30 Day 818R Build Progress Report

[Dave Smith]

30 days ago, we decided to try and build an 818R and make it to the Ultimate Track Car Challenge (which is held a week from today, July 18th). This is part of a pilot episode of a potential reality TV show. I thought it might be a little bit of manufactured drama, but now 25 days into the project, it is definitely a pretty significant challenge that we decided to take on. The good news is that the engineering team has done a great job in taking our 818R benchmark and going to the next level with logical changes. We will summarize the things we did to the car to make it faster when we get home from the track the week after next. Here are some photos of the project just for fun. Full details will follow as we really don’t have time to communicate most of this work.


The project is to take the set-up from the already fast 818R (blue car above) and make it even faster with an all-new 818R build.


We thought for a few seconds of cannibalizing the 818S for parts when the STi block we were using was found out to be junk, but the car was just too pretty and we found another mill.


170,000 mile Subaru donor car started the project. We bought the car from Christian at High Octane Images (sorry Christian, we didn’t want you to see your baby gutted).


The new car chassis and body was rolled into R&D.


Parts from the demo rolling chassis were used.

[img][/img]
https://www.factoryfive.com/wp-conte...0624-03861.jpg


Jesper installs Wilwoods smaller (and lighter) disc brake kit.

[Dave Smith]

The STi block was torn down and upgraded. Turbos were ordered, the transmission was sent out to be upgraded.


We decided to try a red gel-coated body because we didn’t have time to paint the car and we are considering offering different color gel-coats.


Body fitment was actually pretty fast. We are using a white deck and white hood to replicate the paint scheme of the blue 818R, but in red and white.


A lot of suppliers have helped with parts. KONI, Wilwood, Electromotive, etc. APR sent us their latest road race wing that promises to deliver a tremendous amount of rear downforce. Picture above shows our custom positioning jig for the frame mounts (that’s a joke).


The turbo runs with a bigger intercooler and heat exchanger. Front headlights are replaced with blockout panels and we are adding front canards for more front downforce.


John helps fit panels while the engine goes together.

[Dave Smith]

Tony Zullo finishes the front end. Note the front splitter is a bit further out.


Dan helps with wiring.




This picture is from Thursday evening with only four before the first track test scheduled for Tuesday and UTCC is on Friday.


The front end is mostly done (above) and Jim works on wiring (below).



Next week, the team will be on the road with the car and I will report from VIR on the status if the team doesn’t kill me before then.

[gwarden]

looks like an great car good job. I saw it in the build stage and want to see it run.
When will they be at VIR?

[Doowop]

Dave,
Thanks for sharing. I can't wait to see how the car does and see a full detailed report of the mods. THanks

[metalmaker12]

Nice job boys once again, like the upgrades!!! Now go kill em dead

[Mitch Wright]

The carbon headlight block outs, is that something that will be offered in the future?

[Mitch Wright]

The carbon headlight block outs, is that something that will be offered in the future? The car looks great, looking forward to getting started on my R project next month.

[C.Plavan]

Need a driver

[Canadian818]

Nice stuff! I want those front canards! Any ETA on the show airing?

[apexanimal]

how about some body fitment tips?

[waruaki]

how about some body fitment tips?

+ 1

[Mitch Wright]

Is the drivers side aluminum intrusion panel coming with the new R Kits?

[FFRSpec72]

Is the drivers side aluminum intrusion panel coming with the new R Kits?

Its not an intrusion panel, just normal aluminum panel, mine had them, replaced them with real 1/8" steel intrusion panel.

[Dave Smith]

Update, Sunday July 13: The guys worked through the weekend and completed the red 818R. This week, we have a few days to do some shake down testing and driving before heading to VIR for the Ultimate Track Car Challenge on Friday, July 18th.


We didn’t have time to paint the car, so we used the opportunity to test gel coat color in red. The blue car was painted and the red car here is red and white gel coat. Tony buffed the red gel coat and didn’t have time to touch the white gel coat, but everyone agreed they look pretty darn good.

[Canadian818]

Can't wait to see how it does at VIR. Any plans to wind tunnel test the new wing and canards?

[bbjones121]

Looks great! Can't wait to see how it does and learn more about the build.

[David Hodgkins]

I'd love to see more details about the build! How did you attach the wing?

Do you see any new parts coming out of this development process?

[Mitch Wright]

Good luck and also looking forward to build details.

[Dave Smith]

We won't have time this week to do anything other than get to the race and hope to do well. Racing has always been a bit of a frustration as we have to run a company at the same time and commonly we race with a lower budget and shared resources. Still, this car does have some cool changes that we want to test out on the track. The canards are one for front downforce and the vent cut-outs are bigger for cooling and DF. The rear wing has a new and very strong frame mount since the wing is capable of much more df than we had before. We probably won't get a chance to run it thru the tunnel (I wish we could) so we'll have to trust John George's feedback at speed and balance it in the real world. We'll probably go back with those settings (to the wind tunnel). One part of the reason for the effort was also to finalize set-up specs and the R version manual. When we get back from VIR we'll complete the R assembly manual and add complete details on proper set-up and try and make sure to transfer all that learning to the community. There will be tons to report from the track sesh and days following.

[Mechie3]

Bigger vents for cooling? Is this a change to the hood?

[ehansen007]

Best of luck guys! Looks so cool. Amazing when you have a build team and a lot of room how fast it can go! I spent all weekend with John Tongish just installing the under-aluminum and I am beat. Can't wait to see your results!

[C.Plavan]

We really need an "R" wing mounting "kit"...... Stress REALLY

[Brando]

the wing is capable of much more df than we had before

I was under the impression the old wing created more than enough downforce. Why did you guys opt for more?
Did you go with the APR GT-1000?

[metalmaker12]

Update, Sunday July 13: The guys worked through the weekend and completed the red 818R. This week, we have a few days to do some shake down testing and driving before heading to VIR for the Ultimate Track Car Challenge on Friday, July 18th.


We didn’t have time to paint the car, so we used the opportunity to test gel coat color in red. The blue car was painted and the red car here is red and white gel coat. Tony buffed the red gel coat and didn’t have time to touch the white gel coat, but everyone agreed they look pretty darn good.

If it's not painted how did you get the red and white on the top panels, vinyl??

[Jim Schenck]

The old wing did provide enough downforce to balance that setup but we are hoping the more aggressive front end treatment on this car will require more rear wing to balance it out. Besides the canards and the larger air outlets (just cut larger not a different hood) we also have extended the splitter out further which is why we felt we needed the extra supports. We also pushed the front of the doors inboard to make more space for air to get out behind the front wheels, and maybe have one more thing to add after our test but before VIR.

And the red on the decklid is vinyl.

[bbjones121]

When can we find out about the one more thing??

[Frank818]

We also pushed the front of the doors inboard to make more space for air to get out behind the front wheels

Interesting. Did you require new/modified parts for that it's just a simple fitment adjustment with the existing door/side panels and current frame?

[Kyle@AJW]

Is that a 6 speed that I see in there?

[EricScottZehnder]

Really glad to see the canards and better front wing (with supports). I would love to see this offered as an aero option officially. The regular carbon fiber rear wing supposedly balances with the regular front wing at like 0 or 1 degree with 5 or 10 being way to much. With the new front aero, I would think the regular rear aero could still be used but just at a higher degree (5, 10, etc).

Looking forward to testing videos and lap times!

[C.Plavan]

How about some interior shots. Fuel cell area etc? Good luck on the test!

[Brando]

We also pushed the front of the doors inboard to make more space for air to get out behind the front wheels

Interesting idea. So I suppose you didn't install the splash guards behind the front wheels to make that work

[FFR-ADV]

The old wing did provide enough downforce to balance that setup but we are hoping the more aggressive front end treatment on this car will require more rear wing to balance it out. Besides the canards and the larger air outlets (just cut larger not a different hood) we also have extended the splitter out further which is why we felt we needed the extra supports. We also pushed the front of the doors inboard to make more space for air to get out behind the front wheels, and maybe have one more thing to add after our test but before VIR.

And the red on the decklid is vinyl.

Looks Great Jim!

Are you using the GT-1000 ? What are you expecting for cornering G's with this new aero kit? With this wing it certainly could be neck straining.

http://www.aprperformance.com/index....sk=view&id=352

Nice job! I look forward to seeing what it does on the track.

[Brando]

I spoke with APR, it is the GT-1000

[ssssly]

Sorry if I missed it in the post someplace, but could you provide the specs on the wheels?

[bbjones121]

Do we know if the transmission is going to be something like this?
http://forums.nasioc.com/forums/show...&highlight=lsd

[Bob_n_Cincy]

Do we know if the transmission is going to be something like this?
http://forums.nasioc.com/forums/show...&highlight=lsd

It looks like an STI 6 speed to me
Bob

IMG-20140711-04064.jpg

[Frank818]

@Wilwood guy

Not sure which rear brake setup you are using here, but when using the 12.19" #140-7006 1999-2004 Impreza WRX, the pads are over hanging. We seem to all have that problem, are you in a position you can help?

[Dave Smith]

Update, Wednesday July 16:

We ran Lime Rock yesterday to test and tune. Its a good thing we did as we had a stuck master cylinder which completely melted the front brake caliper pistons. The boys at Wilwood are FedExing us new front brakes since we are heading today for Virginia. We did manage to run a 56.3 seconds lap time which is pretty darn fast on an old set of slicks (we’re saving the new ones for UTCC). Didn’t have enough time to optimize downforce as we had some cooling issues. The crew has been working on the cars all morning and we are loading up shortly.


Here’s what happens where your brakes don’t let go and you keep racing.


Both 818Rs are about to be loaded on the trailers even though it doesn’t look like it. The red car is testing a recessed door cut-out (that’s the black area on the leading edge of the door). We probably will not be able to get to the wind tunnel on this trip, but this part and the new wings/canards really need it.


John George will be driving and he is bringing his tech gear.


Last challenge on the list seems to be getting the alternator working. A new one is minutes away.

[C.Plavan]

Much higher roll bar than the Blue car. Also they added the same cross bar in the interior.