The Columbus Newb Build v.Kylecivicsi's 99 Civic Si

[Kylecivicsi]

This is my first real post on CR, let's see how bad I can manage to screw this up

 

More background info on me can be found in my intro thread (which I can't view anymore, and therefore, cannot link directly to) which is titled "Newb from Louisville, KY".

 

I'm doing a full 2.0L GSR longblock rebuild, and possibly (hopefully?) a new turbo setup on my 99 SI.

 

Build Specs (as of now):

 

84mm GSR Block with Darton MID sleeves

89mm CRV Crank

Block machining done by Slowmotion's machine shop

9.7:1 CP pisons

Manley turbo tuff rods

Honda OEM bearings/water pump/oil pump/timing belt/gaskets/etc

 

B16A2 head

Skunk 2 Pro 1 Cams

Skunk 2 Pro Series Cam Gears

Supertech springs/Ti retainers

Hondata IM gasket

Hondata 4 bar map sensor ( as well as boost control components and solenoid)

Decking, new valve guides, new valve seals, etc

Possbly a Victor X Intake manifold and skunk 2 pro/black series 70mm TB

 

Summit ignition box (mallory hyfire 6 in a different enclosure)

MSD external coil distributor cap

Crane Cams PS92 Coil

Turbo-LS (honda-tech screen name) ignitor bypass module)

NGK 7mm spark plugs

NGK plugs (yet to be determined correct temp)

 

 

Other than that:

Hasport 70a Billet engine mounts

Competition clutch stage 5 sprung with "xtreme" pressure plate upgrade

AEM Digital UEGO wideband

AEM Analog Boost

Autometer gauge cluster mount

Upgrade from old s200b to s300v2 hondata

 

Current Turbo Setup:

60 trim .63ar garret turbo

erl cast manifold

custom ac&ps friendly down pipe

Garret bar/plate IC core with custom endtanks

Tial BOV and Wastegate

 

 

I decided to take on the remove and re-install, as well as the long block rebuild labor by myself (with some help from a friend and co-worker). I am really interested in doing the tune by myself as well, but that is still up for debate at this point. I hope this will save me enough money to afford an upgrade to either a gt35 or 6262 turbo with a topmount manifold and larger IC. We will see where the budget stands once this thing is running...

 

To tackle the longblock build I needed to beef up the tool arsenal, and parts have started rolling in.

 

Torque Wrenches:

I went with gearwrench because they are made in the USA, very affordable, and come with the calibration/verification in the box. got 1/4", 3/8" and 1/2"

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0130.jpg

 

Rod stretch gauge and dial bore gauge both from Jegs

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0129.jpg

 

El cheapo tap/die set, ring filer, and plastigauge kit. Again, from Jegs.

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0131.jpg

 

Ignition setup, and high performance bread machine, from Summit and Jegs.

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0132.jpg

 

Rediculously large bottle of Royal Purple assembly lube, from Summit.

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0134.jpg

 

Lastly, shout out to Summit for sending free swag with my purchase!

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0133.jpg

 

Any questions, feel free to ask! I'm sure I forgot something, but I'll keep this update as best I can. The motor will be pulled tomorrow, and once the block returns from the machine shop, the mayhem can continue. My order from Matco Tools will be in Thursday, as will my pistons, springs/retainers, and clutch... Here we go!

Edited July 4, 2012 by Kylecivicsi

[10phone2]

good for you, your off to a good start. Good luck with the build.

[Ef8sirJunkie]

Looks like your off to a good start. i wanted to give you a heads up Comp Clutch stage 5 happens to have a lot of issues. Alittlelessordaniary on here had a ton of trouble with his and ended up going with their twin disk after a long discussion with their technical team. just a heads up.

[ImUrOBGYN]

Good luck and welcome. (As I missed your intro thread.)

[Kylecivicsi]

Thanks for the well wishes guys. I'm pretty excited for the progress so far, can't wait to see 500whp

 

As for the CC stg 5, I have read a lot on honda-tech and most all of the reviews are pretty positive as far as holding power and daily driveability, so I suppose we will see. I was surprised when I opened it and saw that the pucks are SSSSSUUUUUUPER thin. I definitely expected them to be much beefier. I've never had a ceramic puck clutch though, so maybe (hopefully) that is the norm.

 

Small update: put in 7 hours working on removing the engine. All that should be left is the lower ball joints, driveshafts, and unbolting mounts. No pictures, but it was nothing exciting.

 

Also, more tools, and some parts came in today! That always makes the day better

 

Matco 0-4" micrometer set with calibration rods:

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0139.jpg

 

From Matco: Tiny 72 tooth, 3" long, 1/4" drive ratchet; 1/4 and 1/2 inch impact swivels, straight and bent feeler gauges

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0138.jpg

 

Matco 1/4" and 3/8" wobble extension sets:

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0136.jpg

 

Matco ring compressor set:

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0141.jpg

 

CP 9.7:1 84mm pistons, rings, pins, etc.

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0142.jpg

 

Competition Clutch stage 5 sprung with "xtreme" pressure plate upgrade:

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0140.jpg

 

First piece of old turbo setup to be cleaned and restored:

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0135.jpg

[Alex L.]

Nothing better than presents from Matco and/or Snap On. Very anxious to see how this build pans out.

[DaddyBuiltRacing]

Those reviews lie..... I am not really allowed to speak on the product but someone in this thread already did and summed it up perfectly.

[trix-storm]

Nice tools and excited to see the build progress.

[Ef8sirJunkie]

Those reviews lie..... I am not really allowed to speak on the product but someone in this thread already did and summed it up perfectly.

 

I will say the stage 4 seems to be holding up well in another customer car. I have personally seen 5 maybe 6 stage 5's fail. im just giving you a heads up and i like the build and dont wanna see you down because of their mistake.

 

And yes Josh can no longer talk about Comp since their is a deal worked out between them.

[Kylecivicsi]

Any input on a fuel system for this build? Currently on a walbro 255 with precision 1000cc injectors. Looking to make 500whp or so. Can I get away with adding a bosch pump inline, with larger -an lines, new rail/fpr? Will the precisions work well with a higher base pressure? my understanding is that I will likely only make it to 400-450 on E85 with my current setup.

[Kylecivicsi]

Small-ish update:

 

A bunch of parts have been coming in, and a bunch of money has been going out. Got word that the block will be ready for pick up tomorrow, which is exciting. The head was disassembled and dropped off monday of this week, should be a 2 week (or so) turnaround on it.

 

The engine and transmission are out of the car, the transmission is awaiting a liberal cleaning before a gloss black facelift. The oldschool garrett core IC needs a lot of love, and there are some IC pipes to polish up as well.

 

I decided I'm going to try E85 on startup, and see how I like it. I'll be running a 300lph deatschwerks in tank, feeding an 044 bosch inline, using the stock feed/filter/return. Everything from filter to return will be -8. Golden eagle fuel rail and fuel lab regulator are awaiting delivery.

 

As far as the cams go, I was stuck between these and the GSC T1s, but I intend on going 62mm topmount/ramhorn in the not-so-distant future. I hate buying things twice, so at the possible short term loss of some HP, I'm going with the pro-1s. It doesn't hurt that I got a really good deal on them brand new (570 shipped).

 

Some more eye candy:

 

Gauge cluster bezel for my AEM wideband and AEM analog boost gauges (awaiting delivery), 044 install kit from B&R fittings (HIGHLY recommended), and freshly disassembled/cleaned Tial BOV:

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/fd0a5ee2.jpg

 

 

Matco valve lash adjustment tool, Turbo-LS ignitor bypass module, Supertech springs/retainers:

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/159d9ffe.jpg

 

 

Hasport 62a billet mounts:

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/73ea77d6.jpg

 

 

Next is probably the part I am most happy about. This thing look incredible. Welds look almost robotic, the powdercoat is flawless, and I love the way the logo imbossed in the top. I am INCREDIBLY happy with the quality of this piece, and HIGHLY recommend Brian and B&R Fittings for anything. There was even a small shipping mix up, and Brian was quick to remedy the situation, no questions asked. Big thanks to him for excellent customer service and an INSANELY high quality product.

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/c3107717.jpg

 

 

Close of up the logo, looks great in person.

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/f7a25a34.jpg

 

 

New cams and Hondata IM gasket:

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0143.jpg

 

 

Used Skunk2 pro series crew checking in. Intake manifold, cam gears and 70mm TB:

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/a06c801d.jpg

 

 

Before and after IC Cold side resto:

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0135.jpg

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/IMAG0145.jpg

 

Breather fittings/hose/block plug, fuel pump wiring kit, marshall Fuel Pressure gauge (which is made in china, despite saying Anaheim, CA on the face...BOO), mac boost solenoid and ECU components for s300, GE squirter block offs:

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/60b7d525.jpg

[Kylecivicsi]

More goodies! Battery relocation kit, terminal block, moroso disconnect, dial indicator stand, degree wheel, and 25' of 8AWG for the alternator->battery line.

 

http://i111.photobucket.com/albums/n158/kylebloomer/Rebuild/b5d792ff.jpg