Category: 818R Race Car

Trans Protection and Rear Wing Chassis Mount

I am long overdue for an update so here goes. I have been slowly working on the rear car and putting together a solution to protect the transmission and also provide a rear wing mount.

These were the inspirations.
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Welded some mounts to the rear chassis brace.

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Set up the frame for this structure. I used clevis ends on the tubing ends to attach to the chassis. That way I can remove the whole structure if I need to pull the engine.

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Fabricated some saddle gussets to reinforce the cross members.

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I cut away a lot of the rear bumper. The plan is to replace the cutout with a black metal mesh and then just go with a pair of circular tail lights on the ends. The rear wing supports would then attach through there along with running the exhaust through the center.

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I have a cross member that protects the transmission.

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The whole thing can rotate up or be completely removed.



More Panels, Tabs, and Rivnuts

I think I am overdue for an update!

My goal is to rivnut most of the panels. This requires fabricating and welding on a bunch of tabs.

Front underbody:

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Center underbody:

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Side body panels (with CF splitters):

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I picked up a JD2 M3 tube bender for building my own rear chassis wing mount/transmission protection.

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Digging the open rear end and the rear attached wing supports; wonder if anyone has tried this.

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Front Firewall and Intrusion Panels

Finished most of the front firewall, intrusion panels, and interior panels. Rather than using rivets and drilling into the chassis tubes, I ended up welding on a bunch of tabs and using 1/4 and 10-32 rivnuts.

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For the intrusion panels, I used 6061-T6 1/8″. The interior panels were actually the FFR exteriors, but I trimmed them for the interior. All the panels are then fastened using 1″ counter sunk spacers.

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Also cut away the door mounts.



Bye Bye STI

Off to a new home in Oregon…

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Shafted

Man, you guys make it sound so easy! Tried the hose clamp method without any luck. I am using the STI rear shaft. The groove in the FFR shaft is deeper and looks wider. I think that makes easier. Yet another STI issue it seems.

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Damaged Axle Shaft

I was having a hell of a time trying to get the rear outer CV back onto the rear axle shaft. The circlip was a real bitch. Using a hose clamp and a hammer didn’t work. So I took the 12 ton press to it and damaged the splines.

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The sad thing is I only removed the rear outer CV to investigate which axle shaft to use. Then discovered the rear shafts were the ones.  Sigh….off to eBay to find another rear axle assy.



Axle Shaft Fun

Spent today figuring out which axle shaft is going to be just right. From others, it sounded like I was going to be using the front shafts and dealing with the extra length. Well that’s not the case with the 2004 STI. Fortunately, I can use the rear shafts. So with a 2004 STI you can use the rears, keep the outer CV on and then just switch out the inner with the front inner.

Here are the specs:
Axle / Spline Count / Diameter / Length
FFR 80237/ 29 / 0.935″ / 20.75″

2004 STI Front Shaft / 32-30 / 1.02″-0.9625″ / 20.75″

2004 STI Rear Shaft / 30 / 0.9625″ / 20.75″

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Better Slider Handle

The Sparco slider handle was too wide and didn’t have enough vertical clearance with that front diagonal cross brace. Fabbed a new one using the ends of the Sparco handle.

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The new one…

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More room to pull up on the handle now…

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Making Room for the Trans

So FFR says these 0.6″ spacers that came in the 6-speed kit go between the transmission and the mount. Doesn’t work for me.

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In this pic, the transmission is resting on the pan (on the chassis). The transmission mount bolts aren’t long enough to accommodate the spacers. No new transmission mount bolts in the kit either. So used some other long bolts for testing. The spacer probably needs to be more like an inch or so to work. So maybe this is another 04 6-speed incompatibility.

So modified the chassis (Zach’s way).

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Fits perfectly!

Also cleaned up the tail housing with the freeze plug. Great idea Kurk!

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Engine and Transmission in the Chassis

Got the transmission back on the engine and into the chassis to check out the clearance issues with the transmission oil pan. My 6-speed kit came with 4 .60″ spacers. I assumed that these were the spacers Jim Schenck mentioned they used to clear the chassis. There aren’t any instructions for the spacers. I am guessing they go on top of the engine mounts. Have an email out to FFR to confirm.

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Out of curiosity I tried two at the transmission mounts. No way.

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Assuming these spacers go on top of the engine mounts, that pushes the engine even closer to the top cross bars making an already tight area even more so.  A chassis modification might still be the best way to go.