1999 Honda S2000 JDM
Discussion
It’s fair to say the compliance bushes in the front wishbones had too much compliance…
New Mugen bits are replacing these old OE parts, which although ‘uprated’ look absolutely the same as the OE Honda parts down to the moulding of the part numbers and machining marks…
You can’t buy them separately from Honda though so glad they are available, even with Mugen tax applied.
New Mugen bits are replacing these old OE parts, which although ‘uprated’ look absolutely the same as the OE Honda parts down to the moulding of the part numbers and machining marks…
You can’t buy them separately from Honda though so glad they are available, even with Mugen tax applied.
Definitely get it running before worrying about the odd bush! I’m not a fan of poly pushes as they feel like such a bodge using the bush as a bearing, so has to be rubber of some form for me. Do it once do it right, even if that takes longer as the budget has to be stretched.
Opinions vary of course and I’d much rather see a car being out and enjoyed with poly bushes than not!
All bushes now done, the pile of remains bears witness to the joy of getting them out!
The big vertical compliance bushes were the easiest, put some preload onto them, then waft a blowtorch over the outside of the wishbone and they crack free.
Now started on the front upper ball joints, one had seized so hard you could only move it in the vice with a hammer…
Got the old ones out easy enough with the eBay special ball joint removal G clamp thing.
New ones on order, should be here Tuesday.
Hopefully we can get all the remaining wishbones etc painted up by the end of the week and start reassembling the suspension.
The big vertical compliance bushes were the easiest, put some preload onto them, then waft a blowtorch over the outside of the wishbone and they crack free.
Now started on the front upper ball joints, one had seized so hard you could only move it in the vice with a hammer…
Got the old ones out easy enough with the eBay special ball joint removal G clamp thing.
New ones on order, should be here Tuesday.
Hopefully we can get all the remaining wishbones etc painted up by the end of the week and start reassembling the suspension.
Did the front ball joints today and did the last batch of suspension painting last night.
I’m off to see my parents for a couple of days so hope to find my son has the complete underside cleaned back ready for paint.
Also hope to find the unicorn being carried by a flying pig, but we can dream
I’m off to see my parents for a couple of days so hope to find my son has the complete underside cleaned back ready for paint.
Also hope to find the unicorn being carried by a flying pig, but we can dream
A good portion of the underside did get done whilst I was away, not exactly finished though…
However the subframe (finally!) returned from powder coating yesterday so we did the more interesting job of the rear suspension dry build this evening.
Currently nothing suspension bush related is torqued up until it’s on the ground, and the adjusters are all set in the middle. This should hopefully allow the 5 miles to the specialist to do the geometry without it trying to kill us
Still lots to do and need to replace a ball joint gaiter we spotted a split in, but new OE brakes can go on tomorrow then we can put this assembly to one side and get back to the grind…
However the subframe (finally!) returned from powder coating yesterday so we did the more interesting job of the rear suspension dry build this evening.
Currently nothing suspension bush related is torqued up until it’s on the ground, and the adjusters are all set in the middle. This should hopefully allow the 5 miles to the specialist to do the geometry without it trying to kill us
Still lots to do and need to replace a ball joint gaiter we spotted a split in, but new OE brakes can go on tomorrow then we can put this assembly to one side and get back to the grind…
Quick update on progress:
The struts are back together and the dampers are all apparently still good.
Brakes rebuilt with new rubbers on the sliders and new bolts.
New Honda disc/pads and Goodrich flexis:
Finally making progress on the arches, almost clean in this pic:
Got some paint on! Both rear arches and the boot floor in 2k epoxy.
…and the top coat of tinted Raptor. Really happy with how it turned out, even if the colour match is a bit off.
Now to repeat the process down the sills and the back of the front arches as we have a deadline of a hillclimb school approaching!
The struts are back together and the dampers are all apparently still good.
Brakes rebuilt with new rubbers on the sliders and new bolts.
New Honda disc/pads and Goodrich flexis:
Finally making progress on the arches, almost clean in this pic:
Got some paint on! Both rear arches and the boot floor in 2k epoxy.
…and the top coat of tinted Raptor. Really happy with how it turned out, even if the colour match is a bit off.
Now to repeat the process down the sills and the back of the front arches as we have a deadline of a hillclimb school approaching!
More scrubbing, grinding and painting…
Both front arches, floors and sills done.
I’ll get the rest of the masking off tomorrow then we can finally start putting the car back together!
MOT and alignment booked for 20th so hope it’s all up and running for Loton park Hillclimb school on the 24th.
Painting upside down is a right pain! Two seconds at a time max with the normal spray gun for the epoxy.
Silver Raptor where you can see it inside the arch liner (as original) and extra under the front of the sill which was originally bare and covered in surface rust.
Whole underside to the tunnel in Raptor. Trying to draw the line as to where to stop is so hard!
Mix and match: Tinted Raptor, 2k epoxy and original Honda primer
Both front arches, floors and sills done.
I’ll get the rest of the masking off tomorrow then we can finally start putting the car back together!
MOT and alignment booked for 20th so hope it’s all up and running for Loton park Hillclimb school on the 24th.
Painting upside down is a right pain! Two seconds at a time max with the normal spray gun for the epoxy.
Silver Raptor where you can see it inside the arch liner (as original) and extra under the front of the sill which was originally bare and covered in surface rust.
Whole underside to the tunnel in Raptor. Trying to draw the line as to where to stop is so hard!
Mix and match: Tinted Raptor, 2k epoxy and original Honda primer
Lancia888 said:
Quality work , can I book mine in please?
£50 an hour, no worries I’ve just told my son (it’s his car) I’m never doing another job like this again
The result is a nice one, but so much labour to get there.We had a good day on the car today and got the back end in together with brake lines, exhaust, prop etc.
Front suspension and fluids tomorrow then we can start with cosmetic stuff like wings and lights
Edited by gary71 on Monday 9th August 19:47
LG9k said:
Loving this thread, so good to see an old car refreshed so well.
On thing to check if you haven't already (and I'll be very surprised if that is the case) but double check the fuel lines for rust under the rear subframe as it's very common.
One esteemed S2ki-er recommends putting some sort of grease inside the poly bushes to make them work better - all beyond me but maybe a useful tip.
Cheers, no problems with the lines, all looks good under there including the brake pipes. On thing to check if you haven't already (and I'll be very surprised if that is the case) but double check the fuel lines for rust under the rear subframe as it's very common.
One esteemed S2ki-er recommends putting some sort of grease inside the poly bushes to make them work better - all beyond me but maybe a useful tip.
No poly bushes on here so don’t need to worry about that one
Got the fluids done today, front suspension is taking a bit longer than planned due to working out where everything goes and what sequence to build in.
Filling the diff and box would have been impossible without the little Sealey pump, great little tool.
Diff drain plug is 23mm and needs a spanner as there’s no clearance to the subframe, Amazon same day delivery to the rescue
Brake hose routing is making no sense so I’ll try again tomorrow when I’m more awake
Filling the diff and box would have been impossible without the little Sealey pump, great little tool.
Diff drain plug is 23mm and needs a spanner as there’s no clearance to the subframe, Amazon same day delivery to the rescue
Brake hose routing is making no sense so I’ll try again tomorrow when I’m more awake
Cheers for the positive comments, helps the motivation!
Didn’t get many photos of the next stages as we just cracked on with it.
Refitting the wings was simple. The bumpers, undertrays, and arch liners not so much.
Every fixing fought us, many of the originals underneath were long gone so had to be improvised. I’m not entirely sure how they were holding on before!
The bumpers don’t match the body and the lights match nothing! Maybe I’m just too fussy
Fit and finish not withstanding it’s great to get it back in one piece.
Other than refurbished wheels and new tyres the outside looks the same as when we bought the car. Good to know the mechanical bits are sound though.
Paint will get a once over with the polisher to get a shine, particularly on bonnet and boot lid, but it won’t make it all the same colour so we won’t get too carried away!
Found the LH sidelight has gone out once we got the car outside. Such a pain as you need to drop the arch liner out to get to it…
MOT and alignment booked on for next Friday. Might have a quick look myself at the alignment to get it somewhere close for the drive over as it looks to be running 5 deg toe out!
Didn’t get many photos of the next stages as we just cracked on with it.
Refitting the wings was simple. The bumpers, undertrays, and arch liners not so much.
Every fixing fought us, many of the originals underneath were long gone so had to be improvised. I’m not entirely sure how they were holding on before!
The bumpers don’t match the body and the lights match nothing! Maybe I’m just too fussy
Fit and finish not withstanding it’s great to get it back in one piece.
Other than refurbished wheels and new tyres the outside looks the same as when we bought the car. Good to know the mechanical bits are sound though.
Paint will get a once over with the polisher to get a shine, particularly on bonnet and boot lid, but it won’t make it all the same colour so we won’t get too carried away!
Found the LH sidelight has gone out once we got the car outside. Such a pain as you need to drop the arch liner out to get to it…
MOT and alignment booked on for next Friday. Might have a quick look myself at the alignment to get it somewhere close for the drive over as it looks to be running 5 deg toe out!
Deep (ish!) clean of the interior and a machine polish of the outside today.
It won’t make it all the same colour but at least it’s shiny now!
20 years of DNA to be removed from the interior. And of course extra JDM points for finding 10 yen under the carpet
These seats look dark and dirty, but 30 minutes of scrubbing doesn’t seem to make much difference. Will try again!
Real shame the Japanese sat nav doesn’t even turn on, obviously it’s not going to work but it would be nice if it lit up. Project for another day.
It won’t make it all the same colour but at least it’s shiny now!
20 years of DNA to be removed from the interior. And of course extra JDM points for finding 10 yen under the carpet
These seats look dark and dirty, but 30 minutes of scrubbing doesn’t seem to make much difference. Will try again!
Real shame the Japanese sat nav doesn’t even turn on, obviously it’s not going to work but it would be nice if it lit up. Project for another day.
LG9k said:
In case you were wondering, that plastic clip on the floor is the rear view mirror surround.
Brilliant! I’d been trying to work out what it was. Thought it was some sort of bolt cover for the seats, but that didn’t fit either. I’ve just tried it on the mirror and it fits but whatever clip it used to have has long gone so that will go in the box of bits. Drove it for the first time today after a basic string alignment… it’s SO much better than before, matching tyres probably account for most of it but it’s really nice.
Proper alignment on Friday and then we can enjoy it for the summer.
2nd gear synchro is weak though, which is going to be frustrating as quick downshifts are off the menu.
Looking for a good used box if anyone has one gathering dust!
Proper alignment on Friday and then we can enjoy it for the summer.
2nd gear synchro is weak though, which is going to be frustrating as quick downshifts are off the menu.
Looking for a good used box if anyone has one gathering dust!
Edited by gary71 on Thursday 19th August 07:41
And an MOT pass with no advisories! Result.
Based on its checkered past that now looks like a dodgy MOT
Now the geometry is done it brakes in a straight line and feels more planted.
I’m happy just how close I got the toe settings with a bit of string and a ruler
Looking back through its history the last set of front pads fitted cost £15… fitted. That might explain the brake pedal going slightly soft after one enthusiastic roundabout stop…
New Brembo front pads now bought to be fitted tomorrow and bedded in on the way to Loton park!
I hate MOTs. Worse than exams, particularly after we’ve put so much work into the car.
Great to get a clean pass.
A box of gearbox parts is travelling the globe from Japan and together with a good used 2nd gear pair and a set of synchrotech carbon rings. A local enthusiast has offered to rebuild the box using these bits for £100… cheaper than me buying the tools to do it!
Other than this gearshift issue the car is so sweet so this will be lovely once it’s sorted.
Based on its checkered past that now looks like a dodgy MOT
Now the geometry is done it brakes in a straight line and feels more planted.
I’m happy just how close I got the toe settings with a bit of string and a ruler
Looking back through its history the last set of front pads fitted cost £15… fitted. That might explain the brake pedal going slightly soft after one enthusiastic roundabout stop…
New Brembo front pads now bought to be fitted tomorrow and bedded in on the way to Loton park!
I hate MOTs. Worse than exams, particularly after we’ve put so much work into the car.
Great to get a clean pass.
A box of gearbox parts is travelling the globe from Japan and together with a good used 2nd gear pair and a set of synchrotech carbon rings. A local enthusiast has offered to rebuild the box using these bits for £100… cheaper than me buying the tools to do it!
Other than this gearshift issue the car is so sweet so this will be lovely once it’s sorted.
t We had a couple of odd noises from the back end after the drive home from Loton so had a good poke underneath today.
One of the rear disc backing plates was bent and was running about 0.5mm from the disc so any vibration and it buzzed against it. Quick tweak and that’s done.
The bigger noise was the exhaust banging on the subframe when it was really hot. Think we might have bent it accidentally whilst moving it around so we dropped it off, bent it back and it fits! Tailpipes are now in the middle of the bumper and it doesn’t knock.
And we cleaned (some of) the garage floor with thinners and a DA polisher with a 3M pad! Fumes!!!
One of the rear disc backing plates was bent and was running about 0.5mm from the disc so any vibration and it buzzed against it. Quick tweak and that’s done.
The bigger noise was the exhaust banging on the subframe when it was really hot. Think we might have bent it accidentally whilst moving it around so we dropped it off, bent it back and it fits! Tailpipes are now in the middle of the bumper and it doesn’t knock.
And we cleaned (some of) the garage floor with thinners and a DA polisher with a 3M pad! Fumes!!!
We did a trackday at Oulton Park yesterday… didn’t go entirely to plan!
On the sighting laps I ribbed my son for a particular bad gearshift when the revs flared, he protested he’d done nothing… (you can see where this is going)
He did about 5 laps in the first session and came in describing the symptoms of a slipping clutch, I went out to double check and accelerated from the end of the pit lane and got 7k in 2nd at 20mph... Limped it back to the garage and parked it so we still had enough clutch to get home.
Box is now 3/4 out ready for the final push today. Got to be the hardest box I’ve ever had to remove, and I’ve done a Triumph Stag…
We were taking it out anyway to fix 2nd, but this just increased the parts bill! Also found a tear in one of the engine hydro-mounts so a pair of those will be on the list as well.
All the fun of old cars!
On the sighting laps I ribbed my son for a particular bad gearshift when the revs flared, he protested he’d done nothing… (you can see where this is going)
He did about 5 laps in the first session and came in describing the symptoms of a slipping clutch, I went out to double check and accelerated from the end of the pit lane and got 7k in 2nd at 20mph... Limped it back to the garage and parked it so we still had enough clutch to get home.
Box is now 3/4 out ready for the final push today. Got to be the hardest box I’ve ever had to remove, and I’ve done a Triumph Stag…
We were taking it out anyway to fix 2nd, but this just increased the parts bill! Also found a tear in one of the engine hydro-mounts so a pair of those will be on the list as well.
All the fun of old cars!
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