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Old 01-03-2011, 02:24 PM   #76
Britain
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1700lb AX Car w/ Spec-C

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Being out of town for a week got me out of the groove for a couple of days, but I started back in it last night.

The first thing that I tackled was the routing of the coolant lines for the turbo. The stock routing simply would not clear the firewall, here is how it originally looked.



After a little cutting and welding, they are now routed properly.



And here they are with the coolant hoses attached. The feed line comes from the reservoir tank and the return goes to the stock location at the back of the head.



In a previous image, you may have noticed that rubber coolant line ran very close to the exhaust downpipe...a little too close for comfort. I therefore constructed an aluminum coolant line that routes farther from the exhaust.

Here is the original rubber coolant line in place.



And here is the aluminum coolant line.



Another item that I had some comment on was regarding the structural integrity of the square tubing engine mount bar. I had plans to reinforce this from the beginning, but I needed to finish the mounting of a few other items before constructing this plate. It is 3/16" mild steel cut out on a waterjet and stitch welded across the entire length.





The aluminum coolant pipe will be supported with a bracket hanging off this plate.

The last thing I started work on was the mounting of the pedal assembly. I explored the option of bolting it to an aluminum plate then securing that plate to the floorboard, but the entire thing was going to raise the pedal assembly an additional 1/2" off the floor. I have now decided that I am going to weld in a steel plate in-between the floor ribs to reinforce the floor pan and provide a flat surface to bolt the pedal assembly in.

Here is the floor pan in the pedal cluster area, you can see the multiple ribs and recesses. (Ignore the brake master assembly in there, I haven't lifted the car off the lift to pull this out yet)



Here is the steel plate that cut out to fit, there will be some vertical plates welded to the bottom of this to account for the variation in floor thickness.



And here is Tilton pedal assembly in its final resting place. The new pedals will take some getting used to, but at first pass I like them.



More to come soon,
Britain
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Last edited by Britain; 10-23-2012 at 01:06 PM.
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Old 01-06-2011, 12:38 PM   #77
franticfam
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Default Vanagon engine mount?

Britain- nice job. I might be able to use something like the Vanagon mount myself. Can you provide a link or the name of the company? I couldn't find it on the web. TIA- Jim
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Old 01-07-2011, 03:26 AM   #78
Racerfab
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Hello. Nice job with everything. I have made several NASCAR oil and coolant reservoirs using the fluid level sight-tube feature. The parts are easily purchased through McMaster-Carr. They are stainless steel threaded 90' fittings screwed into welded-in 1/8" pipe bungs on the tank. Male 1/8" pipe on one end, 1/4" female compression fitting on the other. Joined by a section of tubing, not sure what you need for that. Good luck!
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Old 01-07-2011, 11:56 AM   #79
Britain
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Quote:
Originally Posted by franticfam View Post
Britain- nice job. I might be able to use something like the Vanagon mount myself. Can you provide a link or the name of the company? I couldn't find it on the web. TIA- Jim
The mount is from Small Car Performance.

-Britain
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Old 01-07-2011, 02:46 PM   #80
franticfam
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Default Vanagon mount

Thanks- Jim
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Old 01-07-2011, 05:18 PM   #81
MConte05
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Man, awesome build. Actually just ended up going with a V8 Spec-C myself.

This needs to get moved to Members Gallery so it can get the recognition it deserves!
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Old 01-07-2011, 07:41 PM   #82
feint05
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i admittedly enjoy working on my car more than driving it, so this labor of love is my version of a bitchin good time, great work, we were talking about this on my radio show the other day congrads your were inately mentioned on San Diego talk Radio
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Old 01-08-2011, 05:54 PM   #83
Britain
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Progress has been a bit slow the last couple of days, but it is starting to pick back up.

Finished up the front truck area. I replaced the foam in the fuel tank and completed all the fuel lines.



Got the AIM MXL dash mounted and ordered the Subaru interface harness so that I can read everything off the ECU.



I also started plumbing all the brake lines and drew up the wiring diagram.

-Britain

Last edited by Britain; 10-23-2012 at 01:07 PM.
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Old 01-08-2011, 05:59 PM   #84
wrxtremeWGN
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simply amazing, love this project!
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Old 01-09-2011, 12:39 AM   #85
Yint
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I think I am in love (subscribed!)
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Old 01-09-2011, 02:43 AM   #86
Britain
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It is definitely a labor of love...and speed.

I am out in the garage now...but I will have some more progress pics to show in a bit.

-Britain
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Old 01-09-2011, 06:07 AM   #87
Britain
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I got the welder back from my buddy who I am borrow it from so I was able to make good progress tonight. First I finished up clean the firewall. There were several large holes that were used to secure the 914/6 engine mount that have now been welded up.



View from the backside of the firewall with the holes welded up and the brake line rerouted to avoid hitting the turbo.



Turbosmart Dual Stage Boost Controller taken off my '69 912 Turbo project. This will work well for those tighter courses or wet weather occasions.



Pedal assembly plate welded in. These welds are not as pretty as I would have liked, however trying to weld in the cramped footwell was not easy and I had to ensure I didn't burn thru the floorpan.



Tilton pedal assembly mounted. The positioning is perfect and the mount is very sturdy.



Intercooler ice box mounted. This will fit just in front of the passenger seat when I take passengers.



Ice box plumbing. There is a ball-valve to drain the water under the car.



Ice box plumbing view down to the water pump. Had to route the lower water hose thru the crossbar so I welded in a tube to keep the strenght.



Off to bed, more to do tomorrow.

-Britain

Last edited by Britain; 10-23-2012 at 01:07 PM.
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Old 01-11-2011, 01:00 PM   #88
1vintageporschelover
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Default this build is incredible

its so far above my skill levels but I appreciate your skills. please keep updates coming. do you plan on ever getting to the southeast with this car?
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Old 01-11-2011, 10:16 PM   #89
Britain
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Thanks.

Southeast is just about as far as you can get from the PacNW...I don't see myself traveling that far any time soon...sorry.

-Britain
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Old 01-12-2011, 06:35 PM   #90
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You've come a long way Britian! Looks like they did a decent job of welding the exhaust.

YOu want a full time co-driver this year? I'm 98% sure I totaled my car, so I might be looking for a ride. You could always kick out the co-owner!

See ya at Sykart.
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Old 01-12-2011, 06:59 PM   #91
Britain
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You totaled your car...Holy $hit! What happened?

I am getting closer everyday to getting this car running...not long now.

-Britain
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Old 01-16-2011, 06:50 PM   #92
binjoau
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just read the whole thread! Great work and well done for taking on something custom! Always harder but always more rewarding
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Old 01-16-2011, 07:41 PM   #93
wrxtasy555
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Awesome build!

Looking forward to its first AX.
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Old 01-17-2011, 02:48 AM   #94
Britain
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Took the son karting yesterday. It was his first time at a dirt flat track and although he started off slow, he really got the hang of it and it was a lot of fun.



Anyway, back to work. Got the business end almost completed. Just had to put the seat back in to feel the new pedal/shifter/dash set-up. I will admit, I did sit there and make car noises for a bit. The last thing that needs to get done here is a panel for the ignition switches.



Reinstalled the engine to take some measurements for the throttle cable and clutch hose. Got the air intake installed and a bracket made to mount it.



Fuel lines installed. Startlite line may cost a little bit more, but it is SO much nicer to work with and lighter.



Got the intercooler back from being welded up by Marty Staggs (www.m-specmotorsports.com), turned out perfect.



Starting to fab up a heavy duty mount off the engine block. The intercooler is fairly heavy as it sits and will be twice as heavy when the water is added.



Hopefully I can wrap up all the fab items over the next week or so and then focus on the wiring. Although I am still waiting on my custom flywheel, I am still on track to have this thing fired up by the beginning of Feb.

-Britain

Last edited by Britain; 10-23-2012 at 01:08 PM.
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Old 01-17-2011, 02:19 PM   #95
wrxtasy555
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That thing is going to be crazy fast.

Are you going to have to get it tuned?
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Old 01-17-2011, 03:19 PM   #96
Britain
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Yep, car will be tuned at Cobb Tuning Surgeline here in Portland.

-Britain
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Old 01-17-2011, 05:38 PM   #97
Homemade WRX
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that looks like a lot of intercooler for that turbo

amazing project though and I like the trick tube through the chassis for the water pump line. Nice pump too...looks just like mine
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Old 01-17-2011, 06:09 PM   #98
Britain
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Yea, the intercooler is a little bigger than required. Garrett no longer sells the smaller core for 500hp applications so this core is the 750hp core. The pressure drop is minimal so either way it shouldn't be an issue. My goal is to get the intake air below ambient and with the icebox set-up it should be feasible.

-Britain
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Old 01-19-2011, 02:18 AM   #99
Britain
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Was able to take the intercooler mount to the machine shop today and get welded up so that I could finish the routing of the intake piping. I also had some aluminum standoffs machined up to mount the bracket to the top of the engine block where the original alternator and power steering brackets were secured. I will take the rest of this to get welded up later this week.





Intake piping between the turbo and intercooler mocked up.





Even though I rotated the compressor side of the turbo I was still able to use a Grimmspeed bracket (with a little modification) to lock the internal wastegate closed.



Found a nice solution for the oil feed to the turbo from Forced Performance. Consists of a custom made banjo bolt machined with an AN-4 male fitting on the end. The stock hard line that used to feed the turbo has a machined fitting to cap the oddball size threads. I will run a short lenght of AN-4 hose over to the turbo.



While I was having other aluminum stuff welded today, I took the time to add some reinforcements plates to the shifter housing after I found that it was flexing just a little bit where the cable mounts.



-Britain

Last edited by Britain; 10-23-2012 at 01:08 PM.
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Old 01-23-2011, 07:22 PM   #100
Britain
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I was on a roll last night and up pretty late, but made some good progress.

Intercooler mounting completed. Everything fit pretty well considering I had to mock it up at home and take it to a shop to get welded.



Turbosmart BOV mounted on the underside of the intercooler just before the throttle body.



New gauge panel completed and mounted. I had this piece waterjet so that all the holes with line up properly and saved me a bit of time.



Front fuse box and relays for fuel pump, radiator fan, and intercooler water pump.



ECU mounted in the trunk. Not looking forward to sorting out the wiring.



I should be able to get the engine back in there this evening and start finalizing all the plumbing.

-Britain
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