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Formerly weebeastie
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So I have no idea how I've missed this post, but first off, you won't regret going with the CSS process. I had it done to the DOHC ZC (built with GT28RS turbo) I run in my Wagovan. Such cheap insurance!

Second. Holy cow man, I'm from Burlington. Keyed in when you said TCS, and I'm familiar.

Perserverance is the key and it looks like you've got it. I've been down this road before. Especially tuning my own, and learning a few hard lessons with head gaskets, and a lost block. Keep at it. Mine had to sit for a year once because I didn't have funds to put it back together.
 

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93 Civic HB SI
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Discussion Starter #142
So I have no idea how I've missed this post, but first off, you won't regret going with the CSS process. I had it done to the DOHC ZC (built with GT28RS turbo) I run in my Wagovan. Such cheap insurance!

Second. Holy cow man, I'm from Burlington. Keyed in when you said TCS, and I'm familiar.

Perserverance is the key and it looks like you've got it. I've been down this road before. Especially tuning my own, and learning a few hard lessons with head gaskets, and a lost block. Keep at it. Mine had to sit for a year once because I didn't have funds to put it back together.
Thanks man! It's always great to meet another fellow NC Honda nut. I honestly can't believe I haven't seen your build up until this point as well, with as much reading as I've done over the last year haha. TCS really took care of me, great guys. Can't wait to bring the civic back after these changes. If you ever go by to see them, ask them about the crazy story of how they finally received their GTR!

I am looking forward to getting block back from CSS, hopefully it will help with some of the issues I've run into with head gaskets. I had my local machinist repair the pulled head stud threads in the block. He had to use some special inserts that were like helicoils on steroids, due to compatibility issues with ARP head studs. They are special order from some place in Europe, and hes one of the only machinists in the state who has the driver tooling to install them.

CSS is in process now, and then back to machine shop for boring out to larger pistons. The car should be ready by spring!
 

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Formerly weebeastie
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Fantastic! So they didn't use timeserts?

The CSS definitely helped mine. It still won't like any amount of detonation but instead of cracking a sleeve or blowing the rods out, it'll likely just blow the head gasket. Should help with lift as well, at least a bit because there is a greater mating surface area. Such cheap insurance, especially for a D series block. What are your goals once its back together? Just a street fighter or taking it to Piedmont/Rockingham, or want to take it around VIR?
 

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93 Civic HB SI
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Discussion Starter #144
The guy really seemed to know his stuff when it came to inserts and head studs, and said that I would get incorrect thread engagement with the ARPs, something to do with the super exact cut of the stud threads compared to inserts, and that these more expensive versions were a much better tolerance. When I say expensive, the timeserts are about $5ish a piece, where as these were about $11 a piece.

I will find out more details about the insert company and their products next time I get to the machine shop for boring and piston work, and share with everyone.
 

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93 Civic HB SI
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Discussion Starter #146
Who is JD? I assume its not someone at TCS? I'm always down for meeting others, especially tuners! What is his experience?

I really want mild power for track day type fun, exactly like you mentioned earlier for days at VIR. I want the engine built to sustain roughly 400WHP, but it will not be tuned to run more than 300-350WHP. Any more than that, basically spinning tires (the typical high powered Honda soundtrack BAAAA BAAAAA BAAA BAAAAA BAAAAAAAA BAAABAAAA). With as light as the car is (2100 lbs) it should have a comparable power to weight ratio against a bunch of other heavier common sports cars.

I have been a NASA and SCCA member for a while, but the only time I've ever brought my own car out to track is with SCCA down at Sebring in Florida with my 92 Prelude like 10 years ago haha. I've been to track with other friend's cars, driving to dial in brake bias and suspension settings during test and tune type weekends, but never actually pushing limits with my own creations. Street racing is not my scene, it's a terrible environment for pushing limits.

I can't wait for next spring/summer to get here! I have a busy but fun winter ahead of me getting this engine back together!
 

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Formerly weebeastie
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Joseph Davis = JD. Probably the best D series tuner on the East Coast. Sounds like a plan man. I'm planning to have mine ready to run some charity laps at VIR soon. What suspension did you go with?
 

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Formerly weebeastie
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Nope, I hit the whole thing and forgot I saw K-tuned coilovers. I read through it late last night, so I'm sure I got a little foggy through there. The dyno he uses is in Traveler's Rest, SC, but he might be willing to come here if he tuned both our cars lol. I have access to a dyno in Burlington. Maybe its something to look into. He prefers using ECTune, but I know he can use most any Honda tuning software. Told me he'd kick my tail if I asked him to tune it obd0 with Tuner Express lol.
 

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Formerly weebeastie
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Yes, but we have to pay to use it. I get a decent deal by the hour. And if anything explodes, we clean it up, and still have to pay for the time.
 

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93 Civic HB SI
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Discussion Starter #153
Thats badass man! What kind of rate do you get? I'd be down to do a couple pulls in the spring if possible just to dial in my current tune! You can PM if you don't want to make the rate public :) I'll bring the floor dry lol.
 

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93 Civic HB SI
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Discussion Starter #154
Some updates to the rebuild:

1. My local machinist finished adding the required inserts to the pulled head stud threads on my block.

2. While it is there, he is going to line bore the crankshaft main bores to straighten things up.

3. After he's done with that, I am sending the block to Jeff at CNCWerx to get CSS done. I'm crossing fingers hoping that this will provide more material for the head gasket to bond with, creating a better head gasket seal. We will see what happens on the current tune when I get it back together :)

4. Robgoof was the one who pointed out that my dilemma here could be remedied by using D17 pistons. That was freaking awesome and the following were ordered in the 75.5mm offering, will be here tomorrow:



5. All other engine gaskets have also been ordered, as well as one of those thermal intake gaskets as I noticed intake temps were really high over the summer. Will hopefully help a bit to lower heat transfer to the intake.

6. New ARP head studs and ACL race main and rod bearings have been reordered.

7. I also opted to purchase a lower timing belt cover, since I lost my homemade timing mark indicator. A timing cover wasn't that much.

8. Need to go out and drain the 93 octane from the civic tank so it doesn't go bad, and fill up my truck with it.

9. I bought new Rotella T6 5w-40 and a filter, 2 new quarts of Torco MTF from Synchrotech, and 2 gallons of 50/50 premix coolant

10. Pull my injectors off the manifold, and get them cleaned/flow tested again. Also need to buy a one-way check valve to go between my fuel pressure regulator and the manifold, so that boost pressure doesn't push down on the diaphragm.

11. A new Cometic head gasket. Thickness will be determined once I get the block back from CSS and have time to figure out the quench distance using clay.

12. Wish list - These things will happen once the car is actually up and running again:

a) New camshaft of some kind with new valve springs to accompany. Need to rid the overlap created by the stock VTEC profile to make more power. Any cam recommendations within the $250-350 range?

b) Larger saturated injectors - looking at FIC 1000cc's. Kinda pricy, does anyone have any recommendations regarding decent injectors at a better price than FIC?
 

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Sloppy Jalopy
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nice! :)
forged piston longrod build.

Been wanting to try a thermal spacer ,was thinking of it today actually ..whats with that?
 

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Formerly weebeastie
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I like #9

As for the camshaft, have you ever looked at Colt Cams? Specifically the TriFlow design? Worth giving a look at.
 

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93 Civic HB SI
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Discussion Starter #157
nice! :)
forged piston longrod build.

Been wanting to try a thermal spacer ,was thinking of it today actually ..whats with that?
Lol, great minds think alike? Nah... more like great minds eat alike haha. Mmmm, thermal spacer steaks....

I've never used one before either. Don't know what I was expecting, but it appears to be a really thick piece of Teflon cut into the shape of an intake manifold gasket. There might be some reuse-ability associated with it? But I'm sure it will seal well seeing that the whole thing is pipe thread tape lol. I'm curious to see what my IATs will look like in the summer.
 

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93 Civic HB SI
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Discussion Starter #158
I like #9

As for the camshaft, have you ever looked at Colt Cams? Specifically the TriFlow design? Worth giving a look at.
I have not looked at Colt Cams yet. Their website says they are closed for the holidays, but I will give them a shout in the new year. I'm curious what their prices might be like, it seems like they do a regrind on your provided camshaft? If their prices are competitive with off the shelf offerings, I might have them go ahead and do their magic.
 

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93 Civic HB SI
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Discussion Starter #159 (Edited)
So, new parts have trickled in over the last couple days:










I also went ahead and purchased a Brian Crower BC0070S valve spring and retainer kit. The retainers are steel, not Ti. This saved about $120 bucks off the cost of a spring/retainer kit. Don't really need Ti retainers, not planning on revving this engine past 7500 RPM so lightweight valvetrain components are not too much of a concern, and steel is more robust than Ti in the long run.

Will continue running the stock valves and keepers, since my machinist last time said the keepers still had good shoulders and valve stem keeper grooves were still in good shape.

Still up in the air on injectors and camshaft. I will call Colt Cams as suggested by Soul, and see what their offerings look like. I am leaning towards 1000cc injector offerings from FIC, because they are a solid brand and rep, and 1000cc will allow me to run E85 to my desired power level this time around.

This will actually be my first time doing any kind of personal 'street' tuning on E85. Moving from normal gasoline, does anyone have any rules of thumb they like to shoot for when tuning E85 AFRs under boost?
 

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93 Civic HB SI
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Discussion Starter #160
So, with the camshaft suggestion from Soul and doing my own research, I'm going to have Colt Cams in BC, Canada regrind my stock D16Y8 cam into his Tri-Flow version 2 design with profile features specific to a turbo setup.

I was initially leaning towards the Brian Crower stage 2 turbo cam since it was available 'off the shelf', but I learned that a bit of bottom end and spool time would be lost with that camshaft compared to the tri-flow regrind. The other thing is the steel quality of the cam. Even Geoff at Colt said he wasn't trying to knock anyone's cams by telling me this, but that it is very difficult to buy off the shelf cams from anyone that contain anywhere close to the quality steel that Honda used in their factory cams.

One of my concerns was 'wouldn't grinding material off the original cam make it weaker?' Geoff calmed my concerns stating that even after a regrind the lobe profile he cuts is ultimately 'friendlier' to the finger follower that rides on the cam. And due to the base circle getting smaller, you are not changing the leverage 'force' being applied to the lobe. It is the same forces acting on the lobe just like it was a new OEM version, while still working with OEM quality metal.

For this, his regrind service for the tri-flow v2 profile is $375 plus shipping. This is one thing I'm having to suck up and deal with, the shipping. It is going to cost roughly $100 to send and receive ship my cam there and back. I don't like the idea of paying more than 1/4 of the cost of the service just in shipping, but in this case Geoff REALLY knows what he's talking about. You can just tell which guys know their stuff and are willing to take the time out of their day to educate you about what is being offered. I got that feeling from the first 30 seconds of talking with him over the phone. I have no doubt it will be a good quality unit when he finishes, so I'm gonna suck it up and do it.

I look forward to using this cam, have heard really awesome things about it and seen some decent videos related to the tri-flow design.
 
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