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Thread: RM1Sepex Build Thread

  1. #841
    Senior Member RM1SepEx's Avatar
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    Busy day worked on that inside corner, another little tab, a couple rivets, ready to upholster. The aluminum tab on the top will be used with a Dzus fastener to hold down the engine cover, no hood pin

    Here is a shot of my finished center hood support. It holds the hood a full inch higher than the FFR piece of aluminum with the bulb molding on the top! More room for wipers!

    I'm mounting my rear CF locking hood pins to the side panels not the rear clip. I had to space it down with aluminum spacers. I made a simple bolt up with a point on it to accurately center the holes to be drilled... Tomorrow perhaps?

    The gold line shows where I'll shorten the trunk hinges... the rest gets in the way, easy to drill a new hole and relocate that second bolt

    I got my aluminum IC bracket back from welding. You can see that the core will be fully exposed to the airstream. Some simple ducting and a sweet scoop and it will be all set. The fan is 10 inch diameter.

    Some shots of my first mock up of the IC tubing. I need to swap out another 2 1/2 tube with a 45 degree bend. Perhaps 2 inch would fit better and reduce turbo lag. (at the expense of increased drag)

    I made up a BPV manifold and used a 1.25 aluminum tube to dump into the intake tract's 2 3/4 inlet tube.

    P1120113.JPG P1120120.JPG P1120119.JPG P1120118.JPG

    P1120117.JPG P1120116.JPG P1120115.JPG P1120114.JPG

    P1120111.JPG P1120121.JPG
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  2. #842

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    Im assuming you are going to build some sort of scoop to channel air more directly into the intercooler?

  3. #843
    Senior Member RM1SepEx's Avatar
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    yes... short term aluminum (I have the tools and technique) long term CF (Zero DB Motorsports! )
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  4. #844

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    Im planning on building some CF ones as well. I plan on using the donor front mount intercooler as a rear mount and duct the side scoops towards it. I will have fender flares to accomodate my 295's so i plan on having some pretty aggresive scoops

  5. #845
    Senior Member RM1SepEx's Avatar
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    Visited FFR yesterday, thanks to Joe Scott for spending 2 hrs with me as I crawled over the red 818S checking out the areas that I had questions with

    First monumental update, a trunk does exist, it is made for the use of the FFR exhaust adapter and a stock downpipe. I was not allowed to take photos as it isn't finalized. The top does fit in the trunk. It finishes the area well however it isn't very deep due to the position of the downpipe using the FFR kit exhaust adapter.

    Here is a front photo of the hood with the FFR wipers, Joe told me that it is a bit close to the left wiper stalk so it isn't quite ready to ship... it will be soon

    I was able to work a deal to obtain the sheetmetal console pieces to replace my original fiberglass ones.

    The padded dash and doors look very nice, sadly I didn't realize that a CF spoiler was available... I'm working that one, I'm sure that Joe will work with us.

    The top is high quality and getting in and out was OK even with it up. The rear angle is awkward but the car's design pretty much dictates where it has to go. Storage in the trunk is a def plus.

    Since I'm using a bellmouth and almost straight down Cat and exhaust I can make a bigger, deeper trunk. The added a support just behind the IC to hold up the engine cover, I'll need to add one as I did on the hood. My hood is a bit farther forward and hinged. Using a 5 inch standoff from the 1 in square tube gives me about a full inch more clearance for wipers, hopefully I can get something under the hood with only the wiper arms visible at the park position

    P1120141.JPG P1120140.JPG
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  6. #846
    Senior Member AZPete's Avatar
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    Thanks, Dan.
    818S/C : Chassis #25 with 06 WRX 2.5 turbo, ABS, cruise, PS, A/C, Apple CarPlay, rear camera, power windows & locks, leather & other complexities. Sold 10/19 with 5,800 miles.
    Mk3 Roadster #6228 4.6L, T45, IRS, PS, PB, ABS, Cruise, Koni's, 17" Halibrands, red w/ silver - 9K miles then sold @ Barrett-Jackson Jan 2011 (got back cash spent).

  7. #847
    nkw8181's Avatar
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    FFR's wiper solution looks pretty clean. thanks for the pics.
    Nolan
    65 coupe Gen 3 "Phoenix" build
    http://thefactoryfiveforum.com/showt...032#post297032

    818 s (with r windscreen ) 350 rwhp. Registered and street legal (SOLD)

  8. #848
    Member projectrally's Avatar
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    Dan,

    I've been threatening to come visit for way too long, but now it looks like you're going to be seeing entirely too much of me. I'm picking up my kit on Wednesday...

  9. #849
    Senior Member RM1SepEx's Avatar
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    You are welcome to drop by any time... are you all set to pick it up?

    Talk to Joe Scott when you are there, perhaps he can give you my new Carbon spoiler and save me $15 shipping!
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  10. #850
    Member projectrally's Avatar
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    Quote Originally Posted by RM1SepEx View Post
    You are welcome to drop by any time... are you all set to pick it up?

    Talk to Joe Scott when you are there, perhaps he can give you my new Carbon spoiler and save me $15 shipping!
    I am going down to do a little last minute shooting for the project we've been working on. I'm taking my father-in-law's 03 Suburban, and I'm going to just rent a U-Haul 12x6 open trailer. I talked to Nate Johnson and he said that the kits are packed well enough to make the 3-hour drive back in an open trailer. All the boxes will go in the 'burban.

    Happy to pick up the spoiler for you. Shoot Joe an email to let him know, and I'll remind him while I'm down there. We'll have to make it a point to meet up this weekend because I'm flying out to Monterey on Monday for the week. Mazda saw Racing the Rock and they want to show it at their big 25th anniversary bash for the Miata at Laguna Seca. The ND is getting unveiled next week while we're out there, and Tracy and I were given invites to the unveiling. We'll get to see it two days before the public!

  11. #851
    Senior Member RM1SepEx's Avatar
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    why rent a trailer? as long as you have trailer brakes use my 8.5 x 16 enclosed Thule
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  12. #852
    Senior Member Aloha818's Avatar
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    Quote Originally Posted by RM1SepEx View Post
    Visited FFR yesterday, thanks to Joe Scott for spending 2 hrs with me as I crawled over the red 818S checking out the areas that I had questions with

    First monumental update, a trunk does exist, it is made for the use of the FFR exhaust adapter and a stock downpipe. I was not allowed to take photos as it isn't finalized. The top does fit in the trunk. It finishes the area well however it isn't very deep due to the position of the downpipe using the FFR kit exhaust adapter.

    Here is a front photo of the hood with the FFR wipers, Joe told me that it is a bit close to the left wiper stalk so it isn't quite ready to ship... it will be soon

    I was able to work a deal to obtain the sheetmetal console pieces to replace my original fiberglass ones.

    The padded dash and doors look very nice, sadly I didn't realize that a CF spoiler was available... I'm working that one, I'm sure that Joe will work with us.

    The top is high quality and getting in and out was OK even with it up. The rear angle is awkward but the car's design pretty much dictates where it has to go. Storage in the trunk is a def plus.

    Since I'm using a bellmouth and almost straight down Cat and exhaust I can make a bigger, deeper trunk. The added a support just behind the IC to hold up the engine cover, I'll need to add one as I did on the hood. My hood is a bit farther forward and hinged. Using a 5 inch standoff from the 1 in square tube gives me about a full inch more clearance for wipers, hopefully I can get something under the hood with only the wiper arms visible at the park position

    P1120141.JPG P1120140.JPG
    Thanks for sharing your trip photos with us. Looking forward to the trunk details, but the hacked up hood for the wiper is awful! Actually, beyond awful!
    "In wine there is wisdom, in beer there is strength, in water there is bacteria."

    818 (Chassis #34) Delivered 9/25/2013, First start 3/2/2014, First drive 4/5/2014, Registered 8/28/2015, First Dyno 3/18/2016, First SCCA event 4/3/2016, First car show HIN Honolulu 4/23/2016

  13. #853
    Senior Member AZPete's Avatar
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    Projectrally, the U-Haul 6 x 12 trailer has a narrower tail gate. FFR can lower the kit into the trailer but then you won't be able to roll it out on a dolly or drag it out until you remove the body panels. Once the body panels are removed, the frame will fit through the rear gate. Don't ask how I know.
    818S/C : Chassis #25 with 06 WRX 2.5 turbo, ABS, cruise, PS, A/C, Apple CarPlay, rear camera, power windows & locks, leather & other complexities. Sold 10/19 with 5,800 miles.
    Mk3 Roadster #6228 4.6L, T45, IRS, PS, PB, ABS, Cruise, Koni's, 17" Halibrands, red w/ silver - 9K miles then sold @ Barrett-Jackson Jan 2011 (got back cash spent).

  14. #854
    Senior Member RM1SepEx's Avatar
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    MRI yesterday, PT for my shoulder today.... MRI shows active MS at 5th and 6th cervical, not good... same place that made me numb from the chest down in 1991. Working through the "issues" but very frustrating.

    PT on my shoulder not going well either, was told to stop working on the car, unknown if the MS is attributing to the shoulder inflamation

    GRRRRR

    Weather has been great, enjoying the convertibles and bikes, life is good
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  15. #855
    Senior Member wleehendrick's Avatar
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    Hi Dan, sorry to hear that. Best wishes for your recovery/management.

  16. #856
    Senior Member AZPete's Avatar
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    Damn, I hate to hear that news! Dan, I wish you speedy improvement.
    818S/C : Chassis #25 with 06 WRX 2.5 turbo, ABS, cruise, PS, A/C, Apple CarPlay, rear camera, power windows & locks, leather & other complexities. Sold 10/19 with 5,800 miles.
    Mk3 Roadster #6228 4.6L, T45, IRS, PS, PB, ABS, Cruise, Koni's, 17" Halibrands, red w/ silver - 9K miles then sold @ Barrett-Jackson Jan 2011 (got back cash spent).

  17. #857
    818 builder metalmaker12's Avatar
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    Godspeed my brother!
    818S frame #13 Jdm version 8 ej207

  18. #858
    Member projectrally's Avatar
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    Dan, that's terrible news. I'm truly sorry to hear it.

    Thanks for the offer to use your trailer. My father-in-law has a trailer I'm going to use. 14x6 open construction trailer. Heading down to pick up the kit morning. Should arrive at FFR tomorrow morning around 10AM. Can't wait.

  19. #859
    818 Junkie... bstuke's Avatar
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    Sorry to hear Dan, hang in there buddy..
    818R For Sale!
    818R Sale Thread
    PADI Master Scuba Diver Trainer, PADI TecRec Gas Blender Instructor, Operations Manager - DNS Diving, Grand Cayman

  20. #860
    Senior Member Frank818's Avatar
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    Sorry again Dan. Any ETA on fixing these issues or some "parts" are BOed?
    Frank
    818 chassis #181 powered by a '93 VW VR6 Turbo GT3582R
    Go-karted Aug 5, 2016 - Then May 19+21, 2017
    Tracked May 27/July 26, 2017
    Build time before being driveable on Sep 27, 2019: over 6000h
    Build Completed Winter 2021

  21. #861
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    Sorry to hear this Dan. Here's to a quick recovery.

  22. #862
    Member projectrally's Avatar
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    Carbon spoiler acquired! It's sitting in my office wrapped in foam and plastic.

  23. #863
    Senior Member RM1SepEx's Avatar
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    Adam, still planning on stopping by soon? Many B?O on your 818R?

    Edit: Adam swapped to an S! Thanks for getting my spoiler.

    Received my addl 45 for the IC plumbing today, should be able to finalize mockup soon.

    Can't do any drilling or nutserts by order of my Dr. and PT Did work on a small footwell mod today:

    P1120143.JPG

    This allows for a much cleaner finish of the sidewall with vinyl. I have to cut the fatmatted aluminum for speaker magnet clearance...
    Last edited by RM1SepEx; 08-29-2014 at 04:33 PM.
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  24. #864
    Senior Member RM1SepEx's Avatar
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    Been a while, shoulder range better, rotator cuff, worse... never ends!
    \
    Did get under car finally, removed/repaired rear transaxle cover leak, I had to use a stone to make sure the cover was flat, I had a couple high spots and a slow weeping leak

    Removed headers, mounts and oil pan, pickup windage tray

    replaced motor mounts and transaxle mout with Cusco units, replaced stock 05 oil pan with STI pan, pickup and windage tray. Installing heat shield headers to fuel tank today

    obtained new aluminum FFR shifter, found it was almost 3/8 too wide for the tunnel. Had a friend machine a circular spacer, narrow cable holder, narrow steel cable "washers" to fit

    P1120218.JPG P1120219.JPG P1120220.JPG P1120221.JPG

    P1120222.JPG P1120223.JPG P1120226.JPG P1120227.JPG P1120228.JPG
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  25. #865
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    Dan,

    I have a transaxle cover leak as well. I figured I just did a poor job at sealing it. I'll look into making sure it's all even. Let us know your impressions of the shifter once installed.

  26. #866
    Senior Member AZPete's Avatar
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    I'm glad you are back working on your 818 again. The studs are in the mail.
    Pete
    818S/C : Chassis #25 with 06 WRX 2.5 turbo, ABS, cruise, PS, A/C, Apple CarPlay, rear camera, power windows & locks, leather & other complexities. Sold 10/19 with 5,800 miles.
    Mk3 Roadster #6228 4.6L, T45, IRS, PS, PB, ABS, Cruise, Koni's, 17" Halibrands, red w/ silver - 9K miles then sold @ Barrett-Jackson Jan 2011 (got back cash spent).

  27. #867
    Senior Member RM1SepEx's Avatar
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    The shifter is much more positive feeling, it comes from Ktuned, just like Wayne's. I think that the plastic shifter felt spongy because the two cable holders at the front were too flimsy and they distorted a bit adding slop. This one is very nice looking but I'm still mounting it inside the tunnel. The knob is back ordered from FFR.

    I broke down and ordered insulated garage doors so I'll be able to do more work over the winter. I need to be able to drive to next year's open house...
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  28. #868
    Senior Member RM1SepEx's Avatar
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    Thanks for those studs Pete I'll try to put them to good use. See those brackets that you asked about right in front of my IC Pete?

    multi part heat shield work ongoing... not sure how much to leave open to the elements, much harder to do after engine install

    Mocked up the side mount IC and related tubing. I should have used the smaller 2 inch tubes vs. 2.5 inch, the clearances are tight. Won't know how it will work until I fire her up again. I might have to alter positioning slightly when I remount my body panels. I hope it goes much faster this time.

    P1120229.JPG P1120230.JPG P1120231.JPG P1120232.JPG

    I also did a bunch of wire relocation etc... I'll be able to mount the fuse box in the center tunnel. I plan on having it much higher than the FFR examples, so I can make a sort of easily removable tray over the fuse box for quick access. P1120233.JPG

    I'm playing with the shifter location as well so modifications to the FFR aluminum console are coming too...

    BTW the shifter knob will be here tomorrow, fastest BO delivery ever from FFR! !!
    Last edited by RM1SepEx; 10-23-2014 at 09:47 PM. Reason: Forgot about knob delivery
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  29. #869
    PLATNUM Supporting Member
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    Very nice work Dan!

  30. #870
    Senior Member Tamra's Avatar
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    Looking great! Glad you are feeling better

  31. #871
    Senior Member JAubin's Avatar
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    Nice work on the BPV adapter, very clean way to do it...the fuse panel location looks good too. I've been planning on doing a large removable panel somewhere on the console to access the fuse boxes, this sparks some good thought. Glad to see you back at it!

  32. #872
    Senior Member Frank818's Avatar
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    Dan, the picture makes the IC piping so damn close to the tower brace, that's probably part of the tight fighting you mentioned?

    I see your tunnel alu does not have a top section? You cut it? Sorry if I missed that pages ago.
    Frank
    818 chassis #181 powered by a '93 VW VR6 Turbo GT3582R
    Go-karted Aug 5, 2016 - Then May 19+21, 2017
    Tracked May 27/July 26, 2017
    Build time before being driveable on Sep 27, 2019: over 6000h
    Build Completed Winter 2021

  33. #873
    Senior Member RM1SepEx's Avatar
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    Frank, IC piping, yup clearance is tight, I expect clearance to increase when I re-attach the header and up pipe, turbo is floating right now. Using 2 inch tubing gives much better clearance, I may just order it and swap it out, the 2 vs 2.5 discussion is a big controversy... increased drag vs decreased volume and less lag. I don't think that it will matter much at say 500 cfm having 7 feet of 2.5 or 2 inch tubing isn't much air volume (7 ft of 2 inch tube is only 1.5 cubic feet of volume) 500cfm is 8.33 cubic ft per second so the lag due to pipe vulume at 500cfm is only .2 seconds or so, 2.5 pipe might get closer to .3 seconds of airflow at 500cfm

    I chopped off the top of the tunnel months ago, I plan on a higher tunnel all the way to the console. I think my shifter will be farther back than FFR's revised location. I'm thinking a cup holder insert over the fuse box... I'm also considering an alternate EBrake handle setup, I'd prefer it on the passenger side of the tunnel

    The final location will be a bit different too after I remount my body panels and adjust position to fit. I went to Cusco mounts to reduce movement and plan on adding the other brace if I can to further limit movement.

    I need Craig's CF air scoops for the side too
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  34. #874
    Mechie3's Avatar
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    Let me know when you need cup holders. I know a guy with access to a CNC and stuff like that. haha
    Zero Decibel Motorsports
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  35. #875
    Senior Member Frank818's Avatar
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    Dan, I have a 2.5" turbo outlet going down to 2.25" piping. I don't think it's optimal when you have a smaller piping than the outlet. The turbo needs to push harder per rev due to restriction and it might be more difficult to reach higher pressures. Would also increase temps somewhat. So far I have no facts, but I have spent years thinking about that in during my sleep. I cannot try 2.5" as my cooler is 2.25" anyway. Maybe 2.25" could be a good compromise for you?

    Who is using that passenger side ebrake so far?
    Frank
    818 chassis #181 powered by a '93 VW VR6 Turbo GT3582R
    Go-karted Aug 5, 2016 - Then May 19+21, 2017
    Tracked May 27/July 26, 2017
    Build time before being driveable on Sep 27, 2019: over 6000h
    Build Completed Winter 2021

  36. #876
    Senior Member RM1SepEx's Avatar
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    The std wrx has a 1.75 turbo outlet, my IC is 2.5 in and out. Many turbos in excess of 300 whp still use only 2 inch tubing. I think I'll end up with a minimum clearance of 1/2 with my 2.5 tubes, 2 inch would give me another 1/4. The throttle body is 2.75 inches. It's a tough trade off increased volume and lag vs increased resistance to flow with a smaller tube...
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  37. #877
    Senior Member RM1SepEx's Avatar
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    Question: Why does it always seem to be when you are finally going to mig something at 5 PM that you setup up the weld and pull the trigger to 1/2 inch of mig wire and an empty spool? Naturally the local hardware store closes at 5PM UGH

    I'll work on some other stuff tonight, I found that the nice nutsert tool's face is too far out for std mcmaster rivets so I had to grind it a bit or it strips out the threads vs controlled crush of the nutsert! Do I put the rear wheel well nutserts facing the interior of the car or towards the tire???
    \received the B/O shift knob, wrong thread, apparently for some reason Jim S had changed the shift shaft on my unit, new shaft already in hand and installed!! I found the new shifter to fall right where I like it if I mount it in the original FFR location, naturally that isn't where it needs to be to fit the new aluminum console. Looks like some more fabrication work is in order!
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  38. #878
    Senior Member RM1SepEx's Avatar
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    Busy Day! finally welded up 90% of my exhaust, not sure exactly how I'll finish up the exit through the body. screwed up, lost my balance, got a nasty burn on my hand from the hot weld... oops, at least my hands are numb and messed up, took about an hr before the pain level was at my normal level!

    P1120235.JPG P1120236.JPG P1120237.JPG

    P1120238.JPG P1120239.JPG

    You can see how the shifter looks when positioned in the original position defined by the FFR build manual. The new shifter is quite a bit lower and falls at hand nicely relative to the steering wheel.

    Another body tip: when the front edge is positioned 5/8 back from the front frame edge you can take a tape measure and hook the end in the square top tube behind the door opening and it is exactly 8 inches to the body's edge as shown. You can use this measurement to confirm that both sides are even

    A side note:

    Like Brooker, I visited FFR and discussed my "issues" with the kit personally with Dave. My attempts through email and PM's didn't work as Dave gets too many emails etc and they get "lost" If you have issues, call Dave directly, he will respond and work to make you happy.

    He agreed that my kit's body was not up to the quality of their kits and that I shouldn't be expected to repair the poorly filled edges and voids. He also agreed that my powder coat was defective. I also suggested improvements in the prep for the powder coat with an increase in price for the service, Dave's response was as Brooker indicated. I requested and was given a refund of my powder coat purchase price, I used that refund to purchase the new billet shifter.

    Unlike Brooker my kit is much farther into assembly. I was given the option of replacing the badly molded panels and we exchanged 8 pieces. FFR had new body panels molded to replace mine in white.

    I've started reassembly with the new panels. The hood and both side panels are quite a bit different from my original panels (serial # 17) and are far better quality. I'm pretty sure that the molds have been revised. They line up better and it's easier to get the gaps even.

    I am still planning on an initial build in white gel coat. I also feel that FFR could benefit from some quality program development. Even tho that is what I used to do for work as a manufacturing consultant, a job doing it for them isn't in my future!

    I could not agree more with Brooker's assessment, I'd consider buying from FFR again, but I also can't just accept that it's a kit and just deal with it and move on. I will indeed end up with a kick*** car when it is complete.
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

  39. #879
    Senior Member Frank818's Avatar
    Join Date
    Jun 2013
    Location
    QC, Canada
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    I'm happy you found a solution to your body panels endless work!
    Frank
    818 chassis #181 powered by a '93 VW VR6 Turbo GT3582R
    Go-karted Aug 5, 2016 - Then May 19+21, 2017
    Tracked May 27/July 26, 2017
    Build time before being driveable on Sep 27, 2019: over 6000h
    Build Completed Winter 2021

  40. #880
    Senior Member RM1SepEx's Avatar
    Join Date
    Jul 2011
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    Freeport, ME
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    Question for those with mounted bodies...

    I'm installing my new panels, I found that I'm having difficulty with my new driver's side panel. On my original panels when I placed the lower front edge 5/8 back from the edge of the aluminum/tube I measured exactly 8 inches from the inside edge of the square tube high behind the seats as shown here

    P1120235.JPG

    now on my driver's side panel if I place it 5/8 back it is only 7 7/8 to that edge and I can't fit the heavy door latch bracket in place, it can't rotate with the slots provided and seat to the rear of the fiberglass.

    I feel that it is far more important to get the rear area and doors square than the lower edge. My original panels were 5/8 back in the lower edge and 8 inches at the rear on both sides...

    I've also found that the new driver's panel doesn't seem to have the gas cap assembly seat as low in the body, the top edge seats above the body line... I think that I remember the original being a bit lower. It also didn't have the clearly defined divot in the center to locate where to drill the hole for the cap.

    thoughts?
    Last edited by RM1SepEx; 11-29-2014 at 03:38 PM. Reason: spelling
    Dan

    818S #17 Picked up 8/1/13 First start 11/1/13 Go Kart 3/28/14

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