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Just waiting for my dinner to cook so i thought i would get on the computer for a bit.

New torch landed. Started to think ive spent a fair chunk of cash on tools and stuff recently  😦

49972986148_b82505b5eb_b.jpg2020-06-05_02-03-28 by Bean Beano, on Flickr

I got the new torch fitted, I had to swap a wiring connector over for the button on the torch as i dont have a foot pedal for my machine, then fit the quick connect connector for the gas then i was good to go.

So i got the screamer pipe welded up. I tack the pieces together in a few places around the pipe as if you just start welding one side it pulls away on the other side and you then end up with a big gap and its just hard work.

49973457026_d3dbe35261_b.jpg20200605_132607 by Bean Beano, on Flickr

I leave the wastegate on clamped up tight just to help with any warpage that might happen to the v band flange.

49972941313_65971f4927_b.jpg20200605_133304 by Bean Beano, on Flickr

Happy enough with the welding, while i was tacking it i went in the house for something so knocked my gas off then forgot to knock it back on when i started again (i often do this) so ended up with a bit of a mess from that.

Edited by Bean
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Tonight ive been working on mounting the intercooler.

I cut some pieces of aluminium rod which i will weld to the intercooler for the mounting points.

49975089542_65c669eab4_b.jpg20200605_180617 by Bean Beano, on Flickr

These were a bit of a challenge for me to weld on. i had never welding anything aluminium this big before and the intercooler just acts like a huge heat sink so i was welding this at 150 amps i didnt want to go any higher and risk damaging my new torch. Once a bit of heat built up in the core and i worked out a bit of technique it went a bit better.

49974827781_270d730601_b.jpg20200605_190740 by Bean Beano, on Flickr

i got them all welded on and centre punched.

49974306948_b815364667_b.jpg20200605_202210 by Bean Beano, on Flickr

Then drill a pilot hole and then a 5mm hole.

49975088957_cecb9bda18_b.jpg20200605_203009 by Bean Beano, on Flickr

Then tapped them to m6 x 1.0. i used two different taps one to start it off then another to get the threads right to then bottom. i wrapped a bit of tap around the drill bit to make sure i didnt go into the intercooler core.

49975088972_e4f04526cc_b.jpg20200605_203342 by Bean Beano, on Flickr

I then drilled the holes out on the mounting bar and got it mounted in place then tack welded it at each side.

49975088942_5df9337d9e_b.jpg20200605_211506 by Bean Beano, on Flickr

Pretty chuffed with that so far. Im going to take it all off tomorrow and get it fully welded and get some paint on the bare steel.

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I got the mounting bar fully welded and end mounting points cleaned up and primed. I cleaned up and sprayed the front end of the car about 3 years ago but in a  few small areas there was some rust staining like around the holes in the front panel and a few small bits on the mounting points. so they were all ground back and primed too.

49993010461_00f37aa96c_b.jpg20200606_150207 by Bean Beano, on Flickr

I went over the areas i cleaned and primedthem which left primer patches in random places so i just gave the lot a coat while i was at it.

49992494368_4b5c5d8a24_b.jpg20200606_150255 by Bean Beano, on Flickr

I found a nice place to mount the boost solenoid on its 3d printed mounting bracket (im impressed with this 3d printed mount its very well made and finished).

49992488833_8f5a56436c_b.jpg20200609_173306 by Bean Beano, on Flickr

I wanted to put the solenoid on a connector i just thought it was a better way of doing it. So i found out about deutch connectors and bought the crimpers and the parts to make up the connectors, im sure they will come in handy for something else in the future.

ignore the rusty ABS mounting bracket i will get to that eventually.
Connector made up and wires ran.

49992490658_14ce1982e3_b.jpg20200609_173356 by Bean Beano, on Flickr

Tonight i remade the cold side pipework from the intercooler on the drivers side. I wasnt happy with the first attempt and it was slightly smaller pipe so i ordered some 63mm ali instead and made a load of cuts and started moving them about until everything lined up nice. I also found out about this gold kapon tape which is good for mocking up as it leaves no residue on the pipework.

Its tight but i wont have to cut the arch liners or anything else.

49993264787_6656089266_b.jpg20200610_205138 by Bean Beano, on Flickr

I made a start tacking it togther but will carry on with it tomorrow.

I got distracted from the teg a bit and spent quite a bit of time putting my old honda scooter back together. Its not finished but it looks almost complete now. Ive had enough of that for a bit so plan to carry on with the dc2.

Also had some movement on the paypal claim for that snapped welding torch. Paypal said i can return it for a full refund if its in the condition i received it in. Not sure how that will work but im going to get it sent back tomorrow and upload the tracking details to paypal and hopefully i get my money back for it. Also the replacement band saw is out of stock until the end of July and they were going to collect this one yesterday but i said i needed to keep this one until the new one arrives so atleast ive still got a saw i can use until it goes back.

Hopefully more progress tomorrow.

Edited by Bean
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I got the intercooler pipes finished off i think. i still need to pressure test them for any leaks just incase.

I learnt alot from this job about aluminium and the settings i need to use on the welder and allowing for the part heat soaking so it was definetely worth the challenge. the welds arent pretty or anything but its all good practise.

49999276801_79a06471a6_b.jpg20200612_163255 by Bean Beano, on Flickr

49999527447_cbd4754e3d_b.jpg20200612_170707 by Bean Beano, on Flickr

49998755703_21fa4d3cf7_b.jpg20200612_170721 by Bean Beano, on Flickr

49999526967_f925ef4159_b.jpg20200612_170755 by Bean Beano, on Flickr

49998755213_8a5035b6ae_b.jpg20200612_170809 by Bean Beano, on Flickr

One thing which is a bit strange is the dump valve placement on the pipe that came with the intercooler. it sits underneath boost pipe so you cant see it. im not sure why it was done like this. I might change it in the future but it can stay for now.

49999526932_e4b7ac869b_b.jpg20200612_170835 by Bean Beano, on Flickr

Ive also finally managed to buy an evo 9 10.5 turbo after looking for a while for a sensibly priced one. It already has a pipe welded onto the compressor flange and it has been ported too, im not sure if this will make any difference or not. Once that arrives i will swap it over.

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Evo 9 turbo arrived yesterday. Seems like ive spent ages looking for one of these.

50012558148_34f457353e_b.jpg20200616_150412 by Bean Beano, on Flickr

50013348132_d0d63949db_b.jpg20200616_150423 by Bean Beano, on Flickr

Its been modified quite a bit with the compressor housing ground down so it doesnt need as much room to fit it, they have made a good job of it too.

Its had a 3" collar welded onto the into and smoothed inside. The exhaust side has been ported out and smoothed and a 2" collar welded onto the outlet side and slightly ported.

Edited by Bean
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New turbo vs the old one. Even thought its been modified quite a bit its quite a bit bigger than the old one. Maybe hard to tell in the pics.

50015966338_7e1968fd9d_b.jpg20200617_141522 by Bean Beano, on Flickr

Exhaust side.
50016124713_9240cccc0e_b.jpg20200617_141644 by Bean Beano, on Flickr

I welded the waste gate up on this one to make sure there was no little leaks. I used stainless filler wire for this as that works best when welding cast stuff like this.

50015965373_d9603b8cd2_b.jpg20200617_141624 by Bean Beano, on Flickr

Moved the fittings over for the water lines and oil feed, and the studs which seemed to take ages.

50016124543_5169f21b68_b.jpg20200617_145925 by Bean Beano, on Flickr

Fancy titanium bolts used for the turbo elbow.

50016656761_872861b71a_b.jpg20200617_155351 by Bean Beano, on Flickr

The compressor side is quite a bit bigger on this turbo and the oil line doesnt fit right so i will have to make a new longer piece and route it from the front of the car.

50016238248_0e34d0ac0b_b.jpg20200617_180625 by Bean Beano, on Flickr

Boost pipe needs extended a bit and slightly modified.

50016238198_7573b68f4d_b.jpg20200617_180638 by Bean Beano, on Flickr

All on and bolts tight. It feels like ive turboed this car about 8 times.

50016769086_2497717494_b.jpg20200617_183155 by Bean Beano, on Flickr

When ive sorted all the little bits i will decide what im doing for an air filter and if ive got anything in the garage i can use or maybe need to buy one. If i have to buy one i will probably get an ITG filter. My mate who maps cars always reconmends those ones.

 

Edited by Bean
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Yesterday i got the new longer oil feed made up. I actually ended up making two as the first one i made i must have marked the hose by accident with my pen when i was marking the length on it. So i cut it where the mark was, not realising the actual mark i made was a bit further down 

The hose and ends were for Torques and they arrived next day, great service.

50023614851_80e044e7cc_b.jpg20200619_131217 by Bean Beano, on Flickr

Fitted.
50023071388_8c8ed3e0bc_b.jpg20200619_141115 by Bean Beano, on Flickr

I then moved onto sorting out the radiator. I was about to remove the rad mounts when i thought there was maybe a chance the full length dc2 rad might fit as they are quite thin.

50023614676_85c898e0c2_b.jpg20200619_145628 by Bean Beano, on Flickr

I got it in
50023614676_85c898e0c2_b.jpg20200619_145628 by Bean Beano, on Flickr

50023071103_6f67789822_b.jpg20200619_145653 by Bean Beano, on Flickr

I even got the stock fan in.
50023873427_7bf5eff873_b.jpg20200619_150702 by Bean Beano, on Flickr

But it was just too tight up against the oil and water lines ( i could have re routed them) but it was very close to the edge of trhe turbo flange on the manifold and i thought with the engine movement it was jsut a bad idea plus it was a fight to get it in there and would just make things hard to work on down the line. I also would like to get some sort of AC in the car at some point even if i have to use some custom or modified lines and smaller ac rad. The full size rad just would not leave any room for any ac stuff.

50023873382_ba93ffc835_b.jpg20200619_150651 by Bean Beano, on Flickr

So i carried on with the original plan of removing the lower rad mounts.

50023873412_5d555bfba4_b.jpg20200619_171150 by Bean Beano, on Flickr

Behind them was a bit of rust as its an area you just cant get to so i gave them a quick clean up. Im going to do a bit more work on that lower panel before they go in just making sure its 100% rust free.

I then cleaned up the rad mounts and left them soaking in a boiling keg of deox C all day then warmed it up at about midnight so hopefully they should be pretty clean. Im sure ive got another set of these i cut off one of the aerodecks i stripped for parts but not sure where i put them.

I also got a few other little bits done like i lowered the throttle body bracket as the stock type r strut brace wouldnt fit. I think im going to fit a type r throttle body as i think they are a little bigger than the B18c4 unit, i will need to run a different throttle cable which i think an EK9 one would work. Im probably going to fit the type r water/ oil cooler / warmer unit from the back of the block as the B18c4 didnt come with that either.

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3 hours ago, Pikey009 said:

Great progress mate well done. Fuck AC though lol I think it’ll be more trouble than it’s worth, that’s what daily drivers are for. 

I love coldness mate, im always hot. i know we dont need it alot in the uk but when youve got it its soooo nice. im gutted the EP3 had great aircon after it got a new ac rad and regassed then when i dropped the subframe to do the clutch i left one of the pipes mounted to it by accident and it split the pipe 😂 gutted.

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It’s funny you should say that, I’m exactly the same but a toy for me will have no compromises ha ha I don’t even care if somethings got a radio. How’s the ep3 going? A lad at work just bought a rough one, was dirt cheap though 

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Its still going its got 160K miles on it now. The gear linkage bolts came loose the other day so she had no 1st 3rd or 5th gear 🤣

All fine now ive bolted it back down. Not sure how much longer it will last, arches are pretty rusty and a few areas underneath are too. Its recently had a new abs sensor and 2 new bottom arms as they were rotten through with holes in them full of rust. It still drives great though, shes had it 6 years now i think.

Ive been telling her for about 3 years to save up to buy something else. She used to have one of the 2.2 diesel civics i think it was a 2013 plate. I think that will be what she gets next, it was a great car but it was on a lease through work and it wasnt a very good deal. Really good family car though, not as much fun as the EP3 but it would be alot better on fuel.

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Just been donig some bits and bobs on the teg. The rad brackets are taking a few goes to get all the little speccs of rust out. Ive also put a few small brackets in from the engine bay de rusting too. Really i would like the stuff to replate them but i dont really think ive got the room for it currently.

brackets and mounts bubbling away.
50037406417_ed5e01ce80_b.jpg20200623_135041 by Bean Beano, on Flickr

This has always been a bit of an eye sore so im going to clean this up.

50037148506_65a9acf10f_b.jpg20200623_133149 by Bean Beano, on Flickr

New longer fuel line made up, fittings from Torques arrived next day again.

50036603393_3ff44548fb_b.jpg20200623_124545 by Bean Beano, on Flickr

and fitted. The stock one was in the way of the intercooler pipework and it was a bit tight. I thought about going for a new inline filter at the same time but i just wanted to keep the stock setup and use OEM type fuel filters. I used a teflon PTFE braided hose for the fuel line AN6.

50037406462_ce22520bf6_b.jpg20200623_125736 by Bean Beano, on Flickr

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On 6/21/2020 at 11:03 AM, Bean said:

Its still going its got 160K miles on it now. The gear linkage bolts came loose the other day so she had no 1st 3rd or 5th gear 🤣

All fine now ive bolted it back down. Not sure how much longer it will last, arches are pretty rusty and a few areas underneath are too. Its recently had a new abs sensor and 2 new bottom arms as they were rotten through with holes in them full of rust. It still drives great though, shes had it 6 years now i think.

Ive been telling her for about 3 years to save up to buy something else. She used to have one of the 2.2 diesel civics i think it was a 2013 plate. I think that will be what she gets next, it was a great car but it was on a lease through work and it wasnt a very good deal. Really good family car though, not as much fun as the EP3 but it would be alot better on fuel.

6 years already! I remember when you got that. His is solid, no body rust but the engine bay needs sorting as it’s crusty

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21 hours ago, Pikey009 said:

6 years already! I remember when you got that. His is solid, no body rust but the engine bay needs sorting as it’s crusty

Yeah 6 years and over 60k miles done in it. Its been a decent car. Who needs a family car when you can just use a EP3. A good rust free one will be worth keeping hold of they will start dissapearing in the next few years and a good one will be hard to find.

Ive just been popping in and out of the garage doing a few little bits.

Got these de rusted and epoxy primed.

50040001978_d100c5b65d_b.jpg20200624_121110 by Bean Beano, on Flickr

I did a little more work on the intercooler mount / brace, gave it a light sand with some 600 / 800 and ground a small bit of weld splatter off it and gave it some more primer in a few places where it got scratched from all the intercooler fitting. Im going to paint this with the front end of the car so i dont have to mix the paint twice

50040555931_0b610459b5_b.jpg20200624_121122 by Bean Beano, on Flickr

Not the best pic but I got these sprayed silver and clear coated. Its been a good day for painting stuff in the sun.

50040555981_7e3d3414bb_b.jpg20200624_151242 by Bean Beano, on Flickr

and the rad brackets in epoxy primer just to stop them rusting for now.

50040002268_314ec920ef_b.jpg20200624_151256 by Bean Beano, on Flickr

I've also been building up a substantial amayama order of honda and toyota parts, bits for the teg, bits for my scooter and bits for my Starlet Turbo. The starlet needs the front end resprayed i was gonig to take it down to a bodyshop down the road but ended up having  a few beers then realised i best not 🍻

Edited by Bean
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  • 2 weeks later...

No more real updates as i hurt my back so had to take it easy this week. Me and the  GF did get the air filter and pollen filters changed on on her EP3 today though, i got her to do most of it so shes trained up now. The pollen filters were mankey they have been in the car for 6 years and over 60k miles, next time i will change them more often haha. The air filter probably didnt need changed but it was only 9 quid for a blue print one.

The new rad arrived though.

50061804807_f61a64aaab_b.jpg20200630_131209 by Bean Beano, on Flickr

Im really impressed with it, the quality looks really good.

50061559886_145a1fdbe1_b.jpg20200630_131220 by Bean Beano, on Flickr

Also my new fuel filter finaly landed.

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