I'm doing a full 2.0L GSR longblock rebuild, and possibly (hopefully?) a new turbo setup on my 99 SI.

Build Specs (as of now):

84mm GSR Block with Darton MID sleeves
89mm CRV Crank
Block machining done by Slowmotion's machine shop
9.7:1 CP pisons
Manley turbo tuff rods
Honda OEM bearings/water pump/oil pump/timing belt/gaskets/etc

B16A2 head
Skunk 2 Pro 1 Cams
Skunk 2 Pro Series Cam Gears
Supertech springs/Ti retainers
Hondata IM gasket
Hondata 4 bar map sensor ( as well as boost control components and solenoid)
Decking, new valve guides, new valve seals, etc
Possbly a Victor X Intake manifold and skunk 2 pro/black series 70mm TB

Summit ignition box (mallory hyfire 6 in a different enclosure)
MSD external coil distributor cap
Crane Cams PS92 Coil
Turbo-LS (honda-tech screen name) ignitor bypass module)
NGK 7mm spark plugs
NGK plugs (yet to be determined correct temp)


Other than that:
Hasport 70a Billet engine mounts
Competition clutch stage 5 sprung with "xtreme" pressure plate upgrade
AEM Digital UEGO wideband
AEM Analog Boost
Autometer gauge cluster mount
Upgrade from old s200b to s300v2 hondata

Current Turbo Setup:
60 trim .63ar garret turbo
erl cast manifold
custom ac&ps friendly down pipe
Garret bar/plate IC core with custom endtanks
Tial BOV and Wastegate


I decided to take on the remove and re-install, as well as the long block rebuild labor by myself (with some help from a friend and co-worker). I am really interested in doing the tune by myself as well, but that is still up for debate at this point. I hope this will save me enough money to afford an upgrade to either a gt35 or 6262 turbo with a topmount manifold and larger IC. We will see where the budget stands once this thing is running...

To tackle the longblock build I needed to beef up the tool arsenal, and parts have started rolling in.

Torque Wrenches:
I went with gearwrench because they are made in the USA, very affordable, and come with the calibration/verification in the box. got 1/4", 3/8" and 1/2"


Rod stretch gauge and dial bore gauge both from Jegs


El cheapo tap/die set, ring filer, and plastigauge kit. Again, from Jegs.


Ignition setup, and high performance bread machine, from Summit and Jegs.


Rediculously large bottle of Royal Purple assembly lube, from Summit.


Lastly, shout out to Summit for sending free swag with my purchase!


Any questions, feel free to ask! I'm sure I forgot something, but I'll keep this update as best I can. The motor will be pulled tomorrow, and once the block returns from the machine shop, the mayhem can continue. My order from Matco Tools will be in Thursday, as will my pistons, springs/retainers, and clutch... Here we go!

 

Looks good so far, though I'd pick the GT35 (and its variants) over the Precision. Seems pretty good so far..

 

Thanks! Always good to have the FI section Demi-god on your side

I'm kind of interested in the wolverine (per my earlier PM to you), but I don't really know much about it. I have been out of the turbo game for 5 years or so, and everything is newer and better, so I have to do a lot of research. I'd really like to break 500, and have some room to stretch the build's legs once I save up for a wide front/paint/wheels/tires. I know 500 is likely unreasonable for street duty, but I'm going to have to learn that the hard way haha.

 

none of your pictures work...

 

sounds like your computer is broken...

 

Ah, try it now, I reorganized my photobucket and I guess it killed the links.

 

uh no... it gave the typical picture is missing or moved thing.
read his last post... ***

 

So they work now?

 

yup, work just fine

 

worked for me, he pulled a ninja edit you came into the thread too soon and I came in too late... oh well carry on!

 

something like that I guess...
better question, who rearranges photobucket? lol

 

nice build. i have just about the same exact engine setup shy of the pro1 cams im using 01 itr's.

i very much like theshodan's advice about going with the gt35. to really get the most out of that setup you'd want a larger turbo and better exhaust manifold, but it seems like you are working toward that in the future.
you will very much like that comp stage 5 clutch, im still impressed with mine a year later.


what fuel are you planning on running?

 

I'm still up in the air about fuel. I'm leaning toward E85 at the moment, but if I decide against it I will go with a meth/water injection setup.

Small update: put in 7 hours working on removing the engine. All that should be left is the lower ball joints, driveshafts, and unbolting mounts. No pictures, but it was nothing exciting.

Also, more tools, and some parts came in today! That always makes the day better

Matco 0-4" micrometer set with calibration rods:


From Matco: Tiny 72 tooth, 3" long, 1/4" drive ratchet; 1/4 and 1/2 inch impact swivels, straight and bent feeler gauges


Matco 1/4" and 3/8" wobble extension sets:


Matco ring compressor set:


CP 9.7:1 84mm pistons, rings, pins, etc.


Competition Clutch stage 5 sprung with "xtreme" pressure plate upgrade:


First piece of old turbo setup to be cleaned and restored:

 

Any input on a fuel system for this build? Currently on a walbro 255 with precision 1000cc injectors. Looking to make 500whp or so. Can I get away with adding a bosch pump inline, with larger -an lines, new rail/fpr? Will the precisions work well with a higher base pressure? my understanding is that I will likely only make it to 400-450 on E85 with my current setup.

 

I'm using an aeromotive 340 in-tank with Injector Dynamics 1000cc injectors. For 450-500, I won't be upgrading my lines. Just the rail and fpr, which I'm told isn't necessary either. We'll see.

 

Sweet, this looks like a nice build, lots of proper tools. I hope you can remember to document it for us

Subscribed

 

Finally found your freaking build Kyle... You need more pics since you have done alot more stuff. But keep my messy garage out of the pics please. Thank you sir

 

I suggest a different camshaft approach...

Specially with that Turbo manifold.

 

Small-ish update:

A bunch of parts have been coming in, and a bunch of money has been going out. Got word that the block will be ready for pick up tomorrow, which is exciting. The head was disassembled and dropped off monday of this week, should be a 2 week (or so) turnaround on it.

The engine and transmission are out of the car, the transmission is awaiting a liberal cleaning before a gloss black facelift. The oldschool garrett core IC needs a lot of love, and there are some IC pipes to polish up as well.

I decided I'm going to try E85 on startup, and see how I like it. I'll be running a 300lph deatschwerks in tank, feeding an 044 bosch inline, using the stock feed/filter/return. Everything from filter to return will be -8. Golden eagle fuel rail and fuel lab regulator are awaiting delivery.

As far as the cams go, I was stuck between these and the GSC T1s, but I intend on going 62mm topmount/ramhorn in the not-so-distant future. I hate buying things twice, so at the possible short term loss of some HP, I'm going with the pro-1s. It doesn't hurt that I got a really good deal on them brand new (570 shipped).

Some more eye candy:

Gauge cluster bezel for my AEM wideband and AEM analog boost gauges (awaiting delivery), 044 install kit from B&R fittings (HIGHLY recommended), and freshly disassembled/cleaned Tial BOV:



Matco valve lash adjustment tool, Turbo-LS ignitor bypass module, Supertech springs/retainers:



Hasport 62a billet mounts:



Next is probably the part I am most happy about. This thing look incredible. Welds look almost robotic, the powdercoat is flawless, and I love the way the logo imbossed in the top. I am INCREDIBLY happy with the quality of this piece, and HIGHLY recommend Brian and B&R Fittings for anything. There was even a small shipping mix up, and Brian was quick to remedy the situation, no questions asked. Big thanks to him for excellent customer service and an INSANELY high quality product.



Close of up the logo, looks great in person.



New cams and Hondata IM gasket:



Used Skunk2 pro series crew checking in. Intake manifold, cam gears and 70mm TB:



Before and after IC Cold side resto:



Breather fittings/hose/block plug, fuel pump wiring kit, marshall Fuel Pressure gauge (which is made in china, despite saying Anaheim, CA on the face...BOO), mac boost solenoid and ECU components for s300, GE squirter block offs:

 

YOU... Are rich$$$$

Im currently building an ERL SLeeved 85mm GSR block w/b16 head. shooting for 500HP with a silver surfer. Good pics!

 

HAHA hardly. But I did stay in a Holiday Inn last night...

Edit: A lot of these parts became possible when I decided to take on all of the labor myself. I saved almost 3 grand of my budget just by doing that.

 

Jeeze Kyle. everytime I talk to you, more parts are coming in. Seriously man. Even when I built my ranger, I did not have this much stuff coming in at once. I am envious. I think this will walk on the ranger... Even though I swear it wont.

Cant wait to finally see all this stuff go into the car.

 

so would like to share some of those magical tools?

 

More goodies! Battery relocation kit, terminal block, moroso disconnect, dial indicator stand, degree wheel, and 25' of 8AWG for the alternator->battery line.

 

awesome build man!