Chi's K20 Build Completed.. Pic Heavy!


chi-tec

chi-tec

Member
Joined
Dec 3, 2011
Messages
94
Hey, Finished building my K'd DC2 about 4 weeks back..
Thought you may be interested so heres how everything went...

Started the swap in december 2011, this is how its comming along...

BEFORE!! Perfect running stock B18 at 130,000km.. will be missed!...




Start of the project



This is the engine i'll be putting in! Its a K20a2 from a Pre-Facelift EP3



Gutted Bay :(



B-Series Bracket Removal



There's No Going Back Now!



Removed ABS and mounted the new prop valve inside the car!
I thought seeing as im making new lines, i might aswell tuck them!
I used Earls brake fittings! Expensive, but you cant cheap-out with brake stuff!





How the Tucked Brake Lines are running Inside





The Bay is now Stripped and being prepped for paint



Primer



First Coat






And let's not forget the hood to match! Whilst trying to keep the original JDM-ness!!



Then The Clear Coat







The Colour is from a SEAT i believe...it was randomly chosen at the paint shop!
It's Kind of like an Audi Lava Grey



Bolted the Brake lines and suspention back on





Then i Fresh'nd up some parts



Sprayed some VHT silver on there untill i decided what colour to go for!



Rusty Knuckles off my old Ek2



Used some hammerite anti-rust primer then painted them black



And added new lower ball joints

 
DC5 Shifter Installation. Worlds worst template!



Nearly cried whilst doing this!







With some slight modifications i finally got it in there!



With the Brakes and the shifter sorted i started getting some of the interior back in!
Thought id utilise the Ek9 carpet i had in the garage



Clearance on the prop valve



Then after waiting a very long time for this! My Parcel Finally Arrived!!!!





Dont know if you can see of not, but its a HR Tucked Fuel Kit, Rad Hoses, Intake, Shifter bushings and Conversion Harness

Some parts i have acquired...
Premium ProSport Gauges



K-Pro (if you look closely is says hondata lol) no onboard datalogging :(



OEM K20A Light Flywheel 4.6kg's i beleive...



Hybrid Racing Swap Mounts



Something Very Interesting...



B-series clutch! which is almost identical to the k! i wonder if it will work?!?!
I'm going for a new clutch set-up anyway as the release bearing and pressure plates are shot!

I Have other swap parts like the DDS Stage 2.9 Swap Axels and other little random pieces i havent got pictures of. but the main stuff is up there, if i find anything worth posting ill keep you updated!!

The Mess of wires i was left with!!...



The Dash Was then put back in and the wires were tucked



Then came the seats and thats my interior 90% done..
Just need the wire the gauges in!



Sprayed the cam cover in Tahitian Green Pearl (Honda) after Failing to spray it Phoenix Yellow.!!



Got some service parts from Tegiwa...


Got a Rocker cover gasket set and re-installed the cam cover


Installed the light flywheel and Exedy Stage 1 clutch


Prepping the bay with some riv-nuts for the mount installtion. this tool is amasing!!!!


Mounted the fpr


and then with some help from some friends and a hoist i got the engine in




Some pictures of my friend Alan's recent k20 conversion

 
So after installing the rad and playing with K-pro, i got it to run...


20120402_162039 by china man dem, on Flickr

20120323_144553 by china man dem, on Flickr

20120412_162038 by china man dem, on Flickr

20120412_165321 by china man dem, on Flickr

She runs Great!! Gave it a full service.. but still need to change the aux belt!!
The only thing is i get a knocking with these driveshafts on full lock, but on the straight its fine!!!
I'm just gunna try and open them up and re-grease them, see how that goes..!!

The torque is crazy, compared to a B-series!
I think the power is roughly the same, but instead of it all being after 6k..
With the K-series engine the power is more spread out the RPM Range..
I've raced a DC5 since and been on par with it, so i cant imagine what it would be like with a tune!!!!


As soon as i got in on the road i took it to Alan @ Solid Fabrications for one of these...


IMG_0987 by china man dem, on Flickr

IMG_0986 by china man dem, on Flickr

IMG_0980 by china man dem, on Flickr

IMG_0977 by china man dem, on Flickr

IMG_0971 by china man dem, on Flickr

Some more shots of the insane manifold


IMG_5502 by china man dem, on Flickr

IMG_5509 by china man dem, on Flickr

IMG_5506 by china man dem, on Flickr

I don't know if im felling the tailpipe, it's abit too droopy, might get it changed down the line.
But overall the exhaust looks and sounds amazing!! Exactly how i wanted it! I couldn't recommend him enough!
Also he will do everything to your specification! If you ever need an exhaust made............................... goto SOLID FABRICATIONS!!!!!!!!

And to finish the bay off, i have a Carbing 3-point Front Strut Brace waiting to go on!! It's Currently being refurbed!
From This...

IMG-20120410-WA0000 by china man dem, on Flickr
To This....

IMG-20120413-WA0007 by china man dem, on Flickr

Should be picking it up today, so ill post more pictures when i get it and install it!
But thats all for now...
Ive ordered my RBC from the states and should be here soon..
And ive booked a tune with TDI North on Wednesday the 9th of may.. so i cant wait!!!!!

And Last but not least... My Friends Fully Built Civic H2B

IMG-20120309-WA0004 by china man dem, on Flickr

Its made 247BHP | 160 Ft.lb...(i think) BEAST!!!!
 
Looks like a good, methodical high quality build there, well done!

One question though. What's the benefit of that design of manifold? I have never seen anything quite like it before. Is it a brand copy/inspired design?
 
Thats some quality right right there chi! Cool pics. You put a lot of effort into that, and patience!
Can't wait for our mini Bristol Honda cruise. Should be rude!
 
Nice one mate, absolutely awesome build... great detail!
That manifold is insane! :wow:
 
Mate you should crucify a dc5, my 9 had light mods and good remap and there was hardley anything in it when we tested the cars out.
 
Reading a full k20 swap in one post makes it seems so quick and easy. :(


Nice work mate
 
You must log in or register to reply here.
Back
Top