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Old 11-19-2009, 06:44 PM   #1
ic
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Default my 1980 Civic Turbo GSR swap... updated

This is the story of my 1980 Civic (2g) turbo gsr swap. I'm also chronicling this build on www.1stgencivic.com
All work is done by me.

After driving an '89 CRX for 8 years which can be found in some old threads here, I moved on to a '94 Civic EX Coupe. I swapped the motor for a GSR setup and then turbocharged it. It was pretty fast, but just did not handle anything near to what the CRX would do IMO. It was more of a cruise missle.

Well, I eventually came across this beaut from my boss for replacing a head gasket on his G60 Corrado.
Click the image to open in full size.
Click the image to open in full size.
I had those 16" Enkeis laying around and they seemed to fit the car so well I just had to 'buy' it.
Only after having taken delivery on the car did I find out that it actually already had a 1981 Accord engine and trans swap. It was suprisingly quick and very reminiscent of the handling of my CRX, vs the sluggish boat feeling of my 94. Unfortunately, the trans was shoddy and I couldn't take it in 5th gear due to the bad bearings.

Well, I wanted to drive this thing, and I was tired of my 94 that was damaged from end to end. So, what else but to perform a heart transplant, right?!!

Last edited by ic; 10-15-2011 at 09:44 PM.
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Old 11-19-2009, 06:46 PM   #2
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Default Re: my 1980 Civic Turbo GSR swap

Work on the swap began in mid-August 2009.
Unfortunately my picture taking has been a little hit and miss from time to time but I'm trying to get more where there are gaps.

Anywow, here are the early stages.
The chassis mount cups have already been fabricated here and the frame modified. I retained the stock location for the alternator by boxing out the rear of the driver's frame rail.
As you can see in the first pic, I had to notch the lower valence/core support as far forward as I could go. I have a perfect 1.5mm clearance between the turbo and the chassis :shock:
overview
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again
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driver's mount
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trans mount and cancer I'll be fixing later.
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where the torque mount ended up. (reused the stocker and only about an inch off it's original mount lol.)
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On to axles and stuff.
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Old 11-19-2009, 07:09 PM   #3
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Default Re: my 1980 Civic Turbo GSR swap

so here are my grassroots motorsports inspired axles. I know these look scary in the pics but they work, and if they end up being problematic, I now have prototypes and will farm them out to a driveline shop or something.

I had to combine GSR inboard axles with 1980 civic outboards. When installed the joint angles are a bit less than ideal due to motor placement limitations, but even with the wheels turned lock-to-lock, there is no binding of the joints and I've seen several b16 swaps that seem to work and they are dimensionally dealing with the same issues that I am.

These have since been ground down, cleaned up, and painted. But what you have here are the two shafts sleeve welded together via a 1/4 inch thick steel pipe.
Click the image to open in full size.
Click the image to open in full size.

to stay on the safe side, I'll be mostly avoiding clutch dumps and burnouts.
I'll get more pics with joints/boots and installed.
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Old 11-19-2009, 07:17 PM   #4
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Default Re: my 1980 Civic Turbo GSR swap

Looks like a killers swap, and some great work so far! What did you do with the front crossmember? Also, I noticed the Washington plates, where abouts are you?
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Old 11-19-2009, 07:19 PM   #5
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Default Re: my 1980 Civic Turbo GSR swap

Looks great. Can't wait to see some more pics. Nice sleeper.
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Old 11-19-2009, 07:22 PM   #6
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Default Re: my 1980 Civic Turbo GSR swap

Quote:
Originally Posted by 2ndGenGuy View Post
Looks like a killers swap, and some great work so far! What did you do with the front crossmember? Also, I noticed the Washington plates, where abouts are you?
Thanks for the encouragement. I'm not the greatest welder as far as aesthetics, but I can permanently stick some things together lol.

Well, there was a longitudinal brace for the front torque mount like the Accords and Odysseys. That won't be coming back. Hopefully it wasn't that important to chassis stiffness!

I've also got fender braces that I've incorporated you'll see, and I'm sure I'll eventually fabricate some strut braces as well.

Last edited by ic; 11-19-2009 at 07:30 PM.
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Old 11-19-2009, 08:17 PM   #7
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Default Re: my 1980 Civic Turbo GSR swap

Fitting wastegate and intercooler:

external wastegate needs to be rerouted to the side for clearance issues.
Click the image to open in full size.

bumper and valence undergo some heavy plasma cutting to fit the intercooler, which inadvertently fits PERFECTLY. lol
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Click the image to open in full size.

it's all starting to fit and it's getting exciting
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Old 11-19-2009, 08:20 PM   #8
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Default Re: my 1980 Civic Turbo GSR swap

So, a fuel injected turbocharged motor requires a lot of fuel.
I already had an in-tank 255 walbro from the 94 civic, and didn't wan't to have to buy an inline pump, so first I tried to fit the 94 tank. Wouldn't really work. I could have made it fit, but the parking brake cable was pinched, the tank sat much lower, soooo, let's modify some stuff!

I had to cut the top of the '80 fuel tank open like a sardine can, spot weld in the baffling out of the '94 tank, weld the top back on, cut a hole for the in-tank pump mount, weld that in, then finally pressure test everything and fix any pinhole leaks in my welds.

Here you can see the 'door' I had to cut plus the pump mount welded in.
Click the image to open in full size.

Here is a peak at the baffling welded in the tank.
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The Walbro
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And installed
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Old 11-19-2009, 09:52 PM   #9
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Default Re: my 1980 Civic Turbo GSR swap

interesting build, looks cool, GL with the rest of the fab
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Old 11-19-2009, 10:01 PM   #10
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Default Re: my 1980 Civic Turbo GSR swap

Obviously, this requires custom wiring. So why not go full custom? lol
Nod to Chase and his awesome work.

oh the mess
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coming together
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detail
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more
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with custom mounted GM 3bar MAP sensor.
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And more
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By the way... did I mention that trans has an LSD, 6 puck clutch and 7lb flywheel fitted to it? :twisted:
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battery relocation
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jumper posts and cutoff switch so I don't have to remove the fender to have battery access.
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Click the image to open in full size.
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Old 11-20-2009, 10:08 AM   #11
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Default Re: my 1980 Civic Turbo GSR swap

dude that wiring looks sick the battery relocation is also to sweet where do u get that loom stuff you are using on your wire tuck project
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Old 11-20-2009, 12:20 PM   #12
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Default Re: my 1980 Civic Turbo GSR swap

Dude that build is going to be a monster!! What a little sleeper that thing is going to be! Nice work! Do you have a way to drive the cable speedo or are you going to replace the insides? Also, didn't the front crossmember have radius rods connected to the control arms to locate them? Maybe the 2g Civic didn't have the same setup as I'm thinking about...
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Old 11-20-2009, 05:41 PM   #13
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Default Re: my 1980 Civic Turbo GSR swap

Quote:
Originally Posted by jbrokos307 View Post
dude that wiring looks sick the battery relocation is also to sweet where do u get that loom stuff you are using on your wire tuck project
thanks!
I got the wire loom and heavy gauge wire from a local electronics shop as well as from Grainger. I also got the bulkhead connectors (which I haven't shown pics of yet) from www.mouser.com
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Old 11-20-2009, 05:45 PM   #14
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Default Re: my 1980 Civic Turbo GSR swap

Quote:
Originally Posted by 2ndGenGuy View Post
Dude that build is going to be a monster!! What a little sleeper that thing is going to be! Nice work! Do you have a way to drive the cable speedo or are you going to replace the insides? Also, didn't the front crossmember have radius rods connected to the control arms to locate them? Maybe the 2g Civic didn't have the same setup as I'm thinking about...
Ah, the radius rods are functionally integrated into the sway bar. It's a dual purpose unit on these cars and the sway bar/radius rods mount with swaybar type bushings at the very front of the frame rails underneath.

As far as the gauges go, I'm not 100% sure how I'm going to tackle that one. But one idea is to retro the gauges from my '94 into the '80 instrument cluster. Room, however, will be an issue.
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Old 11-20-2009, 06:33 PM   #15
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Default Re: my 1980 Civic Turbo GSR swap

subscribed! sick build
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Old 11-20-2009, 06:51 PM   #16
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Default Re: my 1980 Civic Turbo GSR swap

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subscribed! sick build
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Old 11-20-2009, 07:09 PM   #17
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Default Re: my 1980 Civic Turbo GSR swap

Pulled everything BACK out of the engine bay yet again to lay down some paint. Primed it with a 2K sealer then rattle can'd over it with satin black. (Black 2K topcoat and a bottle of flattener was just seemed like a waste of money. Anyways, now I can always fix nicks and dings with a $3 can of paint.)

Click the image to open in full size.

Click the image to open in full size.

After the black, I put everything BACK in. Ugggh.
You can also see the brake line work here. I DO NOT recommend messing with stainless hard line. Even the annealed stuff if nearly impossible to bend precisely and especially hard to flare (I broke my flare tool in the process). Hopefully they'll seal, but if not, I'll just replace with regular steel lines to get this thing on the road for now.

Click the image to open in full size.

Click the image to open in full size.

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Here you can see where I've relocated the proportioning valve. I'll update with some pics of the hard lines under the cowling later.

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Old 11-20-2009, 08:45 PM   #18
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Default Re: my 1980 Civic Turbo GSR swap

Dude this is just plain SICK!! I am lovin it. I will be keepin a close check for updates.

My Dad has an 82 Civic and to see work done to them like your doing is rare. Keep it up man.
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Old 11-21-2009, 04:07 AM   #19
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Default Re: my 1980 Civic Turbo GSR swap

wow. looking good man! keep it up. hehee.
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Old 11-21-2009, 05:48 AM   #20
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Default Re: my 1980 Civic Turbo GSR swap

lookin real nice. really good work bro keep it up.
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Old 11-22-2009, 11:22 PM   #21
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Default Re: my 1980 Civic Turbo GSR swap

Uh oh. What do we have here?

Ghetto paint booth. Works awesome. Negative pressure keeps all the dust from getting on all the things that would royally tick off my boss lol.

Click the image to open in full size.

Booth coming down, car being revealed

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More car

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De-masked and drying. The car is now Porsche Guard's Red (LM3A) inside and out.
Please excuse all of the orange peel. This is my first attempt ever with spraying automotive paint. I've got about 5-6 full coats over most of the car so hopefully I will be able to do a good sand and polish once it's all cured.

Click the image to open in full size.

Furnace filter taped to a box fan blowing OUT to create negative pressure on the booth. Don't ever try to paint a car red without a decent booth. The paint WILL GET EVERYWHERE PERIOD! It is the worst cleanup job you may ever have to do.

Click the image to open in full size.

Guy-wires to keep the tent from collapsing inward on the car from the negative pressure. (Trust me it fell down twice. It doesn't take much negative pressure to create a lot of unwanted force when you have a couple hundred square feet of loose 'sail'.)

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More to come!
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Old 11-23-2009, 12:16 AM   #22
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Default Re: my 1980 Civic Turbo GSR swap... now with paint!

Damn..
That is epic.
I wish we had cars like that in the AK.
It's all about STi's and EVO's here.
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Old 11-23-2009, 01:27 AM   #23
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Default Re: my 1980 Civic Turbo GSR swap... now with paint!

Hey its nice to see that how civic looks like in 1980 and look how it looks after 30 years
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Old 11-23-2009, 05:04 AM   #24
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Default Re: my 1980 Civic Turbo GSR swap... now with paint!

wow thats all i can say
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Old 11-23-2009, 10:08 AM   #25
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Default Re: my 1980 Civic Turbo GSR swap... now with paint!

I've done the makeshift paintbooth in a garage thing on a 1982 Accord. That was a huge pain in the ***. Plastic just wants to go everywhere (including on your car!) setup is a pain in the ***, teardown is a pain in the ***, the plastic goes everywhere and gets in the way. Nice work! That car is looking like a million bucks! Great color choice too!
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