Re: My 03 GPW S2000 Build
 

And to finish up my 3 day stint of work, today I went ahead and got the PFAB intercooler mounted up

Will take some more pics but there's not much to look at, just some simple bracket work.

Stock grill crew FTW:

http://i849.photobucket.com/albums/a...r/441b2bf6.jpg
http://i849.photobucket.com/albums/a...r/38c1477b.jpg
http://i849.photobucket.com/albums/a...r/176abb7e.jpg


Well that about sums up my weekends worth of work, more to come soon! :tipwink:

Re: My 03 GPW S2000 Build
 

Amazing car! great job on what you've done to it. I also sold my ef to get an 03, but I don't ever miss the civic lol an ap1 is sooo much better

Re: My 03 GPW S2000 Build
 

Bit of an update:

So my mysterious missing fitting for the clutch showed up yest (overnight shipping from penquintuxedo FTMFW) and got the clutch all bled and adjusted out minty!!


http://i849.photobucket.com/albums/a...r/e339609f.jpg

was the fitting I was missing, takes the OEM double flare and looks to be -3AN out to the lines, either way, it popped right in.

Fired up the powder gun again and coated up some more pieces!!

http://i849.photobucket.com/albums/a...r/199f2aa6.jpg
http://i849.photobucket.com/albums/a...r/bbb65fb0.jpg



will be welding some baffles into the VC this week, and then will strip the rest of it down for the flat black powder I have (was going to be too much wrinkle for my liking)

Much more to come in the next few days, getting my inspection done tomorrow, and then I will be cleared to install the rest of the pieces.

We are moving right along here



Got a bit more taken care of yesterday evening. Swaintech has my manifold until Monday so I have been trying to get everything else addressed. When the mani gets back, I will be able to really get after installing the rest of this setup!

AC was already out of the way, But didn't want to take a risk w/ battery, so off to my local stereo shop to take it up the ass on some 0awg wire and terminals!!!

Parts list I used for this relocation:

12' 0awg wire (prob could get away with 10)
2 new battery terminals (local auto store)
Stinger 150amp breaker
Stinger Distrubtion block w/ 2 0awg and 4 4awg inputs
Stinger ring terminals (qty 5)
Short section of cable between bat and breaker
3' 0awg cable for my ground
Firewall grommet


Cabling through FW and grommet installed:
http://i849.photobucket.com/albums/a...r/8b5c78d6.jpg


Moved the EPS module lower to clear room for fusebox:
http://i849.photobucket.com/albums/a...r/3fbbabff.jpg
http://i849.photobucket.com/albums/a...r/6fc1707f.jpg


Ended up mounting the distro block to the top of the EPS module, wanted to keep it all tucked and hide the 0awg as much as possible
http://i849.photobucket.com/albums/a...r/20b85fac.jpg
http://i849.photobucket.com/albums/a...r/c1c0cae2.jpg

Need to fab up another fusebox bracket this evening but you get the idea, Certainly free'd up some room.

http://i849.photobucket.com/albums/a...r/be5c3d15.jpg


So the front is done, everything is tight and placed where it should be, cable is ran through the car and out to the trunk, have to mount the batt box and ground and this portion of the build will be complete.

Will post some pics of the trunk setup when I'm done but it's nothing fancy, just a plain ole black box w/ breaker inside.


Who said Italians don't fit in trunks???

http://i849.photobucket.com/albums/a...r/0fd3c33e.jpg

Moar to come!

Re: My 03 GPW S2000 Build
 

Very nice

Re: My 03 GPW S2000 Build
 

ust another minor update, I have been chipping away at things while I wait for my manifold to return from Swaintech.

All the secondary air injection equipment has been removed, and my Izze engineering air pump sim just arrived the other day, so no worries of CEL with the stock ECU installed.

I had previously fitted the intercooler behind the stock grill , but never got to test fitting any pipes. The PFAB pipes fit great, and only needed minor splash shield modification to fit.

I got after the splash shield with a dremel which made for quick work:

http://i849.photobucket.com/albums/a...r/be1df05e.jpg
http://i849.photobucket.com/albums/a...r/f9dbe747.jpg
I will get some more pics of the pipes installed next time they are on the car, but you get the idea.

Decided my next task should be timing cover/oil drain, so that when I pick up the manifold, I wont have to worry about them.

mmmm wrinkle:http://i849.photobucket.com/albums/a...r/c6a4d58b.jpg

Figured the best spot to start on this job would be the worst spot....Crank pulley bolt.

Those of you who have removed these understand how tight these suckers are, those who haven't.....they are pretty F'n tight :LOL:

The location of the bolt on the S certainly doesn't favor the use of air, but I thought I'd try just to humor myself (and you guys)

Wellll Lets see what 1200 ft/lb of Nut Busting torque can do vs a little 2.0L Honda.......

http://i849.photobucket.com/albums/a...r/1dd46db7.jpg

As you can imagine, the car pretty much laughed at me. Granted I lost some of the potential through the extension and my home compressor tops out @ 140psi regulated line pressure , but still not even a chance.

Special tool time......


I knew my local auto stores don't rent this type of tool, and everyone that I used to work w/ at my old shop has since quit/been fired I was SOL.

Ordering the tool to an autozone/advance takes roughly 2 days, but I have 0 patience and wanted that pulley off!!!!!

So at this point, it's 9pm and I'm standing in the garage looking at my buddy Mike who goes "why don't we weld something up"

Luckily I had a spare crank pulley from who knows what in the bottom drawer of my box and Mikey had some flat stock...in stock. 25 mins of sawzall and some fantastic MIG action :LOL: and special tool # GH3TT0 was born.

http://i849.photobucket.com/albums/a...r/20d506ef.jpg
http://i849.photobucket.com/albums/a...r/cb680fe0.jpg

You know you are jealous!!!!!

http://i849.photobucket.com/albums/a...r/f8301815.jpg

Talk about hood :LOL:
http://i849.photobucket.com/albums/a...r/954124fb.jpg

My trusty jack handle has always been my home crank pulley removal tool of choice, here's the setup in all its glory
http://i849.photobucket.com/albums/a...r/f6df2b4c.jpg

All in all the tool worked flawless, and didn't budge a bit!!!!! I will be keeping this one around ;)

The rest of the install wasn't that bad, the hardline that runs across the top was a bit of a PITA to work with even with all the bolts disconnected and the hose off, but all in all not a bad job for a worry free oil drain setup.

Cover installed:
http://i849.photobucket.com/albums/a...r/1393ae21.jpg




Up next: Fuel pump

Re: My 03 GPW S2000 Build
 

lol i have the same crank pulley puller

Re: My 03 GPW S2000 Build
 

lol

Certainly hood but it works!

Re: My 03 GPW S2000 Build
 

You are worthy of my first Honda-Tech post, saw this build on S2ki and im still jelly of GPW and tan!!!

Re: My 03 GPW S2000 Build
 

dont be a douche...and please refrain from using the term jelly...it makes you look like an idiot

Re: My 03 GPW S2000 Build
 

looks good so far

Re: My 03 GPW S2000 Build
 

UPDATE:

Getting closer here! Got a few things accomplished over the weekend


Hood vents powdercoated semi-gloss black:

http://i849.photobucket.com/albums/a...r/2cdeb982.jpg

TIme for studs:
http://i849.photobucket.com/albums/a...r/f933634e.jpg

ARP vs OEM
http://i849.photobucket.com/albums/a...r/9467336d.jpg

Just another day in the garage (the LS swapped EG was in for wheel bearings, ball joints, tie rods, essentially an entire front end rebuild, god I hate when people buy other peoples projects)

http://i849.photobucket.com/albums/a...r/dca5138e.jpg

ARP studs in:
http://i849.photobucket.com/albums/a...r/fe4d703c.jpg



That was how it sat thursday night, until I got the call from swaintech on friday that my manifold was complete.

Swaintech white lightning coating:

Price: $225 plus tax
Turnaround: quoted 2.5-3 weeks Actual complete: 4 weeks. I called and spoke with them a few times who let me know they were a bit backed up and would be delayed a bit.Overall I am very happy with the coating , just budget yourself plenty of time when sending parts. I will keep this updated w/ how the coating holds up over time.

http://i849.photobucket.com/albums/a...r/4d020f25.jpg
http://i849.photobucket.com/albums/a...r/a48e4524.jpg
http://i849.photobucket.com/albums/a...r/5530d97d.jpg

Despite promising my girlfriend I wouldn't work on the car at all fri/sat while we were together, she knew how bad I wanted to mock everything up and let it slide. :heart:

Mani/Turbo hung:

Inline racing forward facing manifold.
Borg Warner S366 .88 A/R single scroll hotside.
http://i849.photobucket.com/albums/a...r/a0b42d0e.jpg
http://i849.photobucket.com/albums/a...r/9c15d1aa.jpg

Test fitting some of the purp:
Tial 50mm Q
Tial 44mm MVR

http://i849.photobucket.com/albums/a...r/e84934f2.jpg
http://i849.photobucket.com/albums/a...r/c2b05ac9.jpg
http://i849.photobucket.com/albums/a...r/b41fab5d.jpg
http://i849.photobucket.com/albums/a...r/ff15e4ba.jpg

Overall I am pleased with how everything fits currently, the T1R t4 blanket is a bit small and leaves a good portion of the housing uncovered, may have to swap it out :/

and DAMN this is close
http://i849.photobucket.com/albums/a...r/8b711662.jpg

After hustling to get that all mounted while the gf watched tv, I snuck out to the garage while grilling some steaks for dinner and got the downpipe hung up :LOL:

All 3.5 inches of glory tucked up in :thumbup:

http://i849.photobucket.com/albums/a...r/cd4db9bb.jpg
http://i849.photobucket.com/albums/a...r/68bd811c.jpg
http://i849.photobucket.com/albums/a...r/48efe346.jpg


I work Sunday-Thurs so I will be @ work all day tomorrow, but back at it as soon as I am out.
Should have my basemap from Evans Monday at the latest and looking to have the car all put together by this time next weekend!

More to come

Re: My 03 GPW S2000 Build
 

Looking good, about time to update that signature from needs boost to got boost!

Re: My 03 GPW S2000 Build
 

Working on it!

hoping to be driving on base tune this weekend to isolate leaks ect.

Re: My 03 GPW S2000 Build
 

Very clean looking s2000, always been a big fan of the white models. I've been looking around for a GPW one myself lately but having a tough time finding one within the right price range

Re: My 03 GPW S2000 Build
 

Update citttty:

So I have been slacking a bit on the updates, but have still been hard at work here.

After getting everything mocked up and test fit. I started tying up loose ends and bolting things down.

Installed the ID 1000's <--- this went so quick I didn't have time for pics

Installed the FB 340 lph pump<--- Fairly tight space, but anyone who is semi mechanically inclined should be able to accomplish this task...with some patience.

Installed the DFW blockoff plate:http://i849.photobucket.com/albums/a...r/6d1dd5b4.jpg


With everything crucial for the vehicle to run installed, I loaded up my base calibration into my Haltech unit, and crossed my fingers.

Startup vid: (unsure how to embed)
http://i849.photobucket.com/albums/a...h_799090a0.jpg

Direct link to vid:
http://s849.photobucket.com/albums/a...t=799090a0.mp4


As you can see/hear, car fired up and idles next to flawlessly on the base calibration. Checked everything for leaks...timing cover, pan, all oil fittings 100% leak free. Did have a minor exhaust leak on the DP but rotated the clamp and solved that (new clamp otw to me)

Got the coolant system bled out (per Honda service manual)

Quick DIY on the bleed:

1:Drain coolant

2:Crack intake manifold bleeder

3:Remove bleed cap on coolant bypass tube (rubber cap on silver metal pipe on firewall)
Begin to add coolant

4:Close bleeder on intake mani when coolant begins to flow in steady stream

5:Cap bypass hose when coolant begins to flow in steady stream

6:With heat on full, Start vehicle and allow to run until fans turn on twice(both top and bottom hose should be hot, if bottom hose is still cool, thermostat has not opened)

7:Top off overflow and radiator.

8:Run car again to check for leaks.


My setup for this process:

http://i849.photobucket.com/albums/a...r/f3207c40.jpg



With the coolant system bled, I had a few things left to fab up that I could not accomplish in my home garage. Needed to modify some charge piping, and connect my downpipe to the rest of my exhaust.

http://i849.photobucket.com/albums/a...r/8f5c5f81.jpg

Gimped the car out to a friends local area shop: How I arrived (minus bumper :) )

http://i849.photobucket.com/albums/a...r/d70e20ac.jpg


I'd like to stop and thank Daryl Barth of SDUBNY (Suspensionworx) for all the help/fab work throughout this process. Any of you guys that are local(Roc,Buf,Syr) and need paint/bodywork/powdercoat/stereo/fab work. Daryl does top notch work, and is great to work with. He has been in the business for many years, and I wouldn't trust anyone else with my car. Not to mention his Fab/Aluminum welding skills are straight boss :thumbup:

Under the knife:

http://i849.photobucket.com/albums/a...r/887bcfe3.jpg

Hot side:
http://i849.photobucket.com/albums/a...r/703fc14b.jpg
http://i849.photobucket.com/albums/a...r/942c0686.jpg



Will take some more pics of everything else tonight as it was getting late.


As it stands, the car runs and drives, I need to fab up a dumptube, install my wideband, and finish up some vacuum lines and the car will be ready to hit the trailer for our 4 hr journey to see Mr. Jeff Evans on thursday!!!

Re: My 03 GPW S2000 Build
 

clean s2000..makes me miss mine

Re: My 03 GPW S2000 Build
 

Small update:

So I have been working all night/every night on buttoning up all the loose ends as I am quickly running out of time here!

Got my vacuum line (most of it) setup, and half the wideband installed last night.


Hard line setup w/ AEM boost solenoid:

(still need to purchase 1 more hard line/fittings but needed to test fit w. what I had before I would know what length to purchase)

Overall I am happy with how it turned out. Going to also build a little bracket for the solenoid eventually.

http://i849.photobucket.com/albums/a...r/c64df571.jpg
http://i849.photobucket.com/albums/a...r/d721d07e.jpg
http://i849.photobucket.com/albums/a...r/2f778ead.jpg


With next to everything under the hood tackled and ready to go, I needed to work on getting my wideband installed.

This has been something that I have racked my brain about for months, While I would eventually love to get the gauges installed in the mirror. Funds won't allow for that currently. So I needed to find a discrete location for the gauge. I can't stress how much I HATE HATE HATE gauges, I think they look terrible, and ruin the feel of the interior, but, you've gotta have them.

Here's what I decided to do with the AEM uego gauge.

http://i849.photobucket.com/albums/a...r/5924f917.jpg
http://i849.photobucket.com/albums/a...r/334cbade.jpg




All in all, I think the setup has come together rather well. I still have a few small things left to tackle before I load the car up Wednesday night for my 5 hr trip down to see Jeff.

Left to do:

Finish powdercoating valve cover & install
Install lines/catch can
Fab dump tube
Oil change


If anyone can think of anything I have missed, please let me know! It is crunch time, I want to make sure everything is 100% before I blow 300+ in gas towing 6000lbs of enclosed race trailer/s2000 to PA and back!

Re: My 03 GPW S2000 Build
 

not bad...you could have also put it where the audio control circle thingy is...ive seen that done and looks pretty good...i never use the side radio controls so i wouldnt care about losing it honestly

Re: My 03 GPW S2000 Build
 

I have seen a good amount of people put it there as well. I have the modifry DCI harness so I use my controls almost exclusively . I almost NEVER flip the radio cover down, so keeping these was important to me

Re: My 03 GPW S2000 Build
 

i feel ya...ive just never got into the habit of using my left hand for anything other than steering, rolling the window down, and holding my cigarette lol

Re: My 03 GPW S2000 Build
 

To be honest, If I didn't already have the DCI harness it would have gone over there for sure.

The extra features like track navigation ect ect that the DCI allows you to do that OEM would not are reason enough for me to keep it.

I smoke my Ls with my right hand ;)

Re: My 03 GPW S2000 Build
 

well played sir, well played....progress looks good though

Re: My 03 GPW S2000 Build
 

Thanks man, just a few little things left to do and it'll be time to load it up on the trailer.

Thursday is going to be a scary day for this guy.

Re: My 03 GPW S2000 Build
 

i wanna hear this thing at full boost. nice progress man.

Re: My 03 GPW S2000 Build
 

The time you (and me) have to wait for that is coming quicker than I can imagine.

I got the dump tube fabbed up and wrapped last night:
http://i849.photobucket.com/albums/a...r/fba52f6f.jpg

I need to run my catch can lines when I get home tonight, and give the entire car a once over before loading it up.
http://i849.photobucket.com/albums/a...r/e4be612b.jpg

10am appointment with JEFF EVANS TOMORROW!

I swear I haven't been this excited since I got the first gameboy for xmas as a child.