Here we go... I will start and update as i go... answering questions along the way, if anyone has any views/opinions i will gladly answer them... i also accept any HELPFUL critisism :D

Well... were do i start.. we start with a standard 1.6 1994 Civic Esi.. Which has the standard D16Z6 engine with 123hp when it left the factory many many moons ago.





Then this happened...









It got modded... this was over a few years of trial and error... it has been in some states which we wont go over

Anyways... at this point... ya know.. u grow attached to your honda dont u? I thought it was fast but it just wernt doin it for me anymore.... so i researched and found something amazinng! I found that people in america turbo the same car as mine and i was outstanded with the results they were getting! it was a big decision... coz ****... i dint have much money! but as soon as i started buying parts off ebay... i couldnt stop... the addiction grew.... u know wot its like i know u do... heres a few of the parts i bought...

T3 Turbo



RC 440cc Injectors



ARP Head Studs



OBX Cam Gear



Oil Catch Can



Wastegate



Cast Log Turbo manifold



Crower ST2 Turbo Cams



Intercooler



Dump Valve



Stainless Downpipe (Needed serious adjustment)



Nice Shiny Polished Charge Pipes



Oil Lines



So... obviously thats not allll the parts.... on top of that.... if your thinking of turbo'ing yourself.... you will need...

Walbro 255 fuel Pump
All the obvious fittings... couplers, clamps, oil drain hose, vacuum lines, boost controller, oil guage and boost guage as minimum, full exhaust, air filter, crome basemap chip

So... i collaited all my stuff and after just 3 days of hard work with little hickups along the way i finished! and it worked! even to my own amazement becasue i wasnt too sure about it.... if your doing this yourself... the hickups were...

the block needed to be grinded becasue the turbo didnt fit properly.
The downpipe had to be cut and re-welded.
The charge pipes had to be re-ruited around the downpipe.

Overall i think that is'nt to bad for a first attempt!

















And it worked!
http://uk.youtube.com/watch?v=fpCp6PcQe54 << video here

And then disaster happened... I ran it on santa pod... i knew something was'nt right.. but i was abit nieve then.... on the way down to pod it loved the motorway... and on the track it had an explosive start and then slowed as it got past 60mph... so i got it dyno'd there at the track and it showed it was running way to lean past 5000rpm. So i got it booked in for tuning but had to wait a couple of weeks... and one hot day i stupidly take it out on the motorway with hardly any coolant and melt the pistons!





and score the cylinder walls



So.... i honed the bores and fitted these... with little experience of engine building... none in fact.



Eagle rods 8.5:1 vitara pistons, nippon rings, acl bearings.... did a half decent job of it becasue i was very eager to get it back... i built it in all weathers... mainly in the rain!



Note: When your putting new rods in a D16 you have to notch the block and main cap bridge! The bigger rods need clearance!

After i got it all back together.. i was not happy with it... head gasket was leaking and bottom end was knocking. So something had to be done and i was not giving up! no way was i! So ive blagged my university and turned this into my project. Ive bought an engine and stripped it... u can see where im up to with it here..















I know its mucky... but its been through the parafin bath now!





... slightly cleaner





after alot of hard work and cleaning.... very clean engine!!!





Started clean build



Deglazed the bores for the new rings.
Eagle rods and ycp vitaras in with acl race bearings and nippon rings.



ARP 2000 7/16 conrod bolts tightened to 43lbsft, 59Nm



Nicely cleaned up intake manifold. Dismantled and clean all inside, new gaskets and give it a spray




fidanza lightweight flywheel



Sump on...



:D dont mess about me!

 

Heh, reminds me of Jeremy Clarkson from Top Gear.

This is a very nice build. Way to save the D. What kind of T3 is that?

 

and when u say knocking. are u talking about the normal vitara sounds?

 

Ha.. yeah jezzers a legend!

Its a T3/T4 it is a copy but ive ran it before and it works well so im using it again. Cant remember the exact size i think it 57 A/R .50 its pretty big so am thinkin all my powers gunna be up the top end especially with the low comp pistons... will be fun to see what happens!

 

no.. bad knocking! I wernt sure if it was big end or what.. i actually thought it was the big conrods hitting the block at first but they seemed to clear it when i turned it by hand, no restrictions. Your saying vitaras knock? Never heard that one before.

 

very nice man, cant wait to see more

 

hahaha. did it sound like slap?yes. the material vitaras are made out of make them do taht noise.. lol. yes. vitaras knock/slap. i have them in mine.and everyone who has every ran them has had them do that. its one of the downsides of vitaras. did u get your rods from FJ distributors? cuz if not. ur comp is not 8.5:1 search vitara startup. on youtube. and watch. based on clearances yours may be louder or quiter but in the general idea. they sound like diesels.

 

so clean. very impressive. nice job!!

 

An inspiring thread to me, as I'm pretty sure I'm going to need a new engine for my car and this will give me a reason to rebuild my Z6 from the ground up and boost! Nice work!

 

Oh dear... well i didnt just rebuild becasue of that.. the head was leaking also.
Well damn! i dont like that slapping sound!

 

****.. yeah i just checked youtube.. thats exactly the sound.. lol!

 

good luck on the build
setup looks nice man

 

ull get used to it tho lol.
and if u go terbowz u wont mind at all haha.

 

Would someone kindly offer to check my .bin basemap? Someone whos experienced with crome pro, if you pm me your email i will send you the basemap to check. It will be such a great help! Thanks

 

throw a y8 head on it. and secondly the all hondas need to be honned differently than other motors from what ive heard.

 

Thanks for the input but the heads fine.. and the bores are fine

 

first off i wouldnt run it hard on a basemap...i would get it tuned asap...

almost sounded like rod knock in the video.

did you meassure out the bearings? or did you just throw them in there>?

 

the y8 head flows better then the head your running and can hold 25 psi of boost stock. Should have went with je pistons and crower rods those pistons just sound like ***.

 

Very nice build... What kind of numbers ar you throwing down and how much quid did it take to get you there m8?

 

eh wtf? 25 psi stock?

his rods/pistons are fine. Those pistons have proven to handle over 400hp daily with no problems its a good budget set up. why would he want to spend more money on crower when eagles are just as good for his build.

 

WTF x2!
youll blow your engine if he is running 25psi stock!
its 10psi MAX on a stock engine which you can get about 225whp. anymore and stock rods will snap.

 

eh 10psi is all relative to the turbo you use.

a 14b he can run 15 psi and be fine. a sc61 at 10 psi will be cutting it super close.

stock block handles 225 hp max thats a fine line.

 

Well i'll update the figures when i get there.. im not upto that point yet. I would'nt like to add up what ive spent so far... scares me!

 

The video is with stock internals. I am getting it tuned, im tuning it at my university on an engine dyno, just need the basemap to get it started then i can work from there

 

cleaned up the head and sprayed with high temp paint... i chose the traditional red wrinkle paint for the valve cover