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View Poll Results: Startup with new ID1050x or previous EV14s?

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Thread: Frank818 -1993 VW VR6 Turbo donor- Build Thread

  1. #1601
    Senior Member mikeb75's Avatar
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    Score & congrats. Another milestone down, and what a story your build has! Getting towards Iliad epicness.
    818SC chassis #206 EJ207 2.0L VF37 twin scroll || Cusco type RS 1.5 LSD || Wilwood pedal box (firewall attach) || Wilwood superlite front calipers
    BUILD Phase 1: 6/6/2014 car delivered || 5/24/2015 first start || 6/7/2015 go karted || 4/20/2016 hard-top-topped || 10/25/2016 registered || 11/18/2016 inspected & complete
    BUILD Phase 2: 3/8/2017 EJ207v8 || 5/29/2017 re-first re-start || 7/17/2017 re-assembled with race car bits

  2. #1602
    BN's Avatar
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    Congrats for that first step. 👍

  3. #1603
    Moonlight Performance
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    Wow congrats Frank. You are very persistent! Glad you passed yet another hurdle.

  4. #1604

    Yes, I love Technology
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    You gonna frame those stickers and put them on the garage wall later? Congrats - maybe the biggest hurdle is cleared. Glad for you man.

  5. #1605
    Senior Member Frank818's Avatar
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    Good idea I will keep the stickers somewhere, I almost killed myself to get them I can't trash them out!


    Drove the car again in the parking lot today. Definitely since my dyno session the engine is extremely prime!! Super quick on the revs and I know how to tune it that way now.

    However the click-click-click that I used to get all the time when I launch around the rear right wheel has increased frequency. Now it clicks at every wheel turn for about 20 to 40 yards. The clicks increase in frequency the more the wheel turns, so it definitely is related to something that turns connected to the wheel.
    I think my shaft is not long enough on that side, it's really stretched out to almost the max if not the max, and with the evil angle I have there I believe it doesn't turn properly inside the CV. But after those 20-40 yards it stops clicking. That sound really worries me as I cannot find the root cause and I have tried many tests and fixes. Does that since my 1st run ever in summer 2016 and I have removed and re-installed the shaft since.

    I need to show that to my mech before we start working on the engine, I don't want to look into it next spring and then wait 1-2months before I get a replacement part.


    Oh yeah, there is A LOT of dust accumulating everywhere where it's not supposed to. A coat of dust on my gearbox and coats between the door and side sail. Also a lot of rocks inside the front end, over the battery, on the windshield surround, etc. I did not go over 20mph and my straight lines weren't more than 100-150 yards. I can't imagine how bad it is on the roads.
    Do not drive this car on a dusty road! Find a way to block off the air from flowing under the door skin, over the side sail.
    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

  6. #1606
    Harley818's Avatar
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    Hey Frank, good news. Another step towards completion. Congrats and keep with it.....
    Harley
    Bought 2002 Donor Jan 2014
    First Start Jan 18, 2015
    First Drive Feb 14, 2015

  7. #1607
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    Does the clicking stop after 20-40 yards because you accelerate? Or does it go away even if you maintain constant speed?

    I highly doubt this is your issue, but I once had a horrible click develop at full lock on left turns after swapping to my snow tires years ago. Never could pin-point the issue and I drove around all winter with a charged cell phone, warm blanket, and the expectation my wheel was going to make an unexpected stage-right exit at any time. By the time summer came around and I was changing my oil I discovered that the block-ier tread was grabbing an un-trimmed zip-tie and flicking it around.

    And yes, unfortunately the nature of these cars (at least the S model) is that it is a giant vacuum for road debris and dust. Installing all the wheel well aluminum significantly cut down on the gravel ingestion for me, but even after 2 years and over 1000 miles, it still accumulates heavily in the engine bay. And hopefully road dust doesn't ruin your interior - I have to wipe down my dash with nearly every fill-up.

  8. #1608
    Senior Member Frank818's Avatar
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    Quote Originally Posted by phil1734 View Post
    Does the clicking stop after 20-40 yards because you accelerate? Or does it go away even if you maintain constant speed?
    It stops whether I accel or maintain constant speed.
    Does not always stop at the same time, sometimes it's just 2-3secs after a launch, sometimes it's up to 4-5sec (20-40yards). But that's the thing, it stops. If it were the CVs I don't understand how it could stop. I wish I could record a video of this but the engine sound will certainly cover the click sound over the mic. I'll try though.

    Definitely not a zip-tie or something like that, I wish though! lolll I checked my spindles and they have no marks of the boot or boot clamp and the clicking sound is not a scratching sound, it's a clear crisp, sharp and ultra short click. Like when you hit a stick on something, not like when you use the stick to make a scratch on something.

    It's not the axle angle either, cuz on the left side the angle is worse and the sound is on the right side. The only difference is the right side has reach almost full extension on the CVs, whereas the left side still got good play. That's why I lean towards that.


    My interior got dirty after each track session without the body on. I expect a little less dirt now but the suede is pretty good quality, I've tested it. But yeah will require very very frequent vacuum sessions, both inside the cockpit and inside the front/rear bays. And door sills... So very unusual for me to clean those places at such a frequent frequency (probably once per drive!).
    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

  9. #1609
    Senior Member flynntuna's Avatar
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    I wonder if it could be a heims joint Rod end that's going bad?

  10. #1610
    Senior Member Frank818's Avatar
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    I didn't think at all about those. But now that I do, the sound is not suspension related, it's wheel rotation related. There are no rod ends moving at every wheel rotation.

    When I move the car by hand, I don't hear the sound. Or maybe I did hear one click but it's so tame and so rare it does when moving by hand that I can say there is no sound when I push the car. It sort of needs torque, which brings me down again to the torque being pushed through the left axle/CVs.

    The sound of ball bearings hitting each other or snapping in and out their spider "bowl"...
    Last edited by Frank818; 09-24-2017 at 06:58 PM.
    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

  11. #1611
    Senior Member flynntuna's Avatar
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    Here's another look....
    Attached Images Attached Images

  12. #1612
    Senior Member Frank818's Avatar
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    Not possible. Every angle but the front (probably) looks really similar.
    Now, which of the 2 have I built again?
    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

  13. #1613
    Senior Member Frank818's Avatar
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    Actually it's so amazing I'll print those pix and stick them on my garage wall. Hopefully the image quality is sufficient for a letter size paper.
    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

  14. #1614
    Senior Member Frank818's Avatar
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    That car is so fast OFF boost, I wonder how it is under boost...

    In the meantime I was able to take a video of my clicking noise. We can actually hear it a lot better than I thought. Don't mind the video focus that's not the point.

    What are your guesses?

    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

  15. #1615
    Senior Member Frank818's Avatar
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    Inspection time!

    OMG, crap! I just got a call from the inspection shop, ONE week after sending my request to get a VIN! It took just ONE week! That was quick!!! Well after months of all the other steps done prior to this last one...

    My rdv is on Tuesday the 10th at 9ham, IF no rain.


    As it is now, the car will NOT pass inspection, I have a coolant leak on the rad cap (it just started last week!) that I am unable to fix unless I flush coolant and replace the cap. The cap sits a few inches lower than the engine's head and VW expansion tank, so it will pour if I don't flush. I cannot lift the front end, the more I lift, the more the top of the rad goes higher than the cap, cuz the cap is on the tubing and not on the rad.

    Besides I need to buy a 33psi cap to make sure it won't open at 21psi like it does now, which is the same psi (21) as the VW cap. Quickest I've found is buy from Summit on a quick delivery method and hope I bought the right cap style. But still need to flush coolant. Thank god Monday the 9th is a day off in Canada, but still! And it's supposed to rain for 2-3 days this w-e, making testing the car impossible. We've had 1-2 days of rain since Sept 9th and now it may change, oh well.

    I'll try to think what to do about it today.
    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

  16. #1616
    Senior Member Frank818's Avatar
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    Good timing longisland, although I think you just deleted your post.

    I don't think inspection will run it for more than 5mins, I'd be SO surprised if they reach 15. The guy who passed with his 818 this year they didn't even start it.

    I applied sealant around half of the cap and it worked. I let the engine warm up until thermostat was open for quite some time. In the short term it should work. I'll apply more sealant to make sure. This winter I get rid of the overflow and replace it with a straight tube, using only my VW expansion tank.

    The thermostat can't be shut, it's mechanically activated, not sure I can do anything on the tubing as well, but I'll see if I can find a second solution as a failsafe.
    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

  17. #1617
    Senior Member AZPete's Avatar
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    I will keep my fingers crossed until the 10th and I think there are lots of other guys here doing the same.

    Yeah, that's it, I can't fix the front door with crossed fingers, Honey. I can only work in the garage.
    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).

  18. #1618
    Senior Member Frank818's Avatar
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    The myths of exhaust back pressure on both NA and Turbo engines revealed.

    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

  19. #1619
    Senior Member Frank818's Avatar
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    Ever wondered at what speed your aero will work?
    Ever wondered if you should add aero and how aggressive?
    The guy, a serious brain, does use the WRX as an example.

    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

  20. #1620
    Senior Member Frank818's Avatar
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    Flat floor or not?

    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. #1621
    Senior Member Frank818's Avatar
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    Now get the idea of how splitters and diffusers 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

  22. #1622
    Senior Member Frank818's Avatar
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    And then, a question that's been asked on the forum:




    The answer is no, but with a flat floor it's a lot more effective.
    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

  23. #1623
    Senior Member Frank818's Avatar
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    What about strakes in your diffuser? Should you install them?

    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

  24. #1624
    Senior Member Frank818's Avatar
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    Jeff, I've got a video on how to tune sway bars, if you ever want to watch it.
    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

  25. #1625
    Moonlight Performance
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    Hey Frank, I appreciate the offer. I think that I have a pretty firm grasp on sway bar tuning, but I don't pretend to be a know-it-all so post it up and I'll have a look. I'm sure I'll learn something from it! Thank you!

  26. #1626
    Senior Member Frank818's Avatar
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    Not super scientific cuz it's only 6mins, but maybe you'll learn one thing, probably not more.

    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

  27. #1627
    Senior Member Frank818's Avatar
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    I know a lot has been said here about bump steer on the 818 and that Jeff is a super hero on that, he won't learn a thing in this video as well but this is just to show you how very very complex that thing is and that it's virtually impossible to fully eliminate.

    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

  28. #1628
    Senior Member Frank818's Avatar
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    Mechanical Inspection time!

    This morning was my LAST inspection on the list of registration steps in QC.


    This little guy came out of his hideout to say hello, just before the truck would crush him.

    2017-10-10 07.56.04.jpg2017-10-10 08.03.04.jpg2017-10-10 08.25.17.jpg


    This is at inspection:


    2017-10-10 09.52.19.jpg

    The guy even checked if the seatbelts buckled up properly. Both of em.




    With the lady at the front desk we flipped over ALL my invoices and those that had importance to them they kept for photocopies. All the paper work from Transport Canada and import document from Customs (to prove I paid taxes), plus the document for the weight of the car and the police paper work.


    Some more docs were filled up during inspection, and I received a new doc for the VIN being applied on the car. Yes the VIN is on!


    I will receive another doc once the SAAQ engineer approves the inspection.


    And then I have to tow the car again to the inspection shop just to apply a STICKER on the windshield, proving I passed full mechanical inspection. Until then I cannot get my plate.

    The mechanic doing the inspection took many pix cuz the engineer asked him to. He sent them to the engineer. I don't know what he took exactly. Some of these may prevent the engineer from approving my car, I don't know.


    For the mechanical inspection itself, he said he found NOTHING incorrect on my car! Although there is still a very slight chance the engineer will not approve, it is one hell of a pride to know the way I built this car has been certified by an approved SAAQ mechanic.




    If I was able to do what I did on an 818 and pass inspection in QC, it means ANYONE can do ANYTHING on that car, anywhere else in the world. You guys can do it if you design properly and install parts meticulously.
    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

  29. #1629
    Senior Member AZPete's Avatar
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    ". . . pride to know the way I built this car has been certified by an approved SAAQ mechanic" - .
    Frank, that says a lot. You've cleared more hurdles than anyone else, for sure. Your pride is well deserved!
    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).

  30. #1630
    Senior Member Frank818's Avatar
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    Build completed

    THIS BUILD IS OVER!


    Post #1630 marks the end of the build phase of this project. Next posts will be optimisation, evolution and fixes phase.

    Yes, I just got confirmation my car has PASSED, as is, all the countless road blocks to get my plate. Nothing was flagged during that process, which is impossible in a way but it happened!

    I need to wait about 2 weeks before I can drive it, must receive paperwork by mail, then get my plate using that paperwork, then receive my car evaluation report which has started at the end of Sept and then call the insurance and drive!


    I would like to thank everyone, including those with whom I only exchanged once. You've been all SO helpful and without you this wouldn't have work.
    I
    made many friends (priceless) and learned so many things on this forum, it is a HUGE warehouse of info! I hope one day I could share my experience and knowledge better that what I could do for the past 4 years.


    Pete, yes now, now I really start to see all that I have accomplished! I am totally stunned...



    Some closing stats on this build:

    - Started the build phase on May 1st 2014
    - First go-kart on Aug 5th 2016
    - First time car is complete on Aug 5th 2017
    - Started the last 3 steps of registration/approval on Aug 9th
    - Completed last step on Oct FRIDAY THE 13TH 2017 (yes, I will never see Fridays the 13th the same way anymore!)
    - Total build time, including searching for solutions: 3283.5h
    - Total elapsed time: 3.5 years
    - Total work time: 148 weeks, average of 22.19h/work week time.
    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

  31. #1631
    Senior Member q4stix's Avatar
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    Congratulations!!
    I've been passively watching and it's great to see the result of all your hard work! Great job!
    Gen 3 Type 65 Coupe builder

  32. #1632
    Senior Member Bob_n_Cincy's Avatar
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    Congratulations Frank
    When did I tell you that you were at the half point?
    Bob
    818S #22 Candy Blue Frame, Front Gas Tank, 2.5L Turbo, Rear radiator, Shortened Transmission, Wookiee Compatible, Console mounted MR2 Shifter, Custom ECU panel, AWIC soon
    My Son Michael's Turbo ICE Build X22 http://thefactoryfiveforum.com/showt...rts-818S-Build
    My Electric Supercar Build X21 (on hold until winter) http://thefactoryfiveforum.com/showt...e-Build-Thread

  33. #1633
    Senior Member AZPete's Avatar
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    BIG CONGRATS, Frank!! I've also learned a lot from your journey.

    Bob, interesting point. Frank, I figured that your halfway point was January 2016, the 20th month. At that time you, were working on the clutch, axles, and listed 23 items to do before your first start. Interesting.

    Now, open some bubbly.
    Pete
    Last edited by AZPete; 10-13-2017 at 07:03 PM.
    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).

  34. #1634
    BN's Avatar
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    Félicitations now it's my turn ha!ha! Ha!

  35. #1635
    Senior Member Frank818's Avatar
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    Funny guys as always.

    Half way point in hours work time was somewhere around end of summer 2016, a little bit more than 1 year ago, which proves I did put A LOT of work time on the car in just 1 year. I wanted so bad to drive it this summer of 17.
    Half way point in elapsed time was probably spot on Pete's guess. Speaking of Pete, I told myself I'd watch Need For Speed again the day I'll get my approval. I just did, with lots of wine, what a great movie time to relax my brain. And watch that black GTM in the movie.
    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. #1636
    Senior Member Frank818's Avatar
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    Location
    QC, Canada
    Posts
    5,732
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    Quote Originally Posted by BN View Post
    Félicitations now it's my turn ha!ha! Ha!
    You better, we've got some shows or other events to attend!
    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

  37. #1637
    Senior Member flynntuna's Avatar
    Join Date
    Apr 2011
    Location
    San Diego Ca 92106
    Posts
    1,972
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    Tada A well deserved congrats, your story is the definition of persistence
    Attached Images Attached Images

  38. #1638
    Tazio Nuvolari wannabe Scargo's Avatar
    Join Date
    Nov 2013
    Location
    south-central CT
    Posts
    1,611
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    Almost a miracle, eh? Have fun driving it!

  39. #1639
    Moonlight Performance
    Hindsight's Avatar
    Join Date
    May 2014
    Location
    Atlanta
    Posts
    3,402
    Post Thanks / Like
    HUGE CONGRATS FRANK!!!! A job very well done. You were very persistent and were faced with more challenges than most any others (between the engine choice and the extremely challenging registration you went through), but you got it done in the end.

    Looking forward to seeing pics and videos of your car on the street and at some shows. Can't wait to hear that turbo VR6 sing!

  40. #1640
    Senior Member
    Join Date
    Jun 2013
    Location
    Bowling Green, KY
    Posts
    1,382
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    Congratulations Frank, nice work.

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