Jaime's Western New York Build

[Jaime]

Here's a close up of the bypass...

I replace the brake master cylinder nipple on the manifold with a much smaller nipple and used that for my bypass vacuum source.

Here's a close up of the 3 to 2.5 inch hump connect I used the connect to the throttle body...

[Jaime]

The mount is a simple bent piece of steel going to the piece on the transmission that holds the clutch return spring...


Here's a side view to show how far the whole thing sticks up. I have about 1/2 inch between the top of the intercooler and the hatch.

[Jaime]

Good info. At 2lbs per quart, the water only adds 12lbs. So between that and all the other added parts like plumbing and exchanger, Wayne's estimate of 30lbs or so seems spot on. Well worth it if it does the job.

Yup. The intercooler itself is surprisingly heavy, almost 20 pounds. Regardless of the weight, I wouldn't build an 818 without an AWIC. Good thing I saved a ton of weight in wiring, it should pretty much offset this.

[Jaime]

Got my first drive in this past weekend...

[metalmaker12]

Here's the tubes on the side...


And where they go up...

I deff would not mount the awic lines right on the coolant lines.

[Jaime]

I think I'm going to wrap them in pipe insulation. At least they're on the cold side.

[Jaime]

Started fitting the body. This is not going to be fun.

[Frank818]

Got any issues during your 1st drive?

[D Clary]

818 cooling 002.JPG I bought aluminum tubing from McMaster carr. welded a bead around the end to hold the hose on the tube

[Jaime]

Got any issues during your 1st drive?

Amazingly, the engine started the first time I turned the key and the first drive was uneventful. My alignment isn't good yet, but that's minor.

I did have to replace both axle seals after putting the engine in twice. I would recommend either putting the engine in with the hubs mostly unbolted and axles out of the way, then carefully slide the axles straight in. If you don't do that, make sure you have someone helping you who's only job is to guide the axle ends into the transmission.

[Jaime]

I bought aluminum tubing from McMaster carr. welded a bead around the end to hold the hose on the tube

That looks great. I have heat and an AWIC, so I have two extra lines on each side. There's a ton of room on the outboard side, but the tight space is the top and bottom at the front. I might bolt some upside down L brackets to the frame and hang the lines off that.

[Mechie3]

I'm a little late to the party. Your AWIC setup looks good. Same parts I'm using (core and HE). I like your fill port placement, simple and effective (I haven't gotten that far, but have the parts sitting around). One thing I'm going to do is tap the upper corner of the AWIC core with a fitting and route that to a third port on the fill that way it's self bleeding.

The body slowed me down quite a bit (not as much as a baby though, ha!). Read other's threads and see what they have done. One nice thing about getting slowed down is others passed me and I didn't have to figure everything out for myself. I'm using 10-32 rivnuts and bolts to hold most body parts on instead of riveting so it can be easily removed.

[RM1SepEx]

I use 10--24 rivnuts... Jaime, I think that I outlined a good simple process to mount the body and Wayne has published some great tips... I'm about to do mine again... I'm sure it will be faster than the original

[metalmaker12]

I think I'm going to wrap them in pipe insulation. At least they're on the cold side.

I am using intercooler wrap but I would separate them because between the coolant line and the hot side of the awic lines will also help heat soak. I will have my cart back together soon to display what I am doing.

It all looks nice and is coming together nicely

[Jaime]

I like your fill port placement, simple and effective (I haven't gotten that far, but have the parts sitting around). One thing I'm going to do is tap the upper corner of the AWIC core with a fitting and route that to a third port on the fill that way it's self bleeding.

Surprisingly, I didn't really need the fill port after the initial fill. Even though the radiator is under the AWIC, it doesn't spill out if I open the cap. Most of my bleeding was done by running it for a few seconds and topping off the radiator. After the second time around, the fill port stayed full but the radiator took quite a bit of coolant.

My core filled up pretty easily. I just dismounted it and sat it on top of the transmission with the water outlet port on top and ran the pump. I don't think I'm going to put a bleed valve on it.

[metros]

I love coming to this build. Very detail oriented and everything looks to be done with high quality. Congrats on go karting.

[Frank818]

10-24 rivnuts and 10-32 rivnuts. Those are smaller than the 1/4-20 provided by FFR?

[metalmaker12]

This is the wrap I am using on awic linesimage.jpgimage.jpg

[Mechie3]

Frank, yes they're smaller. About 2 bolt sizes down, though you almost never see size 12 bolts. American bolts go typically by sizes from 2,4,6,8,10 then go by fractions starting at 1/4. Went size ten to keep size and weight down. Plus there will be several in a row to bear a load vs just one or two 1/4 20s.

[Jaime]

Temporary Body Alignment Tool^©®TM

[Jaime]

Here's my main problem so far:



I kind of expected this, since this panel wore through the protective duct tape and the powder coat on the ride home right at this spot.

[Jaime]

I use 10--24 rivnuts... Jaime, I think that I outlined a good simple process to mount the body and Wayne has published some great tips... I'm about to do mine again... I'm sure it will be faster than the original

Been reading those thread for a while now. You guy certainly saved me from learning a lot of things the hard way.

I have a bunch of 10-32 rivnuts and button head screws. I'm also hoping I can make these work:

A lot of the bodywork on my Hayabusa was held on with these and I had that up to 190mph with no problems.

[Frank818]

This is the wrap I am using on awic linesimage.jpgimage.jpg

Nice stuff!! What is it called? Emotion Heat Insulator?
I like the fact it has small width.

A lot of the bodywork on my Hayabusa was held on with these and I had that up to 190mph with no problems.

And do you think they would support heavier panels? Or simply add more, maybe.

[Jaime]

And do you think they would support heavier panels?

Yes. If done right, those things will hold on until they break.

[Frank818]

When do you plan on testing these? Might actually be a viable option for me too. But I won't touch that until a few months.

[Jaime]

Trying to get the body lined up now. I have 25 of them here, so pretty soon.

[metalmaker12]

Nice stuff!! What is it called? Emotion Heat Insulator?
I like the fact it has small width.



And do you think they would support heavier panels? Or simply add more, maybe.

Here's the stuff, on ebay or siteimage.jpg

[Jaime]

I'm going a different direction on body mounting. I put all the pieces on, but none are fastened to the frame yet. I did put the bolts and rivnuts between the fenders and sides. The most important thing to me is how the pieces line up relative to each other. They'll get fastened to the car wherever they need to be to get the seams right.

Here's how they lay...

[Jaime]

[Frank818]

Wow, your body fits perfectly! How many hours you put on trimming, cutting and etc.?

Oh wait, I retract my statement, the headlights are not fitted yet, might change a lot of things, as they say. lolll

[Jaime]

That's where my strategy will pay off (I hope). Everything is where it should be right now. My headlights fit as badly as everyone else's. Next, I'm going to assemble the front end off the car and flip it over. Then, I'll trim the fender lips so the tops of the headlights match up nice and set the buckets wherever the bottoms of the headlights land.

[Hindsight]

Interesting approach. Body fitting seems to be like a rubiks cube..... Looking forward to seeing if your method makes it easier.

[Bob_n_Cincy]

Jamie
I'm going to follow your method on the body. Keep us informed. I plan on starting on the body in about 2 weeks.
Bob

[Jaime]

It seems to be working well so far. Here's the outside corner of one of the headlights...



That's never going to fit in the bucket properly. After trimming:

[Jaime]

First headlight is done:



Like everyone else, I had to trim a ton off of the bottom of the fender lip.

[Frank818]

Interesting approach. Body fitting seems to be like a rubiks cube.....

Except that rubik cubes can be completed within 6-7sec...

[Boog]

Except that rubik cubes can be completed within 6-7sec...

But only after years of practice and thousands of completions. Seems like a pretty apt comparison.

[Frank818]

Boog, you're right. Then just imagine Jaime after years of practice and thousands of body panel completions.

[Jaime]

First side bolted into place.



I had to trim a ton of material off the bottom of the fender and drop the bucket about 3/8".

[Frank818]

You might be one the first, but certainly the first "I" have seen, bolting this up for final placement so quickly.