818 Divorce or Separation

[BC Huselton]

I am coming out of a temporary "Separation" from my 818S project which started in late 2014. I don't think I am alone in experiencing what I call "Build Challenges." Some result in giving up on the Project and selling it = Divorce! Some result in taking some time away to sort out how to get thing back on track = Separation!" It might seem odd to thank a Community Forum for "Build Therapy" but I am. The electrical and engine management system really was a learning curve for me. Never did fuel injection before and never did total engine management. So, I turned to working on the body and waiting to sort out all of the engine stuff by watching what others were doing, that worked, in order to pass registration State by State. [I]moved from SC to NC during that time and found NC to be far more demanding than SC. Also had to raise the car an inch.

Thanks to Wayne and some others, I renew my energy for the project and hope to be on the road in Apr.

Here are some pictures of my "Separation Work!" Thanks to everyone who is far more dedicated to sharing and posting than I have been.

1. The enlarged and reoriented side vent, with Monza Cap and side jack port
2. The front engine cover recessed hold downs
3. The new hood with GT 40 vents and inverted wiper panel
4. The front bumper vents with day lights, driving lights and air intakes

Thanks again to the Forum Gang! BC

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[Straversi]

Glad you two are working things out. We'd hate to have to choose sides.....

[BC Huselton]

Glad you two are working things out. We'd hate to have to choose sides.....

The only sides were me and the 818...and the 818 refused to "Talk!" Just smiled back at me.

[Mitch Wright]

Welcome back. For me not putting a target completion time on my 818 project worked for me. I tried to spend 8 hours a week on my build (some weeks more some no work at all) On any of my projects sometimes I just have to walk away for a while to regroup.

[Hindsight]

Front bumper vents look really cool - would love to see a larger picture of the front of the car that shows both vents. Bet it looks really nice!

[frankc5r]

YES, I too have separation anxiety. We have winter home
In Venice, FL which is nice but I miss
working on my 818 coupe. Went back to Mich and my shop
early last year when car arrived from
FFR and plan to do again this year.

[Frank818]

Welcome back from the almost-dead! There are a lot of challenges when building. You killed them all.

I'm very interested in knowing more about your DRL and driving lights!

[mistasherm]

...so that what is happening to me.... I have been away from the build for some time now after going pretty hard on dieting the harness. Over the holidays I had fleeting moments of "what have I gotten myself into" when I would go into the garage for something. I didn't put a target completion date on mine and I struggle to answer the very popular question of "when do you think you will be done?" BUT! The weather will be changing soon, the days are getting longer and I just ordered a part from McMaster so we are on the mend - I even have a target first start date of 1 April.
Good to see that you are back - your pics show some really nice progress!

[Canadian818]

In 4 years I’ve gone 6 months without working on my 818 3 different times. For me, putting in a couple of hours here and there is hard as it almost doesn’t seem worth the time because it’s not enough to accomplish anything significant. I need at least a potential full day to work in it.

[BC Huselton]

Front bumper vents look really cool - would love to see a larger picture of the front of the car that shows both vents. Bet it looks really nice!

Here are pictures of the Front End w/new light package, Hood and Custom Splitter w/center intake. I thought the wiper / hood solution was not great. I turned the FFR fiberglass wiper kit piece upside down and used it as a mold to make make it fit over the wiper arms and add rigidity to the hood along with the GT 40 intake. The Tow Ring attaches to a reinforced front bumper structure running back to the main Chassis under the bottom of the radiator. The original FFR front structure is not strong enough to accommodate any towing...ANY!


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[wirenut]

Wow! That looks amazing!

[flynntuna]

I agree, your work is amazing. I would love to see more pictures and the story of your build. I think the community would be very happy to see that.

[AZPete]

You certainly do beautiful work! In spite of the separation, please post more pics including how your tow ring is mounted.

[Wayne Presley]

You guys should see his work in person, it's amazing!

[longislandwrx]

That's an inspiring tale! My car has been in storage for a year since we sold our house and the priority has been to get moved into our new one...

things like this make me excited to pull it out and get back at it.

thanks for sharing.

[BC Huselton]

You certainly do beautiful work! In spite of the separation, please post more pics including how your tow ring is mounted.
Here are the structural pictures for the Front End. The entire front superstructure was replaced this 1.5' thick wall square tubing with hood front mounting braces and fender supports to limit vibrations, and to avoid having to mount a glass panel to another glass panel with nothing behind it. It also provided support along the front and the rear of the splitter. The splitter without structural support basically just hangs on to the lower front bumper valance. Really flops around down there. Perhaps this has been taken care of with the new body style...Don't know. Also raised the front fender to provide more clearance..I was going to rub with any compression to the front.

The Braces run back to the main chassis and are covered on the bottom by the Splitter and an AL panel. It is designed to pull forward not for lifting or jacking the front end. I installed side jack ports on both sides in order to lift the entire side at one point. You can see it below the side vents.

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[Hindsight]

Very nice!!!!!

[wallace18]

Very nice work! Glad you are staying the course. Sometimes a little separation is a good thing, LOL.

[Jacob McCrea]

Hang in there; if it were easy everyone would do it.

[metros]

I can relate to this thread and your thoughts on walking away from it for awhile. I have done it for chunks of time throughout my build. Selling our house in the coming months has really put a freeze on project car time over winter. I feel like I'm so close to ready to register, yet so far away because of the limited time I have to work on it. Thinking I'll sock away a couple days worth of PTO for the first nice spring weather and reward myself for the work I've done on the house.

Loving the tweaks you've made to the front end. Really looks much more factory and less kit car.

[Mechie3]

I like that front end as well. Looks much more modern.

[turbomacncheese]

So awesome it took me about 10 seconds to realize the fenders weren't on.

[AZPete]

Thanks for showing your work in progress. Please reconcile with your 818 because we need to see more of your beautiful work.

[svanlare]

You are not alone in the start/stop nature of these projects. My work has gotten in the way many times and sometime I look back and see I've done nothing for a while, while other times I have made nice progress. It has taken a lot longer than I expected, and while I'm happy to have a running car that is almost registered, I haven't really started on body work or interior and I'm kind of dreading those projects as I'm worried about getting to the quality I want. I'm Happy to encourage you to keep going as the work you have done is incredible and like others I would love to see more what you have shown here looks amazing.

[BC Huselton]

We are back "Dating" a little! I did find a really good local Subaru specialist Turbo Time in Apex, NC. for engine Therapy. New Block from Top Speed in GA. will have a new harness with a Cobb Access port and be OBD II compliant. 450 HP ready at 22 psi. I am running a G18 @ 13 psi for 300 on the last dyno run. So will break it in for a while before adding more pressure.

Here are some added structural preparation pictures, The double hoop bolt in bar with secondary taller bolt in bar, A six speed lock out arrangement Wayne helped design, the rear "Bump Out" so the tail shaft of the 6 speed fits in, and some pictures of the stock dash install, which makes it much less Kit Car appearing.

Thanks for the encouraging words....things appear promising!

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[AZPete]

Wow! I admire your creative solutions to adapt both FFR and donor components to fit your vision.

[Mitch Wright]

Great stuff.

[Frank818]

Amazing work! Starting with old Camry lights not really designed to look sporty you will completely change its look all around! Impressive job!

[redbudrr]

Your work is truly an inspiration.

[Mechie3]

I hope to be coming off my separation soon. Too many other things calling for my attention. Should be done wiring up a garage heater and then I'll be more inclined to get the other projects done.

[NetWRX]

Nice work! ...subscribed

[Jazzman]

I love all your custom touches. Fabulous work. Please keep posting your progress.

[Bob_n_Cincy]

BC,
Looks like the Corvette ZR1 copied your 818.
I think you should at least send them a letter.
Bob

https://thefactoryfiveforum.com/attachment.php?attachmentid=84063&d=1517331853

https://thefactoryfiveforum.com/attachment.php?attachmentid=84064&d=1523664171

https://thefactoryfiveforum.com/attachment.php?attachmentid=84065&d=1485525864

[David Hodgkins]

Holy Cow that front end is gorgeous!

You are definitely taking it to another level.

Can't wait to see your continued progress.

:)

[BC Huselton]

Bob, my hunch is they would just say "Nice Job!"

Making progress after having to R&R my engine harness and "Reignite" our relationship.

She will look very different after this recent "Face Lifting!"

Gaining on it and hope to have it back together and through NC inspection by June.

Hope you are well, BC

[BC Huselton]

Another date to Turbo Time in Apex NC.

I had originally installed an AIM MXS and want to keep it when I changed to the new Subaru ECU. The folks at AIM have been amazing while we both learned about the 'K-Line interface and the Cobb Access port. Also learned that even if the Subaru ECU says it will provide a Fuel Signal to the AIM it will not, no matter how you tinker with the in tank sensor. Installed an Iron Canyon Sender with a custom sensor ...I have a Boyd tank. Basically the early Subaru ECUs have really slow processors and the AIM prefers higher speeds.

Regarding the questions that have surfaced about Stand Alone ECUs and COBB AP etc. , IMO for a mostly street car the COBB AP is the the way to go. There are experience tuners everywhere and a Pro Tune is not a complex thing. Also if you ever want to sell, you have OBDII that is valuable for many State registrations. You also do not have to try and explain to a buyer how all of the wiring works..anyway, just my take.

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[Zach34]

Need more pictures of that front end. You been holding out on us?

Thanks for the info on the AIM dash. I'll probably go that route when I get there.

[BC Huselton]

Let me know if I can help with the AIM..I did learn a lot and have a number of custom sensor maps built for IAT, Fuel, Oil Pressure and Oil Temp.

[Lumpyguy]

Please make some more of those front bumpers for sale! Also like the double roll bar humps. It was the first thing I did when I got my frame home from factory five

[BC Huselton]

After some added "Separation Time" to Epoxy - Coat the garage floor = really good product = and run 50 amp service for the compressor and welder I am trying to move to "Geterdone" mode.

1. Made it through NC Specialty Vehicle process after an initial rejection because they used the VIN from the Donor Subaru and claimed I stole it! Right! Got the Plate and Registration after 4 months of back and forth with documents.
2. Had to make a very large "Indent" into the door panels to accept the wider OEM dash
3. Needed to close the gap at the Body / Striker Bar and then finish it off with DIY Carpet Webbing..pretty nice product for finishing edges without sewing. Also Hood alignment with wipers so they do not hit the body.
4. Next up = Seats In, Complete the Dash, and Class II Trailer Hitch for Pop Up trailer / Track Day equipment installed, and then maybe some "Identity" Stickers..or should I leave it naked and alone in Black / Red/ White? This decision could generate another Separation Issue if I do not get it right!

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[Wayne Presley]

Carpet webbing? where did you get it?

[BC Huselton]

instabind @ Amazon and Weldwood HHR Cement. Spray 3m 77 or 90 will not hold it in place.

[BC Huselton]

Forgot to say that the Instabind is a great option for the Gap between the door shell and the door panel. I could not make the FFR piece fit and still close the door. You need to trim the white interior cord back about 1/2 and make a point on it and then close the binding on top of it to make a smooth transition to the full cord profile. It will then stick to the interior of the door skin.

Another product is the insulation I found from a roofing job. It is about 1/4 the cost of Dynamat and does the same job. Easy to cut and sticks well. Also much less than the Package FFR offers.

Finally the SD20. I saw the Ford GT Crew at IMSA / VIR using it all over the car. I asked about it and he just handed one to me. I cleans brake dust, adhesive residue, everything on the paint with no paint issues. But, this is my experience and Fords! Beats Goof Off / 3M adhesive remover, Gunk, Glass Wizard stuff ! Test it first! Always.

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[flynntuna]

Forgot to say that the Instabind is a great option for the Gap between the door shell and the door panel. I could not make the FFR piece fit and still close the door. You need to trim the white interior cord back about 1/2 and make a point on it and then close the binding on top of it to make a smooth transition to the full cord profile. It will then stick to the interior of the door skin.

Another product is the insulation I found from a roofing job. It is about 1/4 the cost of Dynamat and does the same job. Easy to cut and sticks well. Also much less than the Package FFR offers.

Finally the SD20. I saw the Ford GT Crew at IMSA / VIR using it all over the car. I asked about it and he just handed one to me. I cleans brake dust, adhesive residue, everything on the paint with no paint issues. But, this is my experience and Fords! Beats Goof Off / 3M adhesive remover, Gunk, Glass Wizard stuff ! Test it first! Always.

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You should link this to the" tips" sticky

[BC Huselton]

Have been "Speed Dating" this last month to get the OEM interior assembled, Front fenders on, Hood on, and Doors reconfigured to accept the wider Dash. I really messed up my original 2002 dash. Wayne saved me with a complete 2006 takeout and with much help from this site got it cut and pasted to fit. Will send picks after I get the AIM Dash and lower panels in place. Making a 3" recess in the door panels is the most complex part.

Final Paint on and trying to keep the overall "Look" clean and simple.
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[07FIREBLADE]

I really need to see the door cutouts... my OEM dash is really messed up and wish I didn't chop it up...

[BC Huselton]

Go back to my page one to see the structure behind the door panels and how I had to cut things to make them work. Once you get them all cut .."Right" it goes together and look non - kit like. It does take a lot of time and re - re - assembly with minor adjustments so you do not over cook the parts and then have to start over again. I did kill my original dash!

Hope this helps.

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[07FIREBLADE]

That looks amazing... What did you do to get the front of the dash to mate up to the windshield surround? Also can you take a measurement from your 1st photo... from the back edge of the door to the very front edge of the cutout where the front of cutout starts. I'm trying to see if how much meat is left on the doors since I have a coupe. I need to consider the window cutouts...

[BC Huselton]

Here you go.

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[07FIREBLADE]

Thanks BC! Looks like you might be running AC in there? Or whats under the dash where the passenger airbag would go. Also do you have any pictures of your mounts for the dash. I would like to compare how you mounted your to the way I did it.

[BC Huselton]

No AC. What you see is the Blower housing for the Heater Defroster. That all gets covered with the Glove box segment. Easy access with just 4 screws.

To see my support structure, go back to page 1 here and scroll down and you will see what I did to attack it to the dash cross rail and then on to the center tunnel.

If you can't find it, e-mail me and I will send you my slides = bchuselton@gmail.com

[BC Huselton]

Things were going along pretty well (Post Separation) and then the "P" word came up! "Paint"...she wants a fresh Clear Coat. Has some original nibs and bugs that are too deep to spot finish in the Black. So I scuffed it down with 800 and shot PPG's new clear. With a new DIY Booth and some great temps outside, I got it to lay down pretty well. I am not DaBat, but it is really smooth this time. Finished it with 3M 5000 then polish and she is happy again.

Also, finished stitching on the OEM dash to match the Sparco seats. Got an 86 Dash from Wayne and after several attempts, built the doors to fit. Makes a big difference...not kit looking with an OEM dash. It can be done!

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[BC Huselton]

forgot to mention. Adding a side jack port is a life saver.

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[Wayne Presley]

Looks great BC, it was an 06 dash though :-)

[AZPete]

Very nice work. I'm glad you reconciled.

[Ajzride]

Looks great BC, it was an 06 dash though :-)

But it makes me wonder how a BRZ/Toyota 86 Dash would fit.

[Zach34]

Any more detail/close-up pictures of those side jack points would be very interesting! Is the CG of the car located that far back?

Looks great!!!

[BC Huselton]

This is a Class II Receiver welded into this spot because of its Structural location not CG. It will lift the rear a little earlier that the front, but it gets the entire side up.
I have a square black rubber plug that fits into the opening. This along with the front and rear structural tow hooks has proven invaluable. I could not find any way to hook into the front end in order to get it up onto a tow truck or onto my trailer. It is a good structural addition to address before securing the body to the chassis..if you are planning ahead. IMO

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[BC Huselton]

I am very lucky to be close to a Subaru Only Shop about 20 miles away in Sanford, NC. Called Turbo Time and Ryan Davis a Cobb Gold Pro tuner. Over the winter we did a number of comparable Cobb Loging sessions using Tial variable Waste Gate Springs and BOV to atmosphere and recirculating. The recirculating BOV made a significant difference in drivability, correcting a sight rich stall conditions between shifts and when coming to a quick stop. And, the Tial variable waste gate made the turbo come on in a far more linear way. The car was so quick, it would want to totally spin up the wheels, and the Tial has leveled out the torque application causing it to be much more fun and controlled to drive. I basically have a target boost control for 1st, 2nd, and then all in available for 3rd through 6th. Makes the entire driving experience far more enjoyable yet still amazing power from 7 to 18 Boost. Easy on the engine too. I have multiple maps for each driving target...Day Driver to Full out Track Day.

Here is the new intake plumbing:
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[Zach34]

This is a Class II Receiver welded into this spot because of its Structural location not CG. It will lift the rear a little earlier that the front, but it gets the entire side up.
I have a square black rubber plug that fits into the opening. This along with the front and rear structural tow hooks has proven invaluable. I could not find any way to hook into the front end in order to get it up onto a tow truck or onto my trailer. It is a good structural addition to address before securing the body to the chassis..if you are planning ahead. IMO

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Thanks for that. I had nearly forgotten about tow points. Adding that to my pre-paint to-do list.

[BC Huselton]

I am very lucky to be close to a Subaru Only Shop about 20 miles away in Sanford, NC. Called Turbo Time and Ryan Davis a Cobb Gold Pro tuner. Over the winter we did a number of comparable Cobb Loging sessions using Tial variable Waste Gate Springs and BOV to atmosphere and recirculating. The recirculating BOV made a significant difference in drivability, correcting a sight rich stall conditions between shifts and when coming to a quick stop. And, the Tial variable waste gate made the turbo come on in a far more linear way. The car was so quick, it would want to totally spin up the wheels, and the Tial has leveled out the torque application causing it to be much more fun and controlled to drive. I basically have a target boost control for 1st, 2nd, and then all in available for 3rd through 6th. Makes the entire driving experience far more enjoyable yet still amazing power from 7 to 18 Boost. Easy on the engine too. I have multiple maps for each driving target...Day Driver to Full out Track Day.

Here is the new intake plumbing:
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Happy Separation: Loaded up for final Dyno Tune, and then to Market. I need to make room for a new project with the Grand Kids. As with each project, I have learned a lot. Not only about the product, but my own ability to sustain the energy to actually deal with all the "Strange Things" that reveal themselves during the build. The dedicated people in this Community are amazing in their commitment to Help each other. My many thanks to all of you and especially Wayne who seems to "Never Give Up" on anyone! Really!

Final Pictures:
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