My Slow DA build...

GENERAL General G2/G2IC Discussion
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[SIZE=“6”]Picture Intensive!!! Be warned your internet will hate me![/SIZE]

Well I’m not sure why I have not posted this on here yet. Most of you guys catch me on Honda-Tech but I figure why not share here. It’s been in the works since '08. Ya I know it’s a very slow process. I am so picky about everything that nothing ever seems to get done. I’m my own worse enemy. Anyways heres my little project…

First day I bought the car from my brother back in 2006. A very clean 1991 Acura Integra GS. Stock car aside from rims, CF hood and JDM one piece headlights. I had wanted a DA since the day he bought it, so he eventually gave in and sold me the car:

I then drove it like this for over a year:


So after much debating and picking up an ef for a DD, I pulled the DA off the road. The money shot!

Enough of that garbage and out it goes:

So those who know me can vouch that I hate clutter. The car is a fully loaded model and needed some “cleaning up”.

I proceeded with pulling A/C, P/S, ABS and wire tuck:
In this photo you can also see a fresh set of Apex’i N1 coilovers that I installed aswell. Pillow ball FTW

There is just no room anywhere to put the fuse box inside the car. I ended up making my own little contraption for the underhood fuse box:

Still dirty, but cleaned up alot:

So I ditched the factory front cross member for a nice ETD bar (this is their newest version) Nice to have a traction bar that doesn’t hang inches off the ground:

The radius rods and heim joints are by far the best I’ve seen in years:

Ok so on to the motor we go. There was lot’s of concideration in the parts to go in this motor. With any luck they will pay off.

I bought a B18A1 block and stripped it down to nothing. Within a week it was in the mail heading to California to a great group of guys. Along with it went all my internals and such. About 3-4 weeks later I recieved this at my front door:

Golden Eagle did a great job! Block was fully balanced and blue printed when I had the block sleeved and machined:

I had GE sleeve my block using their newer style HD sleeves. These sleeves have supports that run the entire length of the sleeve vs others that run only the top. I also had them step deck it:

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For pistons I went with a nice set of lower compression CP’s. In the end these pistons will still net me around 9.5:1 compression so not super low:

Rods are just a simple set of Eagle H beams with ARP 2000 rod bolts:

With the mains I went with something a little different. It was a toss up on either to run a block girdle or run ARP main studs. In the end I went with a set of ARP main studs:

Only issue with these is that you MUST align hone your mains. This wasn’t a problem as my block was being sleeved and align honed anyways. One other thing was the ARP mains are longer then main bolts so the windage tray need some “re-working”:

Ofcourse new “Hype R” waterpump and oil pump had to be installed:

OEM Yamada FTW!:

I’m a lazy man so instead of ordering a new rear seal, I just picked up a new rear cover:

I’m no genius but I think that was where it goes:

I had some -12 AN fittings made up for my block and started installing my GE ls/vtec kit:

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Dirty B16 head with ITR valvetrain

I ordered a nice set of Ferrea SS .5mm OS valves. The intakes are from their competition plus series line up while the exhausts are from their super alloy line up:

The typical dicision was to go with a dished set of valves:

Picked up a vtec solenoid thats seen better days:

Fresh new surface:

Close up of the valves installed. OS valves where almost a must as the exhaust side valve seats had been beat to sh!t. Just a simple 3 angle valve job was done. IMO 5 angle is a waste of money as it’s such a small valve seat surface:

Bad picture but valve guides and seals also replaced:

The intake manifold is port matched to the head:

For Springs and retainers I ditched the OEM ITR stuff for Supertechs titanium retainers and dual valve springs:

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ARP, the standard headstud for us Honda guys.

Proof I infact do work on my own stuff. As you can see I don’t do my own laundry so getting nice cloths dirty isn’t my problem :lol:

I’m not running any P/S so I picked up a Vibrant timing belt tensioner.

Rocker arms, shafts, LMA’s, etc in

Mounts being used are innovative with 75A urethane stiffness.

New GE LS/V kit installed

Black box gone and freeze plug in

Vtec solenoid all freshened up. GE cam seal installed.

CTR cams in. Intake manifold on.

Running GE fuel rail and AEBS IM

New gaskets and bolts used for everything

GE gears on and timing belt on (belt not adjust yet in pic)

Yes I have alot of GE stuff. I think I’ve got a GE sponsorship coming.

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OEM stuff is nice

Picked up a nice valvecover from a great buddy

Ok small little update. Finished up some loose ends and got my catch can in.

And got the Fluidampr in and bolted up.

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Before:

Now:

And all done:

Just need to finsih the FPR and return side. Have all the parts, just need some time

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Aeromotive A1000 mounted and ready to go:

I switched out the blue push lock hose that was on it for some black hose. Looks a little more low key which I think works:

Still trying to figure out where to mount this guy. It’s next on the list.

Had some time to quickly place my guage setup. NOT installed yet, but wanted to see how it’s going to fit and look. I’m happy with it:

And yes, I am a PC and I run windows 7

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So got the driverside wiring all done and cleaned up. Wire tuck in a way but I’m not looking for zero wires here :lol:

Yes the resistor box is leaving as I don’t need it anymore.

Mounted now:

Alt belt in. I know exciting right?

And how it sits as of right now:

I’m still not happy with it all, but I’m getting there I guess.

Finally installed something that was sitting around for way too long:

In:

And of course all new hardware. I think I have a fetish for new oem parts :lol:

Braces and new hardware on:

Oil temp sensor installed:

Almost forgot to do this. Wouldn’t have been very good when I primed the fuel pump lol. Return line on and tight now:

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Got some lines ran. Should look clean when I’m done:

Pod’s installed and cutting for the guages lines starts:

Switched from regular 194 bulbs to LED’s for the guages

Got some injectors. These should do the job nicely

A bag with some extra goodies. I’ll take some pics of them installed tomorrow.

Like I’ll ever use 4 bars of pressure, but it’s nice to know it can read that high…

Fuel pump is back in the tank. Yes I cut a nice hole so I’ll never have to drop the tank again. Don’t worry it will have a nice cover over it. The factory under coating makes it look terrible.

All hooked up and ready to go

No camera stand so it’s very blury without the flash. Looks sick though with the LED bulbs in

Quick shot from the drivers seat

Yay rad hoses

And the sponsorship continues…

Made use of some slick tie straps I got from my good buddy. Looks nice I think

Looks nice and clean with just a few wires left to clean up

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Quick pic of some things I needed

While I had Haza around I put him to work after a short trip to the auto wreaker. Got the OBD2 MSD §§§§§ in and wired to my OBD0 engine harness. Who needs adapter harnesses when you can remake them?!?

Slapped a new OEM rear hub on. Nice and shiney… cause thats what really counts!

Got the new OEM axle seals in. Then finally put in the half shaft and put the axles back in. No pics of that as it’s nothing exciting. The car now sits on it’s two front feet:

I finished all my wiring in the engine bay, all my lines and odd little stuff to connect. Now I’m waiting on getting the turbo stuff all done.

Spoolin is currently in the process of making me a turbo manifold. There is some extra stuff he will be doing to redesign it for my setup so it’ll be here in a month. Phil has been more then fair with me so I’m willing to wait.

One last picture for now guys:

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Some of Phil’s work up close

Had a 5 bolt flang to 3 inch V-band adapter made. V-band is just the way to go these days so everything made was all V-band.

Next up is a custom made topmount turbo manifold. The manifold has been shifted back and with a slight taper heading in from cylinder #1 and down to #4

Thats not an optical trick! The wastegate has been custom made for a single 60mm wastegate with V-band flange. It really makes the manifold piping seem so small! lol

I’m looking forward to controlling boost as low as we choose to and no creeping!

Collector shot

Simple 3 inch V-band downpipe with flexpipe and o2 bung

Looks like it’s going to work well I think

And last some nice hardware they threw in for me to make life easier

I’ve got some in car shots coming but heres a good teaser

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This is how I waste time putting in the new manifold studs.

Still waiting on one more flange and muffler to arrive.

Also grabbed my Tial stuff I had ordered.

Out of the box picture

Wastegate is big, but it’ll get the job done. New 50mm Q BOV is a solid unit and new design features look promising. Should perform well I hope.

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Picked up a turbo blanket from T1. Very nice piece. Quality is great and fitment is very good.

Got around to putting in my Earl’s -3 oil feed line to the turbo. Couldn’t find any good P-clips so I made my own.

Pretty happy with how I was able to run the line and get it to be as little visable as possible.

The best pedal upgrade ever. New rubber.

Picked up a brand new OEM shift rod. After 19 years mine was shot. Bushings are totally worn out.

Going to give Royal Purple break-in oil a try. I could get it for a good price and the thickness I want so I loaded up on some. Also loaded up on some thermo sleeves for my turbo drain line and heat wrap and ties for my downpipe.

Installed some of these to keep my catch can lines in proper position and looking clean.

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Nice, what are you going for with the engine setup?

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Bushings on the old shift rod. So much play in the nylon bushings

Shot of the intercooler. It’s nothing special. I didn’t go massive so we will have to see how it performs at higher PSI

Rear ST sway in

Couple pics of the vibrant muffler and resonator. The robotic welds are just crazy. Flawless really.




Put on a GSR spoiler I picked up recently. The cars getting painted once done so no worries on the mismatched red lol

Chunk of CF I scored couple days ago. I’m a real nerd so enjoy my template :stuck_out_tongue:

Lots of cutting and sanding but heres a before and after…


Getting the old girl turned around

1mm clearance on the lip, lol

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Flat bed and winch because I’m just that lazy…

Up and on. Dont worry we strapped the shit out of it before we left.

I guess first up is some new parts I picked up. Got a nice v-band for the exhaust, silicone couplers, and a wack load of t-bolt clamps.

Also I figured why not make my own rad overflow tank? So I picked up this cool Moroso filler cap.

Next are a couple crap iPhone pictures because my digicam is poop. It likes to turn on and off all the time.

First off was to cut into the rad support to fit the massive Tial 60mm wastegate

Not to worry as we will be boxing in the rad support cut out that we had to make. Will look much better when done.

Also removed the stock lower rad bracket with a handy spot weld drill bit. Worked great. Buffed off the paint and such to get it preped for welding aswell.

Still need to bend up some sheet metal to box in the hole. Then weld it all up.

One last picture for now of where it sits. Snuggled in with my friends CRX project car. Don’t let the outside fool you. Going to be a sick car when done. He’s got it up on K20a.org

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Got some sheet metal cut out to fit in the cut out hole perfectly. It literally snapped into place.

Got it in and my friend did the welding. Looks good I think. You won’t see it but I know it’s there so it needed to be done properly. Also rounded the corners of the inner edges so we don’t slit our wrists on it, lol.

Next was to start cutting up the bumper support. Got it notched out for the intercooler to fit behind it.

To put some strength back into the bumper support we used some steel flat bar. Drilled holes in it to fit the threaded dowels into the bar.


Needed to find a correct size washer to put in the hole. That way once tightened up it wouldn’t pull the dowel into the steel bar which would damage the intercooler. I found the perfect washer. From a used ARP headstud, lol.


And last shot of the intercooler in.

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So I got reacquainted with an old friend, my dremel. After hours of receiving fiber glass and hot plastic bits to the face I was left with this. It was a pain in the ass, but I’m so happy I took my time and had my main man directing me. I wanted to keep my OEM fiber glass replica Aero kit front lip at all costs.



The bumper skin isn’t bolted in yet so I still need to straighten out some gaps and get everything squared up 100%

Heres a pic of the intercooler rebar in place and welded up.

Theres just enough room now to heat wrap the wastegate to prevent the intercooler from acting like a giant heat-sink.

Forgot this picture yesterday. Heres the wastegate in with the rad support boxed in.

Well thats it for now. I got to get some self etching primer and paint everything we welded up nicely. My welder and master fabricator is off again for work, so things will be slowing down again. I hope to keep making progress still though. I’m not a fabricator so it’s been a learning experience, but I’m trying.

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Got cracking on making a fan shroud. Every shroud you can buy online is way too much money and would not have fit correctly on my car. We can’t have that, so I made one from scratch. With the help of my right hand man I was able to get this done in the last week.

So first some self etching primer and 2 top coats later I got the rebar and rad support notch painted. Sorry gay iPhone pictures.

Next was the fan shroud. Got a leason using our sheet metal bender and came up with this.

Started making the end caps. Got creative making the lower cap as I needed it to clear the lower rad hose.

Caps all done

Welded on the caps and sanded down the welds. Lots of time spent on this part. I wet sanded using a 220 grit and then a 440.

So by offsetting my shoud I could move the rad further away from my downpipe. That is the reason for the kick out on the one side and the taper/step down on the other.

Clearance on the lower rad hose neck

And all finished. Cutting the hole was a longer process with the dremel, but a far cleaner cut then using anything else.



The tabs I made took longer then first thought as I had to bend the corners 90 degrees to get more strength into them. Now they don’t flex and are much, much stronger then just the flat aluminum sheet metal. Also got creative with the 60 degree bracket on top as a 45 looks lame and got in the way, haha.

I’ll be doing one last wet sand and then a quick acid rub to get rid of the oxidation around the welds.

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My buddy built something similar and I just couldn’t go without doing something like it. So we had come to the conclusion that the stock overflow tanks suck. Ugly and not practical to relocate without looking horribly out of place. So this is the result…




And lastly how I can check the low and high levels.


Needs a good acid wash and another wet sand to get the scratched out. Then I’ll polish it and the fan shroud at the same time to match the rad.

Working on a turbo brace now for my topmount manifold. Not sure what we will tackle next month but I’ll keep you guys posted.