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Thanks guys. Got another parcel of parts from Japan the other day. So a few more jobs to do on it like fit new rear abs sensor, fit an abs bulb in the dash as it has either failed or someone has removed it. then see if ive any faults with the system.



I think ive sorted the boot leaks out but im still getting a little in the front end so need another look at those. Still bits to do but ive used it for work this week and its been great. JAE was over 500 miles round trip so im confident it would go anywhere now.


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  • 6 months later...

Few overdue updates!

I got the Edelbrock stripped it had layers and layers of paint on it.

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and sprayed wrinkle black.

 

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I fitted this with the thermal inlet and throttle body gasket. I also changd all the seals and little filter in the injectors at the same time.

Battery tray cleaned up and sprayed champ white.

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Then time to kick the GT4 out the garage for a while to work on the dc2.

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Both rear toe adjusters were seized in bad. I couldnt get them out so i took the car to the garage down the road and they had the gas torch on it but nothing freeded them up they even snapped 2 snapon sockets trying!

I had already cleaned up the ends of the chassis legs and the boot floor but the rest of the rear end was ready for a good clean up and i knew it would need some welding.

First i had to get the toe arm off and try to get at this seized bolt/bush. In the end i had to cut through the bolt both sides of the bush then cut the toe arm in half and i managed to get it out.

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rear trailing arm removed

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After a bit of a wizz over with a wire wheel a few holes popped up.

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But i stil needed to remove the end of the seized bolt from the tow adjust slider so i removed it completely from the car by drilling out the spot welds. It got a bit beat up while i was trying to remove the seized arm and it was heavily pitted from rust. I put it in a bilt hamber rust eating solution so see how it would get on.

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Instantly it was fitting away.

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When it came out there was lots of pin holes in it so i didnt want to refit it to the car. I also thought it was looking like a bit much work for me to do on my back. So i rang a guy and he was going to come round for a look before taking it to his garage to weld up for me. Then a mate told me to steer clear of him so i thought it should just man up and keep going.

I needed to make sure i got this part remade exactly right as i didnt want it to affect the alignment of the car. So i thought i would cut a section out of the original a piece at a time and tack them in and see how i got on. It took alot of time but i neded up remaking almost all of it including the toe adjustment slider.

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another side tacked on

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here you can see the old toe adjust slider and the new one ive made ready to tack onto the back of the new piece i made.

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and almost finished. You can see the toe adjust slider part inside the part now.

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It was alot of work but ive offered it up to the car and it should fit good. Theres further cutting fabricating and welding to do first though. Then when this side is done ive the other side to tackle but i dont think that should take as much work... Hopefully.

 

 

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Yeah they love to rust mate.

Im just gunna keep bashing on with it. Its a bit of learning as i go with making the new pieces up. I just got an air saw the other day £20 off ebay and its great. no sparks flying everywhere like the grinder so that should help.

Ive got a bit more done. i had a small hole near where the rta bush bolts so i cut it out and welded a small piece in.

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I also cut a bit out which incorporated a brace point which i think is used on the production line during manufactuing. its a good solid point which is handy for jacking on. Ive got a plate welded in and ive got the brace part cleaned up and had it sitting in rust eating solution over night. So i can weld that back in and then put some new steel around it and get it nice and strong again.

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The part ive cut out to the right is inside the car.

Edited by Bean
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i got a bit more done last night.

More cutting to get back to good metal.

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new repair piece made up and welded in. this took me quite a while to make even though it might look quite simple.

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and from the back i also removed and cleaned up the end of the chassis leg and got some etch primer in there before i welded a piece on the piece back on. I had to cut a flap out to weld part of it from the inside to make sure it was right and then weld that up too.

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I will be cutting the end of the floorpan out and also the bit which goes down to it then its all new and solid. After taht i will probably cut out the whole end of the sill and remake that and weld it in. Then it should be getting a bit more solid by then.

Edited by Bean
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  • 2 months later...

Not done anything over the past few months as i found out my cat had cancer so i spent his last few weeks with him in the garden.

His name was Big Smokes.

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Really miss him every day.

I did pick up another integra the other week. It had been crashed an sat on a farm for a year. A year went by and the guy finally got back to me so i picked it up.Its got a rebuilt b18c6 in it with high comp skunk2 valves HC spoon head gasket, head skimmed and fully rebuilt new bearings ect.

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I will be using a few bits from it for mine then sell and scrap the rest.

I also picked up a precision intercooler and pipes from another Dc2

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  • 1 month later...

Thanks Jay, i only just spotted the post now. Ive not been working on the teg much other than finish welding that part of the floor up. I think its not a bad job.

Still miss the big cat not been the same without him.

few more pics

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Its all welded up up now but no more pics of it im afraid.

Looks like my mate is going to take on making new sills and rear arches for it so all the rust and filler will be cut out and new good metal going in. hopefully in a few weeks we will see some progress.

Edited by Bean
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21 hours ago, Calum122 said:

It's a shame to scrap a DC2, but I don't blame you. I bet that car is an absolute dog!

 

Sterlin work going on here. Keep it up!

Before it was crashed i bet it was a decent car as parts of the underneath are in better condition than mine even though its sat for over a year. I will likely use the petrol tank from it as thats in better condition and quite a few other bits especially the interior.

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Started making up the next repair piece. im going to make this in a couple of pieces to try and get the shape similar to factory, this is the part which has a strengthening piece inside which they use to move the cars on the production line so it needs to be nice and strong.

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  • 2 weeks later...

Been working on this quite a bit the past week or so after work.

i got this bit welded in, took a bit of making this trying to get it close to how they come from the factory.

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Then a bit of grinding, shaping and a bit more welding.

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Then i painted these with electrox

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This piece also has a reinforced piece inside in above the hole so this was welded in good and strong onto the new piece behind it, it was also welded onto the pieces around it.

 

Then i got the toe adjuster just tacked in place for now.

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Also got a delivery of these.

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With various offers on ebay and opie oils ive also ordered:
a walbro 255lph fuel pump
bosch ev14 550cc injectors
the adpater plate i need to fit the evo td05h 10.5 turbo
u pol gravitex white stone chip
white tiger seal for sealing any seams

So theres not many more bits i need to turbo the car, just the oil feed and return lines, t piece for the oil pressure switch, studs and nuts for the turbo manifold, and probably other odd little bits.

Ive started making new pieces for the sills but not got a pic yet. A mate dropped off his folder last night so that should help me.

Edited by Bean
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On 8/17/2018 at 9:52 PM, Calum122 said:

Again, this is mental work. So much love going into this build.

Cheers mate, just finding it hard to keep at it!

Heresthe folder my mate lent to me. it came in handy yesterday.
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this piece goes in the sill as a reinforcement piece.

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This is the piece i made with the folder.

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This is a piece which is sort of like the top inner of the sill, it ties into the sill edge.

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That was yesterdays work.

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My grinder died the other day, metabo one it was and a good one too wont be buying another one of those.
quick trip to screwfix and got this.

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Also ran out of gas so had to go swap the bottle for a full one.
had a delivery of u pol gravitex stone chip, and tiger seal

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 great stuff this used it on my gt4 rebuild and that came out great and still looks mint a few years later.


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Also got a new set of shafts, just incase.

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and a walbro 255lph pump

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Back to the garage now!

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Been smashing this in the garage all weekend and today, feel like crap but got to bash on!

I made a new jacking point
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Starting to tack the new sill in place
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Holes drilled ready for plug welding onto the top piece of the sill.
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Boom, all plug welded.
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Clamping the back of the sill in place, this is all pretty thick stuff as the jacking point ties into this piece.
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and welded in
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There was loads of welding in the sill pieces and the pieces which make them up. Some were welded from underneath, some inside the car and some both. the sill is mega strong now, more so than factory i bet!

The sill is almost finished now, i just need to measure and make two of the square holes for the clips which mount the side skirts. i did one last night and it lined up spot on so hopefully the other two will go well.

Also cut the rusty piece out of the wheel arch tub and welded this piece in then zinc primed everything.
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Came in now for a rest and some tea! might go back out and do some more depends how many pims i have!

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its beat me. went to fit the shocks with the eibachs on and the lower shock bolt is snapped in the arm i must have done it ages ago and forgot about it. had the tig welder on it glowing red and tred to get some grips on it then tried drilling it and a big drill bit snapped in it then i tried to knock the drill bit out with a snap on screw driver and that got stuck and is smashed now lol. tried to remove the arm and that bolts seized too. had enough of it now. Will be at JAE in my GT4 instead ffs.

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  • 4 months later...

Not touched this in ages. ive bought heaps of parts for it like new rear lower hard race oem style arms and hard race front upper arms, theres probably heaps more too.

A guy I know used to build rally cars at M-Sport, then he set up on his own, but hes always busy. I asked him if he would do the arches on the dc2 ages back but he was booked up for most of the year so I looked else where. I gave him a shout in October/ November last year and he said he could do it but it wouldn't be until Dec/Jan. Anyway its booked in for 26th Jan, got my mate with a recovery truck booked in to take it down. I'm just going to get him to finish all the fabrication work off and probably prime all the new metalwork to protect it then I will get someone else to spray it. I've a guy in mind locally who is an excellent painter and he did my GT4 but not sure he will take this on. If not there's a place over in the north east which I've seen do good work so they are an option. There's lots of bodyshops round where I live but most aren't up to much and for any good job they do there's a heap of rubbish ones they have turned out.

So im looking forward to it going then just returning with all the rust cut out, and fresh new steel replacing it. All the work I have been struggling with. I've learnt a good bit from the fabrication work I've done on it but at this rate im just not going to get the car finished and im not confident I could make the new arches up myself anyway, this guy has all the gear and even an English wheel now too so it wont be a problem for him.
Once its back I will get it off for paint then I can put it all back together using all the new parts I've got or picking the best parts from the two tegs. Then I will likely strip the other teg and sell what I don't need, likely keeping a stash of spares. I'm going to hire a carpet cleaner and give the carpet and the interior a good freshen up. Once its all back together I will likely fit the turbo parts.

 

Care package from H-Tune

 

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The old arm on the passenger side was a right ball bag and i had to cut the arm to get it off the car
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The other side all came off pretty easy

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I started knocking the RTA bushes out

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Then started stripping the rear suspension from the donor teg as this is in much better condition underneath

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I wanted to remove the discs but some of the screws were well in, all the others came out with an impact driver but this one wouldnt budge, so i got it nice and hot with the tig welder then built it up with filler wire.

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Then i got some grips on it and it started to come out nicely.

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and out.

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Ive also done a bit more cleaning up underneath the shell and the drivers side wheel arch, still lots to do though.

Edited by Bean
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