Harley's 818S

[STiPWRD]

I also have my rear bumper back from getting a few mods......Vman style.
I'm now able to finish mocking up the rest of my dual exhaust and should be able to post Pics soon I hope.

Very excited to see this!

[matteo92065]

Time for an update.
Like many, I am now re-doing stuff i have already completed. Having too much fun I guess.

Intercooler. I decided I wanted to add some insurance to the heating issues, so I bought a bunch of components from FB. I didn't realize at the time that Mechie has a discount going, so I missed out on that (every little bit helps). I had to play with a bunch of options to get it to work out, but now I'm happy with the ultimate result.
I bought the 600hp version - I figured the extra cooling would be good. I also went for the Cobra circulating pump, and am going to try out the greddy knockoff BOV.
I have a 2002 WRX donor so my heater line is in the center and in the way. To avoid interference issues with the heater line, and the IC hitting the engine cover, I went with a 45 degree reducer from the IC to the throttle valve. I cut it back a bit so its now a 30 degree reducer. This arrangement allow me to fit it in without interference and more space all around.

This is how much I cut off.


With the 30 degree reducer, IC mounting brackets are also easier to form.

I'm using some 1/8 x 1 in SS flatbar which is easy enough to bend and twist into position.

I haven't figured out my BOV hook-up entirely, but I'm hoping to just extend the stock hose to the turbo inlet BOV hose.
The black mark on the top of the IC is where I plan to tap for my intake temp sensor.
Also, I'm planning to tap into the water side to allow a bleed valve for the coolant.

If anyone's interested, I can post all the parts I ended up buying from FB (which you can get cheaper through Mechie)..

Your install looks great. I have done exactly what you are doing.
Unfortunately I did exactly what you did. I ran into a few problems with that set up. They are fixed now but I just want to bring them up so you can fix them if you want.
First, the intercooler is sitting to far back if you are going to run the FFR trunk kit. The trunk will hit the rear support and possibly the intercooler itself. I fixed this by cutting more off of the TB to IC tube (make shorter). Of course I had my front brackets all made and painted before I found this out. If your not running the trunk, no reason to change. Second and last, is if you are going to run an engine cover hinge. If you do, the intercooler needs to be in front of the pivot axis of the hinge. Mine just barely clears now with my IC as forward as reasonably possible. But, if you are not running a hinged cover, your good.

For tapping: The two air temp holes were easy with plenty of material for threads. The air bleed hole on the water side was very thin on mine. Be careful on that one.

Last observation, I see you went with all red. I wanted to do that too, but you cant get the TB to IC 45* coupler in RED! So that's why I have all blue silicone.

[Mechie3]

For the recirc, check out the photos and parts list here from FFR ADV. He got the stuff on ebay.

http://thefactoryfiveforum.com/showt...-Turbo-Install

[Harley818]

STiPWRD - Thanks for the comment on the bumper. Laying the glass today, and pulling the first piece today, then might become a vendor and be able to offer it up. We will see how it turns out.

Matteo, you are right we did exactly the same thing, except I didn't go with all blue. I did get the blue BOV though. I have the hinges from Mike Everson for the engine cover but haven't tried to fit them yet. I guess I better. Because of the dual exhaust, I'll probably have to build my own trunk. Thanks for the heads up on drilling into the IC.

Mechie, thanks for the recirc reference. I knew I saw it somewhere.

[Scargo]

Mmmm. Show cars. Color coordinated. What's the theme?

[Harley818]

It needs to look right, and it needs to look good, but it will be a driven car..... not a show car... and no theme so far.

[Harley818]

Thought i would share my plans.

Credit to Vman for the design, obviously I liked the look he drew up.
Also, I have to credit one of our fiberglass techs for the shaping work.
This is the plug bolted to the back of the car, with the new features done with glass and filler.

bumper 3.jpg

Edit: fixed the attachment pic

[Mechie3]

Attachment isn't working for me.

[bbjones121]

Attachment didn't work for me either.

[Harley818]

fixed now

[07FIREBLADE]

Very nice. I like it alot. You should have a few more made

[flynntuna]

Very cool! you going to paint it blue too?

[Harley818]

I do like the blue which is my back-up color, but I'm thinking grey metal, or lexus silver/grey.
Not sure yet.
I love the new coupe color.

[Frank818]

Flynn, did you simply cut the bumper for your lower opening or you created a round edge all around? Hard to tell on picture.

[Harley818]

the grey primer doesn' help to see the shape.
When I pull the part on Tuesday I will take better pics.
My plan is to cut out the bottom and top with some sort of mesh like the Vman design.

[Mechie3]

I like it. Gives a lot more dimension to the rear vs the flat panel look.

[Frank818]

Very interested to see the results (same color everywhere, no primer) on a close up pic and one away.

[bbjones121]

Looks great! That is exactly what I was thinking about doing.

[Harley818]

We pulled the first part out of the mould today...... looks good.
IMG_2131.jpgIMG_2132.jpg

When I get a chance I'll take a few straight on. These show the profiles from the side. I tried to contour it like the Vman concept.

Heading down to Seattle for the weekend, my son is at a tournament at Uof Wash. so I probably won't update till next week unless I get time tomorrow.

[bbjones121]

Awesome! Will you sell any?

[Harley818]

Probably sell a few.
Depends if I can talk my FRP tech into doing some afterhours work. I asked him if he was interested in building one or two per week.
If there is lots of interest, I will look for a fiberglass shop and get some pricing from them using my mould.

[Hindsight]

I really like it. Very nice fiberglass work. It's definitely an art.

[STiPWRD]

I gotta say that looks amazing

[Frank818]

Wow amazing! I'd be interested to buy depending on the cost.

[bbjones121]

Same here, dependant on price, add me to list.

[R.Spec]

Awesome interested as well!

[07FIREBLADE]

Please say this won't cost an arm and a leg. So down for it depending on cost. Shipping is going to be killer though coming from BC

[Frank818]

BC?
Hey that's true!! He's from Canada! Free shipping for me! lolll Then it makes me want the bumper even more as I'll save one tax and a lot in shipping.

[bbjones121]

Probably sell a few.
Depends if I can talk my FRP tech into doing some afterhours work. I asked him if he was interested in building one or two per week.
If there is lots of interest, I will look for a fiberglass shop and get some pricing from them using my mould.

What about working something out with VRaptor SpeedWorks?

[Harley818]

was out of town for a bit and busy with work and other priorities but had a couple hours today.

Here is the new bumper installed.
DSCF4947.jpgDSCF4948.jpgDSCF4949.jpg

Then with lights bolted in....

DSCF4951.jpgDSCF4952.jpgDSCF4953.jpg

I threw the trunk on but I haven't trimmed the return flanges yet and I have to add something (probably glass in a stiffener) to get it to sit flat.
This should let you see how the finished product looks.
DSCF4955.jpgDSCF4958.jpgDSCF4959.jpg

Next task.... cut the holes for the vent screen.

I haven't looked into making additional parts yet but I will. I need to contact a local fiberglass shop who can build more then I'll get a quote. And I'll check into shipping costs from here vs going down to Washington (1 hour from here) and shipping from there. That may be a problem as the US Border Security may not like me bringing down parts ..... I'll check it out and get back to you all.

[bbjones121]

Looks great! can't wait to see it with the cutouts.

was out of town for a bit and busy with work and other priorities but had a couple hours today.

Here is the new bumper installed.
DSCF4947.jpgDSCF4948.jpgDSCF4949.jpg

Then with lights bolted in....

DSCF4951.jpgDSCF4952.jpgDSCF4953.jpg

I threw the trunk on but I haven't trimmed the return flanges yet and I have to add something (probably glass in a stiffener) to get it to sit flat.
This should let you see how the finished product looks.
DSCF4955.jpgDSCF4958.jpgDSCF4959.jpg

Next task.... cut the holes for the vent screen.

I haven't looked into making additional parts yet but I will. I need to contact a local fiberglass shop who can build more then I'll get a quote. And I'll check into shipping costs from here vs going down to Washington (1 hour from here) and shipping from there. That may be a problem as the US Border Security may not like me bringing down parts ..... I'll check it out and get back to you all.

[Harley818]

Did the rough cut for the vents.
I left about 1/4 in of the flat section for the vent to back up to and to provide a bit of "frame" edge look for the vent.
rear cutouts.jpg
818S rear view.jpg
Vman concept

[Harley818]

Got some time this weekend...... installed Mike everson's engine cover hinges. Worked out great and gives lots of clearance to my AWIC. They are easy to install but I had to add a 3/16 spacer to push it back a bit. My body is located back further than suggested in the manual.
DSCF4963.jpgDSCF4964.jpgDSCF4965.jpgDSCF4966.jpg

Also started to install the rear wheelwells. Had to trim a little to get them to follow the fiberglass better.
DSCF4962.jpg

Got my MR2 shifter set up to mount in the tunnel
DSCF4967.jpg

[bbjones121]

Any updates?

[Harley818]

Taking some vacation, working on other projects.....not having alot of car time lately.....
No pics but I did re-mount my AWIC and HE, got the intercooler all mounted, silicone hoses cut and connected, and HE coolant hoses hooked up. STill have to mount and hook electrical to the pump.
Got part of the 2nd exhaust pipe mocked up, still more to do.
Re-did the MR2 shifter mount with a new aluminum plate, and received one shifter cable..... I thought I ordered 2 but only got one....
Received the rod ends to connect, but now need to source some Aluminum rod for the connections.

[07FIREBLADE]

Saw this thread being bumped and was hoping for good news for news on you possibly selling some of these bumpers to go with my soon to arrive hardtop. I've got some spare cash if you need an incentive

[Flamshackle]

any updates mate?

[Harley818]

any updates mate?

I have a new position at work that requires alot more travel so haven't got much done recently.

I've been doing little things here and there but nothing much to report. Still working on the new shifter, have all the parts, but need the time to put it all together.
I have the new AWIC installed, just need to finish the coolant pump, and still need to finish off the last cutting/fitting & welding of the dual exhaust.

Our fiberglass tech doesn't want to take on the responsibility of building additional rear bumpers, so i will find a local shop to give me a price. Does anyone know what the process is to import parts from Canada to US? I can easily ship from here, but it would be nice to let people know what importation costs are for most of you to the US.
I pick up all my orders across the line in Blaine, WA. so I could drop the occasional one off there, but I wouldn't want to take any personal risk so there may be some charges.

I'll get the part cost first and let you all know.

[Lumpyguy]

Harley do you have any wheel spacers on with the rear rims and how flush did they end up with the fenders?

[Harley818]

Harley do you have any wheel spacers on with the rear rims and how flush did they end up with the fenders?

I do not have any wheel spacers. I was trying to avoid them.
I am trying for the same look you are.
The tires are right flush (maybe slightly proud) with the outside of the fenders with my wheel size and offset.
I ran out to the garage to take a couple pics for you.

IMG_0116.JPGIMG_0117.JPG