Project EJ8… Part 4

220181229_164030

In an effort to keep my promise to you guys I’ve decided to do something a bit different and brought you guys back to back posts. I thought it would be a good idea given the length of time which passed between updates. Although the swap was in place, there were still a host of items I was awaiting on to arrive. We’ll be taking a look at parts as they arrived and also a few hiccups I experienced along the way. In addition there were  still a few things which I needed to take care on where the chassis was concerned in order to move forward with the swap.

 

For those who may want to view this build from the start I’ve provided the link below:

Project EJ8…

 

20171031_113256

Wanting to tone down the bay I was in search for some black couplers; I hit up the guys at JHPUSA for some Mishimoto couplers to start working on the intake system…

20171031_182105

The 3″ coupler fitted to the Skunk2 billet throttle body…

20170819_085229

As I would have mentioned to you guys in the last post, I’m a huge fan of the USDM way of styling so naturally with a naked bay as my canvas I selected a few of my favorite concepts to execute…

20170819_085332

Already having to make some adjustments to my fuel system for the K series motor, I went ahead and picked up a few extras, starting with a Karcepts fuel rail along with a Walbro 255lph pump…

20170819_084929

Wanting to have things looking as tidy as possible I purchased a Russell inline fuel filter…

20170819_090359

20170819_090813

20170819_090742

In addition, I placed an order for a host of Summit Racing AN hose ends in various angles for when the time came to have to fuel lines ran…

20170819_091342

Another look at the fuel hose, fittings and rail…

20170819_091702

Wanting to execute the swap the correct way, I had to purchase an oxygen sensor. After seeking some advice I went ahead and picked up a Denso unit…

DSC_0231

Up to this point I was yet to install the remainder of the Downstar goodies…

20170819_100114

Peering through the master cylinder spacer at the CNC engraved firewall blank…

20170819_100135

20170819_100224

A few shots of the billet aluminum firewall blanks and S2000 master cylinder spacer. The firewall blanks were one of those things which were an absolute must for me as its often reflected in USDM culture. However this would cause me to have to take things a step further in deleting the blower motor assembly and as a result not being able to run air conditioning…

20170819_100306

A size comparison between the pieces…

 

Around that time I got a call indicating that a few more items had arrived…

20171109_112403

20171109_112718

In having the DC5 shifter in hand I still needed a shift knob to complete the setup…

20171109_114213

I opted to go with a Checkered Sports extended billet aluminum knob…

20171220_173522

Boxes on boxes of goodies…

20171220_174439

I was having some fitment issues on the wheels which would require me having to use a spacer. To be on the safe side I opted to place an order for some ARP extended studs given the minimal amount of threads on the factory units…

20180715_162605

When I purchased the motor it didn’t come with a coil plug cover and wanting to have it look as complete as possible. I did some searching around and landed on the brushed aluminum Circuit Hero coil plug cover…

20171220_174632

As I started to assemble the shifter system I realized I was missing the shifter cable clips. I placed an order with Hybrid Racing for some along with their awesome sauce air fresheners…

f58f8fcccd1abcefae472d29c3d3ba42.0

ffd053a4e450e02272774d6033db9f42.0

Even though I received axles with the swap package, I still needed to purchase a half shaft…

20171221_154546

20171221_154644

Unfortunately I wasn’t able to get the bolts with the half shaft, a few clicks later I placed an order for the OEM bolts…

20171031_201951

The Walbro fuel pump wired and fitted to the hanger, just about ready to be dropped into the tank…

 

In the previous post I mentioned I received a radiator with the swap package; however, it would require some modifications based on the vision I had in mind for the bay. Having been around the work ReWeld produced, he would be perfect for the job…

IMG-20180217-WA0067

The location of the existing upper coolant inlet would need to be blanked and repositioned to the side of the radiator…

IMG-20180217-WA0082

A look at the completed radiator so you guys can get a better idea of what was necessary…

20171105_134655

20171105_134719

20171105_134740

A few shots of the motor assembly fitted within the bay awaiting the next few stages…

20171105_134800

Now that I had the motor fitted in place, it was time to start work on getting the fuel system in check. Not versed in this area, I contacted Pierre at S.D.R.R to come and take a look to confirm I had purchase the correct components and take an estimate of what additional fittings I would require…

20170909_172751

20171022_153426

A few shots of the Downstar billet plugs fitted to the firewall…

20180314_081132

With the spindles removed I took the extended studs to be fitted…

20180314_081153

20180314_081136

Out with the old and in with the new…

20180427_063713

During this period I went ahead and swapped some Kumho Ecsta C03s to the front as well…

20180401_155126

Spindles bolted back up to the front end and the brake assembly fitted…

20180304_160950

A glimpse of the interior as I started to get the wiring in order…

20171220_174604

I needed some OEM pieces from AFHK Parts to start buttoning up a few things on the EJ8…

20170528_122747

20170528_123004

After taking a look at the dated antenna gasket I opted to replace it with a new one…

20170528_133644

A common item that is damaged is the hood pull, with mine broken and the car torn apart, I thought it would be best to take this time to replace it…

DSC_0227

DSC_0228

To ensure I had no issues, I picked up a new salve cylinder…

IMG-20171029-WA0127

The S2000 clutch master cylinder with its compact design makes the engine bay less cluttered without having to run a hose to a remote reservoir bottle…

20171106_191114

Due to the angle of the hose connection on factory thermostat housing, it can be a challenge with finding a hose with the appropriate bends…

20171106_185159

To ease with this commonly associated issue I opted to purchase the K Tuned swivel thermostat housing. With the ability to swivel, it allows the water outlet to be positioned to the angle of your liking. Additionally, the unit has some extra ports for a fan switch, the recirculating water hose and also a 1/8 NPT port for gauges…

IMG-20171126-WA0015

I decided to remove the entire OEM housing as I wont be using any of the heater core hoses…

20171127_195006

20171127_194910

A look at the freshly painted valve cover fitted to the motor along with the addition of the Karcepts fuel rail…

20171128_072624

Having the valve cover in place, I installed my Downstar hardware and brighten up the bay…

20171128_072635

Excited about having the Circuit Hero coil plug cover in my possession I decided to test fit and see how the bay was coming together…

 

After securing the remainder of fuel fittings from S.D.R.R, Pierre returned and was able to knock out the fuel system in no time. A huge shout out to him for taking the time to aid me with the setup…

20200425_114448

I opted to run my fuel feed in the centre of the Karcepts rail…

20200425_114356

A look at how the feed line came in from the fuel pressure regulator…

20200425_114511

From the tank the -6 fuel feed goes through the Russell fuel filter on its way to the regulator; with the return line following close by…

20200425_114536

A look at the underside of the car where the AN lines meet the compression fitting and then are converted to the factory hard lines…

 

Although I had ReWeld take care of the adjustments that were necessary on the radiator, I was still having some trouble in finding an upper radiator hose locally. During conversations, he came up with the idea to use an aluminum pipe instead…

20180416_182819

With the pipe acquired, Reudon arrived and began the process…

20180416_182812

Given the complexity of the angles, a fair amount of cutting was necessary…

20180416_182844

20180416_182804

A look after the dust settled and the pies needed had been cut for the upper radiator pipe…

 

The work for the evening wasn’t quite complete as yet. After the decision was made to go K series I began some research on various intake setups. I landed on a concept and we went back and forth for a while about what would be necessary to execute my plans. With the swap finally in place, Reudon could begin the process of moving from concept to reality…

20180413_212409

A glimpse of how the bay currently sat with the first potion of pipe fitted to the throttle body…

20180413_201858

Reudon as he began cutting the stainless steel piping that we’ll be using for the intake system…

20180413_212021

20180413_212035

20180413_214033

A few shots as he was busy at work ensuring the angles on the pies were accurate for what we had previously discussed…

20180413_212345

After the bulk of the cutting was complete, he made sure to mock up within the bay to further confirm he was on the right path…

20180413_212337

20180413_212404

There is no such thing as too much mocking up, a few more as he checked on the estimated final positioning of the pipe…

IMG-20180311-WA0163

Having made some steady progress on the car thus far, a few friends came over to lend a hand…

IMG-20180311-WA0153

It was now time to add some fluids to the motor, I opted to go with Mobil 1 full synthetic 5W-50 oil and the highly recommended Honda MTF for the gearbox…

IMG-20180311-WA0165

IMG-20180311-WA0168

Front end torn apart as we worked on a multiple things at a time…

IMG-20180311-WA0155

A look on the interior as some electrical work was being carried out…

IMG-20180311-WA0189

A helping hand in preparation for fitting the OEM DC5 axles in place…

IMG-20180311-WA0171

IMG-20180311-WA0172

A couple shots of the engine bay as it stood with the clutch master and slave cylinders fitted and bled…

20180421_174941

The headlights sat for quite some time exposed to the element and required some work to get them back to a presentable appearance…

20180421_174806

A close up on the completed right headlight, shout out to Jin for coming through and sorting these out for me…

20180421_155009

Around this same time ReWeld hit me up to let me know he had finished the radiator pipe…

20180421_155139

20180421_155040

A few shots of the pie cut aluminum pipe paired with the radiator…

IMG-20180304-WA0049

The radiator in the bay mocked up…

20180422_190625

A look at the custom upper radiator pipe fitted in place for the moment…

20180425_180534

Having completed the radiator pipe, Reudon returned after tacking together the first portion of the intake…

20180425_180440

20180425_180629

A few varying angles of the intake progress for you guys to get an idea of the direction in which it was going…

20180425_180551

20180425_180615

So far things were going as planned with regards to the clearance with the radiator pipe. It was a matter of getting the remaining pieces together to fully execute the mock up on the concept…

 

 

On that note I’ll close out this post, thanks for taking a look at another installment in the Project EJ8 series. I just want to give a huge thanks to everyone who came through and helped with getting the build to this point.

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out /  Change )

Google photo

You are commenting using your Google account. Log Out /  Change )

Twitter picture

You are commenting using your Twitter account. Log Out /  Change )

Facebook photo

You are commenting using your Facebook account. Log Out /  Change )

Connecting to %s

%d bloggers like this: