San Diego builds, One the easy way, one the hard way

[matteo92065]

I'll post up mostly my 818 build; the easy way. I'm also building one with my boss; the hard way. I say hard way, but its more of a really "involved" way. He is heavily modifying the chassis and body.

Back to mine...
Started with a 06 Impreza 5 speed. But I'm lucky enough to have a 2006 WRX motor available.

06 impreza 200k.jpg08-IMG_8443.jpg09-IMG_8451.jpg11-IMG_8473.jpg13-IMG_8705.jpg

My kit should be delivered in July '14.

The "Hard" way:
15-IMG_8735.jpg There are 5 2010 to 2013 STI motors in this room.
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[Brando]

Where in S.D. are you? Congrats, pretty cool. I'm sure the boss man will kick down some of his mods for you

[wleehendrick]

Good to have some company down here! I live in Encinitas, and am building in San Marcos.

[matteo92065]

The Hard Way is being built right now in Mira Mesa. I'm building mine in Ramona.
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[Brando]

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Woa you weren't kidding! You need to elaborate on the "hard way"... what are you doing?

[apexanimal]

now that's a wrench...

[matteo92065]

Yes, the large wrench was to tighten the ball joint. As others have pointed out; it can be very tight.

In the pictures above the frame is being prepped to stretch it 3" longer.
We put the seat in with tank, without tank, took lots of measurements and compared them to a late model 911. We all agreed that the car will fit a 5'10" guy just right. The owner of the Hard Way is a big 6'2" guy, so the car is getting longer. This is all with a big, wide and comfortable seat.

[MrDude_1]

Yes, the large wrench was to tighten the ball joint. As others have pointed out; it can be very tight.

In the pictures above the frame is being prepped to stretch it 3" longer.
We put the seat in with tank, without tank, took lots of measurements and compared them to a late model 911. We all agreed that the car will fit a 5'10" guy just right. The owner of the Hard Way is a big 6'2" guy, so the car is getting longer. This is all with a big, wide and comfortable seat.

does he realize he can make the seat much much lower, and move it further back with either a slimmer tank, or moving the tank...?

[matteo92065]

does he realize he can make the seat much much lower, and move it further back with either a slimmer tank, or moving the tank...?

Did you miss the thread title? The Hard Way. Just kidding.
I'm posting pictures and descriptions for general interest and the WOW factor. Much of what will be done to this car will not be done to mine or any others. He likes to leave his mark and make things his way. I enjoy seeing what he does, I just thought I would share.

We have tanks, moved tanks, seat has no hardware on it, etc, etc.
He wanted it the car longer. <---- Bottom Line.

[matteo92065]

I don't know if one of these have been posted... So I'll put this up so others can see what to expect...
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[carbon fiber]

Is there any concern with extending the wheelbase, that it could dramatically change handling/turn in of the car?

[matteo92065]

Is there any concern with extending the wheelbase, that it could dramatically change handling/turn in of the car?

I'll let you know when we get both done.

[matteo92065]

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Its now 4" longer.

[carbon fiber]

Very true, you will have a stock wheelbase chassis to compare to. I'm curious myself.

[BC Huselton]

Where is the roll bar? Has it been removed to be heightened as well?

BC

[matteo92065]

Yes the roll bar was also cut off/out. He wants to make it a little higher and maybe put some bends in to match the humps over the engine cover.

[AZPete]

This will be fun to watch! Please keep posting photos.

[matteo92065]

This will be fun to watch! Please keep posting photos.

O.K. here are a few recent pictures...
We bolted a few parts to the long block built by AJW. The Long block is very clean and appears to be a top quality build. Its a pleasure to work on.

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This other motor is the first one that we built in-house. The parts (pistons, connecting rods, etc) all came in boxes that looked like jewelry should be in them.
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[matteo92065]

Instead of running with the "U" shaped bypass hose for the heater core we modified the coolant manifolds. This not only eliminates the additional bypass hose, but also eliminates much of the OEM steel coolant manifolds.
Not this:
cooling bypass.jpg

THIS:
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[matteo92065]

We have been Cadmium Plating all the steel parts and fasteners to give the car that "new" look.
Before:
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After:
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[matteo92065]

The "hard way" wiring is really challenging for me.
We are putting in a 2011 STI motor with DAVS. So we can either put in a 2008+ ECU, with gauge cluster, immobilizer, wiring harnesses (way more complicated than a 2006 WRX system),or I can use a Hydra stand alone ECU that is designed for a 2006 harness, then splice in the B21 plug for the motor. The Hydra was programmed to control the additional cams.
B21.jpg

[matteo92065]

The owner wanted to put in a Carrera GT style shifter. The shift knob is about the same height as steering wheel, it is angled, and the area below would be open.
carrera gt.jpeg

We are using a 1st Gen MR2 shifter and reworking the linkage on the transmission. Both cables will be parallel all the way to the back where there will be a rocker arm for the twisting motion. We just finished the 3-D printed version, the final aluminum one should be done next week. So far it looks like we will have to get new morse cables that are about 7-8' shorter. It really opens up more options for a rear trunk too.

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[matteo92065]

I arranged shipping with Stewart just over a month ago. Communications is sparse at best with them. My first delivery date came and went with no car, no phone call and no email. I finally called them and they said, "sorry our trailer is broken". I know its a whole car and all, but an update and an eta would be very comforting. I guess I am spoiled by UPS & FedEX.

[Brando]

Don't feel left out. Most of us played the waiting game with Stewart. Mine arrived 4 weeks late but in Stewarts defense there was some severe weather going on and they had a rig down.

[mikeb75]

Just be patient until the driver calls, anything else you hear is -um creative. Sorry, that's the way it seems to work. I wrote a rant about it a while ago, and like Brando says, most of us have had the same experience.

Yes, the communication situation is awful and yes it sucks, but truly once the car is in your garage it doesn't much matter. Hang in there.

[305mouse]

It sounds like one of their trucks is always down.

[C.Plavan]

Mine was "Pushed Back" a day because the driver wanted to watch the Green Bay FB game....

[Turboguy]

I arranged shipping with Stewart just over a month ago. Communications is sparse at best with them. My first delivery date came and went with no car, no phone call and no email. I finally called them and they said, "sorry our trailer is broken". I know its a whole car and all, but an update and an eta would be very comforting. I guess I am spoiled by UPS & FedEX.

They were pretty flakey back when we tried to deal with them 8 years ago too.


When all of a sudden the quoted price more than doubled, we said "see ya" to their mickey mouse operation and never looked back.

[D Clary]

I think a lot depends on where they have to deliver cars. The driver who delivered mine lives in Phoenix so his layover there was longer because he wanted to be home for a while. They can fit eight cars in the trailer and they wont head out west without a full load as they already have to return empty. It's just the logistics of the specialized transportation. If you want to save time you can always have it crated and shipped by another courier. I waited eleven moths for my kit so anther five weeks didn't kill me. PS I called the dispatch once a week after 3 weeks just to keep updated. Its your stuff so you need to watch it.

[matteo92065]

It took longer than I thought it should, but it is here. I have number 222. easy to remember.
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I like seeing all the different build locations and conditions that other people have posted. So here is mine.

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[wleehendrick]

Congrats! I better get my butt in gear and finish up #52. I've had my kit long enough it would be embarrassing not to be the first one done in S.D.

[matteo92065]

Finished the shift linkage on the 'Hard way'. The new shift cables are 95" long.
First one done with 3-D printer
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Close to final product. I am looking forward to driving it. I want to see what it feels like.
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[AZPete]

Very clever improved shift cable lever! Are you using the FFR-supplied shifter or the K-Tuned shifter?

[Aero STI]

That turned out awesome. Where did you get all of the shifter cable components, like the rod ends?

[matteo92065]

Very clever improved shift cable lever! Are you using the FFR-supplied shifter or the K-Tuned shifter?

Neither, using a Gen 1 MR2 shifter. It has the cables entering from the rear of the car, so the cables take more of a direct route to the transmission.
post #22 has some pictures.

[Mechie3]

Nice work on the linkage. I prototyped one months ago and then life got busy. I like the red rod ends.

[matteo92065]

That turned out awesome. Where did you get all of the shifter cable components, like the rod ends?

From McMaster Carr part number on the rod ends: 60685K721

[matteo92065]

Nice work on the linkage. I prototyped one months ago and then life got busy. I like the red rod ends.

Thanks! We were going after the same thing. Are you going to pursue your version (see Mechie3 build post #856)? You've indirectly helped me so much on my wiring 11880-Wiring-Guide-06-WRX-Sedan-with-Auto-AC-HVAC, that I'd like to offer you my SolidWorks files to get you going on it again.

[matteo92065]

Its been two nights and I really wanted a roller.
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On the steering... I ended up with aluminum a-arms, and I think a '06 WRX wagon steering rack. QUESTION: What holes do I use on the frame? I put them on the outer most street holes and the tires were really towed IN. I've adjusted the rod ends on the rack about an inch on both sides. Is that too much?? Its seems to me that I could simply use the inner holes on the frame and not adjusted anything. I have two other racks and will measure the center to center distances on them, and I will look at how much thread is left in the rod end.

I looked at the 'hard way' and his is the same as mine.

[wleehendrick]

AFAIK, Aluminum arms only came on WRX/STi sedans with a wider track (and fender flares), so those should mount to the inner most set of holes. The outer set of holes are for stock WRX wagon/Impreza (steel) arms for narrower track bodies. My donor's a 06 WRX wagon, and I used the black steel LCAs on the outer holes. The idea being to put the hubs in the same spot on the 818 regardless of which LCAs are used.