Building an 818R in Mt Pleasant, NC

[wildhorsesracing]

Howdy all,
We have started the process of building our 1st 818R - our plan is to use a stock 2.0L T for ~225 hp and race it in NASA's ST-3 class. Picking up the kit:
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Donor:
donor.jpg

Now all we need to do is start opening boxes and pull apart a Soobie.

I liked the dolly that Factory Five used to roll the chassis around on so much I decided to build one to use at my shop:
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[wildhorsesracing]

Sorry for the delay but we have been busy with the NASA East Coast Championships. We are planning to race our 818R there next year.

Finished up the dolly to roll the chassis around as we work on it.

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wanted it up off the ground to we don't strain our backs.

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[wildhorsesracing]

Started pulling parts off of the Subaru

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- didn't get very far :-(

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[riptide motorsport]

Congrats, inch by inch!

[wildhorsesracing]

Day #2 Hrs: 3 Total Hrs: 5

Took the rear IRS assembly out today:
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[Wayne Presley]

How do you eat an elephant? one bite at a time...

When dropping the motor out of the bottom, leave the dog bone mount and trans mount on until you are ready to drop it out. Allows you to pull the front K member off and get it out of your way. I'd remove the oil filler tube as it might get broken if the motor shifts up against the frame...ask me how I know...

[wildhorsesracing]

Day #4 Hrs: 2 Total Hrs: 8

Removed most of the front end and front doors - almost ready to pull the engine.
818 Day 3 004s.jpg

[Pearldrummer7]

Cool, another R build! I like the mount. Best of luck with it all; feel free to ask "the forum" anything you're confused on.

[wildhorsesracing]

Day #5 Hrs: 4 Total: 12

Removed the subframes and engine/transmission assembly
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Thanks to Wayne for the tip about the oil filler neck - it was definitely going to be snapped off if we left it on!

[wildhorsesracing]

Day #6 Hrs: 5 Total: 17

Lots of small parts/pieces to remove and modify. Removed A/C compressor, power steering pump, lower control arms, front k-member, steering rack, pullled front axles...

Front spindles - clean and inspect:
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Pulled the fuel pump:
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Drilled the brake pedal for manual brakes:
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[wildhorsesracing]

Day #9 Hrs: 2 Total: 25.5

It's been a while since we have been able to work on it. Went to Watkins Glen with NASA-NE and VIR with NASA-MA/SE to do some racing. Finally back in the shop and getting stuff done. Riveted all of the panels on the front and assembled the shocks.

panels.jpg

shox.jpg

Next up is replacing bushings in the front LCA's with new urethane ones.
bushings.jpg

Anyone know if we need this bracket if we are using a Wilwood pedal set?
818 Bracket.jpg

[mikeb75]

That bracket will not be used. If you did not receive an alternate with 3 holes for the Wilwood pedal master cylinders you need to contact FFR to get it shipped to you. You will also need alternate aluminum panels; they are flat with the 3 cut outs and no hump; unfortunately it looks like you've already installed the ones you received (with hump). [my build thread has pictures of the correct panel & pedal plate]

[wildhorsesracing]

That bracket will not be used. If you did not receive an alternate with 3 holes for the Wilwood pedal master cylinders you need to contact FFR to get it shipped to you. You will also need alternate aluminum panels; they are flat with the 3 cut outs and no hump; unfortunately it looks like you've already installed the ones you received (with hump). [my build thread has pictures of the correct panel & pedal plate]

Awesome- Thanks! I'll get one ordered tomorrow!

[wildhorsesracing]

Day #9 Hrs: 2 Total Hrs: 27.5

Bought these containers at Home Depot and organized all of the hardware.

hardware.jpg

New urethane bushings

bushings.jpg

Finished the front LCA's and UCA's:

lcas.jpg

[wildhorsesracing]

Day 10 Total Hrs: 30.5

Took the front suspension back apart to add washers and spacers for the conversion to an 818R:
spacers.jpg

washers.jpg

and I learned a lesson, always read the directions completely. I neglected to line up the cotter pin hole so it would be easy to insert.
lesson.jpg

Cut all of the brackets and assorted electronics off of the steering shaft but left the wheel tilt mechanism.

[wildhorsesracing]

Day 12 Total Hrs: 39.5

Finished the front suspension, the rear suspension and started kleco-ing the bottom on.

Bumpsteer kit waiting for new steering rack to arrive:
bumpsteer.jpg

Rear suspension attached and ready to roll!
rearsuspension.jpg
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Cleaned up the steering shaft and painted it red
steeringshaft.jpg

Started to Kleco the bottom on
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[FFRSpec72]

Bumpsteer kit waiting for new steering rack to arrive:

Do you really think bump steer is necessary ?

[wildhorsesracing]

It is listed in the 818R addendum. After looking at an 818R that was lowered and didn't have the bumpsteer kit it was pretty obvious that the angles of the LCA's to the steering were not quite right. I used to race AIX Mustangs and bumpsteer was a major factor. Bumpsteer kits make a big difference on track, especially if you use the gators as much as I do

[FFRSpec72]

It is listed in the 818R addendum. After looking at an 818R that was lowered and didn't have the bumpsteer kit it was pretty obvious that the angles of the LCA's to the steering were not quite right. I used to race AIX Mustangs and bumpsteer was a major factor. Bumpsteer kits make a big difference on track, especially if you use the gators as much as I do

I agree that certain Mustangs need a bump steer kit, I run a challenge car in the series and the new MKIV spindles that FFR provides come pretty close to removing all the bump steer, so it was a crap shoot to install or not to install, since the spindle had replaceable arms the drilling was not an issue since i can just replace the arms and not the entire spindle like the FX or SN95 spindles. I have put my R on the bump steer gauge and it looks pretty damn close as it sits, granted I'm not at a perfect tested ride height yet but based upon the numbers got, I'm going to wait and see how things go when I get the car buttoned up and on the track

[wildhorsesracing]

Day 12 Total Hrs: 39.5
Didn't get to work on the 818R today, had to change the fan belt on my other obsession:

mooney.jpg

Hopefully we'll get at it this weekend.

[Hobby Racer]

Rear suspension attached and ready to roll!
rearsuspension.jpg

Where did you get the swedge lock rods for the rear suspension?

[wildhorsesracing]

Where did you get the swedge lock rods for the rear suspension?

Speedway Motors - I live in the heart of NASCAR country (Charlotte, NC) so their catalog is a staple around here.

[Wayne Presley]

Where did you get the swedge lock rods for the rear suspension?

I sell them ready to drop in your car.

[wildhorsesracing]

Day 17 48.5 hrs

It's been a while since I posted because I have been busy racing at Watkins Glen, VIR and Daytona.

Here is the latest updates:

Assembled gas tank

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Adapted transmission

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installed new steering rack

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Installed the plate for the Wilwood pedal assembly

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Installed the bottom cover (backwards - tab goes in the front!)

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[Pearldrummer7]

Looks awesome! What fuel pump are you running? My Walbro was very tight in the fuel tank. Had to trim down the hose connecting it to the bracket.

[wildhorsesracing]

We used whatever was in the donor car, it wasn't marked. We too had to trim the hose and the return lines to get it thru the hole.

[wildhorsesracing]

Day 22 Hrs 59.5

Installed a new timing belt and oil pan
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Also set her on the ground today for the 1st time
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We are headed to the Santa's Toy Run at Road Atlanta and taking her to show off
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[wildhorsesracing]

Day 24 Total Hrs: 66.5

Deleted TGV valves

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Installed Radiator

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Installed side intrusion plates and started plumbing for the radiator

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[Niburu]

Well I hope you bring that 818 to VIR.
Since you're running with NASA do you know or met Jon Felton or Chris Cobetto?

[Scargo]

I hate to bring this up, as I am no expert, but how can you use that gas tank in NASA racing? Why would you want to?

[Wayne Presley]

Well I hope you bring that 818 to VIR.
Since you're running with NASA do you know or met Jon Felton or Chris Cobetto?

Lol, Jim is the NASA eastern region director, he may just run a NASA race at VIR :-)

[wildhorsesracing]

I hate to bring this up, as I am no expert, but how can you use that gas tank in NASA racing? Why would you want to?

IMHO: I believe it to be safer than many new car factory tanks. I have raced for 20 years and can vouch that I have seen many tank installations that were far worse than this. In NASA the tank is legal if it is an OEM tank from the manufacturer, this is the OEM tank from Factory Five. With the structure of the cage in the 818R I believe it will take a massive hit to get to the tank.

I also have first hand experience with a fuel fire on track:
https://www.youtube.com/watch?v=shg92VqoSYY

I will emphatically state that you should always wear ALL of your safety gear whenever you are out on track. I had everything but my balaclava on that day and the 2nd degree burns on my neck & chin proved that I shouldn't have skipped that piece.

FWIW: most of the sanctioning bodies approve cars with OEM tanks, even the newer cars with plastic tanks. The Porsche in the video had a factory plastic tank.

[Scargo]

It is precisely for the situation of the rear-end collision you show in the video that I have my reservations about the gas tank in that location and the squared-off welded design. There is nothing in the rear of an 818. We are totally reliant on first, four mount bolts in shear and second, a few bars, to stop the engine from being pushed into the tank. Just like you, this is my humble opinion.

[wildhorsesracing]

Those are valid concerns, but with the lightness of the 818 I think you'll find that the car will deflect & spin, unless it is pinned in. In which case there isn't any car that can take that type of hit and not have issues with fuel. I have seen stockcars on track with fuel cells back into a wall and the steel can cuts the bladder so the cell leaks fuel all over.

I used to race one of these (yellow one):

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And all they have in the rear is a bumper, plastic fuel cell, battery and rear axle before reaching the driver compartment. But they prove to be extremely rugged because they too only weigh 1700 lbs and in most incidents they simply "bounce" off whatever hits them or the tubing takes the energy and deflects it.

[Brando]

Don't leave out the energy that little rubber chicken will deflect

[wildhorsesracing]

Don't leave out the energy that little rubber chicken will deflect

LOL! That was the mascot!
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[Scargo]

This is an area where finishing my schooling might have helped. I agree with your argument that there might not be enough mass to resist movement from an impact and the car would just go flying. I'm sure that X'd member is pretty strong. What if you had your brakes on or, like you say, up against something or another car? Someone on here built a bumper-like cage around the back. Might have been Sixstars. It tied into the sides. I like that concept.

[wildhorsesracing]

And that is something that could easily be added for someone who wants more protection. As we get more built and racing we also add bumper stiffeners so we can do some bump drafting as well.

[wildhorsesracing]

Day 27 Total Hrs: 76.5

LOTS of aluminum work done today. Lower part of the rear firewall is complete, under tray beneath the battery in the front is riveted on, and the tunnel inside the car is covered. Apart from aluminum, we got the shift linkage finished on the end of the transmission and started to mount the shifter in the car, but have to wait for a 25/64" drill bit. Cut the wiring connectors out needed for Wayne @ VCP to make a Megasquirt ECU for us. Lastly, we got the hoses we needed for the engine and started assembling the engine, first by mounting the oil pan then it was time to call it a day.

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[wildhorsesracing]

Day 28 Total Hrs: 83

Big day! We installed the engine and started to hook up the coolant lines and clutch line. Thanks to Wayne @ VCP for the advice about taking off the Oil Filler tube to get the engine in.

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We did notice that our radiator is 1 inch too tall - is that normal? What is everyone using for a radiator?
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We also found a great source for the axles.