Metalmaker12's build thread: part 1 "Parts you need"

[metalmaker12]

• Front spindles with full brakes and front lower control arms
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• Rear spindles with brakes and e-brake handle/cables
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• Steering rack, tie rod ends, and upper steering column assembly
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More in next post

[metalmaker12]

• Engine with turbo and intercooler (if WRX model), Transmission
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• Front seats, front seat belts, and gauge pod
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• Radiator
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• Wheels and tires150741507215073
• Door hinges, front w/ latches,strikers, and inside door handles
• Side view mirrors, left and right
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will keep adding in current and new ones to parts list

[michael everson]

Very nice. I am planning on doing the same type of restoration. I have a full set of STI spindles and huge brakes. I have the spindles all stripped and will powder coat them black. I am also going to strip the black off the calipers and powder coat them red. My aluminum control arms will get polished and clear powder coated.
Mike

[Maximus]

Wow, that engine is sexy clean. What did you do to the engine/tranny?

[metalmaker12]

Thank you mike, I hope your resto comes out clean, post some cool pics and have fun.

Max:
The jdm engine (Version 8 ej207, twinscroll setup) only has 27k, so it is like new. I sand blasted and painted the tranny case with spray can high heat silver. I put on a resurfaced wrx flywheel, a Act stage 1 clucth kit, and installed a used cusco lsd. I also grabbed a set of new intercooler gaskets, alternator only belt, plugs and a gates timing belt kit. I am going to fabricate a custom intake once I know the location of the air inlet.

[Maximus]

Beautiful, that is one of my two engine choices. Did you go over the internals at all?

[wallace18]

Nice thread. You have inspired me to do my own build thread for the 818. It seems like working on the donor thread is too big for good info on each owns build.

[metalmaker12]

My compression and leak down test were very spot on, so I decided to go with it. This is my third ej207, and I have not had a problem yet. I have had some issues with some older, poorly taken care of ej's, but that was a given. You want them stock as can be and low miles, it is my rule of thumb.

Wallace, thank you, and there is much to come. Btw, I am going to moochfest 2013

[metalmaker12]

I will be updating in some time, I have to organize my garage and get in build mode now. I will add once a week to my parts list and finalize it all in a detailed list to showcase. my build thread will have, "parts you need", "build stages" and "road test videos". Heres a quick pic of the garage setup, and some attachments that got in there and dont want to go away lol.

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[metalmaker12]

I am going to trade my JDM STI cluster for a 04 usdm STI tommorow. I am also getting some presents in the mail this week. I should see my stainless steel brake pistons and seals kit come in from Scoobyworx GB. I have ordered newer STI fuel pump setup( which I will mod the STI one with a higher flow fuel pump), and rear view mirror. I will post some pics of me putting the brakes back together, maybe even a video if my computer has the space to store it so I can post it. I will also be going through my harness's and cleaning them up a bit etc.

[gwader]

Let me guess! Green car?

[Mechie3]

I saw those ss pistons a while back. Nice stuff but expensive.

[metalmaker12]

15402 Heres a photoshop idea
My 818S will be pearl white or wr blue with some tasteful manufacture vinyl graphics, carbon ground effects off the 818R with a lower wing. I plan on getting some staggered wheels 18x9-11 in the back with maybe 17-18x8.5 in the front

Mechie, they are not cheap, but they will not give me an issue and last with no lock up and or corrosion. Also as far as I know Subaru does not sell the 4 pot/2pot pistons any longer.

[gwader]

Nice

[metalmaker12]

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Heres more pics that did not load right before and a wheel idea

[rjh2pd]

Do i see a center tach? that's the only way to go imo

[FFR-ADV]

Thanks for doing this thread metalmaker12.

It was nice to meet you at Moochfest yesterday.

2013 is going to be a great year. At the rate of your progress I would not be surprised to see you drive your 818 to the 2014 Moochfest.

Cheers!

[Mechie3]

Do i see a center tach? that's the only way to go imo

I think only the 02/03 WRX came without center tach. All USDM STI and 04+ WRX are center tach.

[JeromeS13]

I'll have a center tach, of sorts. I kept a few goodies after I returned my '08 STI to stock and sold it. :-D

http://i157.photobucket.com/albums/t43/JeromeS13/IMG_20101219_193632.jpg

[metalmaker12]

FFR-ADV: Nice meeting you and your son yesterday. I love doing this thread, and I will be doing more as the weather breaks. My car will be at moochfeast 2014, maybe not painted ,but hopefully registered and insured, if not I will tow it there.

Yea my Version 8 Jdm cluster now traded for 04 Usdm has a center tack, well they all do in that year and many others. Just a nice piece to own and it will make my dash. BTW I am getting the carbon FFR dash for the 818S ( and yea we will be able to interchange parts) with DEFI red lighted gauges that will match the cluster15509

Jerome: Those are cool to!! nice piece

[metalmaker12]

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Here some brake rebuild pics and my 04 usdm sti cluster,The stainless pistons are sweet and they mic out the same as oem ones, but make sure you get OEM dust shields and rings, the scobbyworx ones are crappy!!

[Mechie3]

That actually gives me an idea. I have a fair amount of Ti stock lying around that would be perfect for making new pistons out of. I just wonder if I can get a good enough surface finish without a grinder.

[Xusia]

I think it would be cool to make your own parts. That aside for a moment, is there a performance advantage to Ti in this case? (Other than the weight savings, that is)

[Mechie3]

Don't know, besides less heat transfer to the brake fluid. I have free access to machines, free Ti, free time... lol.

[RM1SepEx]

Ti is very difficult to machine... good luck!

[Mechie3]

I've made a few parts for F500's. We make titanium centrifuge rotors at work. I don't program or machine those, but know the guys who do and they tell me the speeds and feeds so I don't need to be smart. lol.

Metalmaker. Your pics are showing as links and take a while to open unlike your other ones that show up as thumbnails. It might just be my slow home internet.

[longislandwrx]

Metal... are you going to track the car? If so how long do you expect those dust boots to last? I've seen silicone boots that hold up better to track use but most just ditch them after they burn up.

Maybe with such a light car, and it looks like you are using Ti backing plates, they just wont get that hot?

[metalmaker12]

I will hopefully track it 2-3 times a year at Lime Rock Park CT, and Autocross maybe 10 times a year at local events. I have seen them melt up, but that was on 3000-3500 cars. I am guessing with 35%- 50% less weight the 818 should wear out parts less often when subjected to extreme conditions .

Yea they are Ti backing plates, they should dissipate heat better.

sorry about the load time, but it loads fine over here

[flytosail]

Nice group of posts.

Side question: Is there a way to reset the odometer or does one need to get a new set of gauges to start at zero?
if so, what gauges are available and would you recommend?

[metalmaker12]

Factory clusters can be reset to zero, and I will look into it for ya. I might do the same. I had a resource for this but they moved out west, It is a certain software. I will get back to you when I have a reliable solution.

[Xusia]

I think a lot of folks would be interested in that! :)

[metalmaker12]

Here is a reliable link for the cluster, which a friend has used, I have emailed them on all our behalf.
http://www.tacomaspeedometer.com/index/index.php?option=com_frontpage&Itemid=1

[flytosail]

Here is a reliable link for the cluster, which a friend has used, I have emailed them on all our behalf.
http://www.tacomaspeedometer.com/index/index.php?option=com_frontpage&Itemid=1


The speedometer gets the information from the transmission and not a wheel sensor? I am thinking that a accurate speed indication will be important for the 818 to avoid things like the below photo even while going the speed limit.

http://i241.photobucket.com/albums/ff124/flytosail/0a45bd271219a2369bfa9772f25f2a7d.jpg

[Mechie3]

The speedometer gets the information from the transmission and not a wheel sensor? I am thinking that a accurate speed indication will be important for the 818 to avoid things like the below photo even while going the speed limit.


Why would it be any less accurate? A sensor on the trans and on the wheel both make assumptions regarding wheel diameter when converting rpm's to speed.

[Xusia]

^That, and last time I checked, the wheel was directly connected to the transmission via the axle. So rotations measured at the wheel should be the same as those measured at the transmission (output shaft; after factoring in final drive ratio). If they aren't, I'd say we have a VERY serious problem...

[longislandwrx]

Kalstar mentioned zeroing odometers for $189 so he must have the tool.


"Gauge pod resetting......$189.00... Zeroing odometer" from the post cool parts thread.

[metalmaker12]

I will call him, I don't think he has the tool, it is more involved than that, I will check on that too. I think he might know of someone who does this too.

[veloce2]

Are you building the R or S?

[metalmaker12]

RS, S frame, but some R parts so RS lol. Need full windshield and wipers in R.I, and I like having a passenger to glue to the seat

[Vman7]

FFR-ADV: Nice meeting you and your son yesterday. I love doing this thread, and I will be doing more as the weather breaks. My car will be at moochfeast 2014, maybe not painted ,but hopefully registered and insured, if not I will tow it there.

Yea my Version 8 Jdm cluster now traded for 04 Usdm has a center tack, well they all do in that year and many others. Just a nice piece to own and it will make my dash. BTW I am getting the carbon FFR dash for the 818S ( and yea we will be able to interchange parts) with DEFI red lighted gauges that will match the cluster15509


I love that gauge cluster!

metalmaker12, This is a really good thread. Once you get all the part with pics done, this would be a good thread to turn into a document of some kind for ppl to download.

[metalmaker12]

Yea defi gauges are really spot on, plus they match my cluster perfect. I need to put it all together as a download. I will try to do this so we can all have a resource to use. All I need is strikers, (lol cause I don't think I saved them), and a rear view mirror. I got everything else, some things I have two and three of.

[Mechie3]

I sold a pair of strikers to wallace18. Each donor has 2 sets, we only need 1.

[metalmaker12]

Yea I am not coming up with the strikers. I am off to work, but I will look when I get back, hopefully I got them. If not I am taking them off my friends car shhhhhhhhh lol.

[RM1SepEx]

I'm sure that I have an extra set in my boxes of misc parts

[metalmaker12]

Rm1sepex, if you do I will buy them, pm me if you find em and your offer and I will send you my address etc

[RM1SepEx]

You have been extremely helpful in the past (working on the donor thread) for that and exchange for your expertise in the future I'll give them to you...

Not feeling well today, expecting snow tonite and tomorrow. I'll look for them next week.

[metalmaker12]

This is very nice of you, thank you! I hope you feel better. Go get some rest my friend, I just woke up from a nap after work. Talk to you next week

[metalmaker12]

I am starting my fabrication of my 818 downpipe/exhaust setup. I will be cutting the factory Jdm down pipe bell mouth and I have 2.5''304 stainless tubing on its way. I am going to Tig the bends together or have it all bent as a solid piece, either way it will work well. I also have some stainless 02 bungs to weld in place I also have my radiator fans in place on my Koyo. 15925159261592715928

[metalmaker12]

I cut the bell mouth off of the Jdm down pipe and now I am going to blast. I am picking up some 2.5 inch polished 304 stainless pipe this week. I am going to Tig weld the steel to stainless with 309 wire. I am going to attach a 45 degree elbow to the bell mouth and than stop until I get the kit to check for the proper clearances. Once that is done I am going to paint the steel bell mouth with Xtremme temp coatings. I have coated headers with it in the past and it held up better than any other product I have tried.

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[Mechie3]

You're going with an ej207, right? Is the stock downpipe anything special or you just preferred to make your own vs buying one?

[metalmaker12]

Mechie, Yeah ej207 version 8 vf37 twin scroll
As you prob know that the JDM twin scroll turbo/down pipe flange is a different design than the usdm Wrx's and the Sti's. The 818 kit comes with and extension that will not match up to my turbo/downpipe flange and is useless to my setup. So I am just making my own setup. I could try to find a cheap twin scroll down pipe, but I am like 99% sure from my measurements that I would still have to cut it up, or bend it etc, to clear the frame of the 818. So I would rather just make a custom pipe setup that will dump under the tranny between a diffuser. It will most likely cost me less to fab it up than buy something. I am planning on making my own diffuser with an beat up carbon apr splitter I have. Just gotta get the kit so I can start mocking stuff up.

We are in similar lines of work, I just can't bring it home etc lol, you lucky man. I like that bracket, it is a good idea, and the rest is looking great.

heres some ideas that may inspire me16015160161601716018

[Mechie3]

I had a vague recollection that the twin scroll was a unique downpipe, but couldn't remember. I'll have to look through the track gallery again to see if they kept the DP extension, I can't remember. I like the "blown diffuser" idea. Might be easier than my first choice of having it come out either side of the license plate. I can't think of an easy way to route the pipes around the transmission yet.

[metalmaker12]

You could put pipes on either side of the lp, you just have to route the pipes over the tranny, or maybe even under, we just have to see the ground clearance. Either idea would be cool. I am just at the first stage of its design.

[metalmaker12]

Some new parts to add to the parts I need bin. They are also part of the "parts I purchased thread" which is coming. Racing harnesses, Defi boost gauge, plastic braided wire covering, stoptech stainless steel brake lines, Hallman pro manuel boost controller.
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[longislandwrx]

y u going hybrid?

ps the mach v lines are really good at $100/set not sure what you are paying for the stoptechs.

[metalmaker12]

I am running a mbc with an opensource tune, as far as I know I didn't mention I was running a hybrid boost control setup, or engine setup? idk let me know wht your asking.

The stoptechs are $120 shipped ebay, fair price and I have used them before, the mach v's are good too, my buddy has them on his wrx.

[Vman7]

Don't forget to put food & drinks on your list! Gotta keep up that energy....lol

[metalmaker12]

I love to eat so thats a given!!!

I was bored so I took 5 and this fell off 16277


I think it cam out of this 1627816279


Heres a stock 2 port boost setup, mbc 1 and 2 and a hybrid setup
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and yes I used duck tape

[shinn497]

How do you now the downpipe won't match? And how are you fabbing it?

[longislandwrx]

I thought you had mentioned in another post upgrading to a 3 port solenoid, then you mentioned the mbc so I was wondering if you were going hybrid.

[metalmaker12]

The jdm twin scroll downpipes have a different flange than the usdm wrx or sti, so it will not match the 818 kit extension.

I have in the past had a subie with hybrid setup, so i prob thought of doing it, but the mbc has been my favortite, easiest, cheepest solution. At this point if I can save anything in funds it will get me more for other things

[metalmaker12]

Killer B oil pickup tube, baffle and usdm 06 sti oil pan, I figured it is insurance since the oem oil pickups tend to fail, and the killer b unit is spot on. I am also getting a perrin air inlet and I will be fabing up a custom intake and exhaust out of stainless.

[metalmaker12]

Some custom exhaust downpipe work to set up my center exit exhaust system. I had a friend bend my a 90 and a 45 and just measured cut and tacked up my mock up.

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[JAubin]

Looks good, pretty cool to be able to picture it. The more I read about your build the more I feel like I must be stealing your ideas...also planning EJ207 (V7 to keep things easier tho) STI cluster, and DEFI gauges. I figure I'll put them into the center console tho. Do you find the stock STi downpipe flows reasonably well, or did you run an custom setup in the past also? GO BRUINS!

[metalmaker12]

Well I am doing stri gauges now, great minds think alike, we are just real subie guys. The stock jdm sti downpipe flows very well and I tended to keep it for stock turbo applications, but once I went bigger I custom made one. Me and my whole family LOVVVE the B's and Pb's and we hope they win today to move onto the damn penguins.

[metalmaker12]

Also, for those that want to have the exhaust exit on the sides of the plate, there maybe room between the tranny and body, or you can go over it with a couple bends. I might make a mock up for this as well, or I can make some if anyone is interested. If other ideas are out there, let me know, I can mock up, any idea, just send my a design plan of some kind. Once I get a design plan, with angles and measurements and material cost I can keep making them.

[Samiam1017]

MM. What you planning for a muffler. Looks like your running outta room. Is there enough room under the trans for it to exit there? Without it looking like its hanging down or too low? Nice work

[metalmaker12]

I am running no muffler, no cat as of right now. If i need to or want to I will add in a stainless inline cat and or exhaust. Again, this is just a tacked mock up and is subject to modification to finalize proper fitment. As far as clearance, the setup is just missing the rear of the trans and will center exit just under the rear section. The pipe is only about a 1/2 inch behind 1" below the bottom of the rear tranny mount. You wont see it because the tip i am putting on will be a 3" twin tip setup, and the dowpipe is 2.5".

[apexanimal]

What bellmouth is that?

[metalmaker12]

It is a version 8 (2004 JDM STi) ej207 with a twinscroll setup downpipe bellmouth, it sounds like this, but will be louder.

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

[IMPREZvWRX]

That downpipe came out much nicer than mine. It looks really good!

The only full twinscroll downpipes I've found were astronomically priced, but I have seen some reasonably priced flanges. I've had thoughts of starting off with a TurboXS downpipe since the bellmouth is so stupidly huge.

I cut up higher and started with a 3" ERZ (eBay) WRX downpipe, cut off the flange, and 'formed' the bellmouth to the bellmouth of the twinscroll downpipe. I have yet to grind out any extra material on the stock bellmouth, but I hope to do so sooner or later.

[skullandbones]

Hi Metalmaker,

Why did you decide on a single exhaust? I know the obvious reason but was wondering what a split dual would sound like or something with a tuned end. Just curious if you have experimented with the different possibilities. Thanks, WEK.

Note: I did like the video with the single.

[metalmaker12]

I have not tried a split dual setup on a jdm yet. I am putting a double walled stainless tip to my current idea that will exit the center.

It looks like this, the tips are 3" each 17937

[skullandbones]

OK. I see what you're doing. Why fab it when you have a beautiful peice like that. That should look very nice coming out the back. Thanks, WEK.

[metalmaker12]

Mission : July 20th 8am FFR pickup package and return to base, than all hell will brake loose !!!!!

[FFR-ADV]

Congratulations.

I am really liking what you are doing with the exhaust!!

Hopefully FFR will make one as aggressive diffuser as these Lotus aftermarket ones..


http://www.youtube.com/watch?feature=player_embedded&v=q8hIxMzqW0c

A rear diffuser like this would go nice with your exhaust!

Cheers!

[metalmaker12]

Steve, Wicked cool!! I am looking into a diffuser to go with my idea for sure, I will pm you some ideas. I stripped the turbo coolant tank, intercooler, downpipe, etc to make more room to install. I may or might not remove the headers. I also drilled the hole relocation hole in the pedal set. It was just a quick half hour or so. Heres some snaps
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[Frank818]

Congratulations.

I am really liking what you are doing with the exhaust!!

Hopefully FFR will make one as aggressive diffuser as these Lotus aftermarket ones..


http://www.youtube.com/watch?feature=player_embedded&v=q8hIxMzqW0c

A rear diffuser like this would go nice with your exhaust!

Cheers!

Sold out! I want that thing and I want it now!

[Frank818]

Steve, Wicked cool!! I am looking into a diffuser to go with my idea for sure, I will pm you some ideas. I stripped the turbo coolant tank, intercooler, downpipe, etc to make more room to install. I may or might not remove the headers. I also drilled the hole relocation hole in the pedal set. It was just a quick half hour or so. Heres some snaps
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Nice engine and exhaust! Can I buy it? lolll

[metalmaker12]

No !!!! Lol Well everything has a price$$$$;) I made this exhaust and may fab some for certain 818 customers.

[Frank818]

This exhaust will come out right in the middle, right?

No cat, no muffler, good old style exhaust. :)

[metalmaker12]

Yeap

[Mechie3]

That downpipe looks nice. I've never made an exhaust before and doubt it would look that clean if I did.

[metalmaker12]

Mechie, I weld and fabricate all day long so it has become second nature. You do great machine work, I really like your altinator bracket. They both require a high skill set, you could build one just fine. If you have any questions on welding etc pm me, the 20th can not come fast enough. I just got back from stripping another Rex since 3:30 am.

[metalmaker12]

The correct offset wheels.. 17x8 40-45mm offset fronts with 215/40 rubber----- 38,40-45mm offest 17 x9-9.5 with 235-255/40 or 18x9-9.5 with 235-255/35 rears. You can run different stuff, but spacers and or other mods will have to be made. These sizes will work

[Frank818]

255/40/18 rear? That fits without mods?
I thought the FFR recommended max size was 255/35/18.

[metalmaker12]

255/35/18 rear, sorry my mistake, i will edit, but the 40 series might work as well with height adjustment etc.