Built4Track - Project WTF??? - 1991 Honda City

[norledge]

Thought i'd post this up, it's the longest, most indecisive built you're likely to have read, began in June 2008...

[quote="Norledge"]Thought i might post up a few pics of my current toy... 1991 Honda City PGM-FI CZi :P

It's a 1.3 SOHC 16v, 100bhp (book power) and 680kg (again book weight).

The CZi came with a Cussco LSD as standard, and A/C :P

It shares a LOT of Running gear with the civic, (hence the silly wide arches to accomadate the civic steering rack)... i've got some 2006 Civic Type R brakes going on when i can afford the discs :P

According to Honda only 142 were imported...









I'll keep this thread updated with the progress
[/quote]

[quote="Norledge"]Well from finally getting it out on track, i know now...

A) It's still factory limited to 110mph

B) It's AWESOME out of the corners (pushing 90% of big power stuff in the bends)

C) It REALLY looses out on the straights

D) Corners like its on rails, but body roll is silly!!!

The answer???

Coilovers and BOOOOOOOOOOOST :P
[/quote]

[quote="Norledge"]Weighed it this morning...

Partially stripped, half tank of petrol

672kilos
[/quote]

[quote="Norledge"]Also now decided it doesnt need the civic brakes... it was locking up at combe, with its lack of weight i don't think big brakes will do anything.

Just going to replace it with some decent spec standards... if i can find any...
[/quote]

[quote="Norledge"]Sooooo... after the i bodged the standard rad fan onto a civic rad (which is a good 3 inches bigger both ways) the fan sliced through the bottom hose...

Went for a walk over to forge motor sport (litterly accross the road from me) and traded £80 for this little lot...



Normal retail would have been £130 plus VAT... BARGIN

Also got another civic rad from work and mounted a 9 inch slimlie fan to it...



So now hopfully the cooling system is sorted...

Quickshift also fitted, makes a HUGE difference!

Next??? Blue h/t leads to match the pipes :lol:
[/quote]

[quote="Norledge"]More progress today... bye bye A/C





Good 15kg there i think  :lol:
[/quote]

[quote="Norledge"]Dash has come out (only so i can sort out the aweful wiring) as has the carpet and most of the sound deadening

Custom making a set of carbon fibre dials out of a bit of Zonda wing :P

Also got round to fitting the OMP bonnet pins, so now i can chop the slam panel off to make way for the BOOOOST :P
[/quote]

[quote="Norledge"]Sooo it turns out 45psi fuel pressure isnt good for an unmapped car... electronics have gone tits, can't be bothered to work it out so here we come...

2.0 SOHC 16v VTEC City Type R :P
[/quote]

[quote="Norledge"]Ahhhhhh... Herroooo...


[/quote]

[quote="Norledge"]After me and Alex had a quick session between rain showers yesterday we came up with this...





Just a rough idea of the layout... oil cooler sat in play in the wing and turbo roughly where it will sit (you'll be able to see it through the bumper... PIMP)

Playing with a few intercoolers later
[/quote]

[quote="Norledge"]Booost...



Won't be quite so sticky outy :P
[/quote]

[quote="Norledge"]Nothing much happening at the moment...

Spun the impellor housing round so the outlet goes stright up...


Also welded the internal wastegate shut...


Left to do... Fabricate a downpipe, pipe in the internal fuel tank, buy and work out all boost piping, oh, and fit the engine :P
[/quote]

[quote="Norledge"]Glup...


[/quote]

[quote="Norledge"]Been a tad slow... bit of progress...

Motasport rims innit...



Switchboard...




[/quote]

[quote="Norledge"]Sooo... progress has been silly slow of late...

Failed to make it to brands...

But watching the cars has made me want to get it done asap... Engine is in the process of being built, and i'm still hoarding parts like a mad man. Watch this space!
[/quote]

[quote="Norledge"]Headset ordered, so at least can start now!!!

Also stole an idea off Jay (Burp) with this...



Citroen ZX wiper linkage... Single wiper = Less weight and more pimp value
[/quote]

[quote="Norledge"]Ah...

New engine Flywheel...


City clutch on fly... uhoh... it's a bit small...


City Box...


City Box with the civic clutch... Too big in diameter and on the splines...


Problem i have now is this... I need to use the 1.3 City box which runs a 190mm clutch.

But i'm thinking a 190mm clutch won't handle anymore power than standard... and you try finding and uprated clutch for what is basically a honda concerto 1.3...

Only other option i have is to swap the bell housings (which is also the diff casing) and the imput shaft...

Ideas?
[/quote]

[quote="Norledge"]You know me though, don't want to spend too much on something you know i'm going to blow up :P
[/quote]

[quote="Norledge"]And no, i've not decided yet... more worryied about the fact the NS engine mount is totally different and i'm going to have to bodge... AGAIN
[/quote]

[quote="Norledge"]Got bored and Angle Grinder Happy on sunday...



Soo much lighter! Polycarbs up next
[/quote]

[quote="Norledge"]Right so i may as well come clean, as most of you know or have guessed :P

I had been spending sleepless nights trying to work out how to get this chuffing engine mated to the box and into the car... i could think of no feasable way of doing it.

Decided to start looking into cages instead to take my mind off the pain.

£700 for a custom, welded in...

Then it struck me... I've got a mate who builds Class 8 autograss buggies... like this one...



Hmm...

So off i pop up to his workshop... 'How much to cage this?'

£300... Less than Half the price of a custom cage!!!

Then he throws a real spanner in the works...

'Could weld some engine mounts in the back for £50 too...'

£350 for a space frame??? How could I say no??

After abut 30 seconds thought, and pursuasion for Alex i decided on it... Rear engined RWD...

But what engine?

Next day comes, and into work i go... thinking of what i have i could use...

M3... 6 pot, yummy... too heavy and complex...

Volvo 1.7 Turbo, Light, boosted, but old fashioned...

Then walking out into the yard this catches my eye...


1990 Kawisaki ZX10... Quick google shows me 140bhp, 13000 rpm, 6 speed sequential box, and light enough to pick up buy one person.

A quick exchange of £500, and i'm the proud owner of a mobile death machine.

Couple of hours later i'm left with a pile of parts and...


Slight build on the engine, sparks, filter, Heavy duty clutch springs and a new (different pitch) front sprocket. Mixed with a fresh coat of paint.

So thats the engine sorted... Luckily my internal tanks fits nicly where the engine should be...


Open the bonnet to fill the tank... pimp.

Rear suspension time...

Luckily i have one of these...


Mmm, Early Ninties Luxuary Granadaness...

Needed from it... Rear lower arms, Rear Hubs, Diff and rear driveshafts.

That done time to build the custom chain driven diff... pics to follow.
[/quote]

[quote="Norledge"]

Early birthday prezzie
[/quote]

[quote="Norledge"]Finaly... PROGRESS!!!


[/quote]

[quote="Norledge"]Decided on a bit of Diff play today...

Take one 2.9 Granada Cosworth Rear Limited Slip diff... The theory is to strip to the diff and bolt a sprocket to the crown wheel...


Remove Output flanges


Remove bearing carriers... this has kind of stalled the progress... seized solid... fire axe time!

[/quote]

[quote="Norledge"]Got fed up of fiddling with with the silly small thread holding in the bearing in place...



What would i do without my hammer



Anyhoo diffs out.
[/quote]

[quote="Norledge"]FFS, fudging fkity fudge.

Sprocket designed to convert to chain drive doesnt fudging fit.

Arse.
[/quote]

[quote="Norledge"]Anyone remotely interested in anything engineered will be about to cream them selves about...





















Now... :P
[/quote]

[quote="Norledge"]fudge off.



Titanium Can with carbon mount.
[/quote]

[quote="Norledge"]No as much progress as i'd hoped but...





Custom Arms...



Left to do is built the rear 'D' shape to mount the diff and lower arms to, and engine cradle.

Once the engine is mounted we'll get the rear cross/harness bar in.
[/quote]

[quote="Norledge"]Got some progress... No pics though because i've broke my phone.

Picked up my Re-bodged diff designed to hold itself in place. Design failed miserablly so off its gone for attempt number 3.

Got all the rear running gear built up. Just need to shorten the drive shafts before i fork out for customs.

Got some pimping Motorbike mirrors to fit.

And nearly 4 weeks on still not got the coilovers from AST.
[/quote]

[quote="Norledge"]Righty... little more of a verbal update...

It is now on its (ford) rear wheels :P

Well... It would be if we hadn't set the standard ride height with the top of the tyre inside the arch... and the hub two inches wide than the arch :P

Rear suspension if fully adjustable, with 10 degrees of positive and negative camber, 5 degrees of toe in and out, and 3 inches of heigh adjustment (that withot even touching the coilovers).

Basic diff mount is is position, but i've come up with the issue of engine placement, to mount it easily means the whole weight of the enine is on the drivers side... right behind my head. This means all the weight of the car is on the OS... Other option is to move the diff accross as far to the NS as pos... but this means running a one drive shaft about 6 inches long, the other pretty much the full width of the car... which as they are custom shafts, i'm not too keen on.

I WILL try and get some pics soon... Promise :P
[/quote]

[quote="Norledge"]Little teaser...


[/quote]

[quote="Adam86"][quote="Norledge"]Well you hardly had to persuade me...

'Why not just drop an engine in the back?'

' Meh... OK.'
[/quote]

Rear clip of an mr2 turbo would have being ideal its taken off in one piece. Remove the body work and your left with an engine/gearbox in the subframe with driveshafts & hubs etc all held together. Bit late now but l would have bought the engine off you  
[/quote]

[quote="Norledge"]Bit of progress...



Freebie Polycarbs :P
[/quote]

[quote="Norledge"]Update....


[/quote]

[quote="Norledge"][quote="MGM"]wtf dont tell me they went.......
[/quote]

Lol no i took the rear suspension off to stop them getting nicked while its sat on the drive!

And to keep them clean  ops:
[/quote]

[quote="James"]
[/quote]

[quote="woz_106"]you read from the start?

you only needed to ask I can provide a summary for you

[b]Buy car

Drive once

Mince

Cut floor out

Boast how it will be quicker than me 6 months later

Mince abit more

Did I mention Mincing

weld some scaffolding in place

Mincing

Buy some paint

Where we are now[/b]
[/quote]

[quote="Norledge"]OMG ACTUAL PROGRESS!!

The Beginning...


Nice big pile of parts removed...



Now totally free of all wiring loom/plastic poopoo...



Struts off to be sent off this week to Curtis at AST



And tucked back into bed :P


[/quote]

[quote="Norledge"]OMG ACTUAL PROGRESS!!

I'll let the pics do the talking...




















[/quote]

[quote="Norledge"]More power that it's had for a while...


[/quote]

Choppin'.

Tried to do a time lapse kinda thing, but i kept forgetting to take pictures...

Added to the fact I did some of the work Yesterday :P

Anyhoo...















This one makes me laugh... i spent ages after cutting through the floor trying to work out why the two halves wouldn't come apart... then i realiesd it's a T Bar :P





Anyway that's it for today... worst part? Easily dropping the fuel tank... what a mare that was!

[quote="Norledge"]OMG!?


Back on its wheels



Ok so how will this fit in there...



Make shift one poster ramp...



Now to just slide it under there...



And just to show you how this was just meant to be... MR2 Rear Chassis Members...



And City Rear Chassis Members...



And a rough idea of where the suspension turrets sit...



Lunch Break Over
[/quote]

[quote="Norledge"]Taster...


[/quote]

[quote="Norledge"]Reet so here are the near 100 pictures off two cameras, hopefully in order...

First job, drag out the City and MR2



Next Lift the City


Ok... err... what now...


First trial line up... i knew we'd have to chop it up more... just not as much as we did!



A Little mincing...


Chopped the back end down a little bit and tried again...




Hmm... this bit's in the way...


A little more Mincing...

After a bit more chopping, we try again...


At B4T we only stop for ice cream.


Which it turns out, Sam can't handle.



Go on Woz Rag it!


Sooo close...




So... This is it...




Argh... this could be it!!


Slight persuasion and it was down...


fudge it... Lets stick some panels on :P




Look... I've even got reflections!


So the actual view you'll all have as i overtake...


At this point we'd not see Woz for a while... Found him... Mincing on the jobs as usual.


Also had a quick trial fit of my bike can = WIN imo


So yeah done.




Just got the welding to do now...


Not amused :P

[/quote]

[quote="Norledge"]This one didn't upload for some reason... All i can say is if you even need to chop up a car, these rock.


[/quote]

[quote="Norledge"]Right err...

Centralise The MR2
Weld in MR2 Chop
Weld in new full length chassis Rails
Confirm alignment
Build rear cage
Build wiring loom
Build Fuel System
Start
Replace all the panels/lights
Paint
Drive
[/quote]

[quote="Adam86"]Only 2 pics but proof progress was made. Rear clip being stripped to remove engine.





Engine still in clip but now ready to be removed within the next decade  :thumbs:
[/quote]

[quote="Norledge"]So while I'm waiting for Miggy to do his thing, time to move onto other things starting with the brakes...



Some Civic Type R fronts i had lying around should do the trick!!

Here you can see there isn't a huge difference in pad size, more the piston size in the caliper...



After some gentle persuasion...



The Calipers are on



Need some slight 'machining' to clear the inside of these wheels, but still not sure if i'll be running these.

Next up - CTR Discs and Hubs, Titron Bias Valve fitting, then pipes making up
[/quote]

[quote="Norledge"]Bosh...








[/quote]

[The Horse Man]

I hope there is another update to come on this tomorrow. Awesome.

[Conor D]

Are you keeping those (4x100) Honda City alloy wheels?

If they are 4x100, I might want them..

[Haighermeister]

Mental, good work.

[shirt]

love the look of despair on your neighbour and mum's faces

[Dr G]

I fully expect your next update to be "some yuppy crashed a 458 down my road, bought the running gear for a nifty..."

[joe_90]

AHhaha

Comments:
1) You neighbours must love you.
2) Is it straight?
3) You seem experts at taking cars to bits..
3) and fair play.. I hope to see it at combe soon.

[Richair]

You Sir are one crazy nut But clearly in a very good way!

Me likey a lot! Reminds me very much of the Suzuki Cappuccino I saw at the PPC show last week; custom chopped ghetto build with (I think) a busa engine. It was the fasted thing on track all day...

[Mannginger]

That's just silly daft! But I love it, probably more than your neighbours I suspect.

[RobCrezz]

So what engine are you using now? The MR2 lump or the bike lump?

[DS3R]

This is, the stuff of legends.... hats off to you Sir!

[wackojacko]

Gave me a headache reading all of that !


Good stuff !

[TVR Sagaris]

fking brilliant. More please.

[stabbed rat]

Hard to follow but mental all the same. Which engine did you go with?

[shouldbworking]

If that ever moves under its own power I will be astounded. I like the idea of it though

[megatron]

This is brilliant. Need I say more?

[norledge]

joe_90 said:

AHhaha

Comments:
1) You neighbours must love you.
2) Is it straight?
3) You seem experts at taking cars to bits..
3) and fair play.. I hope to see it at combe soon.

1) Most of them are quite interested in it to be honest!
2) Yes :P
3) I use to run a breakers yard :P
3b) It'll be at Spring action Day next year

Richair said:

You Sir are one crazy nut But clearly in a very good way!

Me likey a lot! Reminds me very much of the Suzuki Cappuccino I saw at the PPC show last week; custom chopped ghetto build with (I think) a busa engine. It was the fasted thing on track all day...

That's Chipwizards car, it's a turbo'd busa, and yes, very ghetto built :P

doogz said:

Excellent project mate, hope whoever is doing the welding is a proper welder, or if not, i hope you're going to have it all inspected properly.

Yeah, i've made the sheet work, and chopped up the tubing, but i don't trust my welding enough so yeah i've got a guy who builds grassers doing it for me!

RobCrezz said:

So what engine are you using now? The MR2 lump or the bike lump?

stabbed rat said:

Hard to follow but mental all the same. Which engine did you go with?

MR2 Turbo, 300 reliable BHP. Had a go in a R1 engined Cinq and wasn't impressed... they work in 400 kilo kit cars, but this is twice the weight.

wackojacko said:

Gave me a headache reading all of that !


Good stuff !

Sorry it might make more sense when viewed here...

http://www.built4track.co.uk/t14-project-wtf-1991-...

fesuvious said:

I doff my hat to you sir.

but i'd want proof that the fkers aligned properly before I ask for a passenger ride!

We triangulated it in as many places as we could, i'm pretty happy it is, the rear camber is way out, but theres no weight in back, and it's all easily adjusted.

[RobCrezz]

That's going to be crazy! My old mr2 turbo was pretty fast with 300bhp at 1200kg! Awesome effort

[soad]

Woah, that's mad insane and crazy!

[Old Gregg]

Where have I read this before... 4guk?

Crazy and fantastic, looks like a lot of fun.