SixStarCars' 818S Build Thread

[SixStar]

We will be covering the building of FFR 818S #80 for Charles in St. Louis

Goal:
To build an 818S from one donor as close to the manual as possible while sticking to our client's budget.

Donor:
Our car was purchased through COPart in Denver. Didn't look too bad from the pictures, come to find out....

Not bad right?
12202000001.jpg

Actually kind of nice!!!
12202000002.jpg

Oh snap!! Literally. We knew about this though so no surprises there.
12202000003.jpg

Timing gears sitting on top of the engine never a good sign.
12202000005.jpg

Not even hit that hard in the front, there was some protrusion into the engine bay that hit the side, very odd. But strange things happen in accidents. A word of caution. This engine will need several parts and a bit of work before it can be tested out, as always with crashed cars BUYER BEWARE!!!
12202000006.jpg

Right rear is tossed
12202000007.jpg

Won't be using that mount, or dynoing the car, bummer.
12202000008.jpg

Subframe wasted
12202000010.jpg

Banana!
12202000011.jpg

[longislandwrx]

Craigslist be like, "needs alignment"

[07FIREBLADE]

Craigslist be like, "that will buff right out"

[SixStar]

"Custom rear end"

[Xusia]

Thanks, guys. Those posts just made my day!

[Quiny]

So what did you see behind the dash to know that they flashed the ECU with a Cobb? I have Cobb tuning stickers all over my donor so I assume the same. I haven't looked into it yet but I will want to return it to stock, I hope it can be done with Opensource. I may tune it from there but I always like to start from stock.

[longislandwrx]

The cables near the green test mode connectors were probably pulled down out of the bunch to where they are easy to access, (you need to connect an initialization coupler) indicating that the car had been fiddled with.

[SixStar]

^ Yep. Can't say for sure but knowing what I know it's clear it's been fiddled with.

[DurangoRon]

Unless I missed it, who are you using for shipping? That $857 to Greeley is a great price.

[SixStar]

Unless I missed it, who are you using for shipping? That $857 to Greeley is a great price.

We went through uship.com, it's a bidding site for LTL. I'll get the name of the actual shipper as soon as I can for everyone. That's each car plus crates. So $3114 total. A few hundred off "the other guys" price and they SHOULDN'T get damaged which was our main concern.

[Evan78]

We went through uship.com, it's a bidding site for LTL. I'll get the name of the actual shipper as soon as I can for everyone.

Did you ever get a chance to get the name of the shipping company?

[SixStar]

UPDATE 1: 11/18/13

Tore into the donor today, looks like we have some bent valves on one of the heads, codes lean toward #4 which is interesting since that wasn't the side that was hit. But I have seen this before, the gears that explode generally end up slamming the valves shut and saving them.

Major parts out of the way:
http://i.imgur.com/nyjsiHC.jpg

Your cam gears should NOT look like this!
http://i.imgur.com/VKA7o6z.jpg

Belt on and she runs, but rough. Instant #4 misfire code.
http://i.imgur.com/wpGXwfX.jpg

[BrandonDrums]

UPDATE 1: 11/18/13

Tore into the donor today, looks like we have some bent valves on one of the heads, codes lean toward #4 which is interesting since that wasn't the side that was hit. But I have seen this before, the gears that explode generally end up slamming the valves shut and saving them.

Major parts out of the way:
Attachment 23461

Your cam gears should NOT look like this!
Attachment 23462

Belt on and she runs, but rough. Instant #4 misfire code.
Attachment 23463

Ahh pooey, those image links arent working....I wanna see!

[Frank818]

Nope, not working.

[SixStar]

Not sure why it amended and killed the links, sorry. They're fixed now. I'm only allowed 10 pictures per thread.... even hosted on imgur, seems silly.

[longislandwrx]

Do you guys do any work with Flat Iron?

[SixStar]

Do you guys do any work with Flat Iron?

We have an account there, Preston is the man!! Also we work closely with Dwight and Peter at SCR who build the motors for Flatiron.

Colorado can be very small when you've been doing the same thing for 18 years!

[SixStar]

Looks like both our cars SHOULD be picked up today which means a possible delivery Monday. Stay tuned.

[SixStar]

If it's not one thing it's another. The estimated 11/23 completion date came and went. By the time the cars were done it was the holiday and the freight company tried to pick them up Friday but FFR was closed (rightfully so, I was as well). Driver had better things to do yesterday I suppose, tried today and since they didn't call ahead the cars weren't in the crates ready to go.

Frustrated.

[Frank818]

Ha man. Such bad luck.

[SixStar]

Got some more goodies for our 818 build - http://i.imgur.com/CS3ajRS.jpg

Bad news, I won't be flying to PRI tomorrow as I had to have my appendix removed yesterday... good news I will be able to be at the shop Thursday for the delivery of our 818s! How's that for a silver lining?

[crossbarphoto]

Hey SixStar...when you get cars and get started on the project would there be any way me and my build partner could stop on by and check out the cars and see how things are going and just chat in general about the build process, donor acquisition, etc?

Thanks

Johnstown, CO

[SixStar]

Hey SixStar...when you get cars and get started on the project would there be any way me and my build partner could stop on by and check out the cars and see how things are going and just chat in general about the build process, donor acquisition, etc?

Thanks

Johnstown, CO

Yes of course. It'll be slow going for the next two weeks while I recover, but you're welcome to come by anytime and check them out.

Once I'm done with the chassis mods on both they'll be off to coating, should be gone a week or so. After that they'll live at the shop.

[crossbarphoto]

I was thinking about seeing the delivery, but that probably won't be all that exciting. A couple weeks might be best. I'll keep following this thread to see how things are progressing. We put our order in a few weeks ago so we have time, but there is LOTS to do between now and then. Hope you heal quickly.

Thanks!

[SixStar]

Two large wooden boxes and my Cat 40. Pretty boring.

We'll have a bunch of unpacking photos and maybe a short write up on how it all went.

[longislandwrx]

Why did you decide to get the crate? Short on firewood?

I thought Aloha had said that even with the crate a few parts were scuffed/chipped. Do you think it was worth 700 each?

[SixStar]

Why did you decide to get the crate? Short on firewood?

I thought Aloha had said that even with the crate a few parts were scuffed/chipped. Do you think it was worth 700 each?

Without getting into specifics, another build was delayed after Stewart damaged some parts and caused some other hardships for the customer. Until he's willing to come forward about his experience that's all I will say.

Armed with that information we chose to use anyone BUT Stewart and the $1400 was our way of adding a little extra safety to our delicate and expensive cargo. I'll know tomorrow if there is any damage.

[SixStar]

Todd got into the donor a bit more this past weekend

Seats and some interior stuff:
http://i.imgur.com/Acw89dH.jpg

Cars get very large when you take them apart:
http://i.imgur.com/YLMat4P.jpg

Barf:
http://i.imgur.com/uH2GuhY.jpg

More barf, glad the electrical engineer is in charge of our wiring!
http://i.imgur.com/B8ys6cR.jpg

Cars should be here by 3pm today. Lots more pictures to come. Also check out our Facebook page @ facebook.com/sixstarcars818

[SixStar]

Well the cars FINALLY showed up tonight. Nothing too exciting, just uncrating the R and disassembly. Inventory tomorrow and uncrating the S.

High res album - 27 pictures - http://imgur.com/a/GAFy9#0

[SixStar]

It left FFR on Cap Cod (or something similar) it's at the shop. I'll be there later today.

I can tell you this, the last leg was UPS and what a bunch of useless morons. They showed up Wednesday, I wasn't there since I had only been out of the hospital about 30 hours, one phone call and I could have had someone there in 45 minutes. Instead they chose to turn around and go back to Denver and mark it "refused". They didn't even try Thursday, I was there all day waiting. Then yesterday morning they said it would be Monday, Todd called and chewed them out and they 'found' a truck to bring them up. I'm not sure what they loaded them with but they pushed both crates all the way forward and had zero dollies on the truck. We ended up having to drill holes in the crate and mounting a tow hook, from our NASA TT car, to the actual crate and pulling them to the back with the Cat so that I could get under them. How they thought we'd get them off I'll never know.

The 818R was in great shape, minimal scuffs on the panels, the hood took a little damage being upside down in the cockpit of the car with a few more parts piled on top of it but nothing that won't be covered by the livery wrap. In all I was VERY impressed with the packing job. Wait till you see what we have planned for the crate, can't let all that well engineered lumber go to waste!

[SixStar]

Made it about 90% through inventory of the 818R today. Missing a few key items, won't be able to make it a roller as soon as I wanted, oh well.

Back to work on the S tomorrow. Our photographer will be there to take a bunch of unpacking pictures for the site. Is there anything anyone is curious about receiving your 818 that hasn't been covered yet?

[SixStar]

S is unpacked and inventoried. Got started on the R, first part, doesn't fit. This better not be a sign of things to come

Had to ream the holes for the UCAs to get the bolts to go in. Still looking for the spacers (.821) for "track only", got tired, called it. Three nights in a row of 818 is too much for me right now.

Should have the R rolling tomorrow then I can get it off the lift, get the S on the lift and stripped down to head to paint. No frame modifications on the S we decided.

[SixStar]

Holy delayed update Batman!!!!

We're back hard at work on the #80 818S. Slight changes to the donor used, we went with a 2.5RS for the suspension and steering column as well as some other bits. Ran into a slight issue with the 2.5RS clutch master, it will not work on the 818.

Here you can see that with the RS resi the cap comes into direct contact with the frame before you ever bolt it on
P3051406.JPG

You can see the differance between the WRX and RS resi
P3051404.JPG

Easy fix, just use a WRX resi with your RS donor and move forward!
P3051405.JPG

Here are some more pictures of the build. On to mounting the seats, doors, and hanging the body. Ignore the mismatched rear LCAs - they're temporary!

http://imgur.com/a/WYzNk#0

#80 is a roller! And despite our difficulties in figuring out the seat brackets you can sit in the car and make vroom vroom noises now too!!

My take on the seat bracket instructions:

LFINcBP.jpg

[SixStar]

3/11 update - 1/4s are mounted and aligned. Doors are being hung and mirrors mounted. Hoping to have everything south of the front firewall mounted up by the end of the say.

http://imgur.com/a/6WgPc#0

[Brando]

My take on the seat bracket instructions:

LFINcBP.jpg

That is hilarious

It still would be an improvement over R specific directions

[SixStar]

That is hilarious

It still would be an improvement over R specific directions

We've been building off the 1G manual. I just got the 1F supplement from a fellow builder and it's clearer but we only received 3 seat brackets so we still can't put the passenger seat in.

The R.... well lets just say I'm glad I have an experience hot rod builder helping me. Body mounting on that car is next. Everything needs to be removeable so we're going to have a few extra boxes of rivets and I have a rather large order of Dzus and Moroso fasteners coming from Summit.

[SixStar]

With the chassis and small parts off to paint we're focusing on cleaning up and cutting out the panels for kit #80. Here's some of what we've done so far

P4301562.JPG
P4301563.JPG
P4301564.JPG
P4301565.JPG
P4301566.JPG
P4301567.JPG
P5011568.JPG
P5011570.JPG

[SixStar]

We spend a day last week and most of yesterday de-powering and building racks. Turned out like I'd have hoped, a few snags on the 06-07 rack, not sure if we're going to use it for the R now.
P5051576.JPG
P5051577.JPG

But onto the progress on #80!

Frame is back from paint and it looks amazing! They really do a fantastic job on everything we bring them. We will be picking up all the small parts later in the week, lots to do on the frame before we need all the other bits.

P5051571.JPG
P5051572.JPG
P5051573.JPG
P5051574.JPG
P5051575.JPG
P5061578.JPG
P5061579.JPG
P5061580.JPG

Thanks for checking in! Keith

[SixStar]

Long delay in the build. Two big races this past weekend in Lincoln, Nebraska with another this weekend means lots of race cars in and out of the shop! But here's some progress on the rebuilt engine and transmission.

Engine is an EJ20. Bottom end is fresh from the builder with OEM rings, ACL Race main and rod bearings. Gaskets are all OEM. Heads are machined locally and rebuilt by yours truly. I actually really enjoy assembling heads and engines, it's a zen thing for me. As for setting lash.... there's a special place in hell for the person who invented the shim bucket.

P5171612.JPG
P5171613.JPG
P5201615.JPG

Our transmission builder is one of the best in the state and does a great job on everything we give him. This is the 5MT from the donor car and has been gone through, inspected, cleaned, any worn parts replace/exchanged. While he was in there he threw in a Quaife from Erik at The Race Line.

P5171614.JPG

I will try and get more done and posted this week but we're only here for another two days then it's off to Heartland Park in Topeka, Kansas.

[SixStar]

Found some time to get a bit further on the build. Brakes are done and work very very well even just rolling around the shop.

Cooling lines are almost done. Once the engine and transmission is installed the clutch system can be buttoned up and bled. Run the wiring harness and she SHOULD be ready to start.

P6041616.JPG
P6041617.JPG
P6041618.JPG
P6041619.JPG
P6041620.JPG
P6041621.JPG
P6041622.JPG
P6041623.JPG
P6041624.JPG
P6041625.JPG

We're full blast into the racing season so I'm having to find time for that, keeping the shop running, installing the new AWD dyno, and building #80 and #85. Both my employees quit too so it's just insane the amount of work that's getting done by ONE MAN!

Car WILL be running and driving by the 20th and will be on display at PPIR for the SCCA Match Tour all weekend. I urge anyone local to come by and take a gander.