AWD Civic Coupe Turbo Build
Discussion
I thought i would take my christmas day off to drop some updates on the build..
I havnt had a chance because of the weather but ive made SOME progress.
It turns out my next-door neighbor's husband is a welder on offshore rigs, he came home for christmas a few weeks ago. I asked him to take a look at the welds, from his point of view..
He agrees they look "less than attractive" but he believes they are strong enough. Pointed a few bits out to re-do but im pretty happy with that. My technique is improving slightly..
So some updates,
Ive finished (mostly) the rear subframe. I needed to put in the front diff and prop before i fixed the rear engine mount, so that is still to do.
I also scrapped my previous idea with the front diff.. I modified the original honda hydraulics to do the job but for various reasons i wasnt happy. So i acquired a concentric slave cylinder from a vauxhall corsa and modified it all to fit. Now that will actuate the clutch pack and will be more suited to the skyline controller and the piston size is similar now. So ill have better resolution.
The prop shaft adapter is on, thanks again to Martin from the Civiclife forum who made it for me;
The front diff is on its way, very crudely tacked together just to get the geometry right but its comign together now..
I managed to acquire a set of tarox 10 piston calipers. They were hand painted red and looked a bit worse for wear but i managed to clean them right back up to their untouched anodized finish;
These will be the new front ones, the wilwood ones will be relocated to the rear with some spot calipers for the hand brake.. Obviously ill need to be able to set up the brake bias to get it all balanced..
and then yesterday, i received a nice little surprise from FIBERWORX.. My sunroof intake/bung arrived, my solid carbon fibre front splitter which for optimum effect extends all the way back to the cabin, my fog light air intakes, and panels for the rear firewall all turned up..
Stunning work im sure you will agree.. I cant thank FIBERWORX enough for their help and hard work on all this. I only have a rear diffuser, and front lip to come from them now so its looking well..
Im hoping pretty soon to have the front diff, and fuel cell / radiator mounts done in the front. Finished the engine mounts, strip the engine out and finish welding / bracing it all, prime it, and then when i can now afford it- straight off for paint..
The wheels should be here soon too, looking forward to that..
I havnt had a chance because of the weather but ive made SOME progress.
It turns out my next-door neighbor's husband is a welder on offshore rigs, he came home for christmas a few weeks ago. I asked him to take a look at the welds, from his point of view..
He agrees they look "less than attractive" but he believes they are strong enough. Pointed a few bits out to re-do but im pretty happy with that. My technique is improving slightly..
So some updates,
Ive finished (mostly) the rear subframe. I needed to put in the front diff and prop before i fixed the rear engine mount, so that is still to do.
I also scrapped my previous idea with the front diff.. I modified the original honda hydraulics to do the job but for various reasons i wasnt happy. So i acquired a concentric slave cylinder from a vauxhall corsa and modified it all to fit. Now that will actuate the clutch pack and will be more suited to the skyline controller and the piston size is similar now. So ill have better resolution.
The prop shaft adapter is on, thanks again to Martin from the Civiclife forum who made it for me;
The front diff is on its way, very crudely tacked together just to get the geometry right but its comign together now..
I managed to acquire a set of tarox 10 piston calipers. They were hand painted red and looked a bit worse for wear but i managed to clean them right back up to their untouched anodized finish;
These will be the new front ones, the wilwood ones will be relocated to the rear with some spot calipers for the hand brake.. Obviously ill need to be able to set up the brake bias to get it all balanced..
and then yesterday, i received a nice little surprise from FIBERWORX.. My sunroof intake/bung arrived, my solid carbon fibre front splitter which for optimum effect extends all the way back to the cabin, my fog light air intakes, and panels for the rear firewall all turned up..
Stunning work im sure you will agree.. I cant thank FIBERWORX enough for their help and hard work on all this. I only have a rear diffuser, and front lip to come from them now so its looking well..
Im hoping pretty soon to have the front diff, and fuel cell / radiator mounts done in the front. Finished the engine mounts, strip the engine out and finish welding / bracing it all, prime it, and then when i can now afford it- straight off for paint..
The wheels should be here soon too, looking forward to that..
5potTurbo said:
purplecivicturbo said:
aye yeah, 10 pistons. They seem like a really good set of calipers.
Its funny to think the car started with 2 single piston calipers and drums, now it has 28 pistons.. (20 front, 16 rear)
Im anxious now to get the front splitter blade on .etc
20 + 16 = ?Its funny to think the car started with 2 single piston calipers and drums, now it has 28 pistons.. (20 front, 16 rear)
Im anxious now to get the front splitter blade on .etc
Sorry i just re - read all the again, my maths was rubbish!
Just to clear it up, there are 20 pistons on the front (10 x 2) and 10 on the rear (2 x 4, plus 2 handbrake) = 30 pistons total (28 hydraulic)
Not that the actual number of pistons matters too much. I believe the idea of increased piston number is to apply as close to equal force across the pad as possible..
I just had an email from the chaps making my wheels and all seems to be gonig to plan. The rears have been painted and the fronts should be done today..
Just to clear it up, there are 20 pistons on the front (10 x 2) and 10 on the rear (2 x 4, plus 2 handbrake) = 30 pistons total (28 hydraulic)
Not that the actual number of pistons matters too much. I believe the idea of increased piston number is to apply as close to equal force across the pad as possible..
I just had an email from the chaps making my wheels and all seems to be gonig to plan. The rears have been painted and the fronts should be done today..
purplecivicturbo said:
Not that the actual number of pistons matters too much. I believe the idea of increased piston number is to apply as close to equal force across the pad as possible..
It also allows a better pad shape - ten tiny pistons allow you to put all the friction onto a longer part of the outside of the disc where the effort is best used.
that actually makes alot of sense..
i havnt measured but based on how small the pistons are, i cant see their overall area being much higher than the wilwood ones...
My new wheels should be here soon, im rather excited to see them to be honest because im not entirely sure if these brakes will fit under them lol..
Anyway, the weather has been awful so ive had no chance to work on the car over christmas.. I have some PU coming so im going to make my own solid engine mounts (for now), and get the engine mounted, finish mounting the front diff, add the bracing to the centre section of the roll cage (for seat belts .etc), plate the outside of the rollcage to the chassis and then fit the 2 fibreglass sheets i have for the middle..
Im not entirely sure about a window yet or how ill do it, but im seriously considering just using lexan bolted to the rear of it as the fibreglass isnt rigid enough to support for example the cabin window from a van..
I also need to measure up the driveshafts.. DSS in the US will be making hte new front ones and modifying the current rear ones..
What i tried to do is to keep the same length on one of them simply to save on postage (seriously). So the passenger side one should need shortening. Ill be measuring this my cutting down my current spare one and then telling DSS how much to remove.
For the front, i have to combine the spare ones with the CRV ones i also have. Ill be doing this by dropping it back down to the road, and sleeving the drive shafts with a steel tube.. This will be welded in place and the axles will be sent like that to the states...
Once i get those back and double check it all, it will be finally ready for paint..
I have also changed the dash computer.. In order to make it as visually appealing, and simpler to develop as possible.. Ive scrapped making my own OS GUI using PICs.. Ive bought a Raspberry PI which i will be either using linux or loading android onto it to develop a GUI. It will interface with a PIC which will control the basic display (for safety reasons) and interface with the CAN bus. The Raspberry will be responsible for all the "fancy" features, like graphs .etc but now this means, as the LINK ECU is on canbus, and all my electronics are on CANBUS. The Raspberry PI will now form a very advanced datalogger as well as display system.. So i will be able to record literally every single thing the car is doing, from wing angle, steering angle, throttle position .etc, my water injection system now wont even need to calculate the fuel flow rate itself as the ECU outputs that on the bus..
Its a much more elegant solution..
i havnt measured but based on how small the pistons are, i cant see their overall area being much higher than the wilwood ones...
My new wheels should be here soon, im rather excited to see them to be honest because im not entirely sure if these brakes will fit under them lol..
Anyway, the weather has been awful so ive had no chance to work on the car over christmas.. I have some PU coming so im going to make my own solid engine mounts (for now), and get the engine mounted, finish mounting the front diff, add the bracing to the centre section of the roll cage (for seat belts .etc), plate the outside of the rollcage to the chassis and then fit the 2 fibreglass sheets i have for the middle..
Im not entirely sure about a window yet or how ill do it, but im seriously considering just using lexan bolted to the rear of it as the fibreglass isnt rigid enough to support for example the cabin window from a van..
I also need to measure up the driveshafts.. DSS in the US will be making hte new front ones and modifying the current rear ones..
What i tried to do is to keep the same length on one of them simply to save on postage (seriously). So the passenger side one should need shortening. Ill be measuring this my cutting down my current spare one and then telling DSS how much to remove.
For the front, i have to combine the spare ones with the CRV ones i also have. Ill be doing this by dropping it back down to the road, and sleeving the drive shafts with a steel tube.. This will be welded in place and the axles will be sent like that to the states...
Once i get those back and double check it all, it will be finally ready for paint..
I have also changed the dash computer.. In order to make it as visually appealing, and simpler to develop as possible.. Ive scrapped making my own OS GUI using PICs.. Ive bought a Raspberry PI which i will be either using linux or loading android onto it to develop a GUI. It will interface with a PIC which will control the basic display (for safety reasons) and interface with the CAN bus. The Raspberry will be responsible for all the "fancy" features, like graphs .etc but now this means, as the LINK ECU is on canbus, and all my electronics are on CANBUS. The Raspberry PI will now form a very advanced datalogger as well as display system.. So i will be able to record literally every single thing the car is doing, from wing angle, steering angle, throttle position .etc, my water injection system now wont even need to calculate the fuel flow rate itself as the ECU outputs that on the bus..
Its a much more elegant solution..
Thats a really nice little case mate! Thanks for that, however because my pi is part of a bigger system, it will all be in a bigger box. But thanks again!
Just a small update tonight, the weather has been too bad to work on the car recently and my work is piling up at home..
I managed to get ahold of a new OEM bumper, unpainted. So ive fitted my new intakes into th enew one with PU sealant / bonding. A nice snug fit, thanks FIBERWORX!
Im just waiting for Fiberworx to send the rear diffuser and the front lip, then i can add the front splitter blade. In the mean time, i ordered some metal for the front diff frame. This will also support the fuel cell and the radiator.
Once ive done that ill be finishing the engine installation and then pulling it all apart again. Ill be finishing up with the welding / bracing, measuring up the driveshafts and then welding in the firewall..
All in all not too much left to do before its respray. Unfortunately i still need a miracle to happen for that one but im hopeful lol.. I approached a spray shop in Blackpool to see if they could help me out, im waiting to see what they say..
Just a small update tonight, the weather has been too bad to work on the car recently and my work is piling up at home..
I managed to get ahold of a new OEM bumper, unpainted. So ive fitted my new intakes into th enew one with PU sealant / bonding. A nice snug fit, thanks FIBERWORX!
Im just waiting for Fiberworx to send the rear diffuser and the front lip, then i can add the front splitter blade. In the mean time, i ordered some metal for the front diff frame. This will also support the fuel cell and the radiator.
Once ive done that ill be finishing the engine installation and then pulling it all apart again. Ill be finishing up with the welding / bracing, measuring up the driveshafts and then welding in the firewall..
All in all not too much left to do before its respray. Unfortunately i still need a miracle to happen for that one but im hopeful lol.. I approached a spray shop in Blackpool to see if they could help me out, im waiting to see what they say..
I think its time for a little update...
I havnt managed to do too much work as i have been working on S2000 and Coil On Plug converters.. However i do have a thankyou I want to say..
Firstly, i sold my intercooler in exchange for 2 smaller ones.. Ive decided to scrap the side intakes on the car as it is going to cost too much money to get a bodyshop to smooth them in.. And there is a weight penalty for the body filler- not really worth it..
Fiberworx are making me some intake scoops of my own design, similar to the Monster Suzuki SX4 PPIHC car.. Theyll be made out of carbon and duct air directly onto the intercoolers mounted in the rear wings.. Here is a pic of the two intercoolers;
And now the thankyou... I dont have the facility to mill or lathe parts here, i can CNC mill but its not upto steel .etc so i have to rely on people helping me out.. A chap called Marin "Civic-T" on the Civiclife forum has turned me these 3 parts;
The larger of them is a spacer to fit between the slave cylinder i installed in the front diff and conduct the load onto the aluminium structure below. I didnt like the idea that the 3 plastic mounting lugs were taking all the force.
The two other parts are identical, because the CRV wheel bearing is so much wider than the civic one, fitting the civic hub means when the axle is tightened it crushes the bearing. These shims will fit onto the driveshaft and make up the extra depth.
Marin and another chap Martin have both given their time to make me parts such as these and the transmission adapter.. A year ago i wouldnt have accepted help because i wanted to finish the car solely on my own. However, in the previous year i have resigned to accepting help, and to be honest its brilliant.. It feels great that so many people are willing to donate their time and skills to help me out wherever they can and for that, if the car is ever finished! i owe them massive thanks!
Also, my new wheels are finished... I have always always loved the banded steels found on older race cars.. Plus these are cheaper than alloys, and i was able to have them customised to perfectly fit my car..
The size is 16", and the rears are 12" wide, the front are 10". They are currently in transit and should be here soon..
Im hoping to finish the work i have on very shortly, and then i can finish the front differential frame, install the fuel cell, radiator, fuel pumps, swirl pot .etc then paint it all up.. Then i need to whip the engine out, finish up all the welding inside and prime that all up..
I havnt managed to do too much work as i have been working on S2000 and Coil On Plug converters.. However i do have a thankyou I want to say..
Firstly, i sold my intercooler in exchange for 2 smaller ones.. Ive decided to scrap the side intakes on the car as it is going to cost too much money to get a bodyshop to smooth them in.. And there is a weight penalty for the body filler- not really worth it..
Fiberworx are making me some intake scoops of my own design, similar to the Monster Suzuki SX4 PPIHC car.. Theyll be made out of carbon and duct air directly onto the intercoolers mounted in the rear wings.. Here is a pic of the two intercoolers;
And now the thankyou... I dont have the facility to mill or lathe parts here, i can CNC mill but its not upto steel .etc so i have to rely on people helping me out.. A chap called Marin "Civic-T" on the Civiclife forum has turned me these 3 parts;
The larger of them is a spacer to fit between the slave cylinder i installed in the front diff and conduct the load onto the aluminium structure below. I didnt like the idea that the 3 plastic mounting lugs were taking all the force.
The two other parts are identical, because the CRV wheel bearing is so much wider than the civic one, fitting the civic hub means when the axle is tightened it crushes the bearing. These shims will fit onto the driveshaft and make up the extra depth.
Marin and another chap Martin have both given their time to make me parts such as these and the transmission adapter.. A year ago i wouldnt have accepted help because i wanted to finish the car solely on my own. However, in the previous year i have resigned to accepting help, and to be honest its brilliant.. It feels great that so many people are willing to donate their time and skills to help me out wherever they can and for that, if the car is ever finished! i owe them massive thanks!
Also, my new wheels are finished... I have always always loved the banded steels found on older race cars.. Plus these are cheaper than alloys, and i was able to have them customised to perfectly fit my car..
The size is 16", and the rears are 12" wide, the front are 10". They are currently in transit and should be here soon..
Im hoping to finish the work i have on very shortly, and then i can finish the front differential frame, install the fuel cell, radiator, fuel pumps, swirl pot .etc then paint it all up.. Then i need to whip the engine out, finish up all the welding inside and prime that all up..
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