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Old 11-17-2013, 03:33 PM   #1
metros
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Default Metros's 818 Build Thread

I've decided to build an 818 because building a kit car is a bucket list item for me. I chose the 818 because of the focus on being lightweight and great power potential of the EJ motors.

In the past I've had an STi with few modifications, turbocharged s2000 with 422rwhp, and LS powered rx7. These cars were all fun and had their own perks and drawbacks. I'm hoping my 818 covers the positive attributes of most of these cars without the drawbacks.

I'm currently slated for August 14th completion of my 818 kit. I'm really hoping that Factory Five Racing continues to up their production abilities to get these kits out faster. In the mean time I need to strip the donor and prepare all the parts needed for the 818. In preparation for this project I've hung several new shop lights and bought a 60 gallon Quincy single stage air compressor.

This weekend I washed my 2002 Bugeye WRX donor car to be parked and stripped. It's always easier to work on a clean car. Here are her last rights.







I purchased the car a few months ago and drove it around to get a feel for it and also make sure everything was working as it should be.

2002 WRX
-vf34
-Turbo xs FMIC
-MRT Turboback
-Kinesis wheels
-Putting down 243awhp - to start.

This weekend I also built my 818 build trolley. When the frame is delivered it will rest here so that I can move it while working on it if desired.



Insert 818 here:


My experience level: I've done a lot of suspension work over the past few years while building the last 3 cars. I replaced all the suspension bushings on my rx7 in addition to the normal coilovers, etc. However, I've never pulled an engine/transmission out of a car. I will be learning a lot throughout this project but am confident I'll be able to put together a very clean build.

But just in case, I've recently become friends with the guys at Mach V Motorsports in Sterling,VA. These guys have a ton of experience with the subaru community and do things right, instead of just getting them done. They're extremely trust worthy and will make recommendations based on your situation regardless of whether it's going to make them more or less money. I'm considering them my golden parachute if I get into a situation where I need a true expert to help me out.

I'll be posting updates here periodically on how stripping my wrx is coming, rehab'ing the donor parts, and finally my 818 build.

For those that don't know anything about a Factory Five 818:
-Factory five racing is well known in the kit car community for producing high quality parts and complete kit cars using only one donor car. The 818 is a car designed by enthusiasts and built using an 02-07 impreza or wrx as the donor. In the 818 the subaru engine and transmission sit behind the driver and the car is converted to rear wheel drive. One of the major goals of the 818 design was keeping it light weight or as close to 818kg as possible. The 818 has reviewed extremely well by Car & Driver as well as a few other sources.

Pictures:






Starting point!


My 818 build thread on the Factory Five forum:
http://thefactoryfiveforum.com/showt...s-Build-Thread
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Last edited by metros; 01-11-2014 at 09:08 PM.
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Old 11-17-2013, 03:37 PM   #2
ubersu
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Very cool project, subscribed!

Ive been tossing similar ideas back and forth for a while. Wish you all the best, look forward to updates.
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Old 11-22-2013, 06:40 PM   #3
metros
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Look what I picked up today! It took MachV less than a week to get this turbo in from Blouch, set up as requested. This particular turbo is a Blouch 18g xt. I opted for the ceramic coating on the hot side, 15psi actuator spring, and 7cm housing.

Holding something that is going to spin that fast and thinking of how tight it must have been engineered to perform is just cool.







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Old 11-23-2013, 09:33 PM   #4
metros
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Car is coming apart faster than I anticipated.



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Old 11-23-2013, 09:49 PM   #5
scubby snack
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world rally blue

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love 818s good luck with the build, looks like you got a very solid donor car to work with which will be a big help!!! im local to factory 5 and have had the pleasure to lay my eyes on there beautiful shop vehicles. you will not be disappointed!!!
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Old 12-01-2013, 08:22 PM   #6
metros
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^^^Thanks, I agree.

Here is where the car sits today. This week I removed the exhaust system, turbo, FMIC, and up-pipe to sell. Also removed the front bumper and drained the coolant/oil.





My investment in an air compressor and tools has really paid off this week. Really helped getting some of these parts off a lot faster.
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Old 12-02-2013, 09:00 PM   #7
DruOdil
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Default good luck

I am also building an 818. You started with such a nice STI. I can't wait to see your finished 818.
Dru
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Old 12-13-2013, 08:12 PM   #8
metros
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^^Thanks. Good luck on your build.

I haven't updated in awhile. Turns out newborns absorb all the time and energy that you may have available.

Every proud father is going to post pictures of their child.



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Old 12-22-2013, 06:36 PM   #9
metros
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This weekend I was finally able to steal an hour or 2 away from the family to get into the garage.

-Removed radiator and fans.
-Removed catch can and coolant overflow.

Just removing that much created a ton of room in the engine bay.
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Old 12-22-2013, 06:42 PM   #10
bluemax189
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2011 WRX
20g

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congrats on your son!
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Old 12-25-2013, 06:09 PM   #11
metros
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^^^Thanks.

Had a very quiet Christmas this year. My son is too young to travel with, which left the three of us home for a very low key holiday. That freed up some time for me to spend in the garage, relaxing.



Today I was able to remove the rear bumper (to sell), rear taillights, side skirts, front fenders, ac condenser, ac hard lines, and windshield wiper assembly. Very productive for only spending a couple hours.
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Old 12-25-2013, 07:02 PM   #12
silverF4turbo
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` BUGEYE GARAGE

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That bugeye is gorgeous... Shame you're tearing apart such a nice/perfectly good car (with Kinesis wheels) to build an 818. Borderline sacrilege since you don't need the chassis for anything - but then again you've owned an LS RX7

Since you're "all in" though, good luck with the build

Last edited by silverF4turbo; 12-25-2013 at 07:08 PM.
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Old 12-25-2013, 07:16 PM   #13
metros
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The chassis will be re-used.

The bugeye was in good shape but nothing overly special. The 818 will be much nicer than that specific bugeye.
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Old 12-26-2013, 11:01 AM   #14
Mach V Dan
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Quote:
Originally Posted by metros View Post
Throwin' up gang signs. Or maybe I shouldn't use the words "throwing up" anywhere near an infant.

--Dan
Mach V
FastWRX.com
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Old 01-05-2014, 08:50 PM   #15
metros
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^^Lulz

Tear down is coming along nicely. Lately I've only been getting an hour or two here and there to work. But considering I've never pulled an engine before I feel like I'm making good progress.

-Alternator/AC Condensor/Power Steering Pump Removed
-A lot of labeling plugs and removing obstacles for the harness

I've punched the pins holding the axle to the transmission out. But haven't figured out how to pull the axles off the male stubs of the transmission. That'll be the next step. Overall I'm pretty close to getting the engine out.



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Old 01-05-2014, 09:34 PM   #16
milab21
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cool build, congrats on the little guy
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Old 01-05-2014, 10:38 PM   #17
ScoobyBenny#3
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Just undo the lower mount of the struts and you'll be able to pull the axles off the male stubs of the transmission. Good luck with the build and congrats on the new family member.
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Old 01-06-2014, 12:34 AM   #18
Nomadgene
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2002 EJ207 V8 1.5xtr
TWIN-SCROLL Black Bugeye

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I appreciate you sharing the build. I plan to do one myself once I get settled again, but will be going for the R model. I'm ready for track work.

I am curious, with the availability of JDM power plants/ front clips….why you would choose to dismantle a running car?

I've done a JDM EJ207 swap on my own bugeye, (which was purchased new and finally got rod knock after 132K hard driven miles). The differences in the power plants is remarkable.

I'm excited to see where this project goes and learn something along the way.

Nice looking kid too.

Thanks again for sharing this with us.
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Old 01-06-2014, 09:15 AM   #19
metros
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Thanks for the tips benny. Removing those made a lot more sense when I was looking it up last night.

This s will definitely see track time. The r isn't necessary to go on track and with the s model I'm able to drive it on the street a lot more comfortably. My s will have the r suspension and r aero package.

I chose my donor because I wanted to drive the car around to troubleshoot any issues before swapping the parts into my kit. I'll still be doing normal maintenance items like wheel bearings and timing belt etc. But this way I was able to get used to how the engine drove and even have it dynod as is before further modifying it.

Plus you'll end up needing to source a lot of parts if you just end up buying the front clip.
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Old 01-06-2014, 01:56 PM   #20
Nomadgene
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TWIN-SCROLL Black Bugeye

Subaru Stars

I was reading else where last night that the R model's roll cage has a bar right near the driver's head which requires a helmet being worn full time….might have to rethink my plan on that.

I re-read the first post and understand now that you purchased the WRX as a donor….not that you built it yourself. After all the time and effort (and expense) I've gone through with my Bugeye, I couldn't imagine parting it out. Guess I'm getting sentimental in my older years…or have watched "Love the Beast" too many times.

Sitting on the front row to watch this.

Curious how the package arrives, do they need a lift? Is the main body on pallets?
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Old 01-06-2014, 05:58 PM   #21
metros
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Yeah if I wss attached to the bugeye then it would be more difficult to tear apart. But I bought that car solely to feed to the 818.

You have to arrange transport of the kit. If you use their preferred company then they bring it in a tractor trailer and have a mini crane type contraption to lower the frame/body off the truck. They loosely fit the body panels to the frame and then ship tons of boxes with transport.

I think I'm going to go pick it up. I've convinced a family member to use his truck and trailer. Plus then I get to look around the factory five facility.
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Old 01-11-2014, 08:52 PM   #22
metros
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I was able to escape into the garage for most the day today and made some great progress!

Removed:
-Driveshaft
-Front axles
-Shifter
-Engine and Transmission
-Front Seats

Once again I have to acknowledge the fact that air tools have been a great investment for this project and many more in the future. My impact gun removed both axle nuts without breaking a sweat.

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Old 01-12-2014, 04:20 AM   #23
fgjghjdyjpeng
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Just removing that much created a ton of room in the engine bay.

Last edited by fgjghjdyjpeng; 01-12-2014 at 04:26 AM.
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Old 01-12-2014, 07:04 AM   #24
ScoobyJD
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Damn think that is a new record, banned after 4 posts!
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Old 01-20-2014, 12:38 PM   #25
metros
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This weekend I was able to get the power steering rack removed and stripped everything away from the front knuckles. Also got the carpet removed and started removing more interior wiring harness.
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