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Thread: bbjones121 - Denver build

  1. #1
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    bbjones121 - Denver build

    My descriptions will be pretty short, I am going to try keeping it mostly to pictures if i can.

    My donor is a 2006 WRX sedan bought on salvage auction, shipped from Seattle. It was hit in front and timing had skipped a couple teeth on the belt, so I tore down the engine to look for any damage. Thankfully there was none.

    So after lots of thinking, I decided to keep my chassis bare until i completely build the car. There are some things i will most likely be welding along the way. I want it all powdercoated, including all my rivnuts.

    I plan to start stock WRX 180ish whp for my vin registration and inspection. When i take it all apart for powdercoating, I have parts to build my motor up and run e85 close to 380whp.

    Enough typing, here we go...

    Oh yeah, the most important thing to say and I almost forgot. I want to thank everyone who has gone before me and documented your work, it has been extremely valuable. I can't truly express my full appreciation and gratitude for everyone's time and energy.

  2. #2
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    Last edited by bbjones121; 05-01-2015 at 10:25 PM.

  3. #3
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    Garage Remodel

    Garage remodel. Took way to long, but a 240v electric heater will warm the garage from freezing to comfortable in about 20mins now.

    Before.
    DSC04040.JPG0917142053.jpg

    During.
    DSC04096.JPGDSC04095.JPGDSC04060.JPGDSC04120.JPG

    Finishing.
    DSC04135.JPG0118151411a.jpg0118151412.jpg

    Cleanup.
    DSC04343.JPG
    Last edited by bbjones121; 05-01-2015 at 10:25 PM.

  4. #4
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    Last edited by bbjones121; 05-01-2015 at 10:26 PM.

  5. #5
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  6. #6
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    Steering Rack

    Steering rack depowering.
    All ports cut off and welded. Pinion welded. Steel and aluminum polished and clear coated.

    DSC04381.JPGDSC04383.JPG

    DSC04386.JPGDSC04387.JPGDSC04388.JPGDSC04389.JPGDSC04390.JPG

    DSC04400.JPG

    DSC04395.JPGDSC04405.JPG
    Last edited by bbjones121; 05-01-2015 at 10:27 PM.

  7. #7
    Mechie3's Avatar
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    Looking good. Car and garage. What heater are you using?
    Zero Decibel Motorsports
    Check out my new website!
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    www.facebook.com/zero.decibel.motorsports

  8. #8
    Senior Member bil1024's Avatar
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    Awesome, looking good!

  9. #9
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    Quote Originally Posted by Mechie3 View Post
    Looking good. Car and garage. What heater are you using?
    Thanks. It is the Dr Heater 988. Little red box.

  10. #10
    Senior Member AZPete's Avatar
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    You do nice work. Keep the photos coming please.
    818S/C : Chassis #25 with 06 WRX 2.5 turbo, ABS, cruise, PS, A/C, Apple CarPlay, rear camera, power windows & locks, leather & other complexities. Sold 10/19 with 5,800 miles.
    Mk3 Roadster #6228 4.6L, T45, IRS, PS, PB, ABS, Cruise, Koni's, 17" Halibrands, red w/ silver - 9K miles then sold @ Barrett-Jackson Jan 2011 (got back cash spent).

  11. #11
    Senior Member Frank818's Avatar
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    Really good to see your build thread for progress and follow-ups!
    Frank
    818 chassis #181 powered by a '93 VW VR6 Turbo GT3582R
    Go-karted Aug 5, 2016 - Then May 19+21, 2017
    Tracked May 27/July 26, 2017
    Build time before being driveable on Sep 27, 2019: over 6000h
    Build Completed Winter 2021

  12. #12
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    Brake caliper powdercoating.
    I knew those huge seat boxes would come in handy.
    Two coat chrome and candy orange.
    0303152148a.jpg

    0303152146a.jpg

  13. #13
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    DSC04413.JPG

    I dont know if this pops as much as i would like. What do you all think?

  14. #14
    Mechie3's Avatar
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    Looks copperish in the photo. Not sure if it's the lighting or the actual part. I like the FFR logo though. It feels more OEM than "818" on the calipers.
    Zero Decibel Motorsports
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  15. #15
    Senior Member billjr212's Avatar
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    nice progress and I like the calipers and logos. Agree that they look copper.

    Curious, where are you hosting your photos? Most (including my own) don't show up for me at work since I'm behind a firewall (imgur and photobucket are blocked).

    Keep the pictures coming!

  16. #16
    Senior Member flynntuna's Avatar
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    Anything is better than "Bronco" orange. lol
    Seriously though, that color gives it a sophisticated look, I like it.

  17. #17
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    Yeah, the lighting is bad in the photo. They are lighter. I will try to get some better photos with them on the car this weekend.

    I am using google+ for photo location. If you right click a photo, you can copy the url. I just past that url in here.

  18. #18
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    Brake Caliper Color

    Final brake color:
    Illusion orange plus clear vision topcoat from prismaticpowders
    DSC04428.JPG
    DSC04429.JPG
    DSC04449.JPG
    Last edited by bbjones121; 05-01-2015 at 10:28 PM.

  19. #19
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    Final Steering rack.
    Polished and ports ground off and welded shut
    DSC04416.JPG

  20. #20
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    Steering and pedals.
    DSC04452.JPG

  21. #21
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    Looking good. Moving along nicely.

  22. #22
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    Pedals

    Final pedal location.
    Welded and supported the gas pedal mount.
    The bracket flexes a lot and the manual calls for rivnut mounting to the chassis, even worse. The whole gas pedal assembly flexes over an inch when you push it down. I bet you would bend the bracket if you were racing.





    I flattened the upper section which sit perfectly on the back side of the clutch shaft tube in the donor pedal box. I cut the top and welded it to the tube. There was still flex, so I used the top piece and made a support.







    Last edited by bbjones121; 05-01-2015 at 11:00 PM. Reason: better picture format

  23. #23
    Senior Member TouchStone's Avatar
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    Does your clutch pedal still work after the welding?
    818S Chassis #288 2.5L 323hp
    Ordered: 9/19/14 Received Kit: 11/2/14 First Start: 5/31/15 First Drive: 6/7/15 Registered: 3/10/2016 Completed: 2/10/2017
    Status: Complete Build Thread Sold 9/22/2017
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  24. #24
    Senior Member Frank818's Avatar
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    Quote Originally Posted by TouchStone View Post
    Does your clutch pedal still work after the welding?
    Yeah I second that, the tube its welded on turns when you press on the clutch.
    Frank
    818 chassis #181 powered by a '93 VW VR6 Turbo GT3582R
    Go-karted Aug 5, 2016 - Then May 19+21, 2017
    Tracked May 27/July 26, 2017
    Build time before being driveable on Sep 27, 2019: over 6000h
    Build Completed Winter 2021

  25. #25
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    Quote Originally Posted by TouchStone View Post
    Does your clutch pedal still work after the welding?
    Haha. Yeah it does. Come on...give me a little credit that i wouldn't do that . I tried to keep my weld from bonding to the inner tube. As far as i can tell there is no added friction.
    Trust me though...i have done plenty of stupid things. Especially with the rear bearings, abs ring, seals when i powdercoated the rear uprights.

    I think it would be easy for FFR to add an extra tab that you could rivet to the pedal box where i welded the back brace (not the tube part).
    Last edited by bbjones121; 03-30-2015 at 08:04 AM.

  26. #26
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    Wheels and Tires

    Factory five gunmetal wheels with Federal 595rsr 255/35-18 in rear and 210/40-17 in front.












    Last edited by bbjones121; 05-01-2015 at 10:55 PM.

  27. #27
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    Finally mounting the seats. Sparco sliders angled up to allow seats to go up over the angled square tube a bit.
    DSC04514.JPGDSC04519.JPGDSC04523.JPG

  28. #28
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    Fantastic progress! I can't wait to see the final product.

  29. #29
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    Thanks chedda. How is yours coming along?

  30. #30
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    5 steps forward, 3 steps back but this time for the better. My build is sitting at ZFABmotorsports for the exhaust mockup and build but then the motor started leaking...

  31. #31
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    Quote Originally Posted by chedda View Post
    5 steps forward, 3 steps back but this time for the better. My build is sitting at ZFABmotorsports for the exhaust mockup and build but then the motor started leaking...
    Bummer, sorry to hear, hopefully it is an easy fix.

  32. #32
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    The heads went to the machine shop. My thread shows all the pictures and what not. It happens when building motors right? lol

  33. #33
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    Quote Originally Posted by chedda View Post
    The heads went to the machine shop. My thread shows all the pictures and what not. It happens when building motors right? lol
    I just saw the pics. Yeah, I will be crossing my fingers when I start mine up. Good luck.

  34. #34
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    If you ever want to come by and check it out, you are welcome to do so

  35. #35
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    Quote Originally Posted by chedda View Post
    If you ever want to come by and check it out, you are welcome to do so
    Would like to. Are you around this weekend?

  36. #36
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    Seats mounted and done. Making the sliding rails work is a pain!






  37. #37
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    Radiator mounted and complete. Mechies brackets work and look great! I welded my own supports to the chassis so they can be powder coated later.








  38. #38

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    Quality work. Keep on with the progress. One milestone at a time.

  39. #39
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    Quote Originally Posted by Kurk818 View Post
    Quality work. Keep on with the progress. One milestone at a time.
    Thanks. Yup, slowly but surely.

  40. #40
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    I would agree with the quality work and I am sure that the finished product with reflect that. I wish I could weld and fabricate like that. I fell like is tend to stumble through it and spend more time fixing the problems I created. Can't wait to see it in person. Keep up the good work.

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