Frank's 818R build

The efforts for street legality started last night. Did some E-brake work, cleaned up the interior a little, and started on my windshield:

I laid the R windscreen over it so I could make similar cuts for the bars. It's probably going to wait until the weekend, though, since another set of hands would help a lot I think.
https://farm1.staticflickr.com/721/2...afc4dae2_b.jpg
https://farm6.staticflickr.com/5814/...3f3176a8_b.jpg

Also, the front rivets on the windshield/screen are going to be replaced with riv nuts to help make the change between windshield and windscreen easier/faster.

As far as I see it, my list is as follows:

License plate mount
Plate light
Charcoal canister
Windshield
Wiper
E brake
Switch plate for interior switches
Rear bumper
Front deck lid
Blinkers


Missing anything obvious?

Just make sure if you (Or anyone) drives an R on the street, wear a helmet. Those angled side bars (near your head) will kill you in a very minor collision.

You're exactly right. I intend to wear a helmet and a HANS anytime I get in the car.

Connecticut reg. requires: hazard switch, factory style 3 point seat belts (no harnesses), shift pattern on knob, label on fuse box (if visible within cockpit). I don't know if N.Y. is similar.

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Originally Posted by tmoretta

Connecticut reg. requires: hazard switch, factory style 3 point seat belts (no harnesses), shift pattern on knob, label on fuse box (if visible within cockpit). I don't know if N.Y. is similar.

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Just a small correction - the seat belt rule is just that it must be FMVSS209 certified. We went through inspection with 5 points without any issues, but they wanted to see the tag. Schroth has some that are DOT legal. They never looked for our fuse box.

Huh. I never thought about DOT approved harnesses. I'll give a call and see what they say. If I need to, I'll pull the second seat and buy a single Schroth just for inspection.

NY has a ton of rules but most of them I'm either exempt from or conform with, as far as I read.

What are those rivets/rivnuts for on the windscreen? I don't have that.

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Originally Posted by Frank818

What are those rivets/rivnuts for on the windscreen? I don't have that.

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Frank- What you see in the photo are nuts and bolts (1/4"-20's) that hold the windscreen to the mount. What I am talking about is how the race windscreen is held on the car. I have it rivited to the frame with 3/16's rivets. Two of them. I plan to replace them with 1/4-20's as well.

Oh! The race windscreen, yeah ok I get it now. :)

Windshield was a ***** to install. I had to trim everything like a hundred times. It sorts fits. 33" to the roll bar and 26.25" to the corner of the door panel. It looks and feels great.

How did you all attach the glass to the frame?

https://farm6.staticflickr.com/5632/...7a004b30_b.jpg

https://farm6.staticflickr.com/5818/...41f53e3e_b.jpg

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Originally Posted by Pearldrummer7

How did you all attach the glass to the frame?

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I had a local auto glass guy professionally install mine for $150 after calling about 10 different places. Just tell them you need to install an MR2 windshield in a convertible, many places will not want to take on the liability of a non-standard glass install.

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Originally Posted by STiPWRD

I had a local auto glass guy professionally install mine for $150 after calling about 10 different places. Just tell them you need to install an MR2 windshield in a convertible, many places will not want to take on the liability of a non-standard glass install.

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+1 $175 with trim rubber

I got it installed with approved glass silicone/caulking, just like it's been done on a normal car. I think it cost me $CAD90, 13 months ago. I promised the guy I'd show him the finished car in June 2015... doh!!! lollll

What pump did you get with your surge tank? Where did you mount it and how's the noise? I got excited buying parts today and picked up some parts for my surge tank including a walbro 255. I just read online that their quite loud, might take it back for a Bosch 044, they're a little quieter.

I have the Walbro 255 and can verify that it is quite loud. I can hear it over the engine.

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Originally Posted by Canadian818

What pump did you get with your surge tank? Where did you mount it and how's the noise? I got excited buying parts today and picked up some parts for my surge tank including a walbro 255. I just read online that their quite loud, might take it back for a Bosch 044, they're a little quieter.

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Quote:

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Originally Posted by Hindsight

I have the Walbro 255 and can verify that it is quite loud. I can hear it over the engine.

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I mounted the surge tank directly to the frame. It's extremely loud; I can hear it over the engine if I'm idling. However.... without a windshield, the car is pretty loud at speed. So....whatever, race car!

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Originally Posted by Pearldrummer7

I mounted the surge tank directly to the frame. It's extremely loud; I can hear it over the engine if I'm idling. However.... without a windshield, the car is pretty loud at speed. So....whatever, race car!

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Is your pump in the surge tank or external?

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Originally Posted by Canadian818

Is your pump in the surge tank or external?

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Mine is internal to the surge pump. I ordered this guy.

Quote:

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Originally Posted by Pearldrummer7

Mine is internal to the surge pump. I ordered this guy.

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Frank, Am I correct in my thinking that you still have original pump in the main tank?
I was thinking that you would only need a low pressure pump in the main tank.
Bob

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Originally Posted by Bob_n_Cincy

Frank, Am I correct in my thinking that you still have original pump in the main tank?
I was thinking that you would only need a low pressure pump in the main tank.
Bob

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Bob,

I've always had a Walbro 255 in my main tank. That's what my (built up) donor came with. I have one in my DD and have found them to be reliable and good for a lot of power. Not wanting to limit my power just to save some money, I got another Walbro 255 for the FST. I'm sure I could get away with a smaller pump in tank at this point.

I forgot to upload this one before. Changed some alignment stuff and forgot that the car handles differently with a passenger (my dad). Got it loose on the first lap and then over corrected. Turned her around pretty quick! You can also hear how loud the fuel pump is (though it's biased since the GoPro is close to it).

https://vimeo.com/142940345

Frank,
I've had many spins like that.
If you look at you steering wheel, You had very little steering input when it first broke loose.
Were your tires cold?
Is your car normally that loose?
Bob

Quote:

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Originally Posted by Bob_n_Cincy

Frank,
I've had many spins like that.
If you look at you steering wheel, You had very little steering input when it first brook loose.
Were your tires cold?
Is your car normally that loose?
Bob

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Bob,

I'm mostly blaming it on both cold tires and lots of on the fly suspension adjustments. Figured I was at the track for the last time for the year, might as well play with stuff! I found some things that worked, and some that didn't (see above for the didn't)

Car is normally pretty stable, especially through minimal steering input turns like that one

That was a real snap! It almost looked like you caught a bit of the curb, but when I looked a second time you weren't on it. Were you letting off the throttle? (trying to get my head around the car behavior since I have no MR engine experience)

I'm sure there's a funny caption between you and your dad :)

Made a bumper for street legality. It's not mounted yet (paint is currently drying), we'll see what NY says.

https://farm6.staticflickr.com/5650/...d691bf74_b.jpg

Oh! Almost forgot!

Check out my windshield! Glass installed by First Class Auto Glass. Was Just under $100 with trim. Fantastic service, we talked cars for a while, they gave me a few cans of cleaner and a roll of their favorite glass wipes. Very good experience.
https://farm6.staticflickr.com/5801/...92c0d5d1_b.jpg

https://farm6.staticflickr.com/5787/...d7356f5f_b.jpg

Also, woke up to this on 10/18-
https://farm1.staticflickr.com/641/2...2b356a06_b.jpg


Winter is coming, and fast. Jealous of all you California guys right now.

Update- sounds like my bumper WILL be good by NY state :) So excited!

Congrats! I can't even imagine snow right now...... crazy seeing that pic.

You will need a bumper if you drive it in snow. lolll

I can't believe you got snow before me. That's almost impossible...

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Originally Posted by Frank818

You will need a bumper if you drive it in snow. lolll

I can't believe you got snow before me. That's almost impossible...

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Quote:

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Originally Posted by Hindsight

Congrats! I can't even imagine snow right now...... crazy seeing that pic.

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Frank- we get a LOT of snow being right on Lake Ontario. It starts in October and usually gone by mid May. Means I have a lot of time to improve the car over the winter (and lots of time to hoon around in my WRX) :)

I like your build man... Kudos!

is the DOT a lot more picky when it comes to inspecting a custom car?
Some of those things... bumper... glass windshield...interior switches (for what) would either get past my radar or seem unnecessary.

As a side note, why did FFR ditch the bumper from the S version? You would think that if you are going at insane speeds on a race track or going at insane speeds on a race track in some form of wheel to wheel racing, that you would want that extra protection.

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Originally Posted by Pearldrummer7

Means I have a lot of time to improve the car over the winter (and lots of time to hoon around in my WRX) :)

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True. We have huge plans over the winter, don't we. :)
Only thing is you won't be able to test your improvements until May. loll

Quote:

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Originally Posted by AgentH

I like your build man... Kudos!

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Thanks! I apprecaite it.

Quote:

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Originally Posted by AgentH

is the DOT a lot more picky when it comes to inspecting a custom car?
Some of those things... bumper... glass windshield...interior switches (for what) would either get past my radar or seem unnecessary.

As a side note, why did FFR ditch the bumper from the S version? You would think that if you are going at insane speeds on a race track or going at insane speeds on a race track in some form of wheel to wheel racing, that you would want that extra protection.

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Agent, the NY DMV is picky about the weirdest things. They have their rules clearly written out, and they really care about some of them to a T, and some are.....eh, whatever.

As for the bumper on the S...I didn't think it really had one in the rear? Either way, what I designed will in no way further protect me at track speeds. That's what the roll cage is for.

Quote:

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Originally Posted by Frank818

True. We have huge plans over the winter, don't we. :)
Only thing is you won't be able to test your improvements until May. loll

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Always ;)

Had to space the license plate lights to make them actually light up the outside of the plate instead of behind it. Naturally, a washer didn't fit where I drilled the holes, so I needed to hack up washers. Everything on this car takes longer than I anticipate! lol

https://farm6.staticflickr.com/5644/...e741c7da_c.jpg
https://farm6.staticflickr.com/5817/...60d302c4_c.jpg

Looks good, though!
https://farm1.staticflickr.com/616/2...e28a296d_c.jpg


Also did my third brake light (high mounted on the roll bar behind the driver's head), some troubleshooting on the blinker/hazard circuit, and some *tuning* of the car (removing engine codes).


I can't figure out one thing, though. When I turn the key to OFF, the ECU loses its retentive power. Trip odometer resets, CELs reset, so I assume learning resets. I'm sure it's from one of the pins coming from the integrated module or something like it that I deleted. However, I can't seem to find any pin that clearly is that constant 12V power to the ECU in the OEM wiring diagram. Anyone have insight to it? Maybe an ECU pinout?

Tons of progress this weekend. First up, garage modification:

Added insulation so you can't see quite as much day light through the roof, and put up plastic on the ceiling. Then I added a thick plastic sheet (4mm) to drape down. The area is big enough to contain the car and still be able to work. It'll be a lot easier to heat this small confined area in the sub-0 temperatures. Also it'll be nice to not have snow getting inside the garage from the roof.
https://farm6.staticflickr.com/5685/...4bd45dcd_c.jpg

Rear deck lid is on! Doesn't fit with the intercooler, so I'm plumbing the turbo directly to the intake(just for NYS inspection).
https://farm6.staticflickr.com/5697/...90322446_c.jpg

Got my weight certificate for NYS inspection. 1,880 lbs according to their scale, with the street windshield and a small steel bumper. I'm not sure how accurate it is, and I have a feeling that's a little lighter than reality. 8,540 for the truck, trailer, car, 2 people, and a few tools. Lots of weight!
https://farm1.staticflickr.com/632/2...4687d17c_c.jpg

Mounted and wired my defroster. I like my little switch panel (with hazard and OBDII port on the bottom).
https://farm1.staticflickr.com/595/2...96d21f1c_c.jpg

On the agenda before my inspection:
-Windshield wiper (assembly should be here this week, courtesy Tamra/Andrew- thanks guys!)
-Charcoal canister
-Cleanup of wiring/fluid leaks
-Intake plumbing (parts on route!)
-E brake tensioning

Frank,

1880lbs is very light. We were only a little below that before adding the body. How full was your fuel tank? Was that without driver? I'd be curious to see the car on quality scales at some point. Do you plan to corner balance it?

Glad we could help on the windshield wiper assembly! It's already at the post office and you should see tracking info update later today.

Quote:

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Originally Posted by Tamra

Frank,

1880lbs is very light. We were only a little below that before adding the body. How full was your fuel tank? Was that without driver? I'd be curious to see the car on quality scales at some point. Do you plan to corner balance it?

Glad we could help on the windshield wiper assembly! It's already at the post office and you should see tracking info update later today.

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This is without driver, and the fuel tank was about 1/3 full (plus the extra fuel in the Radium tank). I do plan to corner balance it once it has the aero on.

I figure the street windshield + assembly, steel rear bumper, defroster, tow straps that were just hanging off of it (since it was just unload/reload without actually driving the car), etc. are all good for ~50-70 pounds.

Awesome! Can't wait to fight with that next.

Must be because you haven't painted it yet ;)

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Originally Posted by Hindsight

Must be because you haven't painted it yet ;)

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Then maybe I won't paint it! haha

Calling Rasmus: what do you think, Mr. Lightweight? Is this scale just wrong?