Muckman’s Integra High Compression Super Build
 

Last year I spun a rod bearing at the track so I set out to rebuild my engine for the 4th time in 8 years. I’m bored with the standard builds – Low compression with an oversized turbo. This time I want to try something radically different and challenge some common myths like -

1.) You can’t safely run high boost with high compression. At least not without race gas.
2.) Turbo Honda’s don’t have any low end torque under the curve. We’re all well aware of this.
3.) Only big turbos don’t suffer from torque/boost taper at high rpm. I hate seeing the big turbo hump in the middle which turns into a 100ft-lbs dive of disappointment.

The goal is to build a responsive high efficiency engine with high compression, a high flow ported head and big cams. I am going to reuse my current turbo setup which consists of a Hytech manifold and a GT3076R-13. I’d like to make at least 500hp observed with lots of torque that is linear and smooth.

To start I’m reusing my B18c Benson sleeved block but had it bored up a size to 84.5mm, replacing the pistons, the LS crank and the 1 spun rod. I need to source a ported head, valve train and cams.

I’ve been running E85 ethanol for 2 years so I already have the fuel system upgraded and ready to go. I have the dual Walbro 255lph pump kit from FullBlown with -8 feed and -6 return. Last year I had ID1000s but maxed them out at 450hp observed (500hp Standard CF). This year I will be running 1600cc Bosch EV14 injectors.

Re: Muckman’s Integra High Compression Super Build
 

i dont want to nitpick but running E85 on this kinda defeats point #1

Re: Muckman’s Integra High Compression Super Build
 

Is that because you consider E85 race gas? Its available at my local pump for $2.99 a gallon. I would consider that pump gas over VP race fuel that cost $10/gallon. Im truly sorry if you dont have Ethanol in your area because youre missing out.

Re: Muckman’s Integra High Compression Super Build
 

No i dont consider it "race gas" but given the fact that E85's limitations exceed even that of 110 octane, and its not a readily available fuel for most of the USA, i wouldnt call it standard either. 91 is probably the most readily available "premium" gas across the whole country with select areas like south jersey having 93. God forbid i venture outside of jersey i have to detune my car to handle 91 octane only. Id love to run a flex fuel sensor and proefi and run ethanol but unfortunately the nearest station is 100 miles away.

Re: Muckman’s Integra High Compression Super Build
 

Valid points. However E85 is readily available to me at my location so I will be using it. Anyways we will be testing the limits of E85. And while we are on the topic of how awesome Ethanol is, this white paper from Delphi shows how far ethanol can be pushed. http://delphi.com/pdf/techpapers/2010-01-0619.pdf

Re: Muckman’s Integra High Compression Super Build
 

13.5:1 compression and 20psi here we come

Re: Muckman’s Integra High Compression Super Build
 

most places have 93.. even nevada has 93, the only places with 91 are cali, and a few other shitty states. we have e85 but its scattered, mostly downtown... the closest station to me is a 30 mile round trip..

i wanna see this build naow lol

Re: Muckman’s Integra High Compression Super Build
 

91 only in OR. :(

In for some high compression and Pro1's!! :thumbup:

Re: Muckman’s Integra High Compression Super Build
 

i really don't get the whole thing about 2 octane points... but oh well.

Re: Muckman’s Integra High Compression Super Build
 

:popcorn:

Re: Muckman’s Integra High Compression Super Build
 

what kind of high compression numbers are we talking?

Re: Muckman’s Integra High Compression Super Build
 

Need a cam eh.. i know someone who knows a guy.

Re: Muckman’s Integra High Compression Super Build
 

First a couple pics of the 2011 damage. Here is the big end of the #4 rod that cost me $200 to replace for a matched Pauter rod. Ugh
http://i1176.photobucket.com/albums/...4/IMG_0014.jpg
A close up of the big end half, trashed.
http://i1176.photobucket.com/albums/...Rod4BigEnd.jpg
Here is the trashed #4 rod journal on the crank
http://i1176.photobucket.com/albums/.../CrankRod4.jpg

I’m not certain what the cause was but the theory is detonation. This engine had about 1500 miles, 100+ dyno pulls, countless street tuning but only 5 track passes. The rod bearings had a clearance of .0015” which is within factory spec but a little tight now in hindsight. We noticed on the dyno a little oil smoking which I later traced back to #4. The combustion chamber of #4 and its valves were slightly oily which are signs of a valve seal leaking. This probably caused detonation as there is evidence of in the flaking of the ceramic coating on piston #4. The slight detonation wasn’t enough to damage the piston but my theory is it squished the oil clearance out of rod #4 when under load.

Here you can see the chips in the Swaintech ceramic coating along the outside from the detonation. It’s light but obvious when you compare it to the other cylinders.
http://i1176.photobucket.com/albums/...4/Piston4a.jpg
Piston #3 to compare. Looks totally fine, as do the others.
http://i1176.photobucket.com/albums/...d4/Piston3.jpg


GSR Head chamber of #4. it’s a little oily.
http://i1176.photobucket.com/albums/...4/Chamber4.jpg
Head chamber of #3 to compare
http://i1176.photobucket.com/albums/...4/Chamber3.jpg


Here is the video of the run where the trouble started. You can hear a loud vibration at the staging line. I knew that noise wasn’t normal but it’s tough to judge under a helmet and with everything going on. Still managed a 12.0 @ 127 with a passenger! Made 2 more passes after this where the vibration developed into a knock and it was clear the car wasn’t driving home under its own power.

[youtube]ZrWS9HDz9w4[/youtube]

Re: Muckman’s Integra High Compression Super Build
 

Oh about 13.5:1

Re: Muckman’s Integra High Compression Super Build
 

isn't .0015" a bit on the tight side considering your output power?

i've gone to .002" on rod clearances with 3 builds so far and oil pressure stays 38-40psi @ idle, w/ normal operating coolant temp.

subscribing for this high CR build :thumbup:

Re: Muckman’s Integra High Compression Super Build
 

I agree with you now. However I had several engine builds prior that were fine with that clearance. Detonation was the demise of them, not bearing failure. Ive reused these Pauter rods since my first engine build. Also many on this forum will tell you they use .0015" on the rods too.

I will be targeting high teens to 2 thou this time.
Learn from experience!

Re: Muckman’s Integra High Compression Super Build
 

Good luck! I love high comp turbo builds!! They are alot of fun on the street, just get a good tire :P

Re: Muckman’s Integra High Compression Super Build
 

Subscribed!

Re: Muckman’s Integra High Compression Super Build
 

Remember that there is summer and winter blends etc. E85 is not consistent and if you are tuning on the edge i can become dangerus if you get a bad tank. A thick racing oil requiers larger clearens than stock stuff. How you use the engine also determance bearing clearance. So one clearance doesn´t work on every engine.

Re: Muckman’s Integra High Compression Super Build
 

This is true. This vehicle is not a DD and sees only blue skies and summer days.
I only get Ethanol from one station and only summer blend.

Re: Muckman’s Integra High Compression Super Build
 

New Parts!

My tuner has been a big inspiration for this project and pushed me to go as high as I can go with the compression. He wanted to do custom pistons. Instead I went with the largest dome off the shelf pistons Wiseco sold in my size - K594M845 with 8.25cc domes. Wiseco says it will have a compression between 13.2 to 14.2 depending on the head used. I’ve always had my pistons ceramic coated in the past for extra protection and this time was no different.

I originally decided to go with the Skunk2 Tuner1 cams because of the rule that Pro1s are too big for a GT30. I later changed my mind and decided to try the new GSC T1 cams. They are a big aggressive cam designed for turbo with less overlap than Tuner1’s. GSC is a great company with great support. I will check v2v clearances for both cams instead I decide to change later down the road.

Plans:
Rebuild short block with looser bearing clearances
Install high compression pistons - Wiseco K594M845 (84.5mm, +8.25cc)
Install new valve train and cams – GSC T1 cams and Supertech valves, springs, retainers
Check piston to valve and valve to valve clearances with new cams.
Bigger injectors – Bosch EV14 1600cc


New Wiseco pistons, 84.5mm, had the domes ceramic coated too
http://i1176.photobucket.com/albums/...ecoPistons.jpg

Setup an assembly room in the basement. Its cleaner than the garage and at a constant temperature.
http://i1176.photobucket.com/albums/...d4/DSC1011.jpg

Had machine shop hone the cylinders up a size to 84.5mm and resurface the deck .006”. Wiseco calls for .003” piston to wall clearance. I went with .0035” p2w because I plan on making a lot of power. I ran .0030” p2w on the last 3 builds, all over 450hp, without any issue.
http://i1176.photobucket.com/albums/...4/DSC01068.jpg

Got a new LS crank. I’ve been using a LS/B20 crank for years. It has a slightly longer stroke than GSR 89mm vs 87.2mm and its usually cheaper. This crank came rebalanced and micropolished. The seller threw in a set of ACL Race STD size bearings for $215. Huge win.
http://i1176.photobucket.com/albums/...d4/DSC1016.jpg

Got my big OEM order in. Gaskets and Orings for the rebuild. Bought new main bolts too as they have been reused many times. Im OCD about rusty bolts so theres a lot of new bolts for all over the car.
http://i1176.photobucket.com/albums/...4/DSC01071.jpg

Re: Muckman’s Integra High Compression Super Build
 

nice good luck wirh the build.

Re: Muckman’s Integra High Compression Super Build
 

Who is tuning it and what system are you running on? Looking forward to seeing what a 13+ compression turbo build does...besides have zero traction

Re: Muckman’s Integra High Compression Super Build
 

Ive been running Demon/Neptune for 2 years and plan to stick with that. However I have been eye balling Hondata coil on plug so I may make the switch if I need more spark juice. Currently I have the MSD Pro-Billet system and have had great success with that. *

Tuner is Rick Gifford of Bald Turbo Freak. He recently moved his operation to a shop called Lifeline Performance in Rochester.

In regards to traction. Ive been using a 4 port boost controller which gives me 5psi (wg) to 30psi range. That enables me to leverage boost by gear and gain full traction in every gear.

Re: Muckman’s Integra High Compression Super Build
 

Looks like you have a very interesting build up your sleeve Muckman. Please post up plenty of videos we can drool at :thumbup:

Re: Muckman’s Integra High Compression Super Build
 

I have seen vids on your youtube channel muckman nice stuff!! I had a 11:9.1 b16 on boost and E85, a bit more tame of a setup made 399hp and 280trq on 15psi outta a Precision 6031 .63 hotside. High compression is def where it's at, if I had the money i'd do a 14:1 b20vtec turbo setup on e85 with the CSS Werx process!

Re: Muckman’s Integra High Compression Super Build
 

Behold my crown jewel - a DART head! *heavenly music*
Dart stopped making these bad boys 5 or 6 years ago so they are rare.
This is pretty much a unicorn.

http://i1176.photobucket.com/albums/...4/DARTHead.jpg
http://i1176.photobucket.com/albums/.../DARTHead2.jpg
http://i1176.photobucket.com/albums/...4/8c50cc9b.jpg


Dart took new OEM Honda P72 castings and worked their magic.
Full CNC porting on intake and exhaust runners.
The intake valves are +1mm oversized.
The combustion chambers are CNC blended.
Here are the flow specs from Dart.

http://i1176.photobucket.com/albums/...NCfullport.jpg
320cfm @ .500" is bad ass.

Re: Muckman’s Integra High Compression Super Build
 

parts are lookin' sweet! :thumbup:

lovin' the engine build inside your room. :beer:

Re: Muckman’s Integra High Compression Super Build
 

Dern!

Re: Muckman’s Integra High Compression Super Build
 

I wish my gf gave head that hot

Re: Muckman’s Integra High Compression Super Build
 

Wow nice find a Dart head, super rear and a killer head. Endyn is the only other compay that does head work on that level IMO. And going on a Benson block too boot. I like the GSR block with the Ls crank. The LS crank is key to increasing the TQ the motor can make. Will be following along.

Re: Muckman’s Integra High Compression Super Build
 

I'm curious how the JG Edlebrock head compares to the Dart or Endyn now because that's what my buddy is using.

Re: Muckman’s Integra High Compression Super Build
 

I didnt know they offered a head. Get the flow chart from Edlebrock.

Re: Muckman’s Integra High Compression Super Build
 

I didn't know either until I saw his and it's still the only one I've ever seen.

Re: Muckman’s Integra High Compression Super Build
 

I started working on the bearings. In the past I only used Honda OEM bearings for the different sizes but they are expensive and I’m not convinced they are any better. I can get a complete set of ACLs (mains and rods) for $100. In my previous engine I used a combination of ACLs where I could and OEMs where I needed a different thickness. And later when I tore it down the ACL bearings looked just as good as the OEM bearings. So this time I will keep it simple and go with ACL Race bearings.

Factory service manual for a B18C1 calls for:
Mains 1, 2, 4, 5: .0009 ~ .0017”
Main 3: .0012 ~ .0019”
Rods: .0013 ~ .0020”

In my previous motors I targeted .0015” for main and rod bearing clearances because it was an easy round number to measure for. And this time I wanted to go with looser clearances towards the big end of the range.

My new target clearances:
Mains 1, 2, 4, 5: .0017”
Main 3: .0019”
Rods: .0020”

The main bearings are all really tight with the new crank. I won’t bore everyone with pictures of this stage.

Clearances with ACL Race STD:
Main 1: .0010”
Main 2: .0010”
Main3: .0012”
Main4: .0010”
Main5: .0010”
Rods: .0010”

These are way too tight! I am going to need the thinnest bearings available. After some research it turns out ACL Race bearings come in a XTR size which is supposed to give .0010” additional clearance so I ordered a set.

Clearances with ACL Race XTR:
Main 1: .0015”
Main 2: .0018”
Main3: .0020”
Main4: .0018”
Main5: .0015”
Rods: .0015”

Mains 1 and 5 are still too tight and the rods are still way off. This is the thinnest bearing on the market so machine work is required to get the clearances I want. I need the rods honed and the crank turned. A lot of people say you can’t turn a Honda crank because they are nitrided and this layer will be removed. This is not true. The nitriding process can be as deep as .0020” so taking half a thousandth is no problem. The alternative to turning the crank is a line hone of the mains. This can be very problematic and expensive. Because the mains caps are steel and the block is aluminum any machine work is going to cut more into the softer aluminum. This moves the center line up and in turn my piston to deck height will be reduced. I can’t afford to risk this as my block has been decked 5 times before. A line hone will also make sure the crank journals are in a perfect line but I’m positive mine is OK as I’ve never had any main bearing issues or uneven wear before.

Re: Muckman’s Integra High Compression Super Build
 

Look up JG Engine Dynamics, that should answer everything you want to know (and maybe more).

Re: Muckman’s Integra High Compression Super Build
 

Im jealous of that head -_-

Re: Muckman’s Integra High Compression Super Build
 

In the damaged #4 pics, it looks like the piston made contact with the head as a result of the bearing going out. The clearance goes away and it tapped the head very lightly. The marks on the piston directly correspond to the chamber edges and squish area.

Re: Muckman’s Integra High Compression Super Build
 

Post the coolllllll parts!

Re: Muckman’s Integra High Compression Super Build
 

I'm really jelly....
Subscribed..
Still jelly..