Metalmaker's build thread begins

[JeromeS13]

Attachment 20730

I wonder if we could mount the radiator BELOW/FORWARD of that support, instead of on top of it? (Just lean it at more of an angle)...

[metalmaker12]

I lined the underside of the tank with 1/16 flat roofing rubber and siliconed it down, also I placed insulation tape on the back firewall frame sections that meet the tank. I did this for sound deadening

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[Mechie3]

How far away are the headers from the gas tank? My headers are still off being coated.

[metalmaker12]

I will measure exactly later but I would say 6-8 inches as a guess

[Mechie3]

Just wondering if a behind the gas tank firewall with a reflective coated would be beneficial or not.

[metalmaker12]

I am thinking a piece of alumium riveted to the frame in front of the engine to the frame with reflective material on it would work well, I got a couple ideas.

[Frank818]

The best (or almost) material to reflect heat is gold, do like the inner panels of the 92-98 McLaren F1. lolll
http://commons.wikimedia.org/wiki/Fi..._F1_engine.jpg

[shim2]

The best (or almost) material to reflect heat is gold, do like the inner panels of the 92-98 McLaren F1. lolll
http://commons.wikimedia.org/wiki/Fi..._F1_engine.jpg

That would be ungodly expensive and completely unnecessary, but it would look nice.

[metalmaker12]

They have that stick on reflective material that's cheap and very effective, which I will be using in various locations.

http://m.ebay.com/search?kw=Gold+hea...Gold+heat+wrap

[metalmaker12]

So I have had some issues during my beta build, but my friends at FFR have helped me out and made the proper revisions along the way, I am going to develop a punch list of the problems and solutions in my next few post. Questions comments welcome.

[flynntuna]

That's a very good idea. A place in the WIKI section of the forum would be extremely helpful to future builders (meaning me) for those problems that make you just sit and stare at for hours with a glazed look scratching your head

[Wayne Presley]

Just wondering if a behind the gas tank firewall with a reflective coated would be beneficial or not.

I put one in my car

[metalmaker12]

FFR has been great working with me, Wayne, Erik, Craig, Dan, Nick and others on sorting out problems and coming up with fast solutions. All the future 818's will be that much better due to all our hard work. Here are some issues and revisions, anyone else can jump in and add a few.

Problem: The lower control arm bushing needed to be mounted under the outside frame point and on top of the inside frame point. There is a little bit of gusset in the way and you have to trim to fit along with enlarging the mount holes a couple sizes.
Revision: All FFR 818 frames going forward will not have this issue

Problem: The filler neck tube is the wrong bend for the top fill provision on the body. Is the old location like the 818 R photo-113.JPG
Revision: A new filler tube has been created by FFR, it just did not get updated in time for the first few kits, but all the beta kits forward will be corrected, will post pics when I receive the new setup

Problem: The wrong axles were sent out to a good chunk of us betas, due to a miscue.
Revision: The correct axles have been ordered by FFR and we will get all new sets

Problem : The left engine mount may be to close to certain headers, and we have to trim the mount by 1/4 inch on its forward facing side.
Revision: The FFR 818 frames going forward will no longer have this issue.

Problem: The kit comes with two right upper control arms
Revision: you have to trim down the welded side on one arm by 1.100' to make it a usable left arm.

Heres some pics of my brake line work
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[07FIREBLADE]

Question for you metal. Are all the brake lines supplied and bent by builder or do we use any portion of the stock lines. Trying to figure out if I meed to keep pieces or not from the donor...

[metalmaker12]

Supplied and we must bend all lines and flare 3-4 ends

[Wayne Presley]

You have to bend your lines, you do not have to flare them. I'm sure MM flared his to have the lines an exact length instead of a loop in the line.

[metalmaker12]

True, you could loop them if you want, but I found it easier to cut cut and fit certain ones. Plus they sent me a lack of shorter line sizes so I had to get resourceful, since I set out to install lines. I also may replace the lines with nickel copper or stainless ones down the road, but I have a solid pedal and they are working nicely now, so there staying as is for some time.

[Bkafe]

Axles are next for me...

How do we tell if we got the wrong axles?
Any idea if Factory Five is being proactive, or do we have to figure it out and call for new axles?

Thx,
B

[Wayne Presley]

do they have the same spline size on both ends? if so you have the right axles.

[metalmaker12]

If you have aftermarket cv's it changes what your asking. Oem and aftermarket inner cv's fronts have a different female spline design. Oem is fine and aftermarket is coarse. So if you have oem axles you want fine/fine spline axles and if you have aftermarket you want fine/ coarse splines to your axles. FFR will send you the correct ones if you have the wrong axles, just let them know. I am thinking at some point they will be sending only oem style axle shafts, but maybe they will offer both, I will ask about this .

[FFR-ADV]

Thanks Metalmaker, Wayne, Erik, Mechie & Timmy318 for blazing a path for us.

My build is getting close! I am scheduled to pick up my 818 less than a month from now. Hopefully most of your catches will be fixed by then (thanks to your efforts).

Cheers!

[Bkafe]

image.jpg

Looks coarse/fine

[metalmaker12]

image.jpg

Looks coarse/fine

from the looks of it they might be the ones that only fit aftermarket cv's, try them, if no luck you need the other ones, whats your part number?

[metalmaker12]

From time to time you might get a part that is bent wrong or wrong in some way. FFR will send you a new one, or you can be resourceful. This tranny bracket had a tab bent the wrong way, I cut and welded it in the correct position.

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I decided to cut my axle ends down, came out better than I thought with a crude angle iron saw.

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Also, everone, I am working with Nick (stickshift84) On some different seat mounting and the steel arm spindle to shock clearance, we will post results.

[GUNS]

Good job man, wish I had your welding skills.

[Erik W. Treves]

I have an extra one

[FFR-ADV]

Nice looking welds!

I expect I might run into the spline issue with a probably typical twist. I replaced my donors CV on the passenger side when I first purchased it last September with a aftermarket one from NAPA. What is not clear to me is how an aftermarket shaft with a different spline pitch could work at all?

The only other fix on my donor was to replace the O2 sensor (got a Bosch one).

Cheers!

[metalmaker12]

Nice looking welds!

I expect I might run into the spline issue with a probably typical twist. I replaced my donors CV on the passenger side when I first purchased it last September with a aftermarket one from NAPA. What is not clear to me is how an aftermarket shaft with a different spline pitch could work at all?

The only other fix on my donor was to replace the O2 sensor (got a Bosch one).

Cheers!

FFR did not know they had aftermarket axles/cv's and went forward to create axles for the kit from after market splins.
That weld was with a short arc mig, nothing crazy, thank you though, I was really just showing that it was a minor fix .Soon you will see some nice looking tig welds from some fabricated brackets.

[RM1SepEx]

Chris, PM me I'm interested in a modified Factory Five 818 exhaust adaptor... I want to bell mouth the adaptor... Any interest in some side work?

[metalmaker12]

pm sent Dan, I have some ideas also to chat about, send my your number again, lost in old pm's, call you lata

[metalmaker12]

Here is some progress on pedals, shifter/cables and e brake etc. I got my brake lines ran and I have a clutch and brake pedal right at the top and ready to drive. I also have my 02 gas pedal in a great location with some modification. I am finishing up my harness re-working and I am about to start installing
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[FFR-ADV]

I look forward to seeing your custom exhaust mounted up in your 818.

Nice work!

[metalmaker12]

I am going to start a re- worked version and see how it looks with the rear section mounted possibly this weekend

[metalmaker12]

A little carbon wrap goes a long way, I am very happy with the results of the wrap I purchased.I also put some skate board gripper on the dead pedals.

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[Xusia]

I like it!

[Frank818]

Nice wrap!
Is that the one from the guy here on the forum? Damn I lost the website and the guy's name... I'll find the thread.

Got it. Kalstar and http://www.ultimatepremiumplus.com/

[C.Plavan]

I like it. looks really good. I may just cover my raw aluminum with that.

I would love to see the modifications to your gas pedal. Looks way better closer like that, and more functional for Heel/toe.

[metalmaker12]

I like it. looks really good. I may just cover my raw aluminum with that.

I would love to see the modifications to your gas pedal. Looks way better closer like that, and more functional for Heel/toe.

All I did was cut the pedal shaft down one 1" and re- welded it together. Remember to remove plastic pedal!!!! I also added some small rivets in the top of the oem- FFR mount to make more ridged. The wrap came out good, it it an art form though and takes practice. My mod for pedal is only for the 02-05 dbc

[metros]

Looking really good. Quality of the wrap looks great and the pedals look perfect with that minor modification.

[C.Plavan]

All I did was cut the pedal shaft down one 1" and re- welded it together. Remember to remove plastic pedal!!!! I also added some small rivets in the top of the oem- FFR mount to make more ridged. The wrap came out good, it it an art form though and takes practice. My mod for pedal is only for the 02-05 dbc

Thanks for that info. My pedal is from a 2007 wrx- So what your saying is, I might not need to modify?