Page 1 of 3 123>
Topic Options
#228212 - 04/06/06 03:48 PM project Teal (w/ lots of pics)
teal_dx Offline
Post Master


Registered: 09/12/02
Posts: 2444
Loc: Ohio
What I've been doing all winter:
I have had my hatch since 2000 and bought it is a DD/winter car so I wouldn't have to drive the Mustang. Well I couldn't just leave it alone, I started with suspension, then intake/header/exhaust, and then a Y8 mini-me swap. Last summer I bought the HX for cheap so that has become my new winter car. I pulled the hatch in the garage thanksgiving last yr and have been working on it on weekends, here's some pics of the progress.



Old motor


bunch of useless clutter left in the bay


here's a pic, had the interior out to convert to manual and for re-routing some of the wiring harness. it was about 0 one night, a good time to remove the sound deadening




a little while later:


And then the wiring:

stock


lengthened

the goal is to re-run the wires for a cleaner engine bay. here the driver side comes out of an existing plugged hole connecting the cabin & inner fenderwell.

The passenger side harness was going to be a pain to remove, so I left it in the car & extended it.



There's also a plugged hole on the right side that connects the cabin to the inner fender area. These wires for the lights/horn/fan will now be hidden.


Car came w/ power steering, but I'm converting to manual. Power racks have a quicker ratio than manual, so converting to manual rather than swapping in a manual rack = teh win

Fuel:


Using an inline fuel filter along with the Earl's fittings to eliminate the ugly oem fuel filter that sits at the top of the firewall.

And what is all this extra fuel for?


The original plan for winter was just to convert to manual & fix the rust, keeping the Y8 mini-me setup. Bryce gave me his old D16z6 (THANKS again!!) which supplied the tranny. I had the block (which knocked) sitting in the corner of the garage in hopes of tearing it down this summer for a re-build to handle some boost. Well after finding a hell of a deal on the Turbo, I couldn't wait... so that plan is in progress right now.



To better handle the boost

oem clutch won't like that so well so:




keeping the weight down, the HVAC, heater core, and blower motor are gone, Power Steering lines, pump, resivior is gone, washer resivior is gone, rear wiper is gone (I kept the windshield wipers & motor cause I'm a wuss) Charcoal canister is gone, SRS is gone, rear seatbelts are gone, Probably going to put the carpet, panels, and rear seats back in the car to be in a lower class for auto-x... also those rims from the HX


They are light as hell but looked like ass from 10 years of road salt

So I did some polishing this winter!
calipers were looking crappy, so while I had them off to install Stainless lines I re-finished those too


can't see much of them thru the beater rims

Last weekend was the first time the car moved since Nov,







I'm sure the neighbors love a teal shell sitting in the driveway




The only additions to this bay will be a motor/tranny, radiator, brake booster/cyl, clutch cyl, and lines and external coil.
No more battery, wires, PS, washer resivior, fuse box, coolant overflow, charcoal canister, fuel filter, brake proportioning valve. all that stuff is either in a cardboard box or relocated somewhere on the car.

After 500 mi with this setup, I'm gonna install the turbo and all the clutter that comes along with it (catch can, vac lines, oil lines, IC, piping)

I'll post the finished car, hoping to have it on the road in a month, after body work & paint job.

The reason I did all this? the 96-98 gt 4.6 isnt the best base for a performance motor b/c of the restrictive heads. Supercharge would cost $3500 and decrease my 1/4 mi by about a second. So why not put that money into a car which has potential to run the same 1/4 mi AND kick ass in the twisties, while getting 30-40 mpg when not being beaten on. And have 2 nice cars, instead of a nice V8 and a deteriorating hatch.

So I'll finally be able to bring my Civic to a CSi meet instead of my Ford
_________________________
6th Gear Advertising what I do for a living
6th Gear Garage shit I build in the garage when I'm not working

Top
Visit Sponsors! Help CSi !
#228213 - 04/06/06 04:04 PM Re: project Teal (w/ lots of pics)
Mad Hungarian? Offline
Post Master Supreme


Registered: 02/23/00
Posts: 13053
Loc: NE OH
wow seriously awesome work, and keep us updated on your project. I remember the first day of seeing the teal beast
_________________________
"I am the sheep that got lost"

2003 Nissan 350z Touring Edition - she gone
2014 Chevrolet Silverado Z71 4x4 Crew Cab

Top
#228214 - 04/06/06 04:06 PM Re: project Teal (w/ lots of pics)
SiWheelman Offline
Post Master


Registered: 03/09/02
Posts: 2512
lookin good. You weren't kidding when you said you had been busy w/ it.
Top
#228215 - 04/06/06 04:11 PM Re: project Teal (w/ lots of pics)
icybishop Offline
Post Master Sr


Registered: 05/17/01
Posts: 7323
Loc: Cleveland, OH USA
wow... fuckin awesome!!!
_________________________

99 ZX2-T | 03 IS300 | 08 GS350

Top
#228216 - 04/06/06 04:14 PM Re: project Teal (w/ lots of pics)
gremis Offline
Post Master Supreme


Registered: 09/10/05
Posts: 20958
Loc: ku country
Keep it up!
_________________________

Top
#228217 - 04/06/06 04:23 PM Re: project Teal (w/ lots of pics)
HotHB Offline
Post Master Supreme


Registered: 09/09/01
Posts: 13975
Loc: Montana
Dude! Those HX wheels look pimpin! By far the best wheel Honda ever made

God those pics bring back memories, love the color

Top
#228218 - 04/06/06 05:28 PM Re: project Teal (w/ lots of pics)
underESTIMATED Offline
Post Master Sr


Registered: 09/16/02
Posts: 4280
Loc: Akron, Oh
This is the best thread you've created about the progress of your car.

I can't wait til you actually finish it, so you'll be more social!!
_________________________

'05 Silverstone s2k (9/4/08 - 2/27/10)
'08 BSP xB (3/1/08 - ?)
Ohio Scions | Ohio Autos | Akron After Dark | Midwest SRT | Civic EG | SRT4mation

Top
#228219 - 04/06/06 07:56 PM Re: project Teal (w/ lots of pics)
12th Monkey Offline
Post Master Sr


Registered: 02/07/00
Posts: 9467
i think i've said it before, but man...you give me a hard on.
Top
#228220 - 04/06/06 08:31 PM Re: project Teal (w/ lots of pics)
tgbastau Offline
Member


Registered: 12/05/01
Posts: 829
Loc: Cleveland Heights, OH
Bad ass Brian! I'm jealous.

I'm hoping my hatch restoration will go as well this summer.


Keep us posted!!
_________________________
Bryce
1992 CBP Si [color:"red"]B16[/color]

Top
#228221 - 04/07/06 09:52 AM Re: project Teal (w/ lots of pics)
Moofaletta Offline
Yup!
Post Master Supreme


Registered: 12/12/99
Posts: 70868
Loc: county
looks good, keep it up and keep updating.
Top
#228222 - 04/07/06 10:43 AM Re: project Teal (w/ lots of pics)
SiAdam Offline
Post Master Supreme


Registered: 07/22/01
Posts: 18810
Loc: West By God Virginia
Awesome buddy.

Keep up the good work...

Are you going to keep the same color, or have it sprayed?

Got Boost is there if ya need it...

_________________________
05 Berlina Black S2000 700whp / 500wtq

Top
#228223 - 04/07/06 10:49 AM Re: project Teal (w/ lots of pics)
todzilla Offline
Post Master Sr


Registered: 04/02/00
Posts: 8414
Loc: Cambridge, OH
Im so jealous. I wish I had that much knowledge of cars to tear em down and install.

Keep it up and keep us posted.
_________________________
'07 GMC Canyonero
"I'm not sure why they call hunting a 'sport', when the hometeam always loses"

Top
#228224 - 04/07/06 10:53 AM Re: project Teal (w/ lots of pics)
TenTwelve Administrator Offline
Fly-over Bottom
Post Master Supreme


Registered: 10/29/99
Posts: 88478
Loc: Lyndhurst, Oh
_________________________



Top
#228225 - 04/07/06 11:26 AM Re: project Teal (w/ lots of pics)
teal_dx Offline
Post Master


Registered: 09/12/02
Posts: 2444
Loc: Ohio
Been reading up alot on turbo setups, there was a lot to learn and I still don't know it all. Been learning some from the Boost forum, and a few other sites too. I'm sure when I go to install I'll be like WTF is this thing for?

I would have never tried a project like this on a newer vehicle, but this car was pretty simple to take apart. Just take it one step at a time and there's really not a whole lot to a car, interior, electrical system, motor & acessories, emissions, suspension... the hardest part is remembering how everything goes back together. After taking everything off the car over the past 5 yrs except for the gas tank, doors, and steering... I can usually look at a part and know where it goes. I do have a small pile of nuts & bolts though that I have no idea where they are from lol.

As for the paint, I debated for a while on the color. Was thinking about a shade of white, then thought about a medium warm silver with a green tint to it. Metallic Earthtones are popular right now. But I'm leaning toward keeping it Tahitian Green Pearl (teal) so I won't have to mess with the doorjambs and if I do decide to leave the interior out, everything will match. Plus I dont want to paint it an aftermarket color because it is the latest trend, and then have it be played out in a couple of years because everybody else does it. Like back in the day Yellow was the shit, then that metallic orange... Keeping it OEM won't date the car, like if people saw the medium warm silver with a green tint, they would say "oh yeah that was hot in 05-06. So I'm gonna re-paint it teal.

Bryce, let me know when you start on your hatch, I'll probably be able to let you know what not to do, definitely label everything or you'll end up with a pile of WTF bolts like me

next few weeks are gonna be bodywork & fabrication. gotta weld in the new rear panels, figure out a way to fab something up to replace the rear area where the side skirts mount to, shave the engine bay, and make a battery tray that will sit inside the front bumper. I never did any of this before, or painted a car before, but its something to learn on!

I'll keep this updated
_________________________
6th Gear Advertising what I do for a living
6th Gear Garage shit I build in the garage when I'm not working

Top
#228226 - 04/08/06 08:13 AM Re: project Teal (w/ lots of pics)
turbo sol Offline
Member


Registered: 09/12/01
Posts: 867
Loc: KC
looks good man, you have been busy! I'll be looking for the final product.
_________________________
89 std hatch = where it all began
93 Del Sol Si turbo = boost is good
89 CRX Si d16z6 = RIP
96 CX Hatch = the new project


Top
#228227 - 04/10/06 02:23 AM Re: project Teal (w/ lots of pics)
Hefay Offline
Poster


Registered: 04/11/05
Posts: 231
Loc: ohio
nice
Top
#228228 - 04/11/06 04:09 PM Re: project Teal (w/ lots of pics)
ALCAP2ONE Offline
Post Master Supreme


Registered: 12/14/05
Posts: 11630
Loc: Akron
amazing
_________________________


Top
#228229 - 04/12/06 09:11 AM Re: project Teal (w/ lots of pics)
SiAdam Offline
Post Master Supreme


Registered: 07/22/01
Posts: 18810
Loc: West By God Virginia
If I have learned anything, it's to label parts and bolts.

I actually get a bag of zip locks and take a magic marker and write on it what it is and sometimes where it goes..

Helps ALOT on the rebuild...

Smoother/quicker...

_________________________
05 Berlina Black S2000 700whp / 500wtq

Top
#228230 - 04/17/06 10:05 PM Re: project Teal (w/ lots of pics)
si1999 Offline
Newbie


Registered: 06/13/01
Posts: 33
Loc: fairborn, oh, usa / Cleveland ...
What did you do to your wheels????
They look amazing.

I think my stock si wheels need that kind of love
_________________________
99 MR si

Top
#228231 - 04/18/06 09:08 AM Re: project Teal (w/ lots of pics)
teal_dx Offline
Post Master


Registered: 09/12/02
Posts: 2444
Loc: Ohio
here you go, w/ pics http://forums.clubsi.com/showflat.php?Cat=0&Number=6734176
have fun!

got lazy over the weekend, didn't do too much on the car....

figured out the fmic mounting and puzzle of piping that came in a box with a bunch of random pieces.

in the bottom right you might have seen my "poor man's" Optima battery:

weighs about 12 lbs, cost $25 Technically it is not as good since it is not sealed like the Optima batteries, but I'm not mounting it inside the car so no setback. That's all for now!
_________________________
6th Gear Advertising what I do for a living
6th Gear Garage shit I build in the garage when I'm not working

Top
#228232 - 04/18/06 05:09 PM Re: project Teal (w/ lots of pics)
underESTIMATED Offline
Post Master Sr


Registered: 09/16/02
Posts: 4280
Loc: Akron, Oh
The driver's side hardpipe looks like it'll be a very close fit inside the bumper.
_________________________

'05 Silverstone s2k (9/4/08 - 2/27/10)
'08 BSP xB (3/1/08 - ?)
Ohio Scions | Ohio Autos | Akron After Dark | Midwest SRT | Civic EG | SRT4mation

Top
#228233 - 04/18/06 10:03 PM Re: project Teal (w/ lots of pics)
si1999 Offline
Newbie


Registered: 06/13/01
Posts: 33
Loc: fairborn, oh, usa / Cleveland ...
Thanks for the great link!!
_________________________
99 MR si

Top
#228234 - 04/28/06 09:11 AM Re: project Teal (w/ lots of pics)
teal_dx Offline
Post Master


Registered: 09/12/02
Posts: 2444
Loc: Ohio
The surgery has begun!!

first I drew a template and cut just inside the line (not enough is safer than too much)



next had to use a wire wheel on a drill to scrape off all of the panel bond, then was able to find the spot welds and drill every one of them out





Pryed it apart with a mallet & a flathead screwdriver, only to find more spot welds to drill out...


Finally drilled them all and was able to pull the panel out.


Looking into the top of the wheel well, you can see the black adhesive strip that Honda used on the seam to prevent rust from starting.


guess it didn't work as well as they thought


drilled the rest of the spot welds out from the fender lip and got the panel off.


damn... gonna have to do some fabricating here, but it doesnt need to look pretty since it won't be seen.


the spotwelds in the wheel well, and the ones that were rusted away near the top.


Inside of the oem panel



Now I know why the body shop told me $3500 If I wasn't this far along and didn't install urethane bushings I'd sell this one and look for a rust-free hatch. If you're ever looking at buying a rust free civic, be sure to take out the interior panel and have a look from the inside. Check where the fender meets the bumper and where the fender meets the rocker panel. That's where it eats from the inside out. 5-6 years ago I had one tiny bubble in the paint on the pass side and the driver side looked perfect lol. There will definitely be no more winters after this!
That's all for this week, stay tuned.......
_________________________
6th Gear Advertising what I do for a living
6th Gear Garage shit I build in the garage when I'm not working

Top
#228235 - 04/28/06 10:04 AM Re: project Teal (w/ lots of pics)
Mad Hungarian? Offline
Post Master Supreme


Registered: 02/23/00
Posts: 13053
Loc: NE OH
looks like it had the 92-95 honda cancer
_________________________
"I am the sheep that got lost"

2003 Nissan 350z Touring Edition - she gone
2014 Chevrolet Silverado Z71 4x4 Crew Cab

Top
#228236 - 05/18/06 08:01 AM Re: project Teal (w/ lots of pics)
tgbastau Offline
Member


Registered: 12/05/01
Posts: 829
Loc: Cleveland Heights, OH
Quote:










Wow, that really makes me nervous to take mine apart now, I'm sure it looks like this or worse.

Also, any updates??
_________________________
Bryce
1992 CBP Si [color:"red"]B16[/color]

Top
#228237 - 05/31/06 03:54 PM Re: project Teal (w/ lots of pics)
teal_dx Offline
Post Master


Registered: 09/12/02
Posts: 2444
Loc: Ohio
Bryce, it would have been 100x easier for me to just buy another hatch. I was only doing this because I had replaced all the bushings w/ urethane ones, but even doing that again would be way easier and quicker than doing this body work, as I am finding out

Oh well I started so I might as well finish!



the rocker panels were rotted


the inside was only surface rust though. Just the part where the side skirts attached were rusted through.





had to make new rocker panels:















and the rotten metal had to be cut out all the way up past the door about a foot and a half.




this piece was only 2 sided, didn't get a final pic after I cut the top off.



got those hard to reach areas as clean as I could and applied rust inhibitor


the inner wheel well cut out areas that were swiss cheese have new metal welded in

inside of rocker panel & back of new sheetmetal was primered & welded on:














that's it for now... next I'm gonna work on getting that main quarter in


Edited by teal_dx (05/31/06 03:59 PM)
_________________________
6th Gear Advertising what I do for a living
6th Gear Garage shit I build in the garage when I'm not working

Top
#228238 - 05/31/06 04:53 PM Re: project Teal (w/ lots of pics)
Stryker124 Offline
Major Member


Registered: 10/22/00
Posts: 1281
Loc: Mentor, Ohio USA
Damn man, that is a hell of a lot of work! Nice job though.

What rust inhibitor are you using?
_________________________
2010 Mazdaspeed3
"Please, please let the warranty expire soon...I needs a downpipe and some ECU work..."

Top
#228239 - 05/31/06 11:27 PM Re: project Teal (w/ lots of pics)
Mad Hungarian? Offline
Post Master Supreme


Registered: 02/23/00
Posts: 13053
Loc: NE OH
holy mother of god, you have truly lost your marbles...lol. You have performed some serious surgery on that honda cancer ridden vehicle. Seriously hats off to you. I can't believe the time you have put into that SOB. I can't wait to see it on the road again. Ya know the sad part is, there are very few people that will ever know just how much you put into it work wise. The good part is that you'll always have that feeling of self satisfaction that you did all of that yourself.
_________________________
"I am the sheep that got lost"

2003 Nissan 350z Touring Edition - she gone
2014 Chevrolet Silverado Z71 4x4 Crew Cab

Top
#228240 - 06/02/06 07:38 AM Re: project Teal (w/ lots of pics)
AllNOS99Si Offline
Post Master Jr


Registered: 04/03/00
Posts: 1869
Loc: Central Ohio
looks like a hellula lotta work for you. My hats off to you for doing it yourself.
_________________________
if that aint country, I'll kiss yer ass

Top
#228241 - 06/02/06 08:55 AM Re: project Teal (w/ lots of pics)
shupadupa Offline
Post Master Sr


Registered: 09/08/00
Posts: 4217
Loc: Painesville, OH
jesus, talk about a weekend(s) project. Good work Brian.
_________________________
'03 AS Evolution VIII GSR
'05 BMW X3 (6-spd manual)


Top
#228242 - 06/19/06 12:00 PM Re: project Teal (w/ lots of pics)
teal_dx Offline
Post Master


Registered: 09/12/02
Posts: 2444
Loc: Ohio
finally feel like I'm getting somewhere on the bodywork....


new rocker panel


new quarter panel. was a PITA to get it clamped in place perfectly. I got pissed eventually and took all the clamps off except for on the bottom and just used my other hand to hold it. Actually worked better!



tacked in place



welded in. Welding beads look pretty, but to keep the metal from warping from heat you have to tack, then tack in between those tacks, then tack in between those etc... so that leaves you with alot of extra grinding to do afterwards.

Started shaving the engine bay...




Every hole is grinded to remove the paint, then welded in.




then those welds are ground down flush with the sheetmetal and uneven areas are welded more and ground down more. repeat process


battery, fusebox, and cruise control holes are too big, need to cut out a piece of sheet metal for these.


just remember which ones you need to keep




ran out of argon so called it a day for welding. that is all for this week of project teal the block should be back from the machine shop soon
_________________________
6th Gear Advertising what I do for a living
6th Gear Garage shit I build in the garage when I'm not working

Top
#228243 - 06/19/06 12:25 PM Re: project Teal (w/ lots of pics)
SiAdam Offline
Post Master Supreme


Registered: 07/22/01
Posts: 18810
Loc: West By God Virginia
Lookin good, where did u get that rear quarter and the piece for the rocker panel underneath...?

That seems like the smart way to go...bondo =
_________________________
05 Berlina Black S2000 700whp / 500wtq

Top
#228244 - 06/19/06 10:43 PM Re: project Teal (w/ lots of pics)
TenTwelve Administrator Offline
Fly-over Bottom
Post Master Supreme


Registered: 10/29/99
Posts: 88478
Loc: Lyndhurst, Oh
You are out of your fucking mind.
_________________________



Top
#228245 - 06/19/06 10:50 PM Re: project Teal (w/ lots of pics)
SiWheelman Offline
Post Master


Registered: 03/09/02
Posts: 2512
damn dude it looks amazing! I'm back in town now and have the car up and running, let me know if you ever need some help or want to meet up.
Top
#228246 - 06/20/06 08:14 AM Re: project Teal (w/ lots of pics)
tgbastau Offline
Member


Registered: 12/05/01
Posts: 829
Loc: Cleveland Heights, OH
Damn dude, that work is seriously impressive. I may have to head over to Crackron to see this in person!



By the way, you don't have this decay on the other side, do you?
_________________________
Bryce
1992 CBP Si [color:"red"]B16[/color]

Top
Page 1 of 3 123>


Moderator:  Murder, TenTwelve 
Hop to:
Shout Box

CSi Sponsors

DallasColo
Dallas Colocation
Brake Kits
StopTech.Sale BBK Clearance
Brake Kits
Brake Kits Cheap
EBC Brake Kits
EBC Brakes
BuyBrakes
Brake Kits-Pads & Rotors Sets
Cruchfield
Audio/Video/Cameras
DeadWood Knives
Knives, Home & Hunting
Samys Camera
GoPros, Cameras, Gear
TireRack
Tires/Wheels/Suspension
Truck Accessories
Tonneaus, Running Boards
1-800-Flowers
Flowers & Gift Baskets
WeatherTech
Coupon Code "take10"
Porsche Brakes
Porsche Brake Upgrades
Artisan Soap Lab
Handcrafted Bodycare
Advertisement

| Brake Kits Cheap | EBC Brake Pads & Rotors | Performance Brake Kits | Porsche Brake Upgrades-Big Brake Kits | WeatherTech Mats -Coupon Code weathertech10