an 8h work in the garage.
I wouldn't work more than 5mins at -14F.

[alpine227]

All the time, I did hook up a small propane heater yesterday. Today it is hovering around -27F I believe I will stay inside for this one. I dress in layers starting with silkies, waffle, then down. No cotton. It does take some of the fun out of it a bit though. I have spent nights in snow caves and foxholes using my boot as a pillow. This cold snap has been pretty uncomfortable though. Definitely testing the daily driver's battery condition.

[alpine227]

The Ez30D isn't the only thing getting an overhaul this winter. So as stating above in my younger foolish days I may have been harder on my body then needed. After 10 years of chronic shoulder trouble I finally had it repaired last week, had a rotator cuff tear, a labrum tear, fraying of the bicep tendon, some other tendon part of the shoulder encapsulation was frayed and the subacromial space was clearanced. And once back to "normal" I will have spinal fusion surgery to repair the damage I managed to do there. The good news is it provides me with lots of down time to order parts and research car stuff.

[Frank818]

That's not a simple flu fixing. loll Glad all seems to go well.

So, how much more torque you got? I mean you, not the car. loll

[alpine227]

No more torque but I think it does entitle me to yell at the neighbors kids to get off my lawn, and complaining about kids these days and thier rock and roll music while shaking my cane madly in the air.

[alpine227]

I suspect a big torque improvement on the car however because of the Ford blue painting I did earlier during the rebuild probably 20% increase across the rev range.

[alpine227]

Took some time to do the boring stuff that can be done with my stellar 20 degree range of motion and started balancing the pistons and wrist pins. Started working ring gaps as well.

Stiches out tomorrow woot woot! No more showering with a plastic bag around my arm. Small victories!

[mistasherm]

I had shoulder surgery about 15 months ago (labrum, biceps tendinopathy, etc.) during the build. I resorted to the smaller, easier things that was able to do but it still slowed me down a bit. I did lose pronation in my arm but it is barely noticeable to me. Take your time with the recovery and you will be back at it in full health in no time.

[alpine227]

I am definitely looking forward to a future without the grinding, popping shoulder. Not so optimistic about the back though. Gotta pay to play though.

[alpine227]

https://i.imgur.com/fvzkktF.jpg
https://i.imgur.com/bAagopf.jpg
https://i.imgur.com/KOf7weN.jpg
Been off grid for a bit, ended up getting another spare EZ30d engine and running it with 5psi at the moment while I rebuild my other EZ30 for boost. Also have a spare EJ205... Feeling pretty good about my odds of having a running car all summer.

[frankc5r]

https://i.imgur.com/fvzkktF.jpg
https://i.imgur.com/bAagopf.jpg
https://i.imgur.com/KOf7weN.jpg
Been off grid for a bit, ended up getting another spare EZ30d engine and running it with 5psi at the moment while I rebuild my other EZ30 for boost. Also have a spare EJ205... Feeling pretty good about my odds of having a running car all summer.

Love the color. Is it from a production car? Car looks great.

[alpine227]

Love the color. Is it from a production car? Car looks great.

Thanks it's a realtivly cheap urkem paint called sparkling Merlot pearl. About $300 for base coat clear coat. I see why paint jobs cost a fortune, the amount of work and OCD needed is incredible.

[redfogo]

I used urekem paint on my 2.5rs rally car. Was amazed and how nice the paint was. For the price you really can't top it. It's held up great for rallying so far. Keep us posted on how it holds on the 818
Paint looks great!

[alpine227]

Thanks, the paint seems to be holding up well the issues with the paint were because of the painter not the product a few dry spots and some runs. A huge bead of sweat landed from from my forehead onto the fender and a few mosquitos decided to land in the wet clear.

[alpine227]

Wanted to give a shout out to hobby racer who fixed the megasquirt code phasing issue. Now we get full coil on plug and sequential injection without having to wire it backwards.

[Hobby Racer]

Glad it worked for you. Even more glad that the developers decided added my code to the firmware so we can all run these H6's.

[alpine227]

Thanks again with the update I noticed my afr's are significantly more stable.

[alpine227]

I had some trouble under 1/3 of a tank on right hand turns so I added a surge tank problem solved no starvation on right handers anymore.

[Hobby Racer]

I added a hydro mat during my build and have had great results. No starvation and it will suck the tank dry before any air gets into the system.

[Aero STI]

I added a hydro mat during my build and have had great results. No starvation and it will suck the tank dry before any air gets into the system.

Yeah, the hydromat will suck the tank bone dry when you run out. Ask me how I know. ;)