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Thread: JJ's 818s Build

  1. #41
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    Quote Originally Posted by TouchStone View Post
    I want to send in my fuel injectors to be ultasonic cleaned, and flow tested. Can anyone recommend a place?
    This place can do it: http://www.deatschwerks.com/services...ector-services

  2. #42
    Senior Member Tamra's Avatar
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    The engine looks great!
    Tamra
    Building 818SR #297 picked up 10/25/14 with Andrew (xxguitarist)
    First start 12/21/14, First "drive" 1/17/15
    First Dyno at EFI Logics 3/7/15- 310whp at 15psi for break in, full spool by ~3500rpm!
    First autocross 3/29/15
    1st Registered 818 in Connecticut 7/24/2015. 9 months - 1 day from kit pickup!

  3. #43
    Harley818's Avatar
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    Dont forget to do Waynes coolant mod into the upper coolant casting before you go any further. It will be much easier before you install the engine, although a few of us have done it.
    Harley
    Bought 2002 Donor Jan 2014
    First Start Jan 18, 2015
    First Drive Feb 14, 2015

  4. #44
    Senior Member TouchStone's Avatar
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    Quote Originally Posted by Harley818 View Post
    Dont forget to do Waynes coolant mod into the upper coolant casting before you go any further. It will be much easier before you install the engine, although a few of us have done it.
    What mod is this?
    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
    joshuajach.com

  5. #45
    Senior Member billjr212's Avatar
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    Quote Originally Posted by TouchStone View Post
    What mod is this?
    See post #8 in the attached.

    http://thefactoryfiveforum.com/showt...7s+coolant+mod

    Alternatively you can get a VW elbow which has a barb off of it to run back to the degas tank. (Goldwing did this and I copied)

  6. #46
    Senior Member TouchStone's Avatar
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    Harley/Billjr

    Ill definatly be adding that port to help fill the coolant. Thanks for pointing it out.
    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
    joshuajach.com

  7. #47
    Senior Member TouchStone's Avatar
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    Sent out my injectors to "deatschwerks", should have them back in a week or two. I like that they send out detailed test results.

    I wrapped my donor exhaust manifold and Grimmspeed up-pipe with DEI Titanium Exhaust Wrap. I'm not sure if this will actually improve performance, I mainly did it for the look. I'm not super happy with the job I did, but my excuse is that the 3 part OEM exhaust design does not make for an ideal wrap.

    Last edited by TouchStone; 05-05-2015 at 11:00 PM.
    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
    joshuajach.com

  8. #48
    Member tebriel's Avatar
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    Quote Originally Posted by rtz View Post
    I used to use racetronix.com back in the day with my turbo saturns.

  9. #49
    Senior Member Bob_n_Cincy's Avatar
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    Quote Originally Posted by TouchStone View Post
    I wrapped my donor exhaust manifold and Grimmspeed up-pipe with DEI Titanium Exhaust Wrap. I'm not sure if this will actually improve performance, I mainly did it for the look. I'm not super happy with the job I did, but my excuse is that the 3 part OEM exhaust design does not make for an ideal wrap.
    The main reason for wrapping the exhaust is to keep the heat out of the engine bay. I used SS hose clamps every so far to keep it tight.
    Bob
    818S #22 Candy Blue Frame, Front Gas Tank, 2.5L Turbo, Rear radiator, Shortened Transmission, Wookiee Compatible, Console mounted MR2 Shifter, Custom ECU panel, AWIC soon
    My Son Michael's Turbo ICE Build X22 http://thefactoryfiveforum.com/showt...rts-818S-Build
    My Electric Supercar Build X21 (on hold until winter) http://thefactoryfiveforum.com/showt...e-Build-Thread

  10. #50
    Senior Member flynntuna's Avatar
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    image.jpgHas any one have any experience with this tool?

    http://clamptool.com/pages/how2.html


    Now back to your regularly scheduled thread.

  11. #51
    Senior Member TouchStone's Avatar
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    Painted tranny plate.
    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
    joshuajach.com

  12. #52
    Senior Member flynntuna's Avatar
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    That is soooo nice, the talent and imagination on this forum is outstanding!

  13. #53
    Senior Member TouchStone's Avatar
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    Went to harbor freight to buy some automobile wheel dollys, however they were on sale and sold out. So instead I built two rollable support bridges out of carpet dollys (inspired by another member). Total cost was around $60 half what I was gonna pay.

    The frame fits just bearly sideway in my garage which means I can turn the car around to drop the engine in.



    Now my daily driver will fit in the garage as well.

    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
    joshuajach.com

  14. #54
    Senior Member TouchStone's Avatar
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    Engine Drop

    Someone made me jealous that they dropped their engine in. So of course I had to do the same.

    I decided to drop in the engine separate from the tranny since many people have complained about the difficulty of getting the engine in the 818. Plus the two were already seperated. Once the engine is in you need to add temporary support to keep it from tilting foward. I used a couple 2x4's, that can be seen in the picture, braced against the steering wheel pump and alternator brackets. (If you know a better way tell me)



    It took me two days to get the tranny in (due to inexperience). I had not aligned the clutch disk with the flywheel bearing. I used an assortment of sockets to fake the alignment tool and eyeballed it. Worked like a charm, very happy thats done .


    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
    joshuajach.com

  15. #55
    Senior Member Tamra's Avatar
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    Congrats on getting the engine in!

    I'm jealous of your garage.
    Tamra
    Building 818SR #297 picked up 10/25/14 with Andrew (xxguitarist)
    First start 12/21/14, First "drive" 1/17/15
    First Dyno at EFI Logics 3/7/15- 310whp at 15psi for break in, full spool by ~3500rpm!
    First autocross 3/29/15
    1st Registered 818 in Connecticut 7/24/2015. 9 months - 1 day from kit pickup!

  16. #56
    Moonlight Performance
    Hindsight's Avatar
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    Nice work!

  17. #57
    nkw8181's Avatar
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    Lookin good!
    Nolan
    65 coupe Gen 3 "Phoenix" build
    http://thefactoryfiveforum.com/showt...032#post297032

    818 s (with r windscreen ) 350 rwhp. Registered and street legal (SOLD)

  18. #58
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    Looking really good. I'm in the Dallas area too. Just getting the donor torn apart and the parts all cleaned and painted. Should only be a month before I get my kit in. Let me know if you need any help. Would be glad to.

  19. #59
    nkw8181's Avatar
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    Sounds like there's three of us now in dallas!
    Nolan
    65 coupe Gen 3 "Phoenix" build
    http://thefactoryfiveforum.com/showt...032#post297032

    818 s (with r windscreen ) 350 rwhp. Registered and street legal (SOLD)

  20. #60
    Senior Member TouchStone's Avatar
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    Awesome! Now its a crowd.
    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
    joshuajach.com

  21. #61
    Senior Member TouchStone's Avatar
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    Replaced my engine mounts with STI mounts. They look like they are just replacement parts but the rubber used is supposed to be stiffer and higher quality. They are also half the price of cusco mounts.

    Now I officially have the engine in.



    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
    joshuajach.com

  22. #62
    Senior Member TouchStone's Avatar
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    Fuel Injector came back from deatschwerks. All 4 are consistent which is good enough for me.

    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
    joshuajach.com

  23. #63
    Senior Member STiPWRD's Avatar
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    I also picked up the stiffer STI (group-n) mounts but I noticed their steel mounting plates didn't include the integrated heat shields like the stock wrx plates. I ended up swapping the steel plates to retain the heat shields with the stiffer mounts.

  24. #64
    Senior Member TouchStone's Avatar
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    Quote Originally Posted by STiPWRD View Post
    I also picked up the stiffer STI (group-n) mounts but I noticed their steel mounting plates didn't include the integrated heat shields like the stock wrx plates. I ended up swapping the steel plates to retain the heat shields with the stiffer mounts.
    I noticed that when I was swapping them out but I didn't think it mattered much.
    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
    joshuajach.com

  25. #65
    Senior Member TouchStone's Avatar
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    Made a temporary table out of the shipping crate my engine shipped in. I'm going to be using it to layout and route wires for my chassis harness. The tape on the table is an initial layout plan for the front and rear or the car. Still need to measure the cabin for wiring.

    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
    joshuajach.com

  26. #66
    Senior Member TouchStone's Avatar
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    A messy table, will most likely get much messier.
    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
    joshuajach.com

  27. #67
    Senior Member Bob_n_Cincy's Avatar
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    Touchstone,
    Take a look at my thread,
    It might help you out. Let me know if you have questions.
    Bob

    http://thefactoryfiveforum.com/showt...l=1#post146406
    818S #22 Candy Blue Frame, Front Gas Tank, 2.5L Turbo, Rear radiator, Shortened Transmission, Wookiee Compatible, Console mounted MR2 Shifter, Custom ECU panel, AWIC soon
    My Son Michael's Turbo ICE Build X22 http://thefactoryfiveforum.com/showt...rts-818S-Build
    My Electric Supercar Build X21 (on hold until winter) http://thefactoryfiveforum.com/showt...e-Build-Thread

  28. #68
    Senior Member TouchStone's Avatar
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    Woot, I've got one working headlight. Actually both would work if plugged in. This was mainly a test to make sure the relays are working as I expect them to.

    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
    joshuajach.com

  29. #69
    Harley818's Avatar
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    Good call on the group N mounts.... from what I hear, the stock ones allow too much movement.
    i got the type N for engine and tranny. They are waaaay stiffer.

    I can relate to the wiring.... it will get way more messy!

    I did something similar, but laid the plywood on top of the rollbar and the front of the car..... right at work height and helped space it out right.
    I used the stock wiring, and just cut out and spliced in where necessary. All works now.

    See post #92, 94, etc
    http://thefactoryfiveforum.com/showt...y-s-818S/page3
    Last edited by Harley818; 04-25-2015 at 01:35 AM.
    Harley
    Bought 2002 Donor Jan 2014
    First Start Jan 18, 2015
    First Drive Feb 14, 2015

  30. #70
    Senior Member TouchStone's Avatar
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    Got my front brake rotors in. The first paint job I did on the calipers is already noticeably flaking (bad paint job or surface prep?). So I think I'm going to repaint my calipers and probably change the color while I'm at it.

    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
    joshuajach.com

  31. #71
    Senior Member TouchStone's Avatar
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    Finished wiring for the front lights and radiator fans. I'm happy with how it looks after the wire sheath is in place.





    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
    joshuajach.com

  32. #72
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    Have you considered putting a connector in the front section of the harness so you can take the nose off with removing all of the individual light plugs and pulling all of the zip ties?

  33. #73
    Senior Member TouchStone's Avatar
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    Quote Originally Posted by Jaime View Post
    Have you considered putting a connector in the front section of the harness so you can take the nose off with removing all of the individual light plugs and pulling all of the zip ties?
    I hadn't considered ever taking the nose off. There is only 8 connectors in the front and I'll be using removable plastic clips instead of zip ties to hold the wires. So it shouldn't be too hard if the need arises.
    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
    joshuajach.com

  34. #74
    Senior Member TouchStone's Avatar
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    Time for a quick rant about Subaru's wiring harness.

    Who came up with the idea to do this to wires? That black stuff reminds me of Silly Putty but much stickier and certainly not silly more like ridiculous ... "Ridiculous Putty"





    I dont know why they couldn't just do something easy and clean.

    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
    joshuajach.com

  35. #75
    Senior Member TouchStone's Avatar
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    More wires

    You can never have too many wires.

    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
    joshuajach.com

  36. #76
    Senior Member TouchStone's Avatar
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    Testing my ECU with a code scanner and amp meter to make sure things are receiving power and communicating. The ECU reported a bunch of engine errors, I cant imagine why.

    I didn't have a car battery laying around so I grabbed the 12V battery from my cordless drill which works fine since I'm not planning on cranking the engine with it. Standalone the ECU uses uses about 3/4 to 1 amp of power.

    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
    joshuajach.com

  37. #77
    Senior Member TouchStone's Avatar
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    Example of a bad solder connection I found off of my donor harness. Since I needed this connector for the wastegate I had to salvage what I could from it.

    Before:


    After:


    As reference this is what a good solder connection should look like. I am very confident that in a pull test the wire would break before the solder connection breaks.
    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
    joshuajach.com

  38. #78
    Moonlight Performance
    Hindsight's Avatar
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    Looks good. Are you using a soldering pencil or a mini torch?

  39. #79
    Senior Member TouchStone's Avatar
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    Quote Originally Posted by Hindsight View Post
    Looks good. Are you using a soldering pencil or a mini torch?
    I use a Hakko 936 solder iron I bought from sparkfun years ago https://www.sparkfun.com/products/retired/9672. An excellent tool with temperature control.
    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
    joshuajach.com

  40. #80
    Senior Member TouchStone's Avatar
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    Mostly done with the harness now, here's some in progress pictures:

    All the wires are laid out and needs a few more connectors from the donor.



    Soldered the main engine connectors to the harness, I used dual lined heat shrink to add support and waterproofing to the solder joint. The black connector has 6 unused wires which were used for the TGV valves and sensors. Would have de-pinned the connector but it would have left openings and defeated the water proofing.


    Installed wire wrap
    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
    joshuajach.com

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