My K20a2 EG build up thread - TONS of pics!

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04-11-2007, 07:56 PM
Extra Made

:goodjob: Amazing and thorough thread..+1 for you man
04-11-2007, 08:11 PM
EJ_Allmota

damn man, you are doing the damn thing..
04-11-2007, 08:59 PM
Fuster_Cluck

Session 019:

:camera: time!!

Removing the gas and brake pedal assembly.

Everything you remove to get the assembly out of the vehicle is 12mm. This is assuming you have the brake booster and clutch slave cylinder removed already.

http://i121.photobucket.com/albums/o..._4356_rs23.jpg

Remove the 12mm nut:

http://i121.photobucket.com/albums/o..._4326_rs25.jpg

Closer look at the nut:

http://i121.photobucket.com/albums/o..._4327_rs25.jpg

Disconect the throttle cable, but how??

http://i121.photobucket.com/albums/o..._4336_rs25.jpg

Ahhhhh, just pinch the 2 clips and it pops out:

http://i121.photobucket.com/albums/o..._4338_rs25.jpg

Cotter pin that will need to be removed once the assembly is out:
(Good luck removing it while the assembly is still mounted)

http://i121.photobucket.com/albums/o..._4339_rs25.jpg

Remove that 12mm bolt and the assembly is ready to come out:
(LAMFExtFTW)

http://i121.photobucket.com/albums/o..._4344_rs25.jpg

One of the harness you'll need to disconnect:

http://i121.photobucket.com/albums/o..._4345_rs25.jpg

Assembly out:

http://i121.photobucket.com/albums/o..._4347_rs25.jpg

Time to work on the clutch assembly:

http://i121.photobucket.com/albums/o..._4351_rs25.jpg

Remove the bolt using your LAMFExt:

http://i121.photobucket.com/albums/o..._4355_rs23.jpg

2 harnesses / 12mm bolt to remove:

http://i121.photobucket.com/albums/o..._4329_rs23.jpg

and the assembly comes out once you disconnect the 2 harnesses:

http://i121.photobucket.com/albums/o..._4359_rs23.jpg

Gas pedal:

http://i121.photobucket.com/albums/o..._4375_rs23.jpg

Bump stop on the gas pedal. Pic so I can reinstall it close to the original setting:

http://i121.photobucket.com/albums/o..._4374_rs25.jpg

Throttle cable clip ($hit's nasty):

http://i121.photobucket.com/albums/o..._4386_rs25.jpg

Pull it outward with some pliers:

http://i121.photobucket.com/albums/o..._4387_rs25.jpg

Pry the rubber protectors out with a flathead screwdriver:

http://i121.photobucket.com/albums/o..._4376_rs23.jpg

2 switches that engage and disengage the clutch?? First time seeing this stuff so I
really don't know. Plus I'm a noob to the technical side of cars :P

http://i121.photobucket.com/albums/o..._4384_rs25.jpg

The assembly cleaned up, ready to be prepped for paint:

http://i121.photobucket.com/albums/o..._4390_rs25.jpg

Speaker wire I need to replace:

http://i121.photobucket.com/albums/o..._4391_rs23.jpg

Thanks for the props again guys.
04-12-2007, 01:55 AM
spacelion

I just read every one of your posts. Nicely done! I wish I had the extra space to do something like this...Would like to see the car in person once it's done! PROPZ! :goodjob:

ps, hood dampers would be badazz, you should do those :yes:
04-12-2007, 11:48 AM
R3RUN

Has anyone ever told you that you should write instruction manuals? Bad ass project sir.
04-15-2007, 10:27 PM
Fuster_Cluck

Quote:

Originally Posted by spacelion

I just read every one of your posts. Nicely done! I wish I had the extra space to do something like this...Would like to see the car in person once it's done! PROPZ! :goodjob:

ps, hood dampers would be badazz, you should do those :yes:

Thanks man!! I thought about getting some hood dampers, but after seeing how the hood will open only so far, I have to pass on them. The car will be at the local meets / shows once complete. You can bet that :cheers:

Quote:

Originally Posted by R3RUN

Has anyone ever told you that you should write instruction manuals? Bad ass project sir.

hahaha.... you're the first to mention that, lol. Thanks for the props!!

Session 020:
(This has been one of the worst sessions)

Rear under carriage cleaning :no: :cry:

I knew the back was nasty as well, but had no idea it would be such a PITA to clean.

Got to love the wheel dollies. Moving the hatch around with nothing up front. Flipped her around in the garage to work on the a$$ end. Yeah, each time I jack the front end up now I have to lift the front end to slide the jack underneath. Yeah, I'm that strong :blah: :lmfao:

http://i121.photobucket.com/albums/o..._4399_rs25.jpg

http://i121.photobucket.com/albums/o..._4396_rs25.jpg

http://i121.photobucket.com/albums/o..._4398_rs25.jpg

See why this $hit is so nasty:

http://i121.photobucket.com/albums/o..._4404_rs25.jpg

I cleaned the back end for about 2 hours taking small breaks in between. This is the result:

http://i121.photobucket.com/albums/o..._4411_rs25.jpg

http://i121.photobucket.com/albums/o..._4412_rs25.jpg

http://i121.photobucket.com/albums/o..._4414_rs25.jpg

http://i121.photobucket.com/albums/o..._4415_rs25.jpg

Still have some more cleaning to do as well. I'm going to pull the entire rear suspension off for cleaning and undercoat everything including the wheel wells :bump:

Got tired of cleaning the rear so I decided to switch things up a bit and clean the bay.
My brother recommended AJAX, so that is what I used:

http://i121.photobucket.com/albums/o..._4405_rs25.jpg

Get it on there nice and good:

http://i121.photobucket.com/albums/o..._4406_rs25.jpg

How do I remove this clip? It's located in the corner below the brake booster:

http://i121.photobucket.com/albums/o..._4408_rs25.jpg

Then I was curious about the stains in the engine bay and decided to test a spot by sanding it down after cleaning:

http://i121.photobucket.com/albums/o..._4416_rs25.jpg

Then I went to work with my razor blade removing the residue from the cowl opening below the windshield:

http://i121.photobucket.com/albums/o..._4409_rs25.jpg

That's it for now. I'll be back hopefully soon with some more pics :camera:

Thanks for looking :police:
04-16-2007, 12:27 AM
5spdfrk

Quote:

Originally Posted by Hybrid93Hatch

I cleaned the back end for about 2 years taking small breaks in between.

You must be really tired of cleaning then, lol.
04-16-2007, 07:00 AM
Fuster_Cluck

Quote:

Originally Posted by 5spdfrk

You must be really tired of cleaning then, lol.

LMAO, I was tired when I wrote that up too :taun:
04-17-2007, 12:21 PM
puregroove

Awesome...you inspire me. :D
04-17-2007, 01:23 PM
joesblk_teg

wow one day when i have the time i plan to do this with a car
04-17-2007, 01:38 PM
jaystar

nice iam doin a k-series in my 2000 Si , how much did u spend in total ???
04-17-2007, 03:13 PM
BigTs13

seriously, i cannot wait till this is done. its gonna be a jaw-dropper.
04-17-2007, 04:45 PM
ATL86

:bow: +1 for you!
04-18-2007, 01:46 PM
sleepys4

you may have said it already, but what kind of camera are you using?
04-18-2007, 04:45 PM
5spdfrk

He's using a canon powershot a95
04-18-2007, 05:41 PM
Ltdnismorace

hybrid, have you already picked up your Kswap engine and tranny? If so, PM me details on it, I may be looking into swapping one into a coupe here soon.
04-18-2007, 10:03 PM
ranj

dude this is sick man.
04-18-2007, 10:34 PM
civic95

Holy Shiat man! I could never get that deep into a project. If I can't finish it in a couple days I would be freaking out. Plus, with my luck it would get totalled as soon as I finished.
04-18-2007, 10:56 PM
Nismo

Did you sell your soul to Harbor Freight? LOL. Any idea how much you have spent so far?
04-18-2007, 11:01 PM
Black R

:goodjob:

saw this on h-t I think... keep it up.
04-18-2007, 11:38 PM
1jdmsx

WOW, this is so detailed, major props man, i have never seen such a detailed writeup in a LONG time. GL on the swap and +1 for your hard work and dedication.
04-19-2007, 03:08 AM
Hektik

+1....
04-19-2007, 12:57 PM
imbosile

wow, i cannot wait to see more

i would love to try to do this some day, +1
04-19-2007, 10:09 PM
VTAC SONN

awesome build
04-21-2007, 05:05 PM
Fuster_Cluck

Thanks guys for the props :bump:

Session 021.

Not to much done, but took care of more cleaning. My buddy was over at the house so not much work:

Dirty front under splash and gas tank / filler neck plastic panels:

http://i121.photobucket.com/albums/o..._4477_rs25.jpg

http://i121.photobucket.com/albums/o..._4478_rs23.jpg

http://i121.photobucket.com/albums/o..._4480_rs25.jpg

No need to buy new ones:

http://i121.photobucket.com/albums/o..._4483_rs25.jpg

Set her up for some engine bay sanding:

(xenon lights FTW again :goodjob: )

http://i121.photobucket.com/albums/o..._4488_rs25.jpg

http://i121.photobucket.com/albums/o..._4493_rs25.jpg

Passenger side sanded down /drivers not:

http://i121.photobucket.com/albums/o..._4499_rs25.jpg

This pic is untouched, so dirty and nasty. Yet so appealing to me: :P

http://i121.photobucket.com/albums/o..._4481_rs25.jpg

I need to know if am I removing gunk, oil, crap or is that OEM coating that I am removing from the gas tank below:

http://i121.photobucket.com/albums/o..._4501_rs25.jpg

http://i121.photobucket.com/albums/o..._4502_rs25.jpg

After hearing the 3m undercoating is no that great I am now leaning towards a nice coat of primer and battleship gray for the under carriage / fender wells :cheers:

I'll be back later to post the next session which will be 51 pictures :camera:
04-21-2007, 05:10 PM
Nittanys1

damn what did you use to get those plastic pieces SOOO clean? they look like you just opened them from their new packaging!!!
04-21-2007, 10:58 PM
5spdfrk

Quote:

Originally Posted by Nittanys1

damn what did you use to get those plastic pieces SOOO clean? they look like you just opened them from their new packaging!!!

Yeh, no joke!

I think that is oem coating on the gas tank. Is it rubbery like? It may be to protect the gas tank and help debris bounce off better. IDK for sure though. Keep up the good work!
04-22-2007, 05:08 PM
Fuster_Cluck

Thanks guys for the props! Yeah, found out the $hit I was getting ready to remove is the protectant on the tank :police:

As far as cleaning the plastic pieces. Pretty much just engine degreaser and some elbow grease :yes:

Here we go, Session 022:

Time for some drilling:

http://i121.photobucket.com/albums/o..._4514_rs25.jpg

Eyeing the spots for the kill:

http://i121.photobucket.com/albums/o..._4504_rs25.jpg

http://i121.photobucket.com/albums/o..._4508_rs25.jpg

http://i121.photobucket.com/albums/o..._4506_rs25.jpg

http://i121.photobucket.com/albums/o..._4507_rs25.jpg

http://i121.photobucket.com/albums/o..._4512_rs25.jpg

http://i121.photobucket.com/albums/o..._4513_rs25.jpg

Took the measurement:

http://i121.photobucket.com/albums/o..._4517_rs25.jpg

First kill:
(Got to figure out how to clean that up)

http://i121.photobucket.com/albums/o..._4518_rs23.jpg

Not bad definitely can clean that up:

http://i121.photobucket.com/albums/o..._4520_rs25.jpg

Tranny bracket removal:

http://i121.photobucket.com/albums/o..._4522_rs25.jpg

http://i121.photobucket.com/albums/o..._4523_rs25.jpg

http://i121.photobucket.com/albums/o..._4524_rs25.jpg

First spot weld loose:

http://i121.photobucket.com/albums/o..._4527_rs25.jpg

Side view:

http://i121.photobucket.com/albums/o..._4528_rs25.jpg

Get the pry bar in there and drill some more:

http://i121.photobucket.com/albums/o..._4529_rs23.jpg

http://i121.photobucket.com/albums/o..._4530_rs25.jpg

Getting there:

http://i121.photobucket.com/albums/o..._4531_rs25.jpg

Many down, one to go:

http://i121.photobucket.com/albums/o..._4533_rs25.jpg

Just wiggled the mount and off she came:

http://i121.photobucket.com/albums/o..._4534_rs25.jpg

Have to fill that in and sand the rest down and fill in:

http://i121.photobucket.com/albums/o..._4535_rs25.jpg

I achieved my goal. No drill holes from removing the mount:

http://i121.photobucket.com/albums/o..._4536_rs25.jpg

Tools used:

http://i121.photobucket.com/albums/o..._4537_rs25.jpg

Result:

http://i121.photobucket.com/albums/o..._4539_rs25.jpg

Welds from the radiator bracket:

http://i121.photobucket.com/albums/o..._4540_rs25.jpg

2 radiator brackets side by side:

http://i121.photobucket.com/albums/o..._4542_rs25.jpg

More spot welds:

http://i121.photobucket.com/albums/o..._4544_rs25.jpg

On to some interior stripping:

One of the most useful tools so far in my build:

http://i121.photobucket.com/albums/o..._4546_rs25.jpg

http://i121.photobucket.com/albums/o..._4547_rs25.jpg

http://i121.photobucket.com/albums/o..._4549_rs25.jpg

Left done / right not:

http://i121.photobucket.com/albums/o..._4551_rs25.jpg

Closer look:

http://i121.photobucket.com/albums/o..._4552_rs25.jpg

Decided to take some off:

http://i121.photobucket.com/albums/o..._4556_rs25.jpg

http://i121.photobucket.com/albums/o..._4554_rs25.jpg

Not so much now:

http://i121.photobucket.com/albums/o..._4557_rs25.jpg

Drivers side BEFORE:

http://i121.photobucket.com/albums/o..._4567_rs25.jpg

Passenger side AFTER:

http://i121.photobucket.com/albums/o..._4568_rs25.jpg

Then I just started trying out things with the wheel, lol:

http://i121.photobucket.com/albums/o..._4560_rs25.jpg

http://i121.photobucket.com/albums/o..._4561_rs25.jpg

http://i121.photobucket.com/albums/o..._4562_rs25.jpg

http://i121.photobucket.com/albums/o..._4563_rs25.jpg

http://i121.photobucket.com/albums/o..._4564_rs25.jpg

http://i121.photobucket.com/albums/o..._4574_rs25.jpg

http://i121.photobucket.com/albums/o..._4575_rs25.jpg

http://i121.photobucket.com/albums/o..._4573_rs25.jpg

http://i121.photobucket.com/albums/o..._4576_rs23.jpg

I need to sand some of that done so I can remove the hood arms:

http://i121.photobucket.com/albums/o..._4565_rs25.jpg

It's pretty bad:

http://i121.photobucket.com/albums/o..._4566_rs25.jpg

wire wheel FTW to remove the glue on the door:

http://i121.photobucket.com/albums/o..._4569_rs25.jpg

NICE!!!! :

http://i121.photobucket.com/albums/o..._4571_rs23.jpg

I even removed the spare tire residue but don't have the after picture with me:

http://i121.photobucket.com/albums/o..._4572_rs25.jpg
04-23-2007, 10:36 PM
Hektik

again WOW ............. simply amazing the amount of work you are putting into this car...i would +1 you again if i could.....
04-24-2007, 07:45 PM
Fuster_Cluck

Quote:

Originally Posted by Hektik

again WOW ............. simply amazing the amount of work you are putting into this car...i would +1 you again if i could.....

Same here, lol. :cheers:

Session 023:

I removed the rear driver wheel and went straight to the camber bolt problem. Surprisingly it loosened up with no problem using the BAMFBB

http://i121.photobucket.com/albums/o..._4580_rs25.jpg

Then I started removing the other 5 bolts that attach each rear corner to the car:

14mm toe adjustment bolt:

http://i121.photobucket.com/albums/o..._4581_rs25.jpg

Toe bolt on the left and 17mm mid trailer arm bolt on the right. The other 17mm bolt is on the opposite side of the trailing arm:

http://i121.photobucket.com/albums/o..._4583_rs25.jpg

There are a few 10mm bolts that hold the ebrake cables in place. You can see 2 of them in the pic below:

http://i121.photobucket.com/albums/o..._4584_rs25.jpg

Blurrry pic of the 14mm bolt you'll need to remove on the inner part of the Lower Control Arm (LCA):

http://i121.photobucket.com/albums/o..._4584_rs25.jpg

Don't forget to remove the brake line clip. Just grip one side with pliers and wiggle it back towards the outside of the car:

http://i121.photobucket.com/albums/o..._4588_rs25.jpg

This is all that holds the rear corner in place:

http://i121.photobucket.com/albums/o..._4591_rs23.jpg

Is this supposed to be crooked like that:
(I'm assuming so. But, since I did not own this car for the first 11 years of its life I have to ask)

http://i121.photobucket.com/albums/o..._4592_rs23.jpg

DumpeD:

http://i121.photobucket.com/albums/o..._4593_rs25.jpg

Looks so pitiful :cry:

http://i121.photobucket.com/albums/o..._4599_rs25.jpg

So, I don't forget what bolts went where:

http://i121.photobucket.com/albums/o..._4607_rs25.jpg

Removed the LCA, camber arm, and toe arm (I don't know their official names):

http://i121.photobucket.com/albums/o..._4615_rs25.jpg

Now, I have to clean this up. I want to disassemble the assembly. Is there anything I need to be aware of? I will just dive in by removing bolts if there is nothing to worry about. I plan to clean everything up, repaint the trailing arm, lca, toe arm, and camber arm. I'm even thinking about replacing the trailing arm bushing why it's all apart. May run it by Tom and see if he can do it for me since I don't have the tool.

http://i121.photobucket.com/albums/o..._4618_rs25.jpg

Besides the glass, windshield and roof molding, and engine/dash wiring harness, steering wheel there is nothing else to remove :no:

Thanks for all the feedback :goodjob:
04-24-2007, 09:29 PM
twinj

This car is going to be topnotch.
04-30-2007, 07:09 AM
Fuster_Cluck

Quote:

Originally Posted by twinj

This car is going to be topnotch.

Thanks man. I'm doing everything possible to make this the best I can.

We now have all the supplies to do the prepping and painting...

http://i121.photobucket.com/albums/o...iller_rs50.jpg

I have pics of the paint if you guys want to see it :ninja:
04-30-2007, 08:22 AM
Ed

Quote:

Originally Posted by Hybrid93Hatch

Thanks man. I'm doing everything possible to make this the best I can.

We now have all the supplies to do the prepping and painting...

I have pics of the paint if you guys want to see it :ninja:

YES PLEASE.
04-30-2007, 05:27 PM
Fuster_Cluck

Quote:

Originally Posted by YSLBTT

YES PLEASE.

I present to you all the color I love sooooooooooooooooo much:

http://i121.photobucket.com/albums/o...nt_cr_rs40.jpg

http://i121.photobucket.com/albums/o...t2_cr_rs40.jpg

The interior / engine bay (possibly exterior too) will be painted before the end of May :yes: :police:
04-30-2007, 05:33 PM
Alan®

shoulda kept it white imho but its your car so do what you like cause your the one thats gotta drive it man keep up the good work
04-30-2007, 05:44 PM
Nittanys1

naw dont keep it white!!! you going to paint it yourself too?
04-30-2007, 05:45 PM
Fuster_Cluck

Quote:

Originally Posted by Nittanys1

naw dont keep it white!!! you going to paint it yourself too?

My brother will be spraying the car :yes:
04-30-2007, 06:52 PM
SNOOPy00

prob the most detailed build in the history of hondas.....+1...and excellent color choice.....i pretty much gaurandamtee I will see this hatch in a magazine...
04-30-2007, 07:03 PM
WhiteAccord

It may look pitiful but it looks pitifully good...
04-30-2007, 10:07 PM
puregroove

DANG!!! Midori green EG! w00t w00t! nice!

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