Managing the build project

I am in uncharted territory with this as my first kit and am working on a project plan to minimize the unforseen compications and costs.

To those who've already built kits: What were the main lessons learned about the project? What are the common pitfalls in the project or areas that require extra care?

I'm also searching for free or open source project management software. I have MS Project for work but will not use company resources for this. I've found several products but would like to hear from people who've actually used them.

Rule #1....don't add up your receipts!

Very Funny Eric... not all of us can do that! I keep a spreadsheet.

I haven't built a car before, but I have both participated in, and managed, projects. I would say start with the basics like your budget and goals. Then figure out if your goals fit within your budget. If they don't, you have some work to do.

Once you've got that worked out, STICK TO YOUR GOALS. If an opportunity comes along (for example, the opportunity to buy a "better" part, or upgrade something), you have to weigh it against your goals. If it isn't necessary to meet your goals, is it worth the additional expense? If it is, can you afford to increase your budget? If not, then you are done. If it is necessary to meet your goals, and you can't afford to increase your budget, then you have to modify or eliminate some goals (meaning, you don't get the part, you live without). This is pretty standard "change control" process designed to control "scope creep."

If you run into a lot of things that are "necessary" to meet your goals, but which you can't really afford, then you did a really bad job estimating the project. You should sit down and determine if you can afford to finish it, or if you should cut your losses. Hopefully that doesn't happen to anyone.

I have used http://www.ganttproject.biz/
I suggest first reding build treads for other FFR cars; making a gantt chart maybe an overkill.

http://www.ganttproject.biz/ is good opensource project scheduling and management software. I also suggest reading build treads for other FFR cars.

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Originally Posted by RM1SepEx

Very Funny Eric... not all of us can do that! I keep a spreadsheet.

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I thought you might like that...

Seriously though, you need to PLAN YOUR BUILD, then BUILD to YOUR PLAN. A spreadsheet will tell you how close you are to your target....works great in theory. I guess it comes down to a couple of things about managing your expectations and what you want to get out of the build from a personal nature. I would absolutely look at the long history of the FFR builders if you are a first time car builder. See what they did. I go into these builds with a "ball park" figure and see if I have enough $$$$ to fund it. I build for the pleasure of building and the challange of creating something from nothing...I am at an advantage because I have built a few of these and KIND OF know what to expect.... My guess for MY build...10K for the kit, 5K for donor ok that's the start...I will probably add a bunch of stuff along the way leading up to the build. I would expect thing like wheels, LSD, interior, stereo, heat, air, performance upgrades will add up... I tried to do the spreadsheet thing, and for me it took the pleasure out of the build...as soon as you take that first go-cart ride or first ride after completion, the spreadsheet will be the last thing you think about and how much over you are...simply won't matter :D :D

But to each his own...my spreadsheet says $15,000...but I know I will blow that! So that's my expectation... My expectation is also that this car is going to be the easiest FFR I have built, the most fun, best performing, and will probably drive to sell off my Cobra since I will be driving my 818 all the time....lol...

The neat thing about this....the FFR kits are a blank canvas, you build it the way you want using whatever method works for you. We have cobras out there like my first donor build that I did for $17000, and then others out there for over 50-60K plus. I went all non-donor on my last build...and it truly is an amazing piece of work...fiinished all the way around...heated seats and all...the all being a fire breathing 408W turbo charged motor that delivers 575 RWHP and 690 RWTQ and weighs in at 2525 with me in it and a full 22 gallon tank.....

let the fun begin...

In this case I would just say use ms project. The company pays for the license and for you to use it for work but when working hours are over, it doesn't cost them anymore for you to use it. I use solid works at work all the time and bring my laptop home sometimes to use it. If it was something that consumed additional resources outside of the base rate the company pays I would agree with you. I'm lucky that my company even lets me use the cnc machines and doesn't charge me for electricity or potential worn tooling.

The nice thing about the 818 is the lack of body work needed... in all my projects paint and bodywork have always been the great unknown. When sending a car to paint you never know what they'd find once they started stripping it, and how many hours it would take to get it right. With the 818 that’s a non-issue.

I've put together my parts list, the best online prices I’ve seen and factored in about 20% in unexpected costs. I should be able to hit this spot on.
I've factored in re-tuning, tire balancing, alignment, registration etc.

I'm also trying to deal with as few vendors as possible to get better pricing on buying everything at once.

When you make your spreadsheet just write down everything you can think of as the ideas come to you, then sort them out later.

I have never built a car (yet), but I have built an airplane which is an order of magnitude more complicated. I've also restored motorcycles and cars and even built my own house, so I know what it takes to get a project finished.

I started building my airplane when I was in my mid 20's. An old experienced builder in his 80's gave me advice that was spot-on. I'll share it with you...

"Go into your shop every day. Most days you will be productive. Some days you'll just stare at at the plans, and that's OK. Even if you just sweep the floor, go into the shop everyday. The project will consume you, and that's OK too. Many tasks you'll map-out in your mind before you ever pick-up a tool. Building a project is not one big task, it's hundreds of small ones that come together over time."

This simple advice has gotten me through many projects because...it's simple. And so are complicated projects when you break 'em down and focus.

There's lots of good stuff above, especially Erik's Rule #1. I bought an FFR roadster kit because it was a "well-worn path" and others knew what parts work and what doesn't. Rely on the forums but wait for several replies. Soon you'll learn who is the most knowledgable.

If you are building for fun, don't have a deadline.
Pete

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Originally Posted by Gary in NJ

I have never built a car (yet), but I have built an airplane which is an order of magnitude more complicated. I've also restored motorcycles and cars and even built my own house, so I know what it takes to get a project finished.

I started building my airplane when I was in my mid 20's. An old experienced builder in his 80's gave me advice that was spot-on. I'll share it with you...

"Go into your shop every day. Most days you will be productive. Some days you'll just stare at at the plans, and that's OK. Even if you just sweep the floor, go into the shop everyday. The project will consume you, and that's OK too. Many tasks you'll map-out in your mind before you ever pick-up a tool. Building a project is not one big task, it's hundreds of small ones that come together over time."

This simple advice has gotten me through many projects because...it's simple. And so are complicated projects when you break 'em down and focus.

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Great advice, not just for building a car, but for life in general.

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Originally Posted by AZPete

If you are building for fun, don't have a deadline.
Pete

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I personally think deadlines or goals are good. If its for fun then a tight deadline is of no benefit, but no goal or deadline results in meandering projects or longer periods of inactivity. Some sort of deadline encourages you to get off the couch and be motivated.

Thanks everyone. There is a lot of good advice there. Especially about going to the shop everyday.

Here's where I am now:
I searched around for PM software and considered ganttproject but ended up trying out 2-plan instead. If that doesn't work out, I will switch to ganttproject.

I am using Springpad as my tool for consolidating all the random pieces of info that I find as I plan the build.

Right now I am working on the project goals, roughing in the milestones, budgeting, and doing a risk analysis.

Goals: Mainly focused on building an out of the box car with minimal mods. I'll live with it for a year to determine what mods I need.
Milestones: Plan, Donor part sourcing completed, build completed, street legal.
Budget: I am going with the $15K projection from FFR and adding 20% contingency.
Risks: Mainly focused on donor part defects, kit defects (I know, I know. But you gotta consider this.), skill deficiencies, and life issues.

Feel free to add or comment.

I also have not built a FFR kit. I commend you for managing your project with a plan. Understanding what you are getting into before you start is hugh and breaking down the tasks and seeing it on paper has value. I would be interested in seeing what you have in your plan.

Your goal of what you plan on building will determine much of how your plan develops. As you could have almost any range of performance you want, I see deciding what you expect to do with the car once do as being the key. That decision leads not just to cost implications but also how much time it will take.

I also need to commend FFR for choosing as its platform the single donor as its plan from the beginning. That goal they made, and they have stated with will make building the car accessable to many, without that choice it would not be my choice for a frist project.

All projects have risks, to me the donor car and not knowing the Impreza looms as the largest risk to the project. The people on this forum have been most helpful. Reading this forum has helped to better understand some of those risks. To keep cost down, I am looking choosing a salvaged donor. I know buying a used car has risk.. and buying a wrecked car you don't touch from an auction has 10x risk... To mitigae the risks I have been spending a large amount of time looking at auction sites and seeing what they sell for. The one of the biggest unknowns for me even if I were to choose well is, how much more effort and cash will be need to be needed to make it function? It seems the rest of the project is controllable .. up to the point of my personal failures that is.

Best wishes on your plans and especially on the build.

John

I built a buggy from plans in about a 10 month period. It's a bit simpler than a car, but many of the suspension and drivetrain bits were custom. I was able to go buy steel in November 2011 and ended up with a fully functional buggy in September 2012. I started a spreadsheet with costs before I ever bought anything, and I came in about 10% over budget by the time I was done. That 10% was due to farming out some of the work like paint and tig welding control arms. That helped me finish and make shakedown runs before driving 10.5 hours up into the upper peninsula of Michigan for a 200 mile ride with the designer and some other home built buggy folks. You have to stick with it and remember what the end goal is. Also, after you sink several thousand into something you're much more motivated to finish.

I do project and team management for a living (IT related) so am familiar with and use various project management tools, methodologies, etc. Having said that, I'm on my second FFR Roadster build, and just use an Excel spreadsheet. For me the important aspect is to have various lists, which Excel worksheets provide. I don't need the time based aspects of a tool like MS Project because I'm both slow and a beginner. So I'm really bad at planning how long tasks should take. (Just tonight I'm installing the E-brake handle in the chassis of my new Mk4 build, something I thought would take an hour or so. I'm in my second or third hour, and still messing around with it. May be the only thing I get done tonight.) I have multiple worksheets in my Excel file, including the basic build plan, planned mods by general category (interior, exterior, engine, suspension, etc. often with links to more information), one for all direct items (e.g. parts that are on the car) and indirect items (tools, supplies, etc.), shopping list, and then a worksheet called specifications where I try to list every single part as best I can, where I bought, when I installed it, mfg, mfg part number, comments, etc. In my Mk3 rebuilt engine I know the source and part number for every single part in that engine. It's amazing how often I come back to that sheet. Also useful for answering questions on the forum when guys asked about very specific details. I use filters in each of the worksheets to keep track of various statuses, like not started, in-process, completed, cancelled, paid/unpaid, etc. Yes I now exactly how much I've spent on both builds to the penny.

I guess my main point is be organized and have a way of keeping track of a lot of data. But don't overthink the build process itself. Just go with it.

Good luck. These are a blast to drive, but I enjoy the build process almost as much. This is a progress report I posted over in the Roadster forum a couple of days ago: http://thefactoryfiveforum.com/showt...rogress-Update

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Originally Posted by Gary in NJ

I have never built a car (yet), but I have built an airplane which is an order of magnitude more complicated. I've also restored motorcycles and cars and even built my own house, so I know what it takes to get a project finished.

I started building my airplane when I was in my mid 20's. An old experienced builder in his 80's gave me advice that was spot-on. I'll share it with you...

"Go into your shop every day. Most days you will be productive. Some days you'll just stare at at the plans, and that's OK. Even if you just sweep the floor, go into the shop everyday. The project will consume you, and that's OK too. Many tasks you'll map-out in your mind before you ever pick-up a tool. Building a project is not one big task, it's hundreds of small ones that come together over time."

This simple advice has gotten me through many projects because...it's simple. And so are complicated projects when you break 'em down and focus.

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It's like the old saying" How can a man eat an elefant? One piece at a time!" Works for everything. Breaking tasks down to bite size pieces makes the job much more palpable.

Yea I am on board with Excel, I use it for a side business and at work and it is so very helpful.