91_Project

When in doubt, use a zip tie lol I like it!

radex7

Right? Or when you cannot use a duct tape.

ProjetEF

wow i have exactly the same issue with one of my climate controle cable, you can be sure i'll use this tip with the tie next time i get the CC off the dash !!!!

nice progress, i'll stay tuned

radex7

Although I spared you from engine building photo log, I just had to share this one with you. New, clean, or rare parts make me giddy so might as well:


Just a basic exedy clutch/plate kit from my fav distributor (shameless plug), but the flywheel deserves a sentence or two. If you are new to engine building I cannot overemphasize how important it is to have a good relationship with the folks at the machine shop. I brought them this nasty, old flywheel, they said $60. Well I thought OK, it is filthy, it is stepped, has pins, so their price sounds fair. They bead bead-blasted that sucker for me!!! For no extra charge.

We are getting close, gentlemen!

rexb16a

Good job man. Looks like you are getting over a hump. Nothing wrong with loosing interest at times and taking a break but don't give up! My build has been going almost 5 yrs now but I should have it back on the road this spring. Once you lay color on it(in the bay for sure) it really seems to give you a sense of accomplishment and spike your interest to keep moving. I too painted all my suspension stuff black at this point but after priming the outside of the car many times and wet sanding over and over all those parts got pretty nasty looking. Take the time to tape all that stuff off while you spray the outside. Sounds like you have the right idea on the outside bodywork. My best suggestion is to buy a couple differ sized sanding blocks(I used Durablock brand on my car and loved them) and try to not use any sandpaper on your car without using a block. There will be some parts that you can't but you will thank yourself later. Also, when in doubt how straight your bodywork is, prime it again and again and use guide coat and block it over and over till you feel confident. Once you get to wet sanding in 320-400 range when your close to paint, you will start t see it shine and really be able to check how smooth your bodywork is. Wipe it off with a wet sponge every little bit to see it glossy to check for imperfections. Other little trick is spray panels down with degreaser and get it super wet to check your work. Keep it up!

rexb16a

Oh and one other thing, to elaborate on something someone else said earlier: if you have a larger surface area like your roof or hood that has multiple imperfections like several dents or the ruffles on your roof, its best to skim coat the entire panel and block it down. If you're not familiar with that term it just means spread a coat of filler over the whole panel. May seem like more work and a lot of filler but 90% of it gets sanded off. If you just try to fix each little thing by itself you will keep sanding through in other areas and chase them all around. Ask me how I found that out. Wish someone would have explained that to me. Skim coat, then us the longest block possible with the longest motions to give the entire panel a smooth contour. Sand as much off as you can without sanding all the way through. Don't wanna sound like a know it all but I just went through this entire process in the last year and knowing these basic things could have saved me a lot of time. But doubting myself and doing things over and over(primed and wet sanded my entire car 3 times) turned out to have results better than any new Honda on the dealership lot. Def paid off. Remember, your body work is 98% of what determines your final paint job!

radex7

^Thank for the advice, rex!

In the mean time, after adjusting the valve lash, I am ready to mate my tranny with the rest of it and shove it in (metaphorically speaking) here:

radex7

Wow, it has been a while! The project is still alive! As the matter of fact, I made some substantial progress, mainly putting the engine in. My current objective is to get it started ASAP, for a couple of reasons: I wanna be able to get rid of excess junk I accumulated in the process, but right now I am uncertain what spares I might possibly need. Also, I am using my daily as a working example of how the damn thing is put together, and I am selling that one soon. So I need to hurry up!




It has been a while since I visited these forums, so my searching skills are little rusty. If you know a shortcut - please point me in a right direction.
I would like to put together a checklist of things that need to happen to a newly built engine/car before it can be reliably run on the road.

Assuming (and hoping) that my engine was put together properly, and everything is up to specs, here is the list of things I should remember (some of them are blatantly obvious, but it is for my own scattered mind, so bare with me, and chime in!).

1. Engine and transmission installed.
2. Exhaust system connected.
3. Cooling system connected.
4. Harness/electrical connected.
   
   Now the fun part!!!
   
   
5. Engine set to TDC.
6. Camshaft position checked.
7. Timing belt tension adjusted.
8. Alternator belt tension adjusted.
9. Engine oil added (Full capacity not Oil Change)
10. Radiator coolant filled and bled.
11. Sparkplugs removed, distributor and fuel injectors disconnected.
    
    Let the cranking begin!
    
    
12. Priming oil pump. Seating piston rings.
13. Sparkplugs installed, distributor and fuel injectors re-connected.
    
    Engine breaking in phase!
    There are numerous ways people do that, I will go with varying rpms/engine breaking recommended in D-series.org. But first:
    
    
14. Start the engine, warm it up with fluctuating in RPM's. Once cooling fan comes on - shut it off.
15. Oil/filter change!
    
    Now it is time for a drive and finish initial breaking in phase...
    To be developed...

Am I missing things? What would you do differently/in different order? I'll edit this once consensus is there.

Thanks!

radex7

Quick question.

I am using a 1991 Si harness pretty much all around the my 1989 project car. In front of the engine bay, left and right side differ a little on that harness, and once I connect my headlamps - 2 plugs, side marker - 2 plugs, and turn signal - 1 plug (bumper) , I am still left with a pair of wires on each side. They are white/green, and blue/red. Can anyone tell me what they could be for? The only thing that is not connected currently is my horn (which I cannot find). But that wouldn't require two parallel pairs would it? Or was 91 Si pre-wired for fog lights and I am still missing my horn wires?

Thanks

kp

My 91 Si has two horns

radex7

Fantastic! Thank you for this confirmation!

radex7

Since it has been only seven years, I decided to either finish it or sell it!

Josip.

Do you plan to sell it after you finish it?