My K20a2 EG build up thread - TONS of pics!

[Extra Made]

Amazing and thorough thread..+1 for you man

[EJ_Allmota]

damn man, you are doing the damn thing..

[Fuster_Cluck]

Session 019:

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.



Remove the 12mm nut:



Closer look at the nut:



Disconect the throttle cable, but how??



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



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



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



One of the harness you'll need to disconnect:



Assembly out:



Time to work on the clutch assembly:



Remove the bolt using your LAMFExt:



2 harnesses / 12mm bolt to remove:



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



Gas pedal:



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



Throttle cable clip ($hit's nasty):



Pull it outward with some pliers:



Pry the rubber protectors out with a flathead screwdriver:



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



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



Speaker wire I need to replace:



Thanks for the props again guys.

[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!

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

[R3RUN]

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

[Fuster_Cluck]

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!

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

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

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

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







See why this $hit is so nasty:



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









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

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:



Get it on there nice and good:



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



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



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



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

Thanks for looking

[5spdfrk]

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

You must be really tired of cleaning then, lol.

[Fuster_Cluck]

You must be really tired of cleaning then, lol.

LMAO, I was tired when I wrote that up too

[puregroove]

Awesome...you inspire me.

[joesblk_teg]

wow one day when i have the time i plan to do this with a car

[jaystar]

nice iam doin a k-series in my 2000 Si , how much did u spend in total ???

[BigTs13]

seriously, i cannot wait till this is done. its gonna be a jaw-dropper.

[ATL86]

+1 for you!

[sleepys4]

you may have said it already, but what kind of camera are you using?

[5spdfrk]

He's using a canon powershot a95

[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.

[ranj]

dude this is sick man.

[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.

[Nismo]

Did you sell your soul to Harbor Freight? LOL. Any idea how much you have spent so far?

[Black R]

saw this on h-t I think... keep it up.

[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.

[Hektik]

+1....

[imbosile]

wow, i cannot wait to see more

i would love to try to do this some day, +1

[VTAC SONN]

awesome build

[Fuster_Cluck]

Thanks guys for the props

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:







No need to buy new ones:



Set her up for some engine bay sanding:

(xenon lights FTW again )





Passenger side sanded down /drivers not:



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



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:





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

I'll be back later to post the next session which will be 51 pictures

[Nittanys1]

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

[5spdfrk]

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!

[Fuster_Cluck]

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

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

Here we go, Session 022:

Time for some drilling:



Eyeing the spots for the kill:













Took the measurement:



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



Not bad definitely can clean that up:



Tranny bracket removal:







First spot weld loose:



Side view:



Get the pry bar in there and drill some more:





Getting there:



Many down, one to go:



Just wiggled the mount and off she came:



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



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



Tools used:



Result:



Welds from the radiator bracket:



2 radiator brackets side by side:



More spot welds:



On to some interior stripping:

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







Left done / right not:



Closer look:



Decided to take some off:





Not so much now:



Drivers side BEFORE:



Passenger side AFTER:



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



















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



It's pretty bad:



wire wheel FTW to remove the glue on the door:



NICE!!!! :



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

[Hektik]

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

[Fuster_Cluck]

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.

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



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

14mm toe adjustment bolt:



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:



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



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



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:



This is all that holds the rear corner in place:



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)



DumpeD:



Looks so pitiful



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



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



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.



Besides the glass, windshield and roof molding, and engine/dash wiring harness, steering wheel there is nothing else to remove

Thanks for all the feedback

[twinj]

This car is going to be topnotch.

[Fuster_Cluck]

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...



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

[Ed]

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

YES PLEASE.

[Fuster_Cluck]

YES PLEASE.

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





The interior / engine bay (possibly exterior too) will be painted before the end of May

[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

[Nittanys1]

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

[Fuster_Cluck]

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

My brother will be spraying the car

[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...

[WhiteAccord]

It may look pitiful but it looks pitifully good...

[puregroove]

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