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Chaife

Lil' Brother's 91 EX Sedan

my youngest brother is growin' up fast, I think I'll build him a car.
I'll be going through this entire car so I feel it deserves a thread of its own.
This car is a '91 Civic EX, completely virgin stock.
5 spd.
D16A6
Cruise Control
Power Mirrors
Power Windows
Power Steering
Power Sunroof (dealer installed I believe)
10" factory front brakes!!
I'm kind of jealous... This car is really nice and super virgin.


boxboy90

nice clean sedan!
89ef2

hot  a gem in itself
EF Sedan Enthusiast

Wow! There's a lot of potential there!
4dred6

EF Sedan Enthusiast wrote:
Wow! There's a lot of potential there!
9grand

Welcome man! Dope sedan! Looks exactly how i got my ex sedan minus the sunroof and ex hubcaps. That sunroof option is dope and it has a sunroof visor. Shocked Interior blue or gray?
Chaife

Thanks guys,   Blue baby!!
This car has actually been in my possession for a few months now.
Pardon me while I get you guys caught up.
Cleaned everything...


All 4 door handle suffered from this...   sticking up.


Broke her down..  So she could get some low and a lip
New Slotted Rotors
New Calipers (painted GOLD)
New R4S track spec pads (from EGR Performance Brakes)
New Stainless Steel braided and Teflon coated brake lines
New set of shocks, KYB Excels
New eBay adjustable springs
New axles
New Tie Rod ends
New Lower Ball joints






Before and after.   (still need to paint some things)





EF Sedan Enthusiast

Good stuff man.  Paint the trim pieces black and it'll look fresh!
89 LX SOHC ZC

Lookin good man.
boxboy90

looks great what are yal plans as far as wheels?
Chaife

We will definitely knock out the trim at a later date.  Gotta get the mechanics of the thing sorted first before I'm concerned with cosmetics on a 16 yr. old boy's car.   haha  

Plans for wheels;  some sort of vibrant but tastefully colored offset steelies.

Addressed the rear..
New Energy Suspension Bushings (all around)
New Drums
New Shoes
New Spring kit

The sunroof glass is broken, so I'm gunna try to source one of those soon.
Also still needs a hood,  and a carpet kit.
Motor smokes too,  so we're gunna throw some new rings in it or find a swap.  Stay tuned!!



Cool flu shot sticker we'll be leaving...
EF Sedan Enthusiast

Chaife wrote:
We will definitely knock out the trim at a later date.  Gotta get the mechanics of the thing sorted first before I'm concerned with cosmetics on a 16 yr. old boy's car.   haha  


Smart
jon_akers

Diggin the sedan, but we really need more info on that wagon in the background.
4dred6

jon_akers wrote:
but we really need more info on that wagon in the background.


that wagon looks so badass
Chaife

Here is a peek at the RTAWD Monster wagon/  Zombie Apocalypse wagon..  and some pictures over the course of the build.









EF Sedan Enthusiast

Holy hell that is one bad ass wago  Twisted Evil
89 LX SOHC ZC

Hell yeah that cool.
Chaife

Glad you guys like it.   Some quick specs. on the wagon.

Drivetrain: Stock
Factory RTAWD 6spd. Manual gearbox
(5spd + "Special Low")

Suspension:
4" lift achieved up front by;
Accord "Monroe" brand shocks
Accord spring
DA Fork
1" body lift
Skunk 2 Upper A arms

Rear received a 3" lift by;
DA Shocks
DA springs
Skunk 2 Camber arms
Skunk 2 toe links
BW Racing LCAs

Rollers:
15x8 Bassett Racing Wheels
4" Backspacing, or "zero offset"
Bead Lock D-holes
27" Super Swampers

Exterior:
Chopped/ Reworked Xterra Roofrack
Custom Roofbasket w/ Power Folding Light Bar
5th Wheel & Tire
Stinger/ Light Bar
Rear mounted/ rear facing light bar
ZG 240 Fender Flares

Random specs.:
Each Wheel & tire weighs in at 88lbs.
10.5" of ground clearance to oil pan
MattyJ

i would totally roll that wagon! glad that you gave some insight into how you got the light on the vehicle along with what wheel and tire set up!

MattyJ
~Sp33~

Rear sway bar delete?

It came with a sway bar?

Looks like a BEAST
Chaife

~Sp33~ wrote:
Rear sway bar delete?

It came with a sway bar?


It sure did,   RTAWD applications had rear sway bars.
4dred6

im in love with that wagon
89ef2

EF Sedan Enthusiast wrote:
Holy hell that is one bad ass wago  Twisted Evil

I would so rock that front grill guard on me sedan Very Happy
~Sp33~

Chaife wrote:
~Sp33~ wrote:
Rear sway bar delete?

It came with a sway bar?


It sure did,   RTAWD applications had rear sway bars.


They didn't, that's why i'm so interested! Is there a build thread for the car do you know?
Chaife

It seems you are correct my friend,   my apologies.
This car was equip with a DA rear bar when it arrived at my shop..
I should not have assumed it was factory.  Although it sure fit perfect..

It does have a thread.
Check out CivicWagon.com,   "Super Swampers on a Civic"
Chaife

My little brother's Birthday was a few weeks back..  
This is what we got poppin' for him for his birthday.
6" Kicker door speakers
6" Kicker deck speakers
10" lightning audio sub
Scosche Box
Scosche Head Unit w/ iPhone control app. crap thing..
400W Dual AMP
a wiring kit and a radio harness.

Maybe a set of tweeters in the near future



89 LX SOHC ZC

Nice.
4dred6

89 LX SOHC ZC wrote:
Nice.
~Sp33~

Chaife wrote:


It does have a thread.
Check out CivicWagon.com,   "Super Swampers on a Civic"


Neat, thanks!
Chaife

A little update,  gettin' this build movin' again.
Time for a rebuild and major engine bay freshening.
89 LX SOHC ZC

Sweet.
stormdrop

that wagon decimates all. this kid is going to have a sweet sedan.
Chaife

Thank you,  and yes he will..   I've have made it a point to ensure that each of my younger siblings have the sweetest Honda/ Acura's I can provide..  (all things considered) They are each proud of their cars and we sure have had a lot of fun building them. I wouldn't have it any other way. Makes being the family mechanic bearable...


Anyway!   more updates,   cleaned the engine bay for quite a while.
Looks better.



4dred6

what a difference   Smile
EF Sedan Enthusiast

4dred6 wrote:
what a difference   Smile
89 LX SOHC ZC

The bay came out nice.
Chaife

Thanks fellas,   I got busy tearing down the headliners, sunroof, and interior trim...   In order to address the shattered roof glass.
Turns out these were produced by a German company called Cars & Concepts back in the early 90's that were HONDA dealer installed..  
After spending a few hours on the phone over the course of 3 or so days,  I was able to track one down in Pennsylvania.   I must have  called 7 or 8 different places and spoke with 10 or so guys that were well versed in the sunroof world.  I even got a quote for $600! My search ended on the phone with the guy that I guess apparently  invented the T-top for the Corvette back in the 70's.  Small world....
He was a gold mine of knowledge,  and had a gold mine of glass roofs.   This is certainly the rarest "Honda" part I have ever purchased.

Popped the glass out




And the headliner..


Also removed the majority of the interior for a much needed cleaning.


And got busy blackin' out some trim as requested    Wink  HAHA

 
Before and after is Hard to see in the cell phone pictures
I'll stop being lazy soon and get the NIKON out maybe this weekend.
EF Sedan Enthusiast

Nice!
TheGreatBacon

Dope! Cant wait to see it in person.
4dred6

EF Sedan Enthusiast wrote:
Nice!
Chaife

Painted the front trim, grill, and lip



The new glass came in,   pretty excited about it.
DOT matrix,  with a beautiful "smoke/chrome" looking German tint from the 90's.

EF Sedan Enthusiast

Awesome!
4dred6

that front end is looking super fresh.
boosted ef2

Car looks good..All u need is sum nice wheels and its perfect
Choocko

Looking good. Im not a fan of the clear, i,like the amber setup, just my preferences.
89 LX SOHC ZC

Lookin good man.
90edbox

Man you have made a mojor difference for the appearence of that ex good woork sir I can't wait to see what's next  Very Happy
~Sp33~

Wow, loving this..
Chaife

Thanks boys,    Plans are to keep it simple and Factory USDM all round.

Been a little busy lately, but unfortunately not with this thing..  I did however, manage to get the roof glass in and sorted.
Wind deflector on and all. Also added some cheapo mirror visors.

4dred6

sweet
89 LX SOHC ZC

Nice. Smile
Chaife

Got started with that motor, Found 2 damaged valves after tear down.  
Time for some machine work and a rebuild. Everything else looked great.. Stay tuned.






The Trans also received a bath.
EF Sedan Enthusiast

Love the progress.  I need to tear down my motor too.
4dred6

EF Sedan Enthusiast wrote:
Love the progress.
TheGreatBacon

Lets see some updates fool! I know you have a stock pile of parts for this thing!
Chaife

lol yeah I've got some,   Cool   tearin' into the bottom end this weekend.
Headed to the machine shop on Monday.  Everything is here to complete a D16a6.  Including new exhaust valves. I'm getting excited.  Here's my parts pile.


Ignore the YCP's, they are for another build in the works.
4dred6

Nice
Chaife

Just got back from the machinist's.  I meant to get up there sooner,   but the snow made that a bit of a challenge since none of NC decided to salt their roads and the pickup truck is only 2WD.  Anyway,  took him the head so he could repair the valve seats and such. Brought him the block and cradle as well. For a deep cleaning.
The pistons that came out were beautiful.. This build isn't particularly performance oriented.. So we just wan't to get her back to tip-top shape with a little extra pep in her step.
I asked for a Port, 5-angle valve blend, hot tank, to have the guides checked, repair valve seats. I might polish the exhaust side and the crank when I get it back in week or 2.




Loaded up and ready to go, The piston set are for my CRX.
WTEF_1102

Dope thread
4dred6

Do work
EF Sedan Enthusiast

4dred6 wrote:
Do work
89 LX SOHC ZC

Nice.
Chaife

Wow,  each member's comment is like reading an open book... Confused     I know I personally always hated when forums had that "Character Minimum" applied to their comment boxes...   But now I see how or why that would be beneficial....   It forces the commenting member to contribute something halfway useful to the thread... Just saying..   This is one hell of a copy/ paste forum, that's a terrible habit to have...
At least that's how it appears on this build thread.

Shoutz outz to TheGreatBacon & EF Sedan Enthusiast for actually having questions and structured comments sometimes.
Chaife

Anyway,   enough giving a F**K...   Today another weather report come in calling for snow...  
I high-tailed it to my machine shop!   As I didn't wan't to get snowed in with no fun new toys to play with..  lol  Smile

He ended up using all 4 exhaust valves.
Shaved the head a bit  (just a light resurfacing)
5-angle valve blend
Reshaped all 16 valve seats
Valve guides checked
Set the valves in with retainers and locks to..
Vacuum check the seal of each valve
Head hot tanked
Block hot tanked
Hot tank cradle

Here she is!!!   ooo soo sexy..



I've got 2 phat piles of motor parts collected now....
One night this week I'll get stoopid with it and build me some motas!

EF Sedan Enthusiast

Twisted Evil
Chaife

I've been working on the block as of late. Slow, Baby steps.
Just waiting for my little brother to get some free time so he can come over and kind of learn what all is being done to his motor while we do final assembly.

mini update. Did a quick ball hone for a beautiful cross hatch wall texture on each cylinder. Rhythm is key here.
The rings should be very happy when they decide to seat.



Here is a picture of the hatch pattern with the oil still in place to accentuate the cross angle for the photo.


Finished product before jumping in the actual bath tub.


After that I washed the block in the tub nearly 20-25 times. Under the hottest water possible. Using a brand new white paper towel each time and wiping each of the cylinder walls to check for any remnants of solvent or hone oil at the end of each cycle. This really did take 25 or so hot washes. 3 or so hours of hand cleaning... It's gunna be prefect.
All debris MUST be removed before we install anything, or else we risk wiping out the brand new rings.


The block is now waiting patiently in a trash bag soaked in WD-40.
Chaife

I spent an hour or 2 hand polishing the journals on the crank (one for my other car too).  My machine shop hooked me up with a strip of crocus cloth that I put to good use.  Here is shot of my work space lol.



They turned out pretty good


Finished (the one laying down flat)


Cleaned it,  WD-40'd, and bagged it.
Chaife

It's time! I think/ hope that my little brother learned a lot.  He was actin' like a sponge..
We Spent last night with a plastigage,   and built us a short block.   I wish I took more pictures,  but your hands stay pretty well oil soaked during assembly.
Here is the crank ready to go on my clean work surface.  


Here is a picture of the gorgeous ACL race bearings


Printed a decent spec sheet.
Installed Crank with plastigage,  Break it down, measure.
Install Crank and pistons (no rings) with plastigage, Break it down, measure.

Was right on the threshold of being worn for ALL specs. Oh well...  Not turning back now. :rolleyes:
Proceeded to construct the bottom end..  Then check for crank end-play.   It's good!
Torque Cradle  
Set 5 rings for each piston with proper offset or stagger
Press pistons in
Torque Caps




Boy that escalated quickly....  


But we now have a complete short block.


Added all bottom end accessories.
I forgot to mention that I also polished the internals of the oil pump.  (the 2 gears.)
FlatTireRacer

Did you check the clearance of the gears to the body of the oil pump after you polished them? That is very critical to your oil pressure.
Chaife

FlatTireRacer wrote:
Did you check the clearance of the gears to the body of the oil pump after you polished them? That is very critical to your oil pressure.


It'll be fine.  It was more of a cleaning,  lightly with a polish wheel.
I have a few pumps if this one decides to fail.
Chaife

The motor is finished and in.  Lots accomplished with lots left to do.
New Clutch
New belts
New fuel filter
New PCV
New battery
New air filter
New dist. cap and rotor
New spark plug wires
New carpet kit is here
New shift linkage that I pieced together from shelf parts... (old one was rusted solid.)
Painted the cross members
Painted various suspension parts
Swapped the manifold and down-pipe for a factory cast CRX Si 4-2-1 for better response.

cleaning up parts during final assembly.


I donated this cover that has no corrosion.


Mounts and battery tray black'd out.


I ran her for about 30 minutes at all types of different RPM ranges to seat the rings.

Please ignore all the ugly stuff and loose ends.

Drained the tank of this shit first... New tank drain plug added. She had some residual after I filled her with fresh fuel.
Chaife

Double header updates!!
Polished the EX exhaust tips. Amazed at the difference. This exhaust sounds absolutely amazing. Very classy.


The remainder of the trim has been painted. Mud flaps also trim black'd. Did the white letters on the rears.
Sprayed some flat black inside the muffler tips to mask some rust.


Added this horn nut cover from a 3rd Gen. Civic Sedan. Power Steering boy! (whatcha know about that?!) HA

EF Sedan Enthusiast

That's awesome!
TheGreatBacon

Cool

Can't wait to make it out to the honda farm and see this thing in action!
spudwrench

Looking good your brother should be one happy camper when you get done with all this.

cant wait to see more
89ef2

 from a fellow ex owner.
Chaife

Spent the morning cutting and laying the carpet kit... Any of you who have done one of these likely feel my struggle. It's finished though, took my sweet time and got it in without making too many mistakes. Here are some shots of the new interior.  




EF Sedan Enthusiast

Those carpet kits are insanely tedious to put in.  Looks good though!
spudwrench

i want to order another carpet kit for mine where did you get yours from and how was the quality and price?
Chaife

Hell yeah they are...  Very time consuming.

Don't order the "ultra plush cut pile" (the more plush the material the thicker it is, the harder it is to work with.) Instead order the thinnest one, the regular 'plush cut pile'
Took me about..   4 or 5 hours.
Got this kit from StockInteriors.com,  Very nice quality,  everything lined right up,  the color is pretty dang close to the factory too,  makes an old car smell new again..
I did an EF hatch years back with ultra plush... I thought it would be nice.. but it sucks to install compared to the regular plush..
Be sure to lay it in the sun for a day or 2 prior to handling (this will make everything more pliable and work out the wrinkles without any effort)
Chaife

Here is how she is sittin' right now. Tinkering with electrical today.


New Hood is here.
EF Sedan Enthusiast

Interesting packing on the hood.
Chaife

EF Sedan Enthusiast wrote:
Interesting packing on the hood.


Yeah I thought the same actually. lol   Seems to have worked though.   I did however pick them up locally.   I'm sure if they were shipped they would look a bit different.  But who the hell can afford that!?  lol
TheGreatBacon

Twisted Evil
Chaife

Shoutz outz to TheGreatBacon for snagging a few sedan goodies from the yard for us.   Now we can try to get this hood on and squared up.  Can't wait.  Should be finished up tonight after work.
Chaife

Got a lot finished on the little white sedan. A few more tasks left at hand. Tag and Reg. next.
New distributor installed, New Hood and stuff too
Here is the new shape it is taking.

89ef2

What sunroof visor is that?
Chaife

89ef2 wrote:
What sunroof visor is that?


To be honest I am not sure. No markings. It's dealer installed from '91.
Whichever visor Cars & Concepts of Germany used in their kits back in the 80's-90's.   It's been very difficult to find information regarding this setup.
EF Sedan Enthusiast

It's coming together nice.
TheGreatBacon

It looks so good with the hub caps!
Chaife

Thanks guys!!  I too am diggin' the way it looks on this set of Acura hub caps.
89 LX SOHC ZC

She's shaping up nicely.
Chaife

Thanks!
Taillight harnesses replaced, All light bulbs replaced
New main relay
New battery
Glove box and other interior covers in place.
Interior is finished except for the headliner
Auto belts sorted and working.
Wrinkled the valve cover again.
EF Sedan Enthusiast

Nice!
Chaife

Thanks!!!!  
How about some pictures!!?   lol


EF Sedan Enthusiast

Looking good.
Chaife

New look for the engine compartment.

Glove box and other pieces in place.
EF Sedan Enthusiast

Very nice!
89 LX SOHC ZC

Awesome.
Chaife

Thanks boys!   Very Happy

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