Lumpyguys 818S build

**Lumpyguy** · 01-30-2015, 05:38 PM

I do not have any machines other than a grinder, cut off tool, Mig welder and a Tig, Oh and a hammer! I am great at tig welding steel and can do aluminum but not as good at it. also I have no argon gas now only 75/25. so I am mig welding the steel.

**Lumpyguy** · 01-30-2015, 05:40 PM

My plan is to wrap the console in Vinyl to match the padded dash and door panels.

**Lumpyguy** · 03-01-2015, 10:32 AM

Well after waiting for clutch and flywheel and some brake parts I was able to get a few more things done over the last few days. this will be it for a few weeks as I am going to South Carolina for 2 weeks. I put the engine and trans together with 2WD conversion, built the driveshfts, made brake lines and installed the brakes, made PCM mounting panel, installed the the rest of the suspension waiting on an end link for the sway bar.

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And I was able to finish the final adjustment of my parking brake, its a 2 inch stroke motor and the first 1inch is dead pull not touching the cables and the next 1 inch is the apply. so at full travel of 2" the actuator stops and the brake is fully applied (So Its is not over streached)

**Lumpyguy** · 03-01-2015, 04:03 PM

I was at the store and found these Stainless steel 1 Liter water bottles and they were only 4.99 each! so I got 3. one for a washer bottle and 2 for coolent over flows (front and rear) I will clamp them to the frame and run a hose thru the top.

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**Lumpyguy** · 03-28-2015, 02:30 PM

well it has been awhile but I got a few more things done. most of the motor is hooked up need to finish turbo and and intake stuff. the next big task will be to start my harness diet and install. I finally got a chance to put the wheels on and roll it out of the garage for some spring cleaning and organizaion. excuse the 4x4 under the shifter I was just figuring location as it will sit on top of my new console. the wheels and tires are not what I am using they are just to push the car around. ops blurry pics

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**Scargo** · 03-28-2015, 04:19 PM

I like the brake line routing. Red, huh? Looking good.

I have a question. I think you have the coolant tubing kit that Michael Everson (http://www.replicaparts.com/) sells? Except for the logistics and impossibility of shipping long pieces, do you think you could have almost all of a complete side of cooling tubing welded together and eliminate a half-dozen hose joints?

**Lumpyguy** · 03-28-2015, 10:37 PM

my coolant tube kit is one that I pieced together with rad hose and aluminum tubing, I was trying something different. for all the hose, clamps and pipeing it was less than 200 bucks. If I was to buy mandrel bent pipe and the cost of welding i could have bought a kit.

**Frank818** · 03-29-2015, 05:27 PM

Red brake flex lines! How neat!

**Lumpyguy** · 03-29-2015, 07:31 PM

didnt need red I just got a deal on them

**bbjones121** · 03-30-2015, 03:13 PM

Looking good. Any more progress on the interior redesign?

**Lumpyguy** · 03-30-2015, 08:00 PM

no not much lately on the interior, I am working on how to mount Waynes shifter inside the console so I only have main body and lever above the console.

I am goin to make new interior door pulls that will mirror wayne's shifter ( Flat aluminum with cutouts like the side pieces of the K-Tuned shifter) also some sort of door open mech as I dont like the looks of the stock subaru door latch handle. dont think I want poppers, maybe some cool mechanical lever off the door pull handle.

**Lumpyguy** · 04-03-2015, 06:33 AM

well I want to send out the console soon to get covered so I had to finish the fab work for the shifter, I made a new mounting plate for the shifter and cable mounts and put under the console so I only have the shifter on top. I think it turned out nice. once the console is wraped in vinyl to match the dash and doors it should look good.

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**Harley818** · 04-03-2015, 11:58 AM

I like how your console sweeps up to the dash instead of flat plate aluminum. I'm thinking of doing something similar.
Whats the ABS canister for near the fuel fill? I guess I missed that post.

**Lumpyguy** · 04-03-2015, 03:12 PM

sorry might have missed that myself, the ABS canister is a carbon cannister for the fuel tank vent (something to suck gas fumes)

**Lumpyguy** · 07-09-2015, 06:53 PM

Well its been a long time but I have a car almost ready for Go Kart stage! after alot of work doing the diet the electrical works! and the engine started right up but ran rough (did not have MAF in and injector Oring leak) fixed all that and she fired up and ran great and on her own!

**Tamra** · 07-09-2015, 08:39 PM

Congrats! Any video of the first start?

**Lumpyguy** · 07-10-2015, 06:44 AM

No, No video I think I was to busy running everything thru my head to make sure it was all there and working to start and the shock of it starting up! I will get my wife to video the first drive for sure when ever that will be.

**Mitch Wright** · 07-10-2015, 08:17 AM

Congratulations

**Frank818** · 07-10-2015, 05:52 PM

Nice! Hopefully the 1st drive will go well!

Make sure your wife doesn't forget to press on the START button for the video! lolll Oops sorry about that.

**Harley818** · 07-10-2015, 11:40 PM

That's funny. My first start was the same. I set it all up checked twice and was too shocked that it started after all the hours on wire diet that I missed my first vid as well. Lol

**Lumpyguy** · 08-16-2015, 03:03 PM

Well I am a day or two from the first gokart run! till a long way to go!

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once the gokarting is done I can wrap and tape all the wiring and secure, paint the exhaust, then I can move onto the body!

**Tamra** · 08-16-2015, 03:38 PM

Looks great! I like the sway bar end link as a pitch stop

Are you worried about your exhaust rubbing against the bumper panel at all? It's a pretty tight fit there.

**Gary Livingston** · 08-16-2015, 05:41 PM

Looks really good Todd. I love the custom mods. What brakes did u get? Rotors? Getting exciting!

**Lumpyguy** · 08-16-2015, 05:50 PM

No I am good on the bumper clearance, it sits in the opening where the mesh/screen would go. I built it all with the side sails and bumper on the car to make sure it all fits. I just need to put a bit of insulation tap in a few spots to keep the potential heat away from the trans and body. I have not finished the tail pipe yet till I know if anything hits while driving.

**Lumpyguy** · 08-16-2015, 05:51 PM

I just got some cheap ceramic pads and cheap drilled rotors off line from TO

BN · 08-16-2015, 09:09 PM

Keep up the good work

**Kurk818** · 08-17-2015, 08:17 AM

Awesome work. Glad to see you making so much progress.

**Lumpyguy** · 08-18-2015, 08:05 PM

First run is in the books! and its was really sucsessfull! after a few runs around the block to feel the brakes and steering I did a big dump and spun the hell out of the tires! only a few things to work on (engine codes) and a few more runs to make sue! I just had a victory beer!

also my AP fell out of the car on a corner and was dragging beside the car! LOL

**Frank818** · 08-18-2015, 08:13 PM

Great, I'll have a beer for you! You just gave me a great excuse!

Your AP? AP Racing calipers? lolll I hope they weren't dragging beside the car!

**Tamra** · 08-18-2015, 09:40 PM

Awesome, Congrats! Any video? Our Access Port came with a magnetic holder that we installed on the dash. I would recommend it

**Lumpyguy** · 09-10-2015, 03:45 PM

Well I am away for work for a few weeks but I thought I would pre fit a bunch of the body to let it sit in its shape for a few weeks. As everyone has noted there is a lot of fine tuning when setting up the panels.

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**Gary Livingston** · 09-10-2015, 04:05 PM

Sweet! Looking good Todd.

**Lumpyguy** · 12-10-2015, 06:40 PM

Well its been some time since I posted anything, I have been busy with work but have taken the last 2 weeks off and finish opening up and widening the side vents and cutting out all the other vents, cutting in the 3rd brake light.

I cleaned and sanded all the panels, primed each panel with 3 coats 2K high build primer, sanded each one and re assembled then all to check that all is still good. now time to remove and put in the basement till paint time.

I remember why I hate body work!

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**Canadian818** · 12-10-2015, 07:21 PM

I like the side rear cutouts you did. Do you have a straight on shot?

**Hindsight** · 12-10-2015, 08:58 PM

Looking good!

**bbjones121** · 12-11-2015, 12:51 AM

Looks great.

BN · 12-11-2015, 04:20 AM

Originally Posted by Canadian818

I like the side rear cutouts you did. Do you have a straight on shot?

Looking good

**Lumpyguy** · 12-11-2015, 06:31 AM

here are few pics of before primer and after as well as driver and passenger side.

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**AZPete** · 12-11-2015, 10:13 AM

Nicely done

**Lumpyguy** · 12-22-2015, 04:43 PM

Well it was another good day in the garage today, I was going to order the FF wiper kit but then thought I could make my stuff work. fabed up everything with a little guessing and measuring and surprise it works. I did have to cut off just over and inch across the back of the hood but it dressed up nice and will put a little edging on it after paint. I also made 2 support brackets on each side of the motor to support the hood.

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