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Thread: Rob T's 818R Build Thread

  1. #201
    Senior Member Rob T's Avatar
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    I plan to rivet to the inside of the wheel well.

  2. #202
    Sgt.Gator's Avatar
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    I love the downspout ducting!
    "Good Judgement comes from Experience. Experience comes from Bad Judgement"
    Owner: Colonel Red Racing
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  3. #203
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    There you go, that should be a big help.

  4. #204
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    Quote Originally Posted by Rob T View Post
    OK...let me start by saying that a sheet metal worker I'm not. But for $20 and a few hours, I have a way to use my existing four holes in the front of the car and get some air to my brakes. Similar to what Gator is trying, but a little bit more of a test. Yes the material is 2X3 steal downspout, which happens to fit perfectly behind the wheel when it is at lock. Install is in two weeks.Attachment 87029

    Attachment 87030
    So got anything planned for the rear? I was thinking of trying to pull airfrom the side scoops.

  5. #205
    Senior Member Rob T's Avatar
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    So: Here are the shots from the install yesterday. It worked out as well as I hoped. $20 of parts and about 10 hours of fun. One really sore elbow (like tennis elbow) from working the rivet gun in close quarters. Also, getting the hose clamps on the nose fittings was a challenge. Luckily, I'm a little guy.

    Picture 1 - flexible hoses mounted in the front.
    Brake 1.JPG

    Picture 2 - View from the side
    Brake 2.JPG

    Picture 3 - View from the side showing relationship to rotor and caliper
    Brake 3.JPG

    Picture 4 - Another side view - complete
    Brake 4.JPG

    Picture 5 - View from the top at wheel lock - no interference
    Brake 5.JPG

    The other side is "identical". Testing will tell how much it helps, but this shouldn't hurt anything.

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  7. #206
    Senior Member Rob T's Avatar
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    Sorry for the picture rotation issues. Not sure how to fix it.

  8. #207
    Senior Member Rob T's Avatar
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    As for cooling the back brakes. I am not sure yet. What I can tell you because I changed the front pads yesterday is this....Front Pads started at 16mm and are now about 8mm. Back pads started at 12mm and are now about 8mm. So....8mm of front wear and 4mm of rear wear during the last 2+ years (1 year in the shop) of Chad and me driving.

  9. #208
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    Ok so no signs of heating on rear brake caliper, pad or disk. Just thought the rear would heat up first due to twice the pressure on the back to balance the system. Guess I'm off on that.

    By the way ducting looks good!

  10. #209
    Senior Member Rob T's Avatar
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    Replaced the brake fluid yesterday. Did a quick drive around the neighborhood. Everything seems good. Need to bed the brakes first at the track Friday. Then some open track sessions.

  11. #210
    Senior Member Rob T's Avatar
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    "rained out". I had the car on the open trailer at 6:15. Started raining. Looked at the radar and it was raining to the North where I was going. Put the car back in the garage and took my other car to the track because I was going with a friend. The other car threw a brake warning during the second set, but I was able to drive a session in my friend's car. Had a great day, but no 818R news or video. Hope to get back out in August....

  12. #211
    Senior Member mikeb75's Avatar
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    See what happens when you put rain downspouts on your car...

    Pitty, was looking forward to your report on this smart/low cost mod. Good luck in Aug!
    Last edited by mikeb75; 07-30-2018 at 08:13 PM. Reason: I can type
    818SC chassis #206 EJ207 2.0L VF37 twin scroll || Cusco type RS 1.5 LSD || Wilwood pedal box (firewall attach) || Wilwood superlite front calipers
    BUILD Phase 1: 6/6/2014 car delivered || 5/24/2015 first start || 6/7/2015 go karted || 4/20/2016 hard-top-topped || 10/25/2016 registered || 11/18/2016 inspected & complete
    BUILD Phase 2: 3/8/2017 EJ207v8 || 5/29/2017 re-first re-start || 7/17/2017 re-assembled with race car bits

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  14. #212
    Senior Member Rob T's Avatar
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    LOL. I didn't think of that. Yep, jinxed myself for sure....

  15. #213
    Senior Member Rob T's Avatar
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    Got to the track yesterday. It was a good day. 4 total sessions. 1 to bed some new front brake pads and three for driving. It was between 70 and 80 for the day with sun and a light breeze. I was at Sandia in Albuquerque. Once again, I had the 1.7mi road course to myself. The car ran well. I had fun.
    Water temp - 180 - 192
    Oil temp - 205 - 210
    AWIC - 102 max (this is hotter than before. I used to get ambient Plus 10F, but I think it is a bit warmer with a shorter, tighter, slower track)
    No issues with the brakes this time. The cooling ducts didn't hurt anything. Next time I will put some temperature paint on them to see how I am doing...
    I probably have 30 heat cycles on my Hoosiers. When Mitch Wright texted me yesterday he called them "hockey pucks" - he's right. They are OK for now....getting seat time.
    The weather said a 15% chance of rain. I have an R with an open trailer. 30 minutes into 3 1/2 hour drive home, the skies got dark. We pulled on the side of the freeway and got out my free HF tarp and some bungies. Had to add some duct tape. For the next two hours (the storm was moving south, so were we), we were in some really heavy rain. The last hour was dry. The tarp is toast, but the inside stayed dry (mostly). I am going to let the car dry thoroughly for a few days before I try to start it.

    I need to figure out some way to make a nice, waterproof and 75mph capable cover for the cockpit. I am open to ideas on materials and how to attach it. The obvious answer is covered trailer. However, my truck can't handle that weight....

    I'll post some video when I have time to upload it. I do know I was 3 seconds faster than last time I was there, and more consistent.

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  17. #214
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    Rob it sounds like a great day. I have talked to a upholstery shop that makes snap on boat cockpit covers that said they could make one for me when I was ready for it. I am sure you could find someone close to home that could make one for you in a choice of colors.

  18. #215
    Senior Member Rob T's Avatar
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    Here is a video from session 1. Best time was 1:37.975 I was pretty consistent all day, even on the heavily heat cycled Hoosiers. I still have a lot to learn in terms of driving, but I had fun.

    https://youtu.be/Ragu2eQ4gHw

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  20. #216
    Senior Member Rob T's Avatar
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    Here are some stats from my GPS and g-meters and the Traqmate software. These are the maxes from the three laps shown, although the numbers were pretty consistent.

    Maximum braking (g) 1.04
    Max accel (g) 0.89
    Max right turn load (g) 1.28
    Max left turn load (g) 1.47
    Max speed (mph) 96
    Max HP 262.78
    Max TQ 206.11

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  22. #217
    Senior Member Rob T's Avatar
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    Track day planned for 10/19. Weather is supposed to be sunny and 65, but rain up until then. I have an open trailer and got caught in a storm last time. I don't want to do that again. Praying for the storm to move through quickly. If I get to the track, I'll be sure to post videos, etc. I am going to try something different with my tires. I'll let everyone know if it works.

  23. #218
    Senior Member Rob T's Avatar
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    The Good, The Bad and The Ugly(a story of my track day....)

    The Good
    1) Weather was perfect. 60F, light winds, clear blue sky.
    2) The car was making awesome power and was running beautifully
    3) Once again, I had the track to myself.

    The Bad
    1) Somewhere around Lap 7 of the first set I started smelling smoke and transmission fluid. Never heard a noise or felt any odd vibration
    2) I pulled off the track and saw a puddle of transmission fluid under the car, coming from the front part of the transmission (not from the axles or the rear)
    3) No level level on the dipstick
    4) 7 hours of driving to and from the track for 7 laps (ouch)

    The UGLY
    1) It's amazing how far 3.5 quarts of transmission fluid can be spread in a 3-ft wide stripe on a race course. (about 1/2 mile). I stayed and helped Charlie and Mike put down the absorbent and sweep the track because they are racing motorcycles over the weekend and the oil would be dangerous for bikes.

    The car is in the garage and I have a busy weekend so I am not sure when I can begin the diagnostic. I am hoping it is something as simple as "the drain plug came out". Which would make me feel foolish, but easy to fix. Thanks again to Mitch Wright for the consulting on next steps. More to come.

  24. #219
    Senior Member Bob_n_Cincy's Avatar
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    Rob, sorry to hear about your bad day.
    Your probably lucky the oil didn't get on the rear tires.
    Let us know the cause when you figure it out.
    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

  25. #220
    Senior Member Rob T's Avatar
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    Bad News. Here are the pictures. A whole blown right through the transmission case. Looks like a piece of some gear broke off and got pushed through the casting by the bolts on the Torsen Limited Slip. Not sure how the gear broke, but this is a whole much bigger problem.IMG_4248.JPGIMG_4249.JPGIMG_4259.JPG

  26. #221
    Senior Member Rob T's Avatar
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  27. #222
    Senior Member Rob T's Avatar
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    Anybody have an idea where this gear tooth came from? There was no "bang" the car was running fine. I just smelled transmission fluid and burnt transmission fluid when it hit the exhaust. Bad news is that I probably don't have time to work on this for about a year and a half. I do have a spare transmission. I really have two options.

    1) Sell everything (not really what I want to do)
    2) Put the car to "sleep" for 14 - 16 months. Then I will have time to work on it and the space to work on it properly. If that is what I need to do, I'd be interested in a list of things I need to do to make sure the car wakes up no worse for the wear.

    Let's hear what you guys think about the failure and my options. I'm bummed because I wasn't even really pushing it. I'll work on the video in a few days and see if there are any clues there. I never dropped the clutch or did any crazy braking down shifts.

  28. #223
    Senior Member Bob_n_Cincy's Avatar
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    Rob,
    I had a transmission failure on my 818 a couple of year ago.
    My 2006 transmission case had never been opened. At that point I probably had 300 hard autocross runs on it. While driving it down the highway I dumped all the oil. Turned out the bolts the hold the ring gear to the differential worked loose and punched holes in the case.



    I picked up a 2012 MT5 transmission for $600 and was back up running a few days later.
    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

  29. #224
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    Shoot that is not what we were hoping for. Looks like a tooth from either the ring or pinion gear. You really won’t know the cause until you pull it apart and take a good look inside. When I have had something like that happen something was floating around in the gear box Like a ring gear bolt or piece of a shift fork or gear. Could just be a gear failure, the good news is you have a spare and it isn’t a tough job to change out.

  30. #225
    Sgt.Gator's Avatar
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    Quote Originally Posted by Rob T View Post
    Anybody have an idea where this gear tooth came from? There was no "bang" the car was running fine. I just smelled transmission fluid and burnt transmission fluid when it hit the exhaust. Bad news is that I probably don't have time to work on this for about a year and a half. I do have a spare transmission. I really have two options.

    1) Sell everything (not really what I want to do)
    2) Put the car to "sleep" for 14 - 16 months. Then I will have time to work on it and the space to work on it properly. If that is what I need to do, I'd be interested in a list of things I need to do to make sure the car wakes up no worse for the wear.

    Let's hear what you guys think about the failure and my options. I'm bummed because I wasn't even really pushing it. I'll work on the video in a few days and see if there are any clues there. I never dropped the clutch or did any crazy braking down shifts.
    Well that answers the mystery. Sorry to see this worst case scenario.

    Option #1 will be tough since the car is broken you aren't going to get a very good price.

    Option #2 is certainly possible and if that's your choice I and other folks here will be happy to help you with advice on hibernation. The short list from me would be to put Stabil in the tank, fill the tank all the way up, and run the engine long enough to be sure the Stabil has made it's way thru the entire fuel system. And of course change the oil before you store it. A battery maintainer is a good idea too.

    You didn't list it but I will: Option #3. Pay a local Subaru specialist shop to mod and install your spare tranny. It shouldn't cost very much.

    And before you put the new spare in you might consider putting reinforcement plates on it. The best known are the Moore Blast Plates. FastWRX also sells their MACH V Transmission Reinforcement Brace.

    And that tranny oil cooler we've discussed.

    Let's get you back on the track!


    http://shop.mooreperformanceparts.co...i-2280992.aspx

    https://www.fastwrx.com/products/mac...kit-subaru-5mt
    Last edited by Sgt.Gator; 10-21-2018 at 12:14 PM.
    "Good Judgement comes from Experience. Experience comes from Bad Judgement"
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  31. #226
    Senior Member Rob T's Avatar
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    I don't want to sell it. I will keep it. I am just short on good work time and the space I need to get serious tearing the car apart. That is why I am considering the storage option. I also want to keep learning. The storage option would "free my brain" for a while and I would stop worrying about it. The blast plates seem like a good idea.

    Rebuilding the engine was a bridge too far, but I feel like I need to be able to pull and re-install the transmission, even if I get help rebuilding it.

  32. #227
    Moonlight Performance
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    Rob, like you, I have no place to work on the 818 at my new house (no garage - currently pricing out having one built but it's SO expensive). For now, I have it stored in a Public Storage unit which costs $225 per month. I could have found one cheaper but I'm also storing all my tools and auto parts in there too so I needed a really large unit.

    As far as the transmission is concerned, for an 818R, I would strongly suggest you convert to a 6 speed and consider adding a transmission cooler. They are much more durable than the 5-speed units. It does require a frame modification and also new shifting linkages and a few other bits, but it's been well-documented here.

  33. #228
    Senior Member Rob T's Avatar
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    Hindsight: I see a 6 speed in my future. I have been talking to Wayne who has done a bunch of them.

    I watched the video and can't figure out where I broke the car. I will post it shortly. Here is a synopsis of the "best of best" numbers from my few laps at Sandia on 10/19

    Best time: 1:38.726
    Braking: 1.07g
    Acceleration: 0.908g
    Right Turn: 1.31g
    Left Turn: 1.50g
    Max speed 97.77mph
    Max HP: 242.18 (calculated)
    Max TQ: 189.28 (calculated)

    60F sunny, light winds. Had the track to myself.

  34. #229
    Senior Member Rob T's Avatar
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    Here is the video from the 10/19/18 session at sandia before the transmission broke.

    https://youtu.be/tj5X32Mmij0

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  36. #230
    Senior Member Rob T's Avatar
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    On Thursday, my car was abducted by aliens in Roswell, NM. On the "spaceship" were some other specimens including a Ferrari F40, a new Saleen pick-up and a Rolls Royce SUV. Fortunately, the aliens released my car, uninjured, in Enterprise Alabama, where Wayne Presley found it.IMG_4938.JPGIMG_4939.JPGIMG_4940.JPG

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  38. #231
    Tazio Nuvolari wannabe Scargo's Avatar
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    But did it breed with any of the other cars? What will Wayne do with it?

  39. #232
    Senior Member Rob T's Avatar
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    6 speed conversion, new clutch, new flywheel. This, after I broke my 5MT.

    At some point in the future, I will have my spare 5MT for sale(not the broken one), a clutch and a flywheel, as well as a torsion LSD, assuming it didn't get trashed when the gear tooth punched through the case (take a look back in my thread to see)

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  41. #233
    Senior Member Hobby Racer's Avatar
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    Which 6 speed did you go with? I recently picked up a JDM 6 speed out of a Legacy Spec B that I'll be putting in next winter. I also picked up the longer ratio 5th and 6th gears so the box will have the same gearing as the USDM Legacy Spec B and the JDM Forester STI 6 speeds. IMHO its the best gearing for an 818.
    MK3.1 Roadster completed 2011
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    818R rebuild with a JDM Honda K24A

  42. #234
    Sgt.Gator's Avatar
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    Quote Originally Posted by Hobby Racer View Post
    Which 6 speed did you go with? I recently picked up a JDM 6 speed out of a Legacy Spec B that I'll be putting in next winter. I also picked up the longer ratio 5th and 6th gears so the box will have the same gearing as the USDM Legacy Spec B and the JDM Forester STI 6 speeds. IMHO its the best gearing for an 818.
    The JDM Forrester STI 6 speed was my swap into my legacy GT Wagon race car. It ran well. The internal oil pump makes hooking up an aux trans cooler fairly simple. I've since replicated it on my USDM 2005 STI tranny. ZF Design rebuilt my STI tranny last winter and put Spec B / JDM Forester STI gearing ratios in it.
    My transmission temp gauge never goes above 180 even in long endurance races.
    "Good Judgement comes from Experience. Experience comes from Bad Judgement"
    Owner: Colonel Red Racing
    eBAy Store: http://stores.ebay.com/colonelredracing
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    2005 Subaru STI Race Car ICSCC ST and SPM
    Palatov DP4 - ICSCC Sports Racer

  43. #235
    Senior Member Rob T's Avatar
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    Great to hear. Thanks,

  44. #236
    Senior Member Rob T's Avatar
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    I picked up my 818R from Wayne in Enterprise AL on my way from Roswell, NM to Woodruff, SC. The 6 speed is in. Wayne ran a pull on his Mustang Dyno. 275 RWHP and 248RWTQ. Need to put some new shaft seals on. Looking forward to getting back on the track. I have a few projects to do at the new house before I get to work on the car. 2,000 pine trees to plant before Christmas....

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  46. #237
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    Enjoy your retirement Rob.

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  48. #238
    Senior Member Rob T's Avatar
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    Well....the car is all back together. Up on jack stands still. Replaced both shaft seals and pulled both stub shafts. One of the seals was completely blown and I ended up using a magnet to get the spring pieces out of the diff. I ordered both of the Company 23 sundial tools. A bit pricey, but they work awesome, right over the top of the stub shaft. My 6MT has both sizes. They made pulling and replacing the sundials a piece of cake. I also developed "my own" trick for the stub shafts. I used a 14 inch nail puller and increasing thickness shims under it. The nail pulling end fits under the CV body and there is a lot of leverage. Once I figured it out, they popped right out. I took the opportunity to install rivnuts on the diffuser to make it removable. Also did the same thing for the back panel. Ran the car on jack stands yesterday up to temperature and to check for leaks (none - I had to pull the pan on the bottom of the transmission and it was my first Permatex gasket). Also bled the brakes. Carolina Motorsports park has some track days coming up.......

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  50. #239
    Senior Member Rob T's Avatar
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    Back on the track! I had my first track day in SC yesterday. Got out to Carolina Motorsports Park. The people there are awesome. It's been a long time since I was in my car. I bedded in some new brakes and did two other 20 minute sessions. I am trying to figure out the new 6 speed transmission and how it feels. The car ran great. The track was wet when we started from an all night rain. I only had 5 cars in my run group. Talk about open track. It was 42F when we started and about 100% RH. Car made great power. Water temps about 175. Oil about 180 to 190. New transmission was 160 after the last session. I'll post some video when I get a chance. Lots for me to learn about track driving. CMP is going to resurface this summer. By fall, it will be a brand new track. If you ever get a chance to come to CMP for their Turn One track days, the staff and drivers are laid back. A fun day. The track is also "safe" with lots of run off area.

  51. #240
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    Right on Rob, good to hear you're back on the track and the car is running well. How is the track at CMP?
    818R Build date 10/31/15

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