K20a2 EG build up, SLOW progress - lots of pics!

[Fuster_Cluck]

<FONT SIZE="5"><FONT COLOR="lightgreen">Welcome to my 95 Vx / K20a2 build thread</FONT></FONT> About Fuster_Cluck: I had a white GSR powered 93 CX a few years back. I did the swap with the help of forums and my father when I needed an extra hand. I changed the timing belt / water pump on my GSR motor. I've done oil changes, tranny & coolant changes, suspension changes on 92-00 Civic's, valve adjustment, and removed a couple motors. This is by far the biggest task I've ever taken on. Started: January 02, 2007 1st drive: September 15th, 2007. Completion: When she's at 375+whp Major props to these 2 guys (SneezinCD5 & pipfrost Would of never made it to the 2007 ATL Nopi Nationals if it weren't for them pipfrost: My father who took 2weeks away from work and his life at home to help me build this hatchback in 11 days from the ground up. Yes, my dad is AWESOME!! SneezinCD5: Responsible for laying the midori green paint. Also, helped the few days before the Nationals. A lot of you know him, his work, and reputation behind it all If you don't know him (Jason) or his work....check it out &gt; &gt; HERE!! <FONT COLOR="red">**Click the pics for larger view**</FONT> <FONT SIZE="1">March 30, 2008 - Commerce, GA; ATL dragway Nopi show Left to Right: Fuster_Cluck - Best of Show (Honda) 1_fly_si - 2nd place (Honda) SneezinCD5 - 1st place (Honda) Brad - 1st place (JDM) 2007 Nopi Nationals ATLanta Motor Speedway Me & pops Sept. 15th, 2007 - - - - - Me & Jason Sept. 16th, 2007 - - - - - - - - - - - 2nd place</FONT> Complete specs HERE at my Honda-Tech Garage **Table of Contents** : (I wish ALL build threads had this) **TIP for searching** Want to search for something specific in my build? If using Internet Explorer press the CTRL + F keys. A "FIND" box should pop up, type the key work, hit enter and see what you find. I will be adding words to make it even easier to navigate for specific work or parts in my build Page 1 (5 pics): -- Bumper, hood, fenders, headlights, doors removed Page 2: (7 pics = 12 pics total thread) -- Dashboard removed Page 3: (14 pics = 26 pics total thread) -- Heater core, A/C blower removed -- firewall mat removed -- SRS unit removed -- Windshield wiper system removed Page 5: (17 pics = 43 pics total thread) -- Rear hatch interior wire tuck -- Dome light removed, -- Looking to relocate fuse box into dash Page 6: (31 pics = 74 pics total thread) -- Some of sneezincd5's work (paint) -- Door breakdown & glue removal w/ dry ice (failure) -- Complete A/C system removed -- Engine bay wiring being removed Page 7: (18 pics = 92 pics total thread) -- Disconnecting everything from the motor to pull shortly. Page 8: (26 pics = 118 pics total thread) -- Motor pulled & Exhaust removed Page 9: (25 pics = 143 pics total thread) -- Interior wiring removed Page 10: (4 pics = 147 pics total thread) -- 1st K series part purchased --&gt; Karcept's shifter kit plate Page 11: (15 pics = 162 pics total thread) -- Charcoal canister removed -- most brake lines removed -- EGR valve removed -- Master cylinder removed -- Fuel filter removed -- Clutch reservoir removed -- More tools picked up from Harbor Freight Page 12: (11 pics = 173 pics total thread) Karcepts shifter kit install part.1 Page 13: (36 pics = 209 pics total thread) -- Removing sound deadning material with dry ice -- Gas tank drained & removed -- Clutch slave cylinder removed -- Brake booster removed -- steering rack removed -- Crossmember removed -- Rear brake lines with fuel lines removed -- Charcoal canister exit release removed Page 14 (39 pics = 248 pics total thread) -- Back hatch glass removed -- Tail lights removed -- Interior clips removed -- Hatch tailgate and release lever removed -- Fuel tank door release removed -- Fuel door removed -- Rear hatch area wiring removed -- Rear bumper removed -- Side skirt clips removed -- Crossmember disassembled & cleaned -- Looking at spot welds Page 15 (16 pics = 264 pics total thread) -- Pics from when I stripped/detailed the interior of the hatch on March 29, 2006 Page 16 (50 pics = 314 pics total thread) -- Drilling spot welds to remove rear seat bracket -- Drilling spot welds to remove SRS mounting block -- Drilling spot welds to remove intake mounting bracket -- Karcepts shift kit cut out complete -- Rear hatch seal removed -- Under Carriage cleaning (50% done) Page 17 (37 pics = 351 pics total thread) -- More supplies purchased from Harbor Freight -- Gas pedal removed -- Brake pedal removed -- Clutch pedal removed -- Rear under carriage cleaning (70% complete) -- Cleaning the engine bay w/ AJAX - test sanding in the engine bay Page 18 (10 pics = 361 pics total thread) -- Cleaning splash guard and gas tank nozzle plastic panels -- Sanding the engine bay -- Gas tank exterior clean up Page 19 (64 pics = 425 pics total thread) -- Tranny mount removed -- Radiator brackets removed -- A/C radiator brackets removed -- Wire wheel interior clean up -- Wire wheel door glue removed (Part 1 - test) -- Wire wheel miscellaneous surface rust removed -- Rear trailing arm assembly removed Page 21 (3 pics = 428 pics total thread) -- Paint revealed (no, it's not white) Page 22 (27 pics = 455 pics total thread) -- Rear wheel wells cleaned -- Paint purchased for metal parts & under carriage -- Undercoating applied to gas tank -- Gas tank painted silver -- Front LCA assembly cleaned w/Ajax ready for paint -- Crossmember cleaned w/Ajax ready for paint -- Front LCA's assembly painted Page 23 (17 pics = 472 pics total thread) -- Pass. back side at door for running wiring -- Crossmember painted -- Filler neck for gas tank cleaned -- Rear trailing arm cleaned -- Exhaust heat shield cleaned -- Trying to remove the metal bracket from engine bay fuse box Page 24 (20 pics = 492 pics total thread) -- Function 7 LCA's purchased -- Trip from ATL to TN to get the motor Page 25 (5 pics = 497 pics total thread) --Checking for LSD --SHG_EasyE custom fuel line & filter set up --SneezinCD5's Sata guns Page 26 (35 pics = 532 pics total thread) --Final prep before painting under carriage --Putting the hatch on the highest jack stand setting using wood blocks --Discovered: How to remove or replace the plastic hood latch holder --Karcepts radiator bracket / coolant reservoir tank relocater arrived --HASport radiator hose adapter for fan and temp switch arrived --G Force 5 point harnesses arrived --G Force harness eye bolts arrived --BSCI Dual Density roll bar padding arrived --Spraying the fender liners with alcohol / wiping down before applying paint --Fenderliners & crossmember area taped off & ready to be sprayed --Graphite wheel paint applied Page 27 (6 pics = 538+ pics total thread) -- Disecting the k20a2 Page 28 (15 pics = 553+ pics total thread) -- Paint supplies picked up -- Mishimoto radiator & 12" arrives -- prepping and painting the under carriage side skirt area -- Sparco seats arrive (wrong ones) -- Rear bmper support removed Page 29 (49 pics = 602+ pics total thread) -- Mounting/lining up the HASport passenger mount -- Removing the plastic hood prop holder from the driver shock tower -- Removing the dash wiring harness -- Sealing the roof braces back to the roof -- Sanding down OEM tranny spot welds -- SneezinCD5 welding some holes shut in the engine bay -- Date found on driver side front bulkhead -- Radiator brackets relocated to drivers side -- Applying body filler to the engine bay -- Sanding the engine bay for paint -- Removing more dead weight (rear seat brackets) -- SneezinCD5 burns his leg while sanding -- Tapping the 4 rear camber bolts -- Primer put down in engine bay -- 2 windshield clips removed Page 30 (14 pics = 616 pics total thread) -- Cool shot of SneezinCD5 welding inside the hatch -- SneezinCD5 wets the engine bay with Midori Green paint Page 32 (10 pics = 626 pics total thread) -- Day time pics of the Midori Green engine bay -- GSR front brakes picked up -- AutoPower roll bar arrives Page 33 (2 pics = 628 pics total thread) -- Pics of Sparco Sprint 5 seats Page 34 (3 pics = 631 pics total thread) -- Circuitworx Hubs Arrive Page 35 (11 pics = 642 pics total thread) -- New rear camber bolts picked up -- Anti seize and Lithium white grease picked up -- Circuitworx Hubs, ARP extended studs, front wheel bearings, and RTA bushings back from the shop installed -- 5 quarts of Mobil 1 picked up on sale -- Rear suspension / brake assembly reinstalled Page 36 (18 pics = 660 pics total thread) --A larger Rex comes down to visit --Front end assembly installed --Pics of her in Central Florida (by Jason) --Steering wheel back in --Shifter box installed onto the Karcepts plate & test fitted --Will grinding out some of the tunnel for the Karcepts kit Page 37 (18 pics = 678 pics total thread) --Jose marking all the dings on the car --Washers picked up for rear camber bolts --Front joints shown-asking how to reinstall --OEM parts picked up (cotter pins, castle nuts, tie rod ends --3/8" drill bit for roll bar and POS tap and die set Page 38 (33 pics = 711 pics total thread) --HASport pass. side mount drilled --Rear lower hatch disassembled --Rear lower hatch emblems removed --EX lip removed from bumper --Door light switches removed --Roof rain guards removed --Loaded up on the F250 and out she rolls to Central Florida Page 39 (9 pics = 720 pics total thread) -- Jose & SneezinCD5 doing the body work Page 40 (19 pics = 739 pics total thread) -- More work from Jose & SneezinCD5 -- Old classic stops by asking about paint Page 41 (3 pics = 742 pics total thread) -- 3" Vibrant Stealth muffler arrives -- Teaser shot of Kteller 3" exhaust Page 42 (30 pics = 772 pics total thread) -- 3" keteller exhaust pics -- Walbro 255 fuel pump arrives -- Hybrid Racing K series harness arrives -- Closer look at the shifter cable connection at tranny -- RSX header removed -- Some block cleaning Page 43 (14 pics = 786 pics total thread) -- Wire tuck hardware purchased -- HID drop in kit w/slim ballasts arrives Page 44 (12 pics = 798 pics total thread) -- SneezinCD5 shoots a clean Chevelle -- Jason and Jose doing some final prepping to interior & exterior Page 45 (4 pics = 802 pics total thread) -- Modifying the stock K20 fuel line to accept a -6 AN hose Page 46 (12 pics = 814 pics total thread) -- SneezinCD5 seals and paints the interior Page 47 (4 pics = 818 pics total thread) -- K pro arrives Page 48 (25 pics = 843 pics total thread) -- Pics of SneezinCD5's wheels (OG Axis Oldskools) -- Wideband O2 arrives -- Vibrant quiet 18" resonator arrives -- Identifying some of the cabin wiring harness plugs -- Nardi steering wheels arrive -- NRG quick release and short hub arrives Page 49 (13 pics = 856 pics total thread) -- Konig Helium wheels and Falken Azenis tires arrive -- Racing Composite lug nuts arrive Page 50 (26 pics = 882 pics total thread) -- Unwrapping / Cleaning dash wiring -- Looking at the in dash fuse box -- Exterior midori paint put down Page 52 (9 pics = 891 pics total thread) -- 2007 Nopi National ATL tickets arrive -- HASport EGK engine mount bolts each labeled showing their lengths -- Autozone coolant loop line purchased/installed -- HASport tranny mount installed on tranny Page 53 (36 pics = 927 pics total thread) -- DTR/SSR 4-2-1 header arrives -- looking at OEM exhaust manifold gasket -- Removing tape / Cleaning of cabin wiring harness -- Sparco seat bracket & slider install to Sparco Spring 5 seat -- Test fitting header to motor -- Pop's arrives -- Draining oil and tranny -- Pressure washing motor Page 54 (45 pics = 972 pics total thread) -- Comparing OEM rear engine mount hardware w/ HASport hardware -- Nice & cool rachets picked up from Harbor Freight -- Grinding out tranny mount to clear tranny stud -- Cleaning brake & fuel lines -- Walbro 255 fuel pump install -- Painting dash brackets -- Hatch makes it back to the LG -- Roll Bar install Page 55 (1 pic = 973 pics total thread) -- Motor is in!! Page 56 (28 pics = 1,001 pics total thread) -- Assembling gas pedal assembly -- Brake lines installed -- Prepping the roll bar for paint -- Torquing pass. engine mount -- Mounting chicken run at firewall for K series wiring -- Motor install -- Temporary foot pedals installed Page 57 (9 pics = 1,010 pics total thread) -- Aeromotive FPR picked up -- Earls fuel filter picked up -- Earls pro lite hose picked up Page 58 (11 pics = 1,021 pics total thread) -- Roll bar painted -- Mster cylinder disassembled & cleaned -- Roll bar installed -- Autozone rear pads picked up Page 59 (6 pics = 1,027 pics total thread) -- Brake fluid picked up -- Looking at the driver side valve cover and misc. parts -- Autozone intake picked up -- BaconLettuceTomato stops by with Goldy Page 62 (4 pics = 1,031 pics total thread) -- Looking at the E and C101 plugs on the Hybrid Racing Harness Page 64 (7 pics = 1,038 pics total thread) -- Pics of the hatch at the 2007 Nopi Nationals Page 65 (4 pics = 1,042 pics total thread) -- Pic from the Nopi Nationals show -- Torching flies -- 1st and 2nd place at the Nopi Nationals Page 66 (9 pics = 1,051 pics total thread) -- More pics from the Nopi Nationals Page 67 (13 pics = 1,064 pics total thread) -- More pics from the Nopi Nationals -- Kpro data log posted Page 68 (9 pics = 1,073 pics total thread) -- Pics of shifter cable modification & install Page 69 (24 pics = 1,097 pics total thread) -- K series engine modification to run wiring -- 3 D series wires needed for K swap -- Primary Oxygen sensor wiring -- Cosmetic rubber caps that make things look good -- Torque stripe -- Clutch line install Page 70 (11 pics = 1,108 pics total thread) --Exhaust flange found --exhaust spring bolts found Page 71 (17 pics = 1,125 pics total thread) --Run into a Mustang on the way to get an alignment --Shots while on the alignment rack at TiresPlus --Head up to see Tom (B18C5-EH2) at Honda/Acura Specialist in Jonesboro. --2008 Mugen Si spotted on the way home. --Taken pics with a parked Ford GT500 Cobra --2 pics of the midori hatch from around town Page 72 (10 pics = 1,135 pics total thread) --A look at the charge harness & extended wires --Aeromotive FPR --A look at the civic brake booster vacuum line --Close look at the vacuum one way valve --Pop's masking off the legs off the roll bar to add a touch of appearance Page 73 (20 pics = 1,155 pics total thread) Page 74 (1 pic = 1,156 pics total thread) Page 75 (59 pics = 1,214 pics total thread) Page 76 (20 pics = 1,234 pics total thread) Here's what I am starting with: I took about 20 measurements of the hood to fender, fender to door, rear quarter panel to door, etc.... I want everything back the way it was before removal Most bolts went back in the thread on the chasis and the rest will be stored like so: It was tough at times, but I did it all myself. Well, me and buddy Jack.... How she sits at the end of day 1: (Love my xenon house lights ) Thanks for looking Modified by Fuster_Cluck at 8:26 PM 4/17/2008

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[toyomatt84]

Subscribed for project interest.

[Sly_Samba]

yes, subscribed for future goodness of this thread.

[whiteef8]

nice. looks like you got a looooong way to go, but I'll be here to help you along

[KYLE.]

word keep us updated

[kangaroo]

Damn that's clean.....can't wait to see the k20 beast!!

[U N S E E N.]

Originally Posted by BORAT

NICE NICE, VERY NICE

[fventura03]

nice, clean car. in for updates

btw what was the reason behind removing the doors?

[cuz_ican]

Originally Posted by fventura03

nice, clean car. in for updates

btw what was the reason behind removing the doors?

[BoostinEJ1]

nice hatch, cant wait to see when its done

[vtec4lyfe]

subscribed!

[SOLtrain "tiiiteboyee"]

very clean car man,wish I had the cash flow and a garage to do something like this,but since i dont im just gona subscribe and stay tuned to ur progress! best of luck man

[Desired_Speeds]

cant wait for updates!!!!

[Arsenal]

Originally Posted by vtec4lyfe

subscribed!

Originally Posted by Sly_Samba

yes, subscribed for future goodness of this thread.

Originally Posted by toyomatt84

Subscribed for project interest.

WTF, you don't have to reply to subscribe, look at the top of your screen.

Good luck with the project

[SneezinCD5]

Cant wait to get her back on the road again. I started my build and gotta post some pics of my progress. Cant wait to put that PPG finish on her.

Wonder who will finish first?

[gsus805]

posted

[teggy182]

i like this car in its previous form, i cant wait to see where its at after this

[schematicsskater13]

good start PM if you want to get rid of those LS mesh

[777sC]

Originally Posted by vtec4lyfe

subscribed!

[ff terror]

best of luck... ur timeline looks too fast tho

[INCNTRL4]

best of luck man, subscribed!

[E-Money]

[RIPracing]

good start GL!

[sixfiveoh]

should be good shit. and just to piss this guy off

Originally Posted by Arsenal

WTF, you don't have to reply to subscribe, look at the top of your screen.

Good luck with the project

SUBSCRIZZLED!

[VRD^sam]

Originally Posted by vtec4lyfe

subscribed!

w0rd