White 1991 Sport Injected, Anti-Lock Brake, 4our Wheel Steering

[MustardCat]

Never made a build thread for my white 91 so I'm going to catch up with this post.

Ever since I did the H22 swap on my black 91 I had a B20a taking up space in my garage. I got out of the Army in June and started watching craigslist for a cheap 3rd gen with a blown engine.

Sure enough one popped up and I went to check it out. 91 ALB all white. It was a little dirty but no major damage or rust and I figured I could clean it up quite a bit. Bought it and brought it home. (Oh and it still had the clock cover! SCORE)

I pulled the blown B21a1. Turns out the kid I bought it from screwed up a timing belt job and destroyed the motor, his loss my gain I guess. That's where the pics begin, click on show spoiler to see the post:


2 JUL 14: B20a Swap

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Half cleaned bay:


B20a getting there:


Destroyed B21a1:

9 JUL 14: Door, more swap

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The hinges were shot so I swapped them out and re-aligned the door:


B20a done:



Ready to drop in:

10 JUL 14: B20a final, balljoints

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B20a swap 90% complete:


Done!:


Replaced some old balljoint boots with ones from a 4G Accord:



At this point I also cut the springs a bit to get rid of the lift kit look. 2.5 coils front and 1.75 coils rear. Handles awesome and rides like stock.

15 JUL 14: Cleaning!

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Time to eliminate 200k worth of dirt. I removed the seats and carpet then hit them with a pressure washer, some soap scrubbing, and finally a shopvac:



After I cleaned the interior I started on the outside. I claybared the whole car and got out my polisher, the paint came out really good. I also had the windows tinted to 20% at this point as well.

30 JUL 14: Mirrors

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Took a picture of my 3 ludes, the old primered 89 is about to get stripped and hauled off:


Fixed my shaky mirrors:

1 AUG 14: A.L.B. fix failure!

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I was attempting to fix my ALB system. I cleaned out the reservoir and tested the solenoids. Everything was good until I checked the pump motor, which was dead:







Motor removed:


I disassembled the motor and it was full of crap. I don't know much about electric motors but I could see that the brushes were completely worn out:



I took it all apart and cleaned everything. I managed to find some compatible brushes in a 2G lude wiper motor. I put it all back together, tested it, and it works! Or so I thought...








After reinstalling it in the car and filling the reservoir with fluid I activated the pump. It ran fine for 5 seconds then stopped, dead again. At this point I'm just going to try and find one that already works and use this old one for spares.

8 AUG 14: First aid kit, fire extinguisher

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I put together a first aid kit for each of my cars and my camping pack:



Mounted in the car with a fire extinguisher as well:

17 AUG 14: Alignment time

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Simulating driver weight:


Smart strings alignment system:



All done:

22-23 AUG 14: North West Prelude and Accord yearly meet

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Pics speak for themselves:

30 AUG 14: Fixing the A/C system

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I replaced the compressor and dryer, then resoldered the CCU:




Refilled the system with Enviro-safe coolant which 1funryd told me about, blows real cold:

13 SEP 14: One of the last good drives before the weather went to shit:

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5 NOV 14: Invasion of the mice!

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Son of a bitch, every winter, always:


I covered the pressure vent in the trunk and blower intake with screen to try and keep the mice out:

9 NOV 14: 4WS swap number 3

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I jacked the 4WS system off my black H22 lude and stuck it on this lude. When I had the rear rack out I noticed quite a bit of oxidation so I decided to paint it and the rear subframe:

30 NOV 14: Front lip, sway bar, bumper support

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Installed a 2g Integra front lip, it follows the bumper profile really good:



Started work on a lightweight bumper support, but I need to buy some more steel:



My rear sway bar is tacked together and I'm waiting on some rod ends to come in so I can complete the endlinks and do a test with suspension travel:

9 JAN 15: Sway bar 2

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I got my prototype 22mm swaybar completed today. Paint needs to dry overnight before I install it for testing.











I almost finished the lightweight bumper support but I thought up a better way to do it so I've cut it apart again to rework it.

10 JAN 15: Sway bar test, front lip 2

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Installed the bar and went on a 30 min drive. Seems to work good and nothing blew up. Cant do a proper test until the roads dry.

The endlinks make some noise at low speed but that's ok on this bar because it's intended to go on my H22 lude. I'll have to come up with a poly solution for the 19mm version I'm going to build to run permanently on this car.






Reinstalled the bumper and got some pics of the Integra lip installed:

4 APR 15: Bumper support finished

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I've been procrastinating but did actually manage to finish the bumper support:







The paint is drying right now. I've got to take some measurements off it tonight and will do the final install tomorrow.

I did weigh it vs. stock bumper setup and this one saves 22 lbs. If the rear ends up being similar that's about 40 lbs saved, which ain't bad.

10 APR 15: Meet

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Here's some new pics from the 4th when Ludcifer, 1Funryd and I had a little meet:

31 DEC 15: Making Front STB

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Started making a STB for this car:







The two point portion is done but its final form should be a 3 point triangle shape tied into the firewall.

1 JAN 16: Making Front STB Part 2

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Here is the firewall/cowl mount:


I forgot to take a picture of the reinforcement bracket that will go onto the back of the sheet metal here. Without it the 3rd point would be mostly for show as the metal here is very flexible.


Here is a rough idea of how it will look when done:

3 JAN 16: Making Front STB Part Final

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Thanks for the comments.

Here is the reinforcement bracket:





The 10mm bolt holds it permanently in place so I don't need to pop the cowl open when I want to remove the STB. The 2 vertical bolts allow me to put a slight pre tension on it.


Just before final welding:




Painted:



Installed:

23 JUN 16: Shocks and Bushings

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Waiting on parts for another project so I decided to move on with this car as I've been sitting on some parts for almost 6 months.

I installed some shocks:




I installed them without the dust covers to check how much travel they have before hitting the bump stops. That came out to be 0 in the front and very little in the rear.

I cut them some and I have a tiny bit of travel now but I'm going to need to make some raised top hats to get the travel I want. After that I'll be able to to start measuring for progressive bump stops. I want to keep the spring rate near stock for a OEM ride quality while cruising, then have it increase rapidly with a little compression.




This is what I'm doing tomorrow:

29 JUN 16: Polyurethane and Raised Top Hats Installed

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I actually finished the poly install Saturday but I got busy helping with 1FunRyd's H22 swap and forgot to post the pics:








Finished the raised top hats today:







I do need to pull the fronts again and stack a few washers under the lower bushing, because the rod sticks up too high right now and touches the hood.

Otherwise I have at least 2" of travel in the front and 3" in the rear now. (Before it was 1/4" front and 1" rear.)

28 JUL 16: Progressive Bump Stops

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Back under the knife:


Installed these progressive bump stops:



Actually, it would be more accurate to think of them as secondary springs. Here is the graph for these stops:



Still rides good. I just need to align it now and do a long test drive to really evaluate how all this work has affected the ride and handling.




Bonus spy shot of sway bars V2.0. They just came back from heat treatment and will go on once they are powder coated:

25 SEP 16: 22mm Sway Bar Installed

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Got the anti-roll bars power coated and installed. Here is the finished product:







Going with black for as many parts as I can to keep the stealth look.

I also replaced the brake master cylinder as it had given up last time I drove it.

17 APR 17 - 13 MAY 17: A/C Conversion

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Maybe I will actually get around to converting those belts sometime...


Anyways, my crappy Four Seasons rebuilt compressor died last year and I'm not keen on paying the huge premium for another (rebuilt) 3G lude compressor. (They are $308 on Rockauto.)


I'm going to try and fit the compressor from a 1G CR-V, which also came on some other Hondas so it is cheap and common (It is a Sanden TRS090 type). I bought a brand new Denso unit for only $210! Rockauto had other brands for only $140.

Anyways here are some pictures of step one, adapting the compressor to an 88-89 alternator/compressor bracket:






The Prelude bolts are too long so I still need to get some from a CR-V. Next step is the more annoying one as I will have to braze/adapt the ends from the CR-V compressor lines onto the Prelude lines. I will also (probably) need to do the wiring conversion to use a single wire compressor.





Some more info.

Line O.D. sizes:
CR-V: Suction 5/8" - Discharge 1/2"
Prelude: Suction 9/16" - Discharge 1/2"
Wall thickness ~1/16"

Here are the stock lines attached to the TR70:


Here are the stock lines on my CR-V attached to the TR090:



As you can see the CR-V lines exit the fittings in the wrong place. I got lucky because the other end of the CR-V discharge line (left) has the exact same fitting, only it exits on the opposite side, meaning it will line up real good with the Prelude line.



The CR-V suction fitting is what will take the most work. I cut it off flush with the top of the fitting then cut a 90 degree bend out of another portion of the suction line and here is where I'm at with that:


Connecting the Prelude discharge line to the CR-V discharge fitting will be easy because I can use a bit of the 5/8" suction line slipped over each end, kind of like this:



I practiced brazing lines together with some of the spare bits from the discharge and suction lines but each time the filler would crack down the middle as it cooled. So I think I'm just going to go with my original plan and TIG weld them. I did another test and it welds fine:





Here is a comparison of the 88-89 (right) and 90-91 (left) A/C brackets. You can see the 90-91 has the compressor mount surface raised/further from block so it would provide much less room to make an adapter. I'll be sticking with the 88-89 bracket for this conversion.



Also here are some pictures showing the TR70 and TR090 side by side:







I've been searching around and I believe our condensers have been discontinued on the aftermarket. Major outlets don't seem to have them and I just bought one on closeout off ebay (This project is starting to break the bank!). If you don't have a new one already you may want to snatch one up while you can.

I have flush and a flusher for all the other components coming. I'm going to tear the whole thing apart, flush all the lines, and replace all the O-rings. It's also getting a new dryer, expansion valve, and AC thermostat.

I also found a filter made just for the TR090 suction line. (The joys of having good support):


For the discharge side I found this universal inline filter:


I'll be installing that one before the condenser as it will hopefully keep debris out of it if I ever have another compressor failure.





After test fitting with the original adapter I felt the compressor was too low and far away from the block. I redesigned the bracket today and here is what the new one looks like:






Tomorrow I will make a heat shield for the compressor and get this adapter painted and installed on the car. After that I will start adapting the Prelude lines to fit it.




Got the compressor installed today:











I've finished adapting the Prelude lines to the TRS090:




I was wrong about the Prelude discharge line, it's not 1/2". It's actually 12mm which means the fittings on that universal filter wouldn't work. So I skipped them and welded the body right to the discharge line. It still unscrews in the middle so I can get to the filter screen.


Tomorrow is pulling every single component and flushing them.


I got this conversion finished yesterday and the A/C is working great!





Here are the tutorial videos showing how to do it:

Part 1: https://youtu.be/8YwUKV0IR9s
Part 2: https://youtu.be/MaHLhNM7KNw
Part 3: https://youtu.be/vHeX154tLd8

3 JUN 17: Bay cleaning and antenna delete

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Cleaned the bay and deleted the antenna:






For those who were wondering about HP loss with this A/C compressor engaged, I tested that today by turning it on during acceleration. I didn't really notice a difference TBH. I'm sure this compressor is more efficient but it could also be because I'm using Envirosafe (propane) refrigerant which runs with lower pressures than R12 or R134a, so maybe the compressor just isn't having to work very hard.

26 JUN 17: Belt conversion, sill install, and exhaust fix

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I did a thing!




Finally installed the Canadian belts. It was more work than I anticipated and involved some fabrication. (Might have involved a 1 3/4" hole saw as well, but you didn't hear that from me. It ALSO might have involved the discovery that Honda doesn't use metric threads for the retractor mount bolts... wtf Honda?)


However if you install the Canadian belts before removing the USDM belts you will find yourself in this hilarious situation:



After I got rid of the USDM sills I was able to install my JDM reproduction sills:





This last winter really killed my exhaust. Water pools in this one section and since I only drive the car occasionally it ate through it real quick:



I'm planning on doing a 2.5" stainless exhaust sometime in the future so I decided to do a dirty patch job for now:

6 AUG 17: Tires and header build

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Installed some new tires recently, sticky!



Also been putting this together bit by bit over the last few months:





Material is 304 stainless. It's going to have 1.63" primaries, 2" secondaries, a 2.5" collector, and v-bands up the wazoo. The design is a bit constricted because I'm fabricating it to fit under the stock heat shield, for stealth.

Still collecting parts for it and a 2.5" exhaust to match. I think I may have everything I need to finish sometime next month.

The current mod list is:
2g Integra front lip
20% Tint
JDM B20A
USDM to OtherDM front seat belt conversion
JDM replica door sills
12lbs Flywheel
AEM cam gears
MustardCat Short-Throw Shifter
Password:JDM shift boot
Skunk 2 shift knob
5th Gen floor mats
Custom front 3 point STB
Full polyurethane suspension
Cut springs: 2.25 coils front, 1.75 coils rear
Sachs dampers with Speedthane progressive bump stops
Raised top hats
Broken ALB
Techna-Fit braided stainless steel brake lines
Powerstop Z23 brake pads
Smoothed out caliper casting and painted black
Falken Azenis RT615+ tires, 195/60R14
22mm rear sway bar
Lightweight front bumper support
4WS swap

[MustardCat]

Since I'm going to be making all that mad power with the header I decided I should do a brake refresh:


Went with Powerstop Z23 pads because they are supposed to be low dusting. New blank rotors in the front, reusing the rear rotors. Brake lines are Techna-Fit braided stainless with a black covering to maintain that stealth look.

These Azenis are quite sticky as when I was following the pad bedding procedure I was doing 40mph-5mph stops at full pedal and was experiencing no lock up except for a slight chirp here and there.

Very happy with the stopping distance right now. Once I get ALB working again it will be even better.