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xylocramer's Boosted Sol Build

21681 Views 147 Replies 30 Participants Last post by  xylocramer
Hey everyone. One day a couple months ago I got it into my head that I wanted to turbo my Del sol. It's a red 1993 Del sol Si D16Z6 5-speed.

It's gone through a few ordeals in its time with me. I got it in the spring of '08. I knew nothing about Honda's other than they got good mileage and people liked to rice them out. Fortunately I managed to avoid ricing my car out.

I had been working on my 1983 El Camino since I was 13 and because of all it's modification I got about.... 12 MPG? It's a beast but that's neither here nor there.

I got the Del sol and drove it to college and used it for daily driving, errands, going to the GF's and whatever. In Feb 2010 The car was stolen off the street over night. The car was completely stock and was actually a little rough. The rear window doesn't work, all the shocks were blown, the hood's dented, the glove box was broken, the shifter knob was hacked off in a cheap attempt for a short shifter. So basically the previous owner abused the car.

Anyway, it was stolen in Feb, recovered in San Antonio in March 2010. The key cylinder and plastic column cover were broken and the car had a few hundred more miles on it, but other than that (and the radio being taken) it was exactly the same.

So we got it back to Austin, I was starting it with a screw driver which was kind of unnecessary, but I was doing it. I figured, who would want to steel a car with no radio that has obviously been stolen recently. WELL.... as it turns out, someone did. At this time I was no longer parking it on the street I came home one day (2 months to the day after the first theft) and it was gone from under my apartment.

Turns out someone tried to take it after I had gone to class in the morning. The broke a little 1/4 window to get in, and were somehow too stupid to start it...... (I was starting it with a screw driver) So they rolled it out into my parking lot and abandoned it. Someone called the cops and the cops took it and impounded it. The tow truck driver broke my rear taillight and dented the area around the licence plate. Of course they never fessed up to it so the trunk area is still dented but I have since replaced the taillight.


TL;DR
Bought car, got stolen twice, recovered twice, started modding it and then I found DSO and got serious.






Here's a pic of the engine basically as I found it. The only thing's I had done as of this picture are put a K&N stock replacement airfilter in, taken off the header, high temp painted and heat wrapped it.


Here's after I got it back the second time and started working on it.




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moar pix bump
looking good holmes
Little update before I go pass out.

1. Got turbo back together
2. Started taking apart car
3. took clutch off only to find that I'm missing a PP dowel and will need a new flywheel
4. Friend has a flywheel he's gonnas gives to mes
5. Tired
6. Got DSM 450cc injectors into rail and ported IM O-rings to fit them
7. Got resistor box wired in thanks to my electrically inclined friend
8. I'm dirty and tired
9. I love DSO
10. ZZZZZZzzzzzzzzzz........
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no sleep do work
So the whole of what I did today was get the clutch swapped and the tranny back on. Long day.

I had to go get the flywheel 30 miles away, then take it to a machine shop to get resurfaced because of light rust. Their flywheel machine was down today, so I went to the only other machine shop in town that's open on a Saturday and has a flywheel machine another 15 miles away. Got it resurfaced. Headed home.

Got the old flywheel off and dropped it on my finger :pinch: crushed it between flywheel and tranny on the ground after I pried it off the crank and it fell the wrong way.

Got the new flywheel on and the new clutch on but I didn't have an alignment tool so I fashioned one out of a 10mm deep socket and some paper towel.

I tried to stab the tranny but the clutch wasn't lined up quite right so I called a few friends and found one with an alignment tool. Got the tranny in.

Received a spare del sol gauge cluster that I'm gonna chop up and mount the RD-1 in :bigok:

Headed to home depot to get some supplies. I'm gonna fill my front torque mounts with polyurethane caulk from home depot. I also got some olds and ends nuts and bolts I needed for mounting things. And I picked up some sheet aluminum to make a heat shield for the Greddy exhaust manifold.

Another long tiring day but I feel like I got almost nothing accomplished today. Better luck tomorrow I guess.
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Quick question that I hadn't really thought about until yesterday.

My goal is ~180WHP. Is the head gonna lift? My guess is that I'll only need about 8psi to accomplish my goals, but do I need to acquire some ARP head studs before I head to the tuners?
get arps just for the insurance holmes
Only thing is, like most people, money's kinda tight.... Like really tight. Anyone got some for cheap?
true but i wouldnt reuse them already used head bolts.... and there is some on ebay for like 90ish bucks
So now I'm thinking about tuning this beast myself. Only thing is I feel like I need a basemap to go off of so that I dont kill the car instantly. Anyone have something that might fit the bill?

or maybe even just point me in a good direction on pgmfi
Ok guys. I've run into a little problem. I'm trying got get the oil feed line hooked up. I've got an Mfactory sandwich plate kit and the little fittings aren't screwing in all the way into the oil feed line. Has anyone had this problem? Please help. Solution?

The threads are clean as a whistle, just tight as hell.






In other news, I got the oil pan swapped out. Took forever to clean the new one because it was on an engine that spun a bearing. I engine degreasered it a couple times, scrubbed it w/ hand a few times with soap and water and then blew it out with compressed air and let air dry outside in the Texas heat.

Also got the poly filled torque mounts on...... turns out the insides weren't quite dry yet. When I bolted them to the frame a couple holes developed and they ooooozed a little bit. Well, just one. I didn't get the other one on cuz I wanted to let it dry some more. but even the way the one that oozed is, I think its pretty solid and when it does cure finally, it'll be really good. Or so I hope.

Gasket scraping sucks to begin with, and sucks even harder on the oil pan with it's raised little bumpy dealys.
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there are basemaps available here Xenocron PGMFI BIN Download Zone

and a few more floating around the web.

that mount should be fine, anything in them is better than stock!

hope you make it down this weekend!! picking up a beefy tripod tomorrow for my vid cam.
Ok guys. I've run into a little problem. I'm trying got get the oil feed line hooked up. I've got an Mfactory sandwich plate kit and the little fittings aren't screwing in all the way into the oil feed line. Has anyone had this problem? Please help. Solution?

The threads are clean as a whistle, just tight as hell.






In other news, I got the oil pan swapped out. Took forever to clean the new one because it was on an engine that spun a bearing. I engine degreasered it a couple times, scrubbed it w/ hand a few times with soap and water and then blew it out with compressed air and let air dry outside in the Texas heat.

Also got the poly filled torque mounts on...... turns out the insides weren't quite dry yet. When I bolted them to the frame a couple holes developed and they ooooozed a little bit. Well, just one. I didn't get the other one on cuz I wanted to let it dry some more. but even the way the one that oozed is, I think its pretty solid and when it does cure finally, it'll be really good. Or so I hope.

Gasket scraping sucks to begin with, and sucks even harder on the oil pan with it's raised little bumpy dealys.
why didn't you take the oil pan to a car wash? they have degreaser and hi pressure soap there etc
<--------- lazy. Closest self car wash is 15 minutes away and I didn't have any cash on me. :sweatdrop:

Still having problems with the sandwich plate to feed line fittings. Don't understand why they dont want to go together and I'm hella frustrated.
<--------- lazy. Closest self car wash is 15 minutes away and I didn't have any cash on me. :sweatdrop:

Still having problems with the sandwich plate to feed line fittings. Don't understand why they dont want to go together and I'm hella frustrated.

pic of how far its going in?
No pics :( I'm at work till 5. But it only goes in less than half a turn finger tight then I can take pliers and BFH it another turn and a half until I start getting really uncomfortable about maybe stripping threads. But I look in and the threads are fine, it's clean and WD-40'd, I've tried 4 different fittings that came with the mfactory plate and it's the same story with every one of them. It really needs to go in like 5x more than it is.
Great build man, I'll keep watching!
Thanks. I've been making a little progress every night for the past 4 nights. Hopefully a friend is gonna come over tonight to help speed up the process a little bit. Goal is boosted, running, and tuned by Saturday.
contact m-factory and find out whats going holmes
Think I might've figured it out. So..... the fittings might be flared. which would explain why they go in a little bit but not a lot. So I got a tap and die (probably spelled wrong) set and I'm gonna see if I can fix it that way.
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