[cavila06]

Hi D-series.org long time lurker, reader, and fan this is my first post and my first build thread ive been into hondas for three years now I have an ej8
which was my first car that I bought with my own money. Now I own an ej6 that I purchased as a shell to build from scratch. This thread will be for my hatchback
I bought the shell for $400 plus a thule roof rack. The back fees were $500 but I figured it was still worth it because its a clean title. I bought this a year ago
and worked on it during the summer on my days off. it is now my DD but ull see end results later. This will be a long thread of the whole process all at once
because instead of updating every three months I figured it be better to show u a years worth of work all at once. This car is far from done but plan to be near
finished within this year. so without boring u anymore ill post up the pics for ur viewing pleasure

Pick up day

damn missing the expensive window

yea cleaning this is gonna suck thank you half ass painter lol

 

[cavila06]

started the wire tuck right away

might as well do a brake and fuel line tuck

 

[cavila06]

little bit of cleaning

brake line fitting put in

learned how to double flare not so bad after 8 million trys lol

 

[cavila06]

attempt to bend the lines this came out like poop

more of the process..

Didnt take out the dash like a boss, hardest part of this tuck is routing everything to the Prop valve

 

[cavila06]

Enough of of that lets look at the heart that I built with you guys as resources (my first build ever, also first time taking a motor apart)
I bought a D16y8 motor that was an 2.5 hours away for $300 complete with tranny wire harness axels etc only thing was cylinder three had low compression piston rings were blown
so i decided it would make a nice vitara build. I went and picked it up in my coupe.... yup im an idiot stuffed it in the trunk and was near impossible to get it out after i got home
...never again hahah good story tho.

Dont recommend this at all but i didnt have an option..

getting it out of the car was insane since it setlled in on the 2 hour drive home

out and ready to dissasemble and put on stand

Tranny off (still good)

 

[cavila06]

taking out the flywheel with no one holding the motor on the floor = fail lol

damn teeth are sharp

Removing the head

 

[cavila06]

up it goes on to the stand

 

[cavila06]

block and head sent out to get machined decked honed bored over.05 etc pressure test on head new valve stems etc.
some pics after recieved.

ready for some paint

Marked cylinders to be notched for eagle h beam rods

 

[cavila06]

Plastiguage main rods

Sensitive content, not recommended for those under 18 Show Content

 

[cavila06]

Also had to notch girddle damn those rods were beefy

Head also back

 

[cavila06]

Bored of motor pics? ....yea me too lets go back to see the engine bay process.. ill come back to the rebuild

Cleaned up the bay some more and started the shaving process, welding, and lots and lots of grinding

 

[cavila06]

PS im no expert welder my friend let me borrow his mig welder and I just started welding as best i could.

 

[cavila06]

Starting the filling with body filler ohhh yeaa I love that smell

Shot a little primer to see how it was turning out
looked good too me but far from done

 

[robscrx]

good luck with your project

 

[cavila06]

Spot putty!!

 

[cavila06]

 

[cavila06]

if youve ever done body work you know the tidious process lol filler, prime, spot putty, prime, guide coat like 30 million times, prime, guid coat spot putty, prime, beer, beer and BEER

nope still not good..

 

[cavila06]

this was done three more times sanding, guide coating, priming, and repeating fun fun
then wet sand and prep for paint.. "its all in the prep" so took my sweet time

Battery bracket was made for my oddessy battery that was gonna go under the fender

tun tun tun





test panel




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Some suzuki color I really liked and I added Gold flake to the clear.. didnt like the look so just added the flake to the paint itself
looked way cleaner.

 

[cavila06]

then finally painted the bay

This was all painted outside wet the sand down first of course to settle the dust and enclosed the area with painters plastic

Cut the paint with 2000 grit then clear coat

 

[cavila06]

Result

subframe was all nasty so painted it as well

During all this the body work on the outside was also being worked on as well as the inside being stripped
im going to lay herculiner inside instead of carpet ohhhh yeaaaaa