Plavan's 818R Build Thread

[C.Plavan]

***I got an email from Dan- My production date moved back October 5th.....***

Someone's 818R just got "hot listed" baby! I'm glad I sent in that email when they asked for volunteers. My production date is now Aug 17th 2013.

My 818R is a "Non Donor" build. I'm just piecing it together. I have probably 80% of what I need already.
This car will be campaigned in NASA racing series on the West Coast in the ST? class. It will eventual make it to the WERC endurance series in the ES class.

Chassis
Powder coated
Carbon Fiber Rear Race Spoiler
Carbon Fiber Rear Race Diffuser
Carbon Fiber Race Splitter
*Special request for the additional crossbar like in the Test 818R. ** I don't need no stinking passengers- Its a race car. I'll scare them in their own car at the track if I need to. Update: They would not do it
I may add it myself.

Motor:
AJW Special 2.5L
2013 STI Shortblock
Balanced/Printed
JE Forged Pistons
STI Nitrated Crank
OEM Bearings
ARP Headbolts
Gates Timing Belt Kit
STI Heads (Single AUCS)
Port/Polish
Upgraded 272 Cams
OEM Head gaskets
Killer B Motorsports (Baffle, pick up, Oil pan)
Torque Solutions Air Pump Delete
Cobb V3 Accessport
Cobb SF Short Ram intake
Killer B Holy Header and Up pipe
Stock TD04 for now... (Looking for upgrade suggestions -TD05?)

Trans:
2005 Legacy GT (4.11 FD) X2
Guard Transmission TBD
Clutch Masters FX400 6 Puck with Aluminum Flywheel

Brakes:
Wilwood 12"ers all the way around. Red/Slotted only
Raybestos ST-43 race pads

Wheels:
2 sets of Racing Dynamics 17x8 and 17x9 et40

Extras:
Racetech Halo seat with aluminum mounts.
Fuel Safe Cell (15 or 18 gallon) with external quickfill/dumpcan setup
Airjacks (wish list)


Just cleaning parts/ wire brushing, then painting.



Putting the Kid to work


Clean parts are fast parts- I have been putting the elbow grease into them.

[C.Plavan]

Reserved.........

[longislandwrx]

It's cool that you requested the crossbar to be added back. I'm not there yet and still need instructors. Although, it will be an easy addition down the road. Had I been smart, I would have sent FFR the disconnect couplers and just paid the labor to have them weld before it was sent to powder coating.

Looking forward to another nice R build, seems like we have a lot of the same ideas.

[D Clary]

Glad to see another r car. I have a donor car but it seems like I'm using less and less from it. I am a ways from my kit. my date is 9/14 so I have a long time to learn from everyone and clean parts. I am starting with the stock 2.0 until I get it sorted out, then we'll see. I do mostly auto X and track days. When you get yours running let me know if you ever head to thunderhill for testing. would like to see it.

[C.Plavan]

Just got an email from Dan about some of my requests/questions. They will not be adding the cross bar to any cars.....kinda sucks. I would hate to mess up the powder coat.

I have 90% of all the parts ready to go, new Subaru hardware, I'll take some pictures of the parts later today and add them to the reserved posts above. The Legacy GT trans is having the TBD installed right now, and I'm just waiting for them to ship my completed race motor from AJW.

[longislandwrx]

That stinks, I did see someone mod a powder coated cage once, obviously ground off the powder, did the welds, and then recoated by building an insulated box around the joint and a heat gun. you couldn't tell. Not sure about longevity but it was pretty cool.

[C.Plavan]

I guess there is always rollbar padding.... haha

[C.Plavan]

It's coming!

[Mechie3]

The moment it first shows up is a bit surreal (at least for me). It's a bit of "this is awesome" and "whoa....it's really here!"

[RM1SepEx]

mod the powder coated chassis, buy a powder kit from eastwood, buy an IR light and you can touch up areas as you wish

[68GT500MAN]

Chad, what is the expected arrival date?
Doug

[wleehendrick]

The moment it first shows up is a bit surreal (at least for me). It's a bit of "this is awesome" and "whoa....it's really here!"

combined with a bit of "what have I gotten myself into"?

[C.Plavan]

Chad, what is the expected arrival date?
Doug

Not sure quite yet. Stewart will pick it up on the 5th I believe.

1. Race motor is waiting in the garage.
2. 5 Speed Legacy GT trans with TSB installed should be finished tomorrow.
3. Tons of NEW suspension parts are waiting to be used
4. I still need to move out the 1972 911 Restoration to my Dad's garage to make room for the 818R.

[D2W]

Is the blue one a real ST? Either way sweet ride.

[C.Plavan]

Is the blue one a real ST? Either way sweet ride.

Thanks- I wish it was real! I would not be racing it if it was $$$$$$$$$$$ . It has a lot of the ST parts, but the chassis is a 69 911E. The rear flares were hand made (English Wheel) using ST flares as a template. One notable fact is that Patrick Long (Porsche Factory Driver) has raced it with me a few times in enduros. I'll be racing it at COTA (Austin, Tx) later this month at the SVRA National Championships. I cant wait to drive that Formula 1 track.

[C.Plavan]

I got the call last night from Stewart. I will have it before noon on Sunday!

[longislandwrx]

very nice!

[68GT500MAN]

Are you going to have an unloading party?
Doug

[C.Plavan]

Are you going to have an unloading party?
Doug

Haha- No. Just got another call....now Monday

[metros]

I'll be interested to see how that header fits in the 818. I was looking at the same one. Looks like a really high quality piece.

[C.Plavan]

Longisland (Jeff) and I have been working on solutions for the 818R spacers (FF5 says to use stacks of washers which I'm not a fan of) This is what I came up with for the LCA (Aluminum).


Outer


Inner

[C.Plavan]

I have been "Nesting" in the garage. I moved the project 911 to my Dads house. Cleaned everything up, and moved the motor to the engine stand. Tomorrow is the big day.

I removed all the stock header junk and installed the new Group N motor mounts. I'm not sure if I'm going to stick with that stock TD04.... I have never been a Subaru guy before, but I have seen bigger snails in the garden.

[longislandwrx]

baby-boy-and-stork-congratulations-front_4.jpg

[C.Plavan]

baby-boy-and-stork-congratulations-front_4.jpg

Hahahahahaha. Good one. T Minus 3 hours.

[C.Plavan]

It's landed. So cool.

I'm going through Box Hell. So far they sent me the wrong shocks (yellow). It came with a Kirkey seat???? I thought it didn't. I'll just sell it if someone wants it.

[longislandwrx]

YES! I declined my seat and received a $395 credit. My red shocks just shipped out today.

And don't socks on the jack stands work great?

[RazzBarlow7]

Good times! Congratulations.

[C.Plavan]

YES! I declined my seat and received a $395 credit. My red shocks just shipped out today.

And don't socks on the jack stands work great?

The driver told me about the socks on the jackstands...... I have never thought of that, great idea! I had four crappy thick green socks to get rid of.

My backorder list:
L/R door liner
Assembly manual
Upper Ball Joints
Front #300 springs
Headlight set?
Brake line 8"
818 Carbon Fiber rear diffuser
818 Carbon Fiber race splitter
Large Road Race Spoiler (dropship)
R shorty windshield.

My Racetech halo seat fits. I'll have to mess around with the mounts, but it is doable. I was worried the halo would be too close to the diagonal bar. It fits perfect, but those darn angled bars near the floor are really going to restrict any movement.




I also ordered a few sets of those CAD spacers I made up. I should have them in a couple of weeks. I'll verify fit and share them with any fellow 818R Pioneers. I'll design the upper mount/spacer when I get some time.

[wleehendrick]

Looks great!

The driver told me about the socks on the jackstands...... I have never thought of that, great idea! I had four crappy thick green socks to get rid of.

Awesome tip... we just moved and my wife was *****ing at me for holding on to some thick old wool socks, instead of donating them. Now I'll rub it in her face for finding a use for them!

[longislandwrx]

The halo on that seat looks perfect. The fronts should be 500lb, so when you call about your red shocks mention that to them. Your rears are probably wrong too, (should be 300lbs)

I think the spacers you ordered will be fine, I posted an image on my build thread.

[RM1SepEx]

Those angled bars do suck, don't they? The seat just fits with almost no adjustment range

[C.Plavan]

Those angled bars do suck, don't they? The seat just fits with almost no adjustment range

Yes they do- I may be cutting out the drivers side and welding in a new brace that does not get in the way. I wont know until I get the pedals/steering wheel in.

[C.Plavan]

The halo on that seat looks perfect. The fronts should be 500lb, so when you call about your red shocks mention that to them. Your rears are probably wrong too, (should be 300lbs)

I think the spacers you ordered will be fine, I posted an image on my build thread.

You are right- I was just typing too fast to get back in the garage. I have the 500lb fronts- waiting for the 300lb rear springs.

[wallace18]

Yes they do- I may be cutting out the drivers side and welding in a new brace that does not get in the way. I wont know until I get the pedals/steering wheel in.

When I was picking up my 818S in August one of the FFR guys ( no name to be mentioned) told me it was OK to get rid of those bars in front of the seat. I made the comment that it impeded much forward and aft movement. So take this as you want. I don't need them removed for me but, I may for a customer car if needed.

[fateo66]

Just out of curiosity, why go threw all the headache of designing and paying for the spacers as opposed to getting new transverse links to give you the offset you need? If you didn't want to pay for aftermarket ones the stock Forester links have the correct geometry.

[longislandwrx]

Does that really give you an additional 7/8" of height?


I thought the forester ones gave you like 7/16s tops.

[taco20]

It's landed. So cool.

I'm going through Box Hell. So far they sent me the wrong shocks (yellow). It came with a Kirkey seat???? I thought it didn't. I'll just sell it if someone wants it.

Hey I would be interested in the seat. What size seat is it? What are you looking to get for it?

[C.Plavan]

Just out of curiosity, why go threw all the headache of designing and paying for the spacers as opposed to getting new transverse links to give you the offset you need? If you didn't want to pay for aftermarket ones the stock Forester links have the correct geometry.

It's not the correct geometry for "R" height. If you raise the LCA's ~1", you need to raise everything ~1"- The UCA need to go up above the mounts now too. So those mounts you have pictured in no way will work for the "R" suspension height. That's why we have to make pieces/spacers out of Aluminum. Plus those are ~$325

[fateo66]

In this picture the I have my LCA in the "R" holes because of the better roll center. I have a handfull of different transverse links and tried every combo possible including mounting the links on top of the chassis mounts and in the end this setup worked the best. Which is why I took the picture without the rear stud bolted in, to show that they were aligned.

One thing to consider is suspension bind, I see all the time people talking about ways to increase caster but don't take into account how it puts pressure on the front bushing. I'm not sure how much the Forrester/ ALK/ PSRS kits offset from the factory WRX/STI but in order to say that the rear needs to be lifted 1" would imply that the front and rear are perfectly lined up and I'm not so confident that they are. FFR designed an built a incredible car but they did over look a few things and some times there calculations are not right IMO. The steering rack in not in the correct location, FFR says to cut 1.1" off the left upper arm but I calculated .222" off the right and .513" off the left in order to make the arm symmetrically adjustable. They use 3/8" sway bar endlinks in a 10m hole and the gas tank is a horrible design for any racing but in a straight line. I'm not complaining here I'm just saying some things need to be taken with a grain of salt and you might want to double check a few things.



The Perrin ones are $325 but stock Forrester links have the exact same offset and can be had for nearly free.

[C.Plavan]

In this picture the I have my LCA in the "R" holes because of the better roll center. I have a handfull of different transverse links and tried every combo possible including mounting the links on top of the chassis mounts and in the end this setup worked the best. Which is why I took the picture without the rear stud bolted in, to show that they were aligned.

One thing to consider is suspension bind, I see all the time people talking about ways to increase caster but don't take into account how it puts pressure on the front bushing. I'm not sure how much the Forrester/ ALK/ PSRS kits offset from the factory WRX/STI but in order to say that the rear needs to be lifted 1" would imply that the front and rear are perfectly lined up and I'm not so confident that they are. FFR designed an built a incredible car but they did over look a few things and some times there calculations are not right IMO. The steering rack in not in the correct location, FFR says to cut 1.1" off the left upper arm but I calculated .222" off the right and .513" off the left in order to make the arm symmetrically adjustable. They use 3/8" sway bar endlinks in a 10m hole and the gas tank is a horrible design for any racing but in a straight line. I'm not complaining here I'm just saying some things need to be taken with a grain of salt and you might want to double check a few things.



The Perrin ones are $325 but stock Forrester links have the exact same offset and can be had for nearly free.

I hear ya. They must be doing something right with the lap times the 818R is posting back East. I agree, it may not be perfect, but we are all learning about this great car.