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Old 01-26-2014, 12:49 PM   #1
Pearldrummer7
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Member#: 277514
Join Date: Mar 2011
Location: NY
Vehicle:
2012 WRX & 818R

Default Frank's 818R build

Hey guys, figured I'd make a build thread to document my Factory Five 818R build. My goal is to have it be street legal, so I can scare friends in it, and of course, to be on track with it as often as I possibly can. Shoutout to my friend Frank at FFR who helped peer pressure me to do this and is helping with every step of the process. Of course, I'm always open to suggestions for this car, so if you have an idea- speak up! I'm not new to Subarus (3rd one) but I'm by no means an expert. Brand new to the Factory Five Forums and I'm excited to see how this build goes!

A quick little 'about me':
At the time of writing- I'm 22, single, Clarkson grad, working as an electrical engineer for a company in upstate NY making automotive aluminum (narrows it down quite a bit). Done a bit of car work, nothing quite this intense. Done a little tracking/autox, nothing too serious either. Currently drive a 2012 WRX that's a bit modded. Want something a little....faster

See here for cost/timeline information


Highlights (Click to see post- to help those stuck on a step!)
Donor:
Picked up my donor locally on 2/8/14 after buying it on 1/25/14
Started teardown
Removed wiring harness
Donor car towed away

Parts:
Electrolysis
New Garage!
Transmission work
Steering work

818:
Delivery day! Brought the 818 home. (7/5/14)
Mounted fuel tank
Front suspension
Installed engine
Brake lines
Seat mounting
Clutch and trans installed
Coolant lines
Wheels
First start
First drive
Tune and Alignment
First autox(bad angle)
Started Body Work
Better autox angle
Race wind screen and dash
Fender liners
Race height

Track:
First track day(NYST)
Second track day (SLMP)
More NYST track time


The quest for street legality:
Windshield
Rear bumper
License plate lights
Defroster
Wipers
Side marker lights
VIN
Plates and timeline recap of street legality process

Other:
Engine swapped lawn mower
First tow
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Last edited by Pearldrummer7; 03-29-2016 at 12:37 PM.
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Old 01-26-2014, 12:50 PM   #2
Pearldrummer7
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Member#: 277514
Join Date: Mar 2011
Location: NY
Vehicle:
2012 WRX & 818R

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Old 01-26-2014, 12:51 PM   #3
Pearldrummer7
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Join Date: Mar 2011
Location: NY
Vehicle:
2012 WRX & 818R

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The donor car:

After a ton of looking, I found a 2002 silver WRX sedan about 2.5 miles from my apartment complex, and maybe 15 from the garage I'm doing the build in (a friend's house).

Motor:
EJ257 block
'10 STi nitride treated crankshaft
Wiseco pistons
Eagle rods
Acl main and rod bearing
ARP head studs
Ej205 heads
Ferrea valves
Combustion chambers custom cnc'd for larger bore
VF39 turbo
Walbro fuel pump
Deatschwerks 650cc injectors
TGV deletes
FMS 3" turbo inlet
Turboxs fmic and recirculating bov
12mm oil pump
New OEM water pump
Full 3in catless turbo back exhaust and catless up pipe.

Transmission:
Exedy stage 1 clutch
Gruppe-S flywheel
Bent 1-2 selector fork :'(
Supposidly JDM micro polished gearset. We shall see when the transmission gets rebuilt

Body is a 2002 silver WRX sedan in pretty good shape. Has full interior (which is mostly ricer-blue...... ) and gauges. It's also really close which is ideal for moving it (I'm still getting a trailer and borrowing a friend's truck, though). Guy has tons of pictures and receipts for all the work. Motor ran nicely and everything looks good so far. I'm hoping it's actually the deal I think it is at $4,800.

Some pictures:


Last edited by Pearldrummer7; 02-10-2014 at 07:15 AM.
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Old 02-09-2014, 09:13 AM   #4
Pearldrummer7
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Join Date: Mar 2011
Location: NY
Vehicle:
2012 WRX & 818R

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Picked up the donor yesterday! My good friend towed it back with his F-250. I didn't think it would engage gears at all, it actually drove just fine. Popped out of first when I stepped on it around the neighborhood a little. No big deal, really. Time to look into fixing or replacing the trans, though!




My small collection of WRXs

Last edited by Pearldrummer7; 02-10-2014 at 07:14 AM.
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Old 02-10-2014, 07:11 AM   #5
Pearldrummer7
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Join Date: Mar 2011
Location: NY
Vehicle:
2012 WRX & 818R

Default

Stripping the donor with my good friend whose garage it's living at. So far, doors, hood, trunk, rear seats, rear seat belts, and tons of trim are gone. Doors (especially front driver) had a bunch of wires in them that I could probably have cut right out, but decided to run through the door just in case I need them for whatever reason. Few hours of work but it felt pretty productive. Labeled some wiring on the harness, too.

And the work begins:


Final door!
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Old 02-10-2014, 05:58 PM   #6
Prettym1k3
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Join Date: Aug 2012
Location: San Jose, CA
Vehicle:
1999 Swpd 6 spd. GM6

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Holy cow I can't wait to see what this build does on the track. More pictures, and keep us updated!
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Old 02-11-2014, 07:12 AM   #7
Pearldrummer7
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Join Date: Mar 2011
Location: NY
Vehicle:
2012 WRX & 818R

Default

Quote:
Originally Posted by Prettym1k3 View Post
Holy cow I can't wait to see what this build does on the track. More pictures, and keep us updated!
Thanks! I absolutely will! I've been taking as many pics as I can. GoPro case is broken so I have to do sketchy things to use the GoPro till Amazon ships me a new case.

Motor will be pulled Saturday with a few friends, here's what we did yesterday after work:
Removed passenger airbag and dashboard, and labeled a ton of wires. Tonight is most likely going to be pulling off the front bumper and taking out front seats.

Before-


After-

Last edited by Pearldrummer7; 02-12-2014 at 06:59 AM.
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Old 02-12-2014, 08:08 AM   #8
Pearldrummer7
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Member#: 277514
Join Date: Mar 2011
Location: NY
Vehicle:
2012 WRX & 818R

Default

Yesterday was a pretty big day! Not doing work on the car tonight, so we worked late last night. Took off carpet, bumper, fenders, ECU, wipers and wiper motor, and labeled a ton of wiring. Pulling the motor Saturday afternoon!

Some pics of the process and the aftermath:




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Old 02-12-2014, 12:50 PM   #9
ajchxc
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Member#: 168943
Join Date: Jan 2008
Location: Victor, NY
Vehicle:
2004 STi
Aspen White

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Looks good! I love, love, love these kits. I can't wait to see progress. On a side note: I love Pearl drums!
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Old 02-12-2014, 12:54 PM   #10
Pearldrummer7
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Join Date: Mar 2011
Location: NY
Vehicle:
2012 WRX & 818R

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Quote:
Originally Posted by ajchxc View Post
Looks good! I love, love, love these kits. I can't wait to see progress. On a side note: I love Pearl drums!
Thanks! I too am excited to see the progress. And yup! I got a custom builder to make my last set, so I don't actually own Pearls anymore but the username was already made haha
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Old 02-14-2014, 07:14 AM   #11
Pearldrummer7
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Location: NY
Vehicle:
2012 WRX & 818R

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Donor car update-
Took off turboback and FMIC, put the front on jacks, found an engine hoist, and removed a couple more electrical connections. Found out the floor of the garage is slightly pitched to facilitate the (probably illegal) floor drain that is totally awesome and handy to have around, so the car didn't jack evenly at all. Rear driver corner was floating, so I don't know exactly what I'll do for removing all the suspension. I'm sure I'll figure something out.... I hope

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Old 02-17-2014, 01:31 PM   #12
Pearldrummer7
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2012 WRX & 818R

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Donor update:
Pulled the motor this past Saturday with a couple friends, I'll put up some GoPro pics of it this evening. Came out pretty nicely, all things considered. We broke an O2 sensor (intentionally) off of the headers on the passenger side, as it was REALLY stuck in there and needed to come out before the engine did. Clutch is beat to crap, but everything else looks really good on it. Zero shaft play on the VF39, and clean fluids all around. Just need to sell some donor parts now!
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Old 03-04-2014, 07:10 AM   #13
Pearldrummer7
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Location: NY
Vehicle:
2012 WRX & 818R

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Little update (pictures to come when I get some free time after work):
Dropped the trans out, and the front suspension. Pro tip- break axle nuts free BEFORE you take off motor and driveshaft, not after We realized that mistake as soon as we looked at axles. Got crafty with a crowbar placed between studs (broke one in the process, but I needed new ones as the old ones were destroyed) and got them off.

Hoping to do some motor work soon- timing belt, clean alternator (Rasmus from FFR forums inspired that), maybe spark plugs and coils, and likely some valve cover gaskets. Anyone have any advice for things I should be doing to the motor while it's easily accessed?
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Old 03-04-2014, 11:45 AM   #14
rs_two_five
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Member#: 99206
Join Date: Oct 2005
Chapter/Region: W. Canada
Location: Cold Lake, Alberta, Canada
Vehicle:
2007 WRX STi wagon
Ducati Hyperstrada, WR450

Default

Here's a few quick tips to when a EJ motor comes out..

Trans off do (rear exposed): Rear main seal, reseal the oil vent on the rear of the RH block half (and upgrade to metal cover if plastic)

Timing belt off: Crank seal, oil pump oring (between the oil pump and block), make sure oil pump rear plate screws are tight (you'll see the phillips heads once the oil pump is removed), replace water pump & thermostat, replace all idlers and tensioner for timing belt. If cam shaft pullies are removed, then replace cam shaft seals.

Intake manifold off: Replace/clean PVC
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Old 03-04-2014, 12:43 PM   #15
Pearldrummer7
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Join Date: Mar 2011
Location: NY
Vehicle:
2012 WRX & 818R

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Quote:
Originally Posted by rs_two_five View Post
Here's a few quick tips to when a EJ motor comes out..

Trans off do (rear exposed): Rear main seal, reseal the oil vent on the rear of the RH block half (and upgrade to metal cover if plastic)

Timing belt off: Crank seal, oil pump oring (between the oil pump and block), make sure oil pump rear plate screws are tight (you'll see the phillips heads once the oil pump is removed), replace water pump & thermostat, replace all idlers and tensioner for timing belt. If cam shaft pullies are removed, then replace cam shaft seals.

Intake manifold off: Replace/clean PVC
Definitely agree on all of these. Except....what is the oil vent? Can you explain or show me? sorry!
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Old 03-04-2014, 04:54 PM   #16
rs_two_five
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Join Date: Oct 2005
Chapter/Region: W. Canada
Location: Cold Lake, Alberta, Canada
Vehicle:
2007 WRX STi wagon
Ducati Hyperstrada, WR450

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more commonly known as the Air Oil Separator.. it's behind the flywheel and looks like this

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Old 03-04-2014, 07:04 PM   #17
strhtjen
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Thanks! I absolutely will!
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Old 03-07-2014, 08:25 AM   #18
Pearldrummer7
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Member#: 277514
Join Date: Mar 2011
Location: NY
Vehicle:
2012 WRX & 818R

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Some update:

Wiring harness is gone! Time to pull rear suspension and get rid of the donor!




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Old 03-07-2014, 08:50 AM   #19
Evans609
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Join Date: Oct 2012
Chapter/Region: E. Canada
Location: Newfoundland
Vehicle:
12 ISM STI
10 OB Ralliart

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Interested to see this up and running. My friend is also putting together a kit car. Goodluck
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Old 03-07-2014, 09:02 AM   #20
Pearldrummer7
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Member#: 277514
Join Date: Mar 2011
Location: NY
Vehicle:
2012 WRX & 818R

Default

Quote:
Originally Posted by Evans609 View Post
Interested to see this up and running. My friend is also putting together a kit car. Goodluck
Thank you! Lot of work to do before we're at that point. My friend with the garage is also leaving soon, so I have to find another garage to do it in before it comes this summer.
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Old 03-07-2014, 09:11 AM   #21
Evans609
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Join Date: Oct 2012
Chapter/Region: E. Canada
Location: Newfoundland
Vehicle:
12 ISM STI
10 OB Ralliart

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yea i hear ya lol my buddy started last summer and there is alot of work! But from the specs and videos it seems like it pays off big time hah
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Old 03-11-2014, 08:09 AM   #22
Pearldrummer7
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Join Date: Mar 2011
Location: NY
Vehicle:
2012 WRX & 818R

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And the wiring nightmare begins! Started "dieting" my donor harness last night, and started the long documentation process. Even with an electrical engineering degree, I'm a bit anxious over this job. I plan to delete the fuses for circuit breakers mounted on a panel in the car (a la F1 GTR). Maybe that's a lofty goal for now, but it's definitely my intention!


My thread of wiring hell. Feel free to contribute.

http://thefactoryfiveforum.com/showt...each-connector

Last edited by Pearldrummer7; 03-11-2014 at 03:03 PM.
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Old 03-11-2014, 03:02 PM   #23
iceyinferno
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Location: Andrews AFB, MD
Vehicle:
2004 STi
Aspen White

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Subscribed! Can't wait to see this project!
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Old 03-11-2014, 03:04 PM   #24
Pearldrummer7
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Join Date: Mar 2011
Location: NY
Vehicle:
2012 WRX & 818R

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Quote:
Originally Posted by iceyinferno View Post
Subscribed! Can't wait to see this project!
Thanks! Neither can I!

If you're local, feel free to swing by Oswego to check out the build as it progresses. Open invite to anyone.
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Old 03-11-2014, 03:04 PM   #25
Pearldrummer7
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Location: NY
Vehicle:
2012 WRX & 818R

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Quote:
Originally Posted by iceyinferno View Post
Subscribed! Can't wait to see this project!
Thanks! Neither can I!

If you're local, feel free to swing by Oswego to check out the build as it progresses. Open invite to anyone.
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