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Old 01-27-2014, 08:01 PM   #26
metros
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Continuing to make fairly good progress. This past weekend I dissected all of the rear suspension/brakes, removed the dash/cluster and continued working the harness free.

High point - My impact gun removing the long bolts that hold the rear lateral links and hub together. Air tools are extremely satisfying.



This guy loves helping strip the wrx.

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Last edited by metros; 04-06-2018 at 09:59 PM.
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Old 01-27-2014, 08:45 PM   #27
SuperFlyTNT2
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Subscribed
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Old 01-28-2014, 01:26 PM   #28
Pearldrummer7
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subbed. Going to start stripping my 818 donor soon. This thread looks super promising! keep up the good work.
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Old 02-09-2014, 05:09 PM   #29
metros
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Almost completely done with the donor! Today I finished removing the wiring harness. Everytime I thought I was getting close it was like a false peak and I'd realize that I had a lot more to remove.

What have I gotten myself into?


I took the harness and laid it out in my basement and oriented it to how it was positioned in the vehicle. That way when I start the dieting process it'll be easier for me to sort.

Only things left on the donor to remove is the master cylinder, slave cylinder, pedals, and charcoal box for the gas tank.

Anybody looking for a shell? I've done the grunt work in prepping it for a racecar build.

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Old 03-07-2014, 12:00 PM   #30
metros
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Update: My donor has long been finished and sold last weekend. It's nice to have some open garage space for parts re-furb now that the shell is gone. I've done a lot of work selling parts and recouped a LARGE portion of my initial investment. After all is said and done I should come out with spending between $1000-1500 on all of my donor parts. I never thought I would be able to recoup that much. Of course those funds have all gone for new parts, tools, and other items. See below.

You know it's a good day when you arrive home from work and find these waiting at your door:


Front and Rear, 4pot kit with 2 piece rotors - should do well in stopping this lightweight car:


Very Cool Parts! Trailing arms to allow wider rear wheels:


The above trailing arms will help me run Mach V "Awesome" wheels - They're going to require some modifications to work, but I think they're sharp, they're pretty lightweight and the price is right.


More updates to come this weekend. I'm in the process of de-powering the steering rack and painting parts/installing new bushings.

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Old 03-07-2014, 08:23 PM   #31
stiwannabe112
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subbed!! I plan on doing this in the future! good luck and keep this up!
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Old 03-08-2014, 09:23 PM   #32
metros
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A teaser of what's to come.


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Old 03-09-2014, 01:33 AM   #33
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Damn think that is a new record, banned after 4 posts!
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Old 03-10-2014, 09:05 PM   #34
metros
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I'll have my kit this weekend!

This past weekend I was working in overdrive trying to prepare parts before the kit arrives. I'll still have plenty of work to do on donor parts when the kit arrives but I did get a good amount accomplished.

I farmed some of the refurbing process out to Mach V Motorsports, who is local to me. Mach V installed new bearings in all 4 knuckles, new balljoints and new ARP studs from an EVO 8. The EVO studs use a coarser thread which will help prevent cross threading when frequently changing wheels for track/street. I also needed 2 new hubs out of the 4, which explains 2 shiny hubs and 2 POR15 hubs.

All hubs were wire brushed and prepped using POR15 Metal Prep, which eats away the contaminants, etches the metal and leaves a zinc coating. Pretty neat stuff. The POR15 shouldn't have any issues adhering for a long long time.







Lateral links - Removed all the old bushings and have some TiC graphite impregnated bushings ready to install. Lateral links were also all wire brushed and etched with POR15 Metal Prep prior to paint.



I knew those old refrigerator racks would come in handy!

Transmission - PPG Helical gear built 5 speed. Thoroughly degreased and also prepped with the previously mentioned POR15 Metal Prep. Can you tell I love this stuff?

3 coats of VHT Engine Paint, came out looking brand new.




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Old 03-16-2014, 09:54 PM   #35
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Success!

On Saturday I was on the road at 1:30am in order to reach Factory Five before they closed at noon. I arrived to find a few other guys that made the journey to pick up their new project as well. The staff at Factory Five took me on a tour of the factory, which was an impressive facility.

I also got to see the showroom full of Factory Five creations to include hot rods, cobra replicas, GTM, and 818!

Love the candy red color!




My new project at last!


All loaded up on my build trolley and strapped down several times over to the trailer. There was also a considerable amount of boxes full of parts.



After picking up we started the journey back and stopped at a hotel in Providence. Turned out the Marriot I had made reservations at wasn't in the greatest part of town. Parking your new project in a lot with broken side window glass, a hypodermic needle, and signs stating "management not responsible for items stolen from vehicles" doesn't exactly allow you to settle in to catch a few Z's. We unloaded all the boxes out of the truck into the hotel room and chained the frame to the trailer with lock. After checking it frequently throughout the night I found everything intact in the morning. Thanking my lucky stars on that one.

Today we drove the 8 additional hours back home without much incident. Just 40 minutes out from being parked in my garage it started snowing heavily. The kit had accumulated a fair amount of slush cover and boxes in the bed of the truck had an inch of snow resting on them. We quickly unloaded the truck and got the boxes into the garage. I cranked my heater up and did the best I could to dry the aluminum panels. Not a big issue because they were going to be painted anyways.

Tucked in for the night in a warm garage:


After a long weekend I'm ready to crash and start inventorying the parts boxes tomorrow!

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Old 03-16-2014, 10:36 PM   #36
Brandon2k13
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Haha, I know exactly the hotel you're talking about in Providence. Not the best part of town to say the least. I'm glad you made out alright, good luck with your build and new son. I'll be tuning into this one!
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Old 03-27-2014, 12:05 AM   #37
lavid2002
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Sub'd man. This looks awesome! I built my first project car the last summer and I am addicted 0.o

When I went and toured the factory 5 facilities the guy kept stressing how everyone wanted to put powerful engines in these cars. He said it was a mistake and that a bone stock WRX EJ255 was plenty for the car because it only weighed ~1,800lb.

I noticed you said the engine you were dropping in had 242 hp "For now"

What did kind of power are you shooting for with this build?

-Dave
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Old 03-27-2014, 01:15 PM   #38
metros
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Yeah, Jay said the same thing when I toured the factory as well.

I think the reason everyone is doing that is because they're used to tuning the subaru engines for their wrx/STi. It's easy to throw a few parts on and push much higher numbers.

I'm not doing anything crazy for my build, power wise. But I will be using a Blouch 18g, lighter flywheel, TGV deletes, AWIC and a few other simple add ons. Nothing crazy but should produce 350-400rwhp with a conservative tune. I'm sure that will be more than enough power, but nobody ever complains about having too much power.
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Old 03-28-2014, 02:45 PM   #39
Mach V Dan
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Quote:
Originally Posted by metros View Post
Nothing crazy but should produce 350-400rwhp with a conservative tune.
Nothing crazy? By my calculations your car will have the same power-to-weight ratio as a WRX with...619 whp. (Assumed 150-pound driver.)

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Old 03-28-2014, 11:05 PM   #40
metros
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Haha, the power to weight ratio is going to be something I can't really imagine until it's built and driving.

350-400 at the wheels sounds fun but within reason. 619 sounds ridiculous.

Stay tuned for some updates on Sunday!
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Old 03-30-2014, 08:45 PM   #41
metros
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Over the past few weekends I've made some decent progress on the kit.

When I first got the kit home I had to clean everything because we got caught in snow on the way home. Unpacked the body panels after cleaning them with Optimum No Rinse and gave the chassis the same treatment.

First up I had to inventory the numerous boxes full of parts. Once that was taken care of I was anxious to get my hands on the kit and get started.





I wanted to hang the suspension first but had a few necessary parts on back order. Instead I started on the front firewall. The aluminum panels come hung on the car with 1-2 metal screws each. In order to rivet the panels to the car I first marked the panels for the cross bar locations. Then remove and mark at 3 inch increments incorporating the holes that were already there from the original screws. All very time consuming as you have to space the rivet holes of each panel to coordinate with each other.



Once the aluminum panels are drilled they get re-installed to drill the chassis for rivet holes.

The aluminum panels can get riveted on as is. But I wanted to dress them up a bit as aluminum shows everything and is difficult to keep clean. I saw another 818 builder use Herculiner, which looked good and would help deaden some sound. I decided to do the same.

Each panel had all the rivet holes de-burred with my die grinder and scotch bright prep pads. Then the panels were scuffed and cleaned with acetone prior to herculiner treatment.



Before riveting the panels in place a bead of silicone is laid where all contact with the chassis is made. This is to prevent squeaks/rattles.

Panels installed




I'm in the process of doing the same for some of the panels in the cockpit.


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Old 03-30-2014, 08:58 PM   #42
metros
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I also finished de-powering my steering rack. In order to do this I had to strip the entire steering rack apart and remove the seal. While it was apart I painted everything and replaced the inner/outer tie rods as well as the rubber boots.



I've also been painting the raw steel brackets that fill all those boxes shown in my garage. I'm using rustoleum black gloss with primer and it's producing great results. I'm also clear coating all of these brackets.



My painting area


All of these parts are being scuffed with my die grinder/scotch bright prep pads and cleaned with acetone prior to paint.

On Deck:


Door bars - Yes, these will be installed in the doors and won't ever be seen. But the voice in the back of my head said to paint them up just like everything else.



Next up - Finish prepping the lateral links with new TiC bushings and FCAR bushings for the front LCA. Install a new gates timing belt/water pump/tensioners on the engine. Remove intake manifold/valve covers for powder coat. Continue on cockpit aluminum panels.

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Old 03-30-2014, 09:13 PM   #43
redrex2002
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im not sure on the cost difference between the herculiner and this stuff but i know a lot of the guys in the hot rod world love this stuff because it helps keep the heat out as well as deaden sound. its worth looking into and i figured i would share. good luck with the build!

http://www.lizardskin.com/
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Old 03-30-2014, 09:42 PM   #44
g2gs
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When I first saw your doner car I thought NOO! How can you take apart such a nice bugeye? as I read on I totally get it now! This looks to be one sweet build and even more fun to drive thinking about the platform, engine, and power to weight ratio this car is gonna be a blast! Good luck with the build! I'm subscribing for sure to follow you on your prgress.
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Old 03-30-2014, 09:46 PM   #45
metros
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Thanks for the info. I am aware of lizard skin but was turned off because it's 2 different products, 1 for sound and 1 for heat. May be useful for inside the body panels though as it's a lot thinner than herculiner. I plan on using a different product for the rear firewall to help block the engine heat. The interior aluminum will just be painted so it can maintain a smooth finish.
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Old 03-30-2014, 10:02 PM   #46
DoingOK
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Damn.....how did I miss this post. Excellent work so far.....I see we may have the same ocd tendencies. ;-)
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Old 03-31-2014, 04:00 PM   #47
metros
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Thanks and yes I have some above average ocd tendencies. Car should be pretty awesome when done.

Just found out I'll be getting a ton of the backordered parts soon. May be able to hang the suspension this weekend.
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Old 03-31-2014, 08:05 PM   #48
Mach V Dan
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How much Herculiner did you use, and how much did it weigh? Just curious.

--Dan
Mach V
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Old 03-31-2014, 08:11 PM   #49
metros
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I would estimate 1/5 of a gallon. No idea on weight. I'm building for the final product to be about 2000 lbs. May be a little lighter given the lightweight wilwood set up I'll be using.
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Old 04-06-2014, 03:29 PM   #50
autoxinvr6
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Nice project!

If you have a minute and don't mind... I was wondering if you could measure the width of the frame where the roll bar is. Specifically the square tube it's welded to, from left to right .

Thanks!
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