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RaceCity_USA




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839 posts [100%]
Burgaw NC
3-13-2004
  94 Integra GSR mid-engine RWD H22A4 conversion« » Reply  Edit



Photo: Ralph Hawkins

The finished car at the Streets of Willow Springs in California for the 2007 Sport Compact Car Magazine Ultimate Street Car Challenge (USCC).


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Index of Updates with Topics:

Page 1 - UCA mounts
Page 2 - weight transfer
Page 3 - UCA mounts
Page 5 - rear frame rails
Page 6 - left spring buckets
Page 6 - right spring buckets
Page 7 - fuel door & tank
Page 8 - tie rods, bump steer
Page 9 - quarter flare, concept sketches
Page 10 - fuel tank inlet
Page 10 - 17x8 TL wheels
Page 14 - exterior, engine installed
Page 15 - weight on the scales
Page 18 - dash, console
Page 21 - HVAC, firewall, steering column
Page 23 - front firewall
Page 24 - heater box, battery mount
Page 26 - shifter mechanism
Page 27 - shifter mechanism complete
Page 28 - E-brake
Page 30 - brake lines, bead roller
Page 31 - shop tour
Page 32 - coolant lines
Page 35 - A/C lines, EGRCV, fuel filter
Page 37 - front camber adjusters
Page 37 - exhaust, fuel filter, clutch line
Page 39 - strut tower brace, fuel lines
Page 40 - engine removal
Page 41 - rt. quarter, shaving, psp bracket
Page 42 - side scoops (NACA ducts)
Page 43 - side scoops installed
Page 44 - fuel tank cover pattern
Page 46 - rear wiper and power window switches
Page 46 - teg vs. prelude door panels
Page 46 - white w/GT stripes?
Page 50 - fuel tank cover, CAI, rear floor
Page 54 - engine cover sketch
Page 55 - heat shields, fuel tank cover
Page 55 - side skirts
Page 58 - LSD
Page 58 - engine cover
Page 60 - cruise actuator, LSD install
Page 62 - LSD installed, seal driver
Page 64 - engine cover hood, rear tie rod boots
Page 66 - engine cover/hood latch
Page 66 - engine compartment fan
Page 68 - "paint booth"
Page 69 - right side bodywork
Page 69 - right side primer
Page 72 - left side primer
Page 73 - hatch & fenders primed
Page 74 - paint #1
Page 75 - paint #2
Page 75 - paint #3a
Page 75 - paint #3b, shell
Page 76 - paint #4
Page 77 - seam sealer
Page 78 - sound & heat insulation
Page 80 - valve cover refurb.
Page 81 - paint #5
Page 81 - paint #6
Page 83 - STS
Page 83 - shell prep.
Page 84 - paint #7 (shell)
Page 84 - final assembly #1
Page 85 - final assembly #2
Page 85 - final assembly #3
Page 86 - final assembly #4
Page 88 - final assembly #5
Page 89 - final assembly #6
Page 90 - final assembly #7
Page 91 - final assembly #8
Page 93 - final assembly #9 (video) startup
Page 95 - final assembly #10
Page 96 - final assembly #11
Page 97 - final assembly #12
Page 98 - final assembly #13
Page 99 - final assembly #14
Page 101 - final assembly #15, Phase II #1
Page 103 - spare tire mount
Page 105 - new muffler
Page 107 - carpet
Page 108 - passenger sun visor
Page 109 - caster, bump steer
Page 110 - tie rods, spring perches, special thanks
Page 111 - traction bar
Page 112 - (video) walk-around
Page 113 - (video) cold start
Page 113 - ITR lip
Page 114 - (video) composite preview
Page 115 - sound deadening, safety harness
Page 117 - (video) "The Back Out"
Page 118 - (video) "Part-Throttle VTEC"
Page 119 - new parts from civic_fan
Page 120 - on the trailer
Page 122 - boot tray
Page 122 - radiator inlet seal
Page 123 - rear diffuser template
Page 124 - rear diffuser, belly pan
Page 125 - wheel well seal, radiator cradle seal
Page 126 - front "A" emblem
Page 126 - under-body aero panels
Page 127 - engine cover carpet
Page 129 - dash end covers
Page 131 - (video) baseline dyno


-------------------------------------------------------------------------------------------

After purchasing a wrecked 97 Prelude VTEC with 90k miles off eBay and a theft recovery 94 GSR in Charlotte, the conversion process is now well on it's way. I spent most of the spring desiging and planning the conversion and began the fabrication process in July.

I basically chopped the front end off the Prelude at the firewall and stripped it down to the front horns shown here with the cross members and lower suspension arms mocked up.

P1

P2

After stripping the GSR down to the shell and shimming under the jack stands to get it level (I have no surface plate), these pics show the frame used to transfer measurements taken from the structure above into the back of the GSR. The frame is square and level so I could use a plumb bob to locate points from the Prelude front structure into the GSR and cut the hole.
P3

P4

P5

P6

P7

Note string down centerline. Very important to have everything centered and square so the car doesn't "crab" down the road.
P8

This shows the cardboard pattern I made of the Prelude horns to help locate the cut as precisly as possible. I had to cut the shock tower out of the way to place the pattern square and level.
P9

P10

P11

The hole's been cut...It's on now!...No turning back
P12

P13

P14

P15

Sorry for the dark pic, but these next few show 97 Prelude front uprights (knuckles,spindles...) purchased from a junk yard adapted to the GSR front suspension for 5 lug hubs all around. This also gives me the large front brake rotors and calipers from the Prelude at all 4 corners.
P16

P17

P18

There are only two things I had to do to use the Prelude uprights. One was ream the lower ball joint hole in the GSR lower control arm to accept the larger Prelude upright lower ball joint. (holes are 7 degree standard taper, 1.5" per foot). The other was to drill and tap the GSR rack ends to accept the Prelude inner tie rods.
P19

I also converted the GSR power steering rack to manual by drilling a 1/2" hole in the rack and removing the piston seal and by connecting the fluid inlets in rack with tubing so the air in the cylinder can move back a forth freely as the car is steered. The 1/2" hole is sealed with a piece of flat rubber held by a pipe clamp.
P20

P21

No longer front wheel drive, thus no front drive axles, I used a 1" grade 8 fine thread bolt torqued to 192 ft.-lbs. to hold the preload on the front wheel bearings. There is a conversion formula to calculate bolt torque for equivalent tension load between two different bolt sizes and thread pitch. I also made a small bushing to hold the 1" bolt centered in the splined hole in the hub.
P22

This pic shows the cuts made in the quarter panel to flare it for the wider track of the Prelude. Otherwise the stock 205/50R16 tires on stock 6.5" wide wheels stick out past the quarter about an inch. I'll flare the quarters out 2" to allow for 16x7.5 wheels in the rear.
P23

This series of pics show front supports from the Prelude being fitted into the hole in the rear of the Integra...
P24

P25

P26

Frame jig used to locate hole is re-installed to locate the frame structure.
P27

P28

P29

Right rear wheel well with lower suspension arms installed to make sure wheel is centered in wheel well.
P30

Left rear wheel well.
P31

The process of welding the frame to the shell has begun and I've been working on adjustable upper control arm mounts. More pics of that coming soon!

Questions and comments are welcome and encouraged.

Thanks,

Modified by RaceCity_USA at 7:54 PM 9/12/2004


Modified by RaceCity_USA at 9:59 AM 9/21/2004


Modified by RaceCity_USA at 6:44 PM 8/27/2005


Modified by RaceCity_USA at 1:18 PM 9/4/2005


Modified by RaceCity_USA at 9:06 AM 9/18/2005


Modified by RaceCity_USA at 8:22 AM 9/27/2005


Modified by RaceCity_USA at 11:25 PM 10/26/2005


Modified by RaceCity_USA at 4:29 PM 11/6/2005


Modified by RaceCity_USA at 4:31 PM 11/6/2005


Modified by RaceCity_USA at 7:20 PM 11/7/2005


Modified by RaceCity_USA at 9:53 PM 12/1/2005


Modified by RaceCity_USA at 12:04 PM 12/4/2005


Modified by RaceCity_USA at 12:37 PM 12/22/2005


Modified by RaceCity_USA at 5:00 PM 12/30/2005


Modified by RaceCity_USA at 12:51 PM 1/22/2006


Modified by RaceCity_USA at 10:36 AM 2/9/2006


Modified by RaceCity_USA at 9:24 AM 2/13/2006


Modified by RaceCity_USA at 7:35 PM 2/13/2006


Modified by RaceCity_USA at 10:53 AM 3/2/2006


Modified by RaceCity_USA at 10:14 PM 3/7/2006


Modified by RaceCity_USA at 8:16 PM 3/10/2006


Modified by RaceCity_USA at 1:18 PM 3/23/2006


Modified by RaceCity_USA at 1:21 PM 3/23/2006


Modified by RaceCity_USA at 4:06 PM 3/23/2006


Modified by RaceCity_USA at 10:15 PM 3/23/2006


Modified by RaceCity_USA at 10:16 PM 3/23/2006


Modified by RaceCity_USA at 4:08 PM 4/2/2006


Modified by RaceCity_USA at 4:09 PM 4/2/2006


Modified by RaceCity_USA at 4:09 PM 4/2/2006


Modified by RaceCity_USA at 12:43 PM 4/13/2006


Modified by RaceCity_USA at 10:26 PM 4/20/2006


Modified by RaceCity_USA at 8:40 PM 4/21/2006


Modified by RaceCity_USA at 10:03 PM 4/23/2006


Modified by RaceCity_USA at 9:04 AM 4/24/2006


Modified by RaceCity_USA at 9:42 AM 4/29/2006


Modified by RaceCity_USA at 10:35 PM 5/3/2006


Modified by RaceCity_USA at 1:51 PM 5/7/2006


Modified by RaceCity_USA at 9:20 AM 5/11/2006


Modified by RaceCity_USA at 7:41 PM 5/18/2006


Modified by RaceCity_USA at 8:33 PM 5/19/2006


Modified by RaceCity_USA at 8:54 PM 5/24/2006


Modified by RaceCity_USA at 5:30 PM 5/26/2006


Modified by RaceCity_USA at 7:40 PM 5/27/2006


Modified by RaceCity_USA at 10:42 PM 5/29/2006


Modified by RaceCity_USA at 9:20 PM 5/30/2006


Modified by RaceCity_USA at 8:40 PM 5/31/2006


Modified by RaceCity_USA at 11:10 PM 6/6/2006


Modified by RaceCity_USA at 10:57 PM 6/12/2006


Modified by RaceCity_USA at 7:39 PM 6/14/2006


Modified by RaceCity_USA at 4:37 PM 6/16/2006


Modified by RaceCity_USA at 11:46 PM 6/21/2006


Modified by RaceCity_USA at 3:36 PM 6/25/2006


Modified by RaceCity_USA at 11:39 PM 6/28/2006


Modified by RaceCity_USA at 11:35 PM 6/29/2006


Modified by RaceCity_USA at 11:02 PM 7/3/2006


Modified by RaceCity_USA at 8:58 AM 7/6/2006


Modified by RaceCity_USA at 8:16 PM 7/8/2006


Modified by RaceCity_USA at 11:10 PM 7/10/2006


Modified by RaceCity_USA at 3:17 PM 7/13/2006


Modified by RaceCity_USA at 6:38 PM 7/21/2006


Modified by RaceCity_USA at 5:14 PM 8/2/2006


Modified by RaceCity_USA at 7:51 PM 8/10/2006


Modified by RaceCity_USA at 12:21 AM 8/18/2006


Modified by RaceCity_USA at 2:58 PM 8/31/2006


Modified by RaceCity_USA at 1:08 PM 9/3/2006


Modified by RaceCity_USA at 10:38 PM 9/10/2006


Modified by RaceCity_USA at 10:40 PM 9/10/2006


Modified by RaceCity_USA at 10:28 AM 9/15/2006


Modified by RaceCity_USA at 1:13 PM 9/18/2006


Modified by RaceCity_USA at 4:24 PM 9/22/2006


Modified by RaceCity_USA at 4:25 PM 9/22/2006


Modified by RaceCity_USA at 3:52 PM 9/28/2006


Modified by RaceCity_USA at 3:52 PM 9/28/2006


Modified by RaceCity_USA at 11:20 AM 10/9/2006


Modified by RaceCity_USA at 10:35 PM 10/16/2006


Modified by RaceCity_USA at 8:03 PM 10/24/2006


Modified by RaceCity_USA at 1:42 PM 11/15/2006


Modified by RaceCity_USA at 11:33 PM 12/5/2006


Modified by RaceCity_USA at 5:58 PM 12/16/2006


Modified by RaceCity_USA at 11:34 PM 1/6/2007


Modified by RaceCity_USA at 2:26 PM 1/27/2007


Modified by RaceCity_USA at 8:36 PM 2/14/2007


Modified by RaceCity_USA at 6:57 PM 2/17/2007


Modified by RaceCity_USA at 2:53 PM 2/24/2007


Modified by RaceCity_USA at 1:26 PM 3/10/2007


Modified by RaceCity_USA at 5:12 PM 3/22/2007


Modified by RaceCity_USA at 7:09 PM 5/8/2007


Modified by RaceCity_USA at 7:09 PM 5/8/2007


Modified by RaceCity_USA at 11:34 PM 7/4/2008

Modified by RaceCity_USA at 11:35 PM 7/4/2008



94 GSR mid-engine RWD H22A4 conversion




chidoks


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1800 posts [100%]
Glassboro NJ
2-25-2002
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (RaceCity_USA)« » Reply  Edit


your pics arent working



95 turbo/nitrous supra
dynos coming..

RaceCity_USA




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839 posts [100%]
Burgaw NC
3-13-2004
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (chidoks)« » Reply  Edit


Sorry for the pic problems. Some of them are showing up, others arn't. It must be an ImageStation problem. Any suggestions other than we-todd-did-racing where I might upload pics to post here?

If I logon with AOL, all pics show up fine. Using Internet Explorer by itself, only some of the pics show up. What gives?





94 GSR mid-engine RWD H22A4 conversion


chidoks


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1800 posts [100%]
Glassboro NJ
2-25-2002
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (RaceCity_USA)« » Reply  Edit


if you want, you can email me the pics...i'll host them



95 turbo/nitrous supra
dynos coming..

RaceCity_USA




Offline

839 posts [100%]
Burgaw NC
3-13-2004
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (chidoks)« » Reply  Edit


I really appreciate the offer, but I think I've got them working now. Please try again and let me know if it's working for ya.





94 GSR mid-engine RWD H22A4 conversion


chidoks


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1800 posts [100%]
Glassboro NJ
2-25-2002
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (RaceCity_USA)« » Reply  Edit


some are working...but a lot arent



95 turbo/nitrous supra
dynos coming..

RaceCity_USA




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839 posts [100%]
Burgaw NC
3-13-2004
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (chidoks)« » Reply  Edit


Thanks for your help. I cleared my browser cache and deleted all cookies to start from scratch. Most of the pics then showed up, however all of them were visible after doing a refresh. Give it a try.





94 GSR mid-engine RWD H22A4 conversion


CivicVX94




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1706 posts [96%]
Florence Ky
4-16-2004
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (RaceCity_USA)« » Reply  Edit


i see every one of them, this looks badass
Goodluck man, be sure to keep us updated




Quote, originally posted by RobT5580 »
Im shooting for 350-400 but dont want to kill my motor because parts are not cheap to fly in from Japan.


lagingtorpe




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611 posts [100%]
jacksonville fl
10-14-2003
 « « » Reply  Edit


some pics are not working.... but damn you got some time and patience!! good work

eLUDEnu


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0 posts [0%]
culpeper va
7-19-2004
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (CivicVX94)« » Reply  Edit


badass!!!!!!!!!!!!!!1



96 prelude vtec
97 toyota tacoma bagged and body dropped


Great sellers: mgags7


Kal




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3173 posts [100%]
Sunny FL
10-1-2002
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (CivicVX94)« » Reply  Edit


good luck! keep us updated.



2001 SSM BB6
2005 SSM EP3

IM feature gets blocked.



Merilious




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585 posts [100%]
Surrey BC
4-20-2004
 « « » Reply  Edit


Looks good, but use PhotoBucket to host the pics.



EG Coupe - Sold
EG Hatch - Sold
Supercharged MR2 - Sold
EF Hatch - Sold
R32 Skyline - Alive and well

RaceCity_USA




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839 posts [100%]
Burgaw NC
3-13-2004
 « Re: (Merilious)« » Reply  Edit


Thanks to all for the encouragement. It's taken longer than I expected, hand whittling all the parts, but it's a lot of fun if I keep my eye towards the end result. Also planning to install the Prelude interior, dash, wiring harness, etc. Suggestions for pics are welcome if there's anything else you'd like to see.

I've just created a PhotoBucket account and will be trying it out this afternoon.

Thanks again,




94 GSR mid-engine RWD H22A4 conversion


2point2




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5442 posts [98%]
Kitchener Ontario
11-8-2003
 « « » Reply  Edit


Nice work man! i really admire people who can do this kind of stuff.



Turbocharged CRX w/Stock H22
10.73 @ 137mph
Pics and Info

RaceCity_USA




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839 posts [100%]
Burgaw NC
3-13-2004
 « Re: (Merilious)« » Reply  Edit


Here are some pics hosted by PhotoBucket of the adjustable upper control arm mounts.

P32

P33

Note -1 degree static camber. Camber gain is to -3.5 degrees at full bump and +1.5 degrees at full droop.
P34

Please let me know if you have any more problems with the previous pics hosted by ImageStation.

Thanks,




94 GSR mid-engine RWD H22A4 conversion


Swags04
Go Eagles!!



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6460 posts [98%]
Central PA
2-23-2002
 « Re: (2point2)« » Reply  Edit


Thats insane

I want it



Nikon D70 & D70s / 80-200 / 28-70 / 18-70 / 50 / SB-600

1 9 9 9 M a z d a M i a t a

The Old Integra... http://www.cardomain.com/ride/641826/2


RaceCity_USA




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839 posts [100%]
Burgaw NC
3-13-2004
 « Re: (Swags04)« » Reply  Edit


Quote, originally posted by Swags04 »
Thats insane

I want it

Interesting you would say that as one of the reasons for doing this project is to use it as showcase for a custom fabrication/motorsports business I'm planning. Hopefully one day I'll have a showroom and you can walk in and buy one, or maybe have one made for you.

Thanks,




94 GSR mid-engine RWD H22A4 conversion


BigPlansNoMoney




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436 posts [100%]
Richmond VA
9-5-2004
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (RaceCity_USA)« » Reply  Edit


Sorry I'm a noob to this Honda stuff....

Are you putting a Teg body on the Lude frame, then putting the Lude motor into the back and making it rear wheel drive... kinda confused? LOL sorry to bother you...



1995 GS-R Sedan (DB8). Bone stock for now. ~220,000miles. Saving for rebuild.

Have any kind of swap? Answer my poll!

JDM Engine Corp.


ludedeg




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488 posts [100%]
Charlotte NC
7-11-2003
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (RaceCity_USA)« » Reply  Edit


Thats some serious fab work. Looks like alot of work. Keep us updated on your progress.




Vouches


R.S.




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1277 posts [100%]
Honolulu HI
5-8-2003
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (ludedeg)« » Reply  Edit




dLo GSR-stolen-now-WRX




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7341 posts [100%]
kyoto sangyo daigaku kyoto, japan
2-19-2002
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (R-Spec)« » Reply  Edit


holy crap... nice



'99 ABP Acura Integra 4-door GSR - 159.1 HP, 118.1 lbs/ft - STOLEN 1/14/06, DB Squad #31
'92 Kawasaki Ninja 250R RIP 1/28/06 (hit a deer)
'99 Yamaha YZF-R6
'04 WRB Subaru Impreza WRX

  take a look!

Quote, originally posted by thehondabuddy »
whatever you get, you should put fur on it. girls will have sex with you if your bike is furry.


Combustion Contraption




Online

8220 posts [99%]
So Cal
1-31-2003
 « « » Reply  Edit


suddenly i feel inadequate...



EARL LASKEY, YOU WILL BE MISSED
http://www.cccylinderheads.comWEBSITE V2 NOW LAUNCHED
"The Horsepower is in the Head"


RaceCity_USA




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839 posts [100%]
Burgaw NC
3-13-2004
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (Justin_Bradley)« » Reply  Edit


If you took a Prelude, chopped off the front end at the firewall, stripped off the fenders, radiator support and other unnecessary stuff, cut a hole in the back of an Integra just the right size to accept what you chopped off the Prelude, and then welded the peice from the Prelude in the hole cut in the Integra, well thats what it is. Its an Integra body with a Prelude drivetrain and suspension in the rear.

Thanks,




94 GSR mid-engine RWD H22A4 conversion


BigPlansNoMoney




Offline

436 posts [100%]
Richmond VA
9-5-2004
 « « » Reply  Edit


So it's a portion of a Lude front end in the back of an Integra



1995 GS-R Sedan (DB8). Bone stock for now. ~220,000miles. Saving for rebuild.

Have any kind of swap? Answer my poll!

JDM Engine Corp.


Medek




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236 posts [100%]
Los Angeles CA
3-5-2003
 « Re: 94 Integra GSR mid-engine RWD H22A4 conversion (RaceCity_USA)« » Reply  Edit


...



CAI, SS brake lines and Brembos, Strut towers & Lower ties. NGK Iridium w/ wires. DC 4-1 header, Carsound Cat.

next = hydro gsr tranny swap w/ 12.5 lbs ACT Streetlight FW, ACT 6 puck, and quafe LSD.

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