Introduction
For some time now I have read and marveled at some of the more in depth rebuild threads posted on this and other well know Honda Forums. I have decided to chronicle the reconstruction and modification of my 91 Civic DX Hatchback. My goal with this thread is purely motivational, as I have no friends in the area that are into modifying Honda’s to push me to stay on track and complete the build. I’m planning on updating this thread as much as I can but at a minimum once a month. My hope is that many of you will enjoy my journey and maybe decide to do a build of your own someday.

Project Goals
I have established a few overall goals for this project in an effort to measure its success. Project goals to be met are as follows:

Primary Goals
1. Completely chronicle my endeavors to reconstruct my 91 Civic Hatchback
2. Complete the Hatchback’s ground up reconstruction
a. CARB Legalize the car’s engine swap
b. Smog and register
3. Unveil the completed reconstruction at a major California import event.
a. Finished car must drive to the event from where it is garaged.

Secondary Goals
1. Build should meet SCCA SM Class requirements for the Solo Competition.
2. Successfully compete in a SCCA Autocross event

By completing the primary goals of the project, the project will be deemed a success. The time frame for meeting these goals will be to complete the build before the end of 2015. Sub goals will be established as I go with time frames for those items. My overall plan for the Hatch is to balance the car and build it to be competitive in autocross as well as useable regularly on the street. This will not be a trailer queen.
The only limits for this project are budget related but I plan to sell off a bunch of stuff I've collected over the years to fund the project.

Background
This Civic is my first Honda and was purchased in the spring of 1997 from Bell Acura in Arizona. It has survived many years of being on the back burner, a divorce, and several moves. It was taken off the road in 2000 and has either been in storage or my garage as I attempted to complete the build. It has had various b-series vtec swaps installed in it over the years with its first being a Gen 1 B16A1 installed in late 1998. Later a B18C1 with a B16A head would replace that engine in October of 1999. I raced it a bit before taking it off the road. Since its retirement from daily service I have been slowly buying parts and working on what I wanted to do for the final build. As for the rest of it I will decide as I go and keep everyone updated.




The Civic Hatch as it looked for the first few years of its life with me. (Photo 10 days +/- after purchase)


The Civic Hatch right before it was taken off the road. I miss that hood.

In early 2004 I began the teardown phase of the project. During this time I took everything out of the car and prepared it for paint. I removed all the interior, glass, wiring, suspension, motor, etc. and placed the car on a dolly so it could be painted. At the time I had a Wings West full body kit painted to match, I was planning to use it as part of the build but the front bumper was stolen during one of my moves.




EF hatchback body fresh from the paint shop.

I decided that I really wanted to do a complete color change to the car. My choice was USDM ITR Champ White mainly because I was on an ITR trip at the time and was planning to do a full ITR swap. At the time I had a JDM front end for the car hence the hood in the photo. Since then I have sold some of the JDM parts I was planning to use and changed directions on how I was going to finish the car.

For the past ten years I have been caught up in other projects and family stuff and nothing has really been completed on the car except all the glass has been re-installed in it.

The Plan
Now you have a bit of the background on the hatchback you may be wondering what my plan is for my hatchback build. The plan is simple make the hatch a California smog legal autocross warrior while maintaining its reliability. I plan to use Honda and Acura factory parts (new and used) where possible to accomplish this task. The power plant I will be using is a 1995 B16A3 I picked up a few years ago to rebuild. You may be asking yourself why is he using a B16, my answer to those of you asking that questions is it will be explained as the build gets further along. The transmission is a 1998 USDM ITR LSD Tranny, yep I’m going hydro. As far as suspension goes it will be a 5x114.3 setup with Skunk2, Tein, ASR, and ITR/CTR Components. The interior will be changed from 4 seats to 2 seats and will be partially stripped with Spoon, Sparco, and Bride component accents. The rest will be put together as the build progresses. The plan for the exterior is to maintain a stock look while incorporating some Autocross friendly components.

Task 1
Begin parts acquisition. I will post photos of parts as they show up.

Update 9/27/15: Engine build change on page 3 to B18C5.
Update 9/2/18: Engine build changes back to B16A3.

 

Sick dude! I also want to build my ef for autocross too. I've been slowly upgrading bits and pieces for it, since it's my daily. Can't wait to see the progress!

 

Well, let's hope your CARB referee doesn't look at your transmission.
Transmissions and transaxles can only be changed along with their matching engine.

 

Thanks for the input I will keep that in mind as I am prepping the car.

Here is my first project update and it has been a busy weekend.

As I began to look around at all the boxes I had in storage I began to realize what a monumental task I had embarked upon. I decided the best plan of attack would be to go box by box and sort things into one of three categories. The first category is the Keep pile, the second is the Maybe pile, and the third is the Sell pile. The one cool thing about all this is the fact that I am clearing out space and making my wife happy at the same time. Just kidding hun!

Below are some photos of what’s currently in the Keep pile. Some of the stuff may give you a sneak peek into what’s to come. For those of you that want to comment about the Spoon ECU and controller, I do realize I can’t use them for the BAR. They are for my autocross adventures and the other ECU is a USDM P30 out of a Del Sol.



The beginning of the Keep pile.

 

very interessting, is there a good kit for hydro-conversion or you will be customizing something ?

keep us updated !!!

 

Finally someone from my time era. I'll be tuning in for the progress.

 

My plan for converting the Civic to a Hydro Tranny is simple… a combination of stock Honda components and the HUSH Performance V2.9 conversion assembly for the EF.I picked one up a while back and decided after my post Saturday to prep the pedals and install the HUSH bracket. The main reason I decided to go with the HUSH setup is because I read a lot of threads about all of the conversion kits out there right now and HUSH’s setup had a lot of positive feedback. I also really like the way it is setup, don’t get me wrong I have Hasport mounts and some Innovative swap parts I just didn’t like the conversion options those two brands had to offer.

My initial imprecision of the HUSH bracket is its very simple, clean, the welds are nice, and the powder coat is clean and unmarred, for now. The bracket supports look like they can take some abuse but only time will tell.

As for the rest of my conversion I will be using a bunch of stock 94 Teg parts to complete my move to a hydro tranny. I have a donor Teg and I think it’s going to be the best $500 I ever spent. I will keep post more as I move forward.



My Hush hydro conversion installed on my pedal assembly (what a Saturday).

 

Saturday’s update, basically the day consisted of continuing to sort through parts and researching the brake setup I want to run on the hatch. I got to a point where I stopped going through parts and decided I would take apart my steering rack and install a quick ratio setup from Quaife. I also went to my local Honda dealer and ordered the replacement parts I need for the reassembly of the manual steering rack. Below is a photo that shows the difference between the two racks and pinions.


Comparison Photos of the Stock EF Manual Rack (Top) and the Quaife Rack (Bottom).

 

This is a nice change of pace. It's nice to see someone working on an 'old' project of theirs. Good luck.

 

Thanks guys for continuing to check in, I'm planning on disassembling the block today to get it ready for balancing and reassembly. I am contemplating waiting to take the block in this week and changing out the stock pistons for some JDM P30's but I am not sure how that will effect me during smog and the CARB legalizing process. Anyone have experience with this?

 

Suspension

Let’s talk EF suspension upgrades. The reason for the use of Tein, Skunk2, and the other components I have chosen to use is:
Although I only listed Tein and Skunk2, I’m also planning to use parts from Energy Suspension, Progress, Buddy Club, ASR, Spoon, and JDM Honda. The main reason I have chosen many of the suspension part brands is because of their experience and success in road racing, time attack, and endurance racing.

My Suspension Plan is:
So this is the plan but like anything plans change as the build gets closer to assembly. Most of the stuff I currently have, so there will be very little deviation from what I have listed.

 

Here is my mid week update. I began stripping down a 95 GSR main wiring harness (the harness that is mounted to the firewall inside the passenger compartment) removing the ABS wiring from it and re-configuring it to fit the civic's fire wall. Other than that its been a slow week.

I have also been updating some of the photos I originally posted with some higher quality ones. Enjoy!

 

I always thought the hatch would make a great auto cross platform. Looking forward to seeing progress.

 

subscribed

 

I have an OBD0 Spoon ECU/vtec controller that is just like yours that I am selling.

Not sure if this would help you out, but it would allow you to remain OBD0 instead of having to convert to OBD1.

Food for thought...

 

First off, I am very excited to see your progress. I am slowly restoring my 1991 Honda Civic Si with 380k miles. Daily driver that I autocross as well. Trying to keep it in the Street Touring Class though. I may bump up, seeing as the limited slip is very helpful in this style of racing. It's daily driver though so I am slowly building it as I go along.

My point in posting is this: I almost went Energy Suspension. I am not going to get into the debate about who is better, because everyone in here will say their own opinion with different reasons. I went HardRace after doing my research. Just ordered the kit a few days ago and it should be in by the end of the week. I'll let you know what I think once I have completed the bushing swap. It will be a while.

My rear trailing arm bushings are completely torn. I've heard that replacing them in itself will improve my Civic's handling greatly.

Looking forward to watching your baby grow.

 

Nice build up. I'll be following to see another fellow ef members build up for race. I myself have a ef sedan for road race. So it's neat to see the differences and what might be different from my build up

 

As a fellow 91 hatch owner and smf autoxer, I'm subscribing.

Just a quick suggestion:

I have the quaife quick ratio rack in my car, and with the 275 Hoosiers, it's a bear.
I deal with it, and love the ratio, but could be faster if I had power steering.

On my upgrade list is to install a ps rack and quickener - along with a ps rack compatible front subframe.

 

Thanks guys your comments are helping me keep on track.

Thanks for the offer but I already have one that I converted to OBD1 for my swap. I'll be posting photos of it and how I converted it to OBD1 shortly.

DEPintheCurve, its funny that you mention just deciding to go with the Hardrace bushings over energy suspension. Shortly after writing that post I decided to lose the energy suspension stuff and go with the Hardrace bushings instead. Back when I first started this project Hardrace was not on the market, I guess my project will benefit by waiting 10+ years to put everything together. Thanks for your thoughts about the bushings and everyone having an opinion. I agree 100%.

 

Hey man,

I was looking for a place that does not charge an arm and a leg for the bushing kit, and I found buyhardrace.com. I contacted them about a military discount and pro-rating me for the full kit minus the LCA bushings (I have them already). He was quick to communicate, friendly and worked with me, even when I had to wait a week to send payment. If you're interested here is the email you can contact him at.

sales@buyhardrace.com

He is also dohcgarage on eBay. The full kit is available for around $300 plus shipping on their website. The only seller on eBay wants like $380. I got the kit shipped minus the LCA bushings for around $270 - with a military discount. Hit them up, I'd buy from the again hands down!

That being said, I guess you probably read the same things I did about the energy suspension setup. I have heard so many different opinions, but in the end I decided because Honda put rubber in there I at least wanted some kind of rubber replacement.

 

Just a couple suggestions take them or leave them:

1. Don't go 5-lug, your limiting your race wheel options/sizes for autox
2. For SMF you want a B20. The b16's are really torqueless and you need decent low end torque at autox.

 

Disagree. The B16 has proven itself countless times as a great reliable autocross motor. I think there is more than just power ratings that define the motor.

Also, the B20 is a CRV motor which is a light truck. Hard to get those Smog legal (California?) in a car chassis. I guess this is more of a fact than an opinion (my first statement is an opinion).

I wanted to say something else! Haha, got distracted. Do you have any aero mods planned or just running it stock body? I've been looking at a lot of FWD time attack videos lately and a front splitter seems to be almost standard. I've seen some pretty neat DIY splitters, not sure what you have planned. I actually mean splitter, not canards. Are you staying with the factory wing or something slightly more aggressive?

I know you want this to be street legal (carb/smog/etc), but do you have any plans for the motor? I'd imagine a Toda rep header and a new exhaust (possibly a removable cat for the track?) would see some power gains over stock. Of course it would require you to get a tune on the secondary ECU.

The suspension set up looks solid and should treat you well in the long run. Bushings and such are a great idea to replace before you hit the track. What size rotor does the EF SiR knuckle use? I've heard that a smaller bar up front with a larger rear bar will help prevent under steer. Of course it's all preference and you won't know until it is on the track.

Regardless, keep it up. It's an interesting build. Much more technical than most that you see on here. It's a nice change of pace.

 

have to also disagree, last years national champ in smf was running a turbo d16.

 

Nice. Subscribed

 

Hey guys,
I feel I need to respond to those individuals that may have read my introduction for the thread and said “Why a B16?” and some that have posted comments about going with a larger displacement motor like a B20 (not to single anyone out).

I will begin my explanation with an apology to those that are easily offended and a simple philosophy I live by, “Balance is key to the success of any project”. I do not subscribe to the theory that bigger is always better. I mean no disrespect to anyone but I don’t expect the min-maxer’s reading this to understand how the smaller B16 can be a contender if a balance between application of power and distribution of weight can be found. Don’t get me wrong I want to compete and win but not at the cost of my reliability or driving enjoyment. I auto cross for enjoyment and the comradery I have found and if I win a few I say, “Sweet… bonus points”. I believe the builders at Spoon Sports have a similar philosophy when it comes to a vehicles balance and building some of the vehicular works of art that they have in the past and continue to build today.

One of the key points in this thread is the goal of passing a CARB review and receiving my CARB sticker. My OBD1 vtec engine options are limited B16A3, B18C1, or B17A. I have had a B18C1 in the car as well as a couple B16’s. I also had the opportunity to drive Katman’s Black sheep Civic with the B17A before it was stolen by some unscrupulous individuals. Very simply I enjoyed auto crossing the B16’s over the one eight’s and quite honestly my first swap was a B16 and you never forget your first.

All that being said I believe I can achieve a good balance with what I am planning to build; of course, only time will tell. And Freemananana, answers to all of your questions are coming and you won’t be disappointed everything you have asked about I have a plan for and some of it no one has ever done yet (at least not that I know of).

DEPintheCurve, thanks for the info on a Hardrace supplier but I had already ordered the bushings I needed earlier this week. They should be in early next week.

My thanks again goes out to everyone that has subscribed and continues to check in and share their thoughts.