ej9 to rally car

[dave benson]

cut hole in roof and fitted roof vent to let fresh air in, and got some sumpgaurd mounts made, with quick release mushroom mounty things, another ebay special ha ha

 

[dave benson]

carbon door and rear quarter trims fitted

 

[dave benson]

Looking good.
Question...,what have you done to plumb the brakes? straight off the master cylinder t'ing off for the front, and running the rear through a bias valve etc, or are you still using the standard distrubution block on the bulkhead? My doner ek4 has abs which i obviously wont be using, just been wondering about the simplest way to plumb it once that is ditched.

Got a test day booked for the 4th of march so after i pick up my ek9 shell tomorrow im going to be a busy boy!!

fitted a 1 " master cylinder, remove everything else, run one outlet to the fronts, split-100% pressure and one to the back-100% pressure but fit bias valve before hydraulic handbrake so you can adjust the rear pressure as 100% will be too much

running standard discs and ferodo ds3000fronts and ds2500 rears, they seem pretty keen so far but not had a real test yet as only just back from rollers and running in !

 

[dave benson]

these arrived from the states ready for the dreaded engine build

 

[wooks]

Sweet, thats exactly what i was going to do! I will be running 282 fronts and 260 rears with ds3000 front and ds2500 rears, we use ds3000 in all our rally cars and wont use anything else, they are superb.

Build is looking lovely mate, very interested where you got your carbon door and rear 1/4 trims from, im failing to find any at all.

 

[dave benson]

performance-trim.com

 

[dave benson]

These are the cams i fitted, toda vtec killers, so it was out with the middle rockers,spacers fitted to replace them, blanks fitted to block the oilways on the others, double valve springs and titanium caps.

The head has been ported and the combustion chambers welded up and reshaped, this had been done when i bought it

so head ready so i thought !!!!

 

[dave benson]

short engine finished

then took the car to leeds to get a custom exhaust made at tony laws, did a great job, 650 pound for manifold and full system with repackable silencers

 

[dave benson]

bare engine in place , time to start fitting exhaust/intake etc

also bonded the windows back in, the wife helped me lol, it was easier than i thought

 

[dave benson]

jenvy throttle bodies fitted, whilst i worked out what to do with all the oe water/oil/vac pipes

Then started on the engine wiring loom, used just the altenator and cooling fan wiring off the standard loom and adapted an omex semi built loom, using about 5 sensors, including fitting a crank sensor whick took a while, making the bracket + fitting a timing wheel to the crank pulley

Also fitted a mondeo coil pack as the distibuter wasn't used

 

[wooks]

Tony Law did the manifold on my group 4 mk2 escort, awsome workmanship!

Sorry if i seam to be raping your thread, just so rare to find someone putting a civic together for rallying, hope you dont mind!!

 

[dave benson]

engine finished and cold air feed made using a pipercross airbox and 100mm ducting, thanks for the sticky thread on this subject

tried to start it but the solenoid wire was stopping the crank sensor working somehow, found this by accident, when i wired it direct from the battery it fired THROUGH THE INLET !

the crank wheel had been fitted 180 degrees out, so had this redone

tried again, started yipee, ran fine but low oil pressure !

checked oil pump, it was fine

took rocker cover off, oil erupting out of the corner of the head, after looking at a spare head realised the brass oilway plug was missing, causing loss of pressure.
replaced this but still a little low

dropped the sump, no 5 main goosed, so had to order new shells

spent an afternoon sliding new shells around the crank, FUN

oil pressure was now fine

 

[dave benson]

took her to mikeanics in congleton to be run in and mapped, he was impressed, wouldn't believe it was a 1600cc, ended up with est flywheel figures of 209 bhp and 135 lbft torque

I was just happy it hadn't blown up, i'm no mechanic by any stretch of the imagination (i work in an operating theatre), but a few books and manuals and this forum and it's all good in the end

 

[dave benson]

took her for a spin WOW, 5 speed dog box, 5.1 final drive + plate diff, she pulls like a train, but was all over the place on ej standard shocks.

suspension arrived that i had made , 3 way adjustable avo coilovers, just finished fitting these today, and car feels much more stable and not quite so scary lol

 

[dave benson]

pics of her almost finished, its been a big job on my own , its a good job i work week on/week off lol

just the dash to tidy up, window film and mudflaps to fit and i think i'm there ha ha

will post some more pics this week and some video if i can

hopefully doing the north west stages in Blackpool on 5/6 february, once i've robbed a bank to buy some tyres, not sure the credit card can take much more !

cheers

 

[dave benson]

Sorry if i seam to be raping your thread, just so rare to find someone putting a civic together for rallying, hope you dont mind!![/QUOTE]

glad to help mate

 

[689R]

wuft how i never seen this before. this is incredible!

 

[wishy]

This is a monster build thread dude , some awesome work

 

[CR1S]

OMG ITBs! we need videos dude this looks amazing!!!

 

[durmz]

this is epic, love it, vids vids