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Creating a modified EF8 Glass Top In Japan.

9K views 34 replies 14 participants last post by  sloshed 
#1 ·
Greetings from Japan.

Where do I start... I'll try to keep this post short, but it's a long intro!

In 1999 I bought a Mugen tuned CR-X SiR a year after moving from the UK to Japan, which I used as a daily-driver in & around Tokyo. Have great memories of the quick progress that could be made with that car.... It was my first V-Tec, of several.

Its raucous nature and small proportions made an indelible impression on me, as well as other memories of a particularly quick EF8 with a B18C in it, that would lap Tsukuba in 1.02's.

It begun to meet the end of my tenure when one morning, whilst late to get to my work - pushing it hard on the motorway, the radiator's plastic top shattered / exploded. Being a hot summer's day I topped up the rad with drinking water I was carrying inside and very slowly made my way to a DIY centre, where I bought a fibreglass repair kit and patched it up enough to continue with my day.
3rd synchro was weak and one of the driveshafts had begun to get noisy.
Time to move on and so I did, to an RX-7 (which I still have to this day!) - the dark side.

But the CR-X had sown a V-Tec seed inside that I didn't know would keep growing. It's not always about maximum power, but the driving experience...
A few years on, I bought a mildly modified NSX. Looked great, sounded awesome with it's tubular artwork exhaust, but aside from attract attention, it didn't do anything better than the RX-7 and I knew it would cost a LOT to build the engine to a better spec. So I sold it.

I then had a 2003 S2000, as another daily which I really enjoyed... But I got a fiance and my border collie wasn't going to fit with her, so the S2K had to go.

A few friends & I got together, developed then endurance raced (Street legal class) a Prelude between 2009-2010. Handled not so well to begin with, but by the end of its development it became a quick car, able to give JIC's higher classed DC5 (non road legal) a run for it's money.
Had fun with that... still have it parked in a corner under several covers.
Can't sell it as it's just had too hard a life, but it's never missed a beat, except losing reverse on several boxes (from botched shifts of some of the lesser skilled drivers!).



A couple of years ago I bought a mint CR-X SiR Glass top. Very close to standard, zero rust, unmarked interior, etc. I knew it would rise in value but put it away & started collecting parts for it.... more on this later.

Last year an Italian customer friend sold his '99 DC2 back to me, as he'd had it 3 years and wanted to sell. I knew how good a car it was because I'd fitted all the parts to it, before it left Japan - so when he told me it was for sale, the deal was done...

It's currently in Portugal, stashed away with family there - so we can use it this summer. Rental cars suck.



I got a 2002 Insight 5 Speed Manual Coupe 6 months ago because I thought it might be fun to see how bad I could get the economy. Quite liked it. Would do a little over 100 mph and I could get 15km / L at worst.
Lent it to one of our staff for a week and he got 26...
Liked it so much, asked me if I'd sell it to him, which I did...

So now I was left with no daily driver... Then I remembered the CR-X and a smile spread across my face.
Finally I had the inspiration needed to make that hidden CR-X something a bit special - that would feed my need for an entertaining, but (slightly?) sensible car. :D
 
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#2 ·
So I pulled the covers off the CR-X and memories started flooding back.
A mint original example with nothing but a set of bloody ugly Mugen wheels! Finally I had a reason to fettle it and make a proper little fun daily driver.

But now this was going to be my car, I figured I'd do it as I want, from the beginning. A car that is comfortable, safe, fast & reliable for road use. It'll never go to a race track.

So this is the list of additional parts I've got / am awaiting for it so far:



N1 Race prepared EK4 engine with EK9 pistons, cams & other internals sensors, etc, complete with OBD2 loom with remapped (ROM Chip) ECU with 9,500 rev limit. Came out of a Civic that was lapping Fuji Circuit in 2.05 so it's a pretty decent engine. Only done 2,000 - 3,000km and in perfect running order. Essentially it's an N1 race legal EK9 engine.

DC2 Type R intake manifold.
Mugen 4-1 stainless exhaust manifold.
Stainless exhaust (Fujitsubo).
Apexi Power FC ECU & Commander & OBD0-OBD2 conversion harness.
OBD0-OBD2 distributor adaptor.
OBD2 injector connectors.
Tegiwa Imports aluminium EF8 radiator (standard fitment position).
Spal 10" puller fan.
Silicone hose set.
New set of fan belts.
Nology Plug cords (Used).
Mugen oil filler, radiator cap and socks.
42 Draft Designs billet oil catch tank with quick-drain kit.
Engine cover - refinished in Type R red crackle finish.
Tegiwa Kevlar coil pack cover.
Skunk 2 engine cover bolt & washer set.
Original engine mounts strenghtened with Silicone (Not sure yet I want to have poly engine mounts on a daily driven road car..)

"Route-6" (JDM brand) close ratio gearbox, with 10% higher ratio final drive & Cusco 1.5 way diff (built & never used by the previous owner).
Cusco Shift linkage bush set.
Honda MTF transmission fluid.

Ohlins C Ring shocks with H&R 35mm lowering springs.
Password JDM 3-point front strut brace.
ASR 24mm adjustable rear anti-roll bar & subframe brace kit.
Work Equipe 03 15" wheels with NS-2R tyres.

Project Mu brake lines.
Project Mu 7-sided wheel nut set.
NSX front calipers with 282mm discs & Civic Type R rear calipers with 260mm discs, plus EK9 1" brake master cylinder.
Ventilated 282mm 4-stud front discs of 25mm thickness.
262mm 4-stud rear discs.
Cusco brake cylinder stopper.
High temp Wedsports brake fluid.

S2000 UK Cluster with plugs included.
K-Tuned S2000 dash converter.
Red stitched leather shift & handbrake boots.
Red stitched (BMW M3) leather shift handle (to replace original plastic one).
EF8 specific seat rails & 2 x matching Recaro SR3 seats - to be retrimmed in black Alcantara & double red stitch by http://www.robson-leather.co.jp
Used door panels (so I don't damage the originals) to be re-trimmed with black alcantara and red stitch also.
Nardi Classic red-stitched 3 spoke wheel.
Mugen pedal cover set.
Type R original DC2 titanium shift knob (used).
Defi DIN Gauge (oil temp, oil pressure & water temp) - black face.
Parrot Asteroid Classic head unit with Bluetooth & hands-free phone + music selection (via iPhone).
Magnetic iPhone holder for navigation.
Cigar Socket mounted digital volt meter & interior temp display.
Tailored floor mats for EF8 with Mugen logos.
Various plastic trim parts, replacement decals & emblems (Honda OEM).
New bonnet catch mechanism, engine bay bolts, fasteners, clips, etc. (Honda OEM)

Orange U.S. side markers (Not sure if I'll fit these, or keep clear ones yet).
LED indicators (Not sure if I'll fit them, though!)
Replica V-Tec DOHC Programmed Fuel Injection - door decal set.
New front lip spoiler fastener set.

I'm sure I'll find other things to add as time goes on.
Tempted to buy a front traction bar kit , plus all new suspension parts, but for now there's plenty enough to find spare time to tinker on this & I've spent more than I had originally intended.

Hopefully finished enough to get it registered and in use around 1 month from now, before we stop work for our summer holiday. We'll see.

Any suggestions, I'd be interested to hear!
 
#3 ·
Part of the reason I want to build this CR-X is that I FINALLY have use our new workshop at home. My days of working on cars with jack stands and getting **** in my eyes are over I hope!
Took us 2 years to build, but it's finally in action. Much easier to tinker with cars like this. Thought I'd share in case it inspires others with similar ideas. House building is a bit like car building... lots of potential to tune things! :p

Workshop was made to be washable... so we can wash engines over the pit, them hose it down with (solar heated) hot water. Can also wash & polish cars, then hose the walls & floors down afterward, to clean it up nicely. Floor is domed for drainage too.



The pit has a lip around it's perimeter so water doesn't get in, but if it does there's a drain / soak pit built in.



We also put a used 3-phase compressor under the (very solid - formica surface) work bench - in an insulated box, vented outside the building, with auto recoil hose. Having 3-phase means I can get a Tig welder at some point. Would be cool to be able to weld aluminium! :)



Imported a pneumatic jack from the U.S. to use when needing to lift one end of a car off the ground, whilst over the pit. Works great.



Lots of magnetic holders & hooks on the walls for tools I use regularly and chests for less frequently used ones, strong shelving, storage boxes & trays, etc.







An old but still excellent Rayburn wood burning stove a friend imported from the UK but never used, was bought and fitted in a corner we built for it. Should keep me toasty warm in winter.

Good lighting, wall sockets everywhere and space for a coupe of bikes stored around the corner in a purpose made area under another raised building.

A 14 year old sound system is connected via Bluetooth. Not used to working with music, so I forget to use it most of the time.

Anyways... enough of the workshop. To get back on track I should post some pics of recent progress.
 
#4 ·
Glued the air conditioning panel with 3M Semi-rigid plastic repair.
Bearing in mind there were small pieces missing, the air conditioning panel came out OK in the end and it's now stronger than original. I'm be careful putting it back on (Previous owner tried to force it in!)



Cut off the original plastic handle off the e-brake and fitted a black leather one (from a BMW M3) with red stitch. This will go with the rest of the black fabric & red stitch I have planned for the Recaro seats, door panel inserts, gaiters, steering wheel, etc.



 
#5 ·
Spent some of the weekend removing the original B16A then cleaning & preparing the engine to go into the car and figuring out the best way forward.



It was fitted to an EK4 N1 Race car; which was subsequently removed and replaced with a B18C (& despite more torque, turned out to be no faster due to lower rev limit!)

Essentially it's an EK9's internals, in an B16A; I'd presume as they're not allowed to change the engine code for the race regulations, but can change internals, etc. It's ODB2, but comparing engine harnesses, the only significant changes I can find to run with the OBD0 harness, are the radiator fan switch (might just adapt the OBD1 type so I can run a lower temp sensor) and of course the injectors.
EK9 injectors are (according to some) slightly larger and apparently they run higher fuel pressure than the CRX too.
The EF8's injectors have white markings, these have yellow so I think they may be different. I'll use the injectors that came with the new engine, since it came with a chipped EK9 ECU, which is OBD2 and designed for use with high impedence injectors therefore, not the original low impedence ones. So the resistor box will be coming off soon as I have tested the engine with the OBD0 loom & original ECU, to make sure it's all alright before converting to OBD2. OBD0>OBD2 distributor conversion kit is on it's way...

I've also bought a used Apexi Power FC OBD2 ECU together with an OBD0 > OBD2 converter harness (previously fitted to an EG6). This way if there's a need for mapping at some stage, the option is there.



Engine bay cleaned and given a coating of light machine oil for protection.





Gearbox has a close ratio Route 6 gearset, with 1.5 way LSD & 10% higher ratio final drive. Should work well with the rev limit of 9,500 and make it possible to get into the V-Tec zone and continue to have it even if I don't change up quite at the redline.

Whilst awaiting the arrival of a Mugen 4-1 exhaust manifold, Tegiwa alloy radiator, EK9 master cylinder & brace, etc. I figured I may as well fill 3 of the engine mounts with silicone, let it dry well & see what the results are like. Unfortunately Mugen no longer manufacture or sell their mounting kits for EF8. If these modified originals turn out to still have too much flex, I may try Hasport mounts later on.



During evenings over the next few weeks I'd like to put the engine. It all depends on how long the manifold, EK9 booster, radiator, fan, etc. will take to arrive, I guess... best avoid un-necessary hassle.
Also got to fit the suspension, NSX calipers, etc. Just waiting on rear calipers & discs, the EK9 booster & Project Mu brake line set...

S2000 gauges are bought, but I want to change the mileage to zero (EEPROM programmer USB unit arrived from China this morning!). I'd rather than keeping the original gauges, since the car has a new lease of life now. Will shoot pics & have documents of mileage till now anyways. Defi gauges to go in, need to buy a new head unit, or perhaps I'll fit one that I'll be getting my hands on in a few weeks, that a friend has just taken out of a car for me.
A Parrot Asteroid Classic, which will give me hands free phone use with voice activated directory, as well voice activated music selection. I'll upgrade the speakers and maybe sound proof a little around where the speakers are mounted, but intend to keep to a basic installation. Decent sound systems are heavy and this isn't the car for such.

Cam cover is coming off the race engine and it'll have another freshly repainted red cover. Essentially it'll shortly have an EK9 engine under the hood, so may as well give some hints of the engine's heritage.
Got a few "Type R" original blank keys ordered, so I can cut spares too.

Always waiting on something, with these things, so I'll take my time and make sure everything is done to the last detail. If it takes me 4 hours to make the loom look & fit like a new OEM one, so be it.

In the end when this CRX project is finished, I'll have: Original B16 Engine & LSD transmission, Original Brake Booster, master, discs & calipers, Original struts, perfect condition original SiR seats, instruments and door panels,(I bought a spare pair of door panels to modify). I'll be looking out for an EF6 (1.5 X) tin top, to convert to SiR spec. at some point, together with the few parts needed to complete such a project. Would seem a shame to waste these parts, or sell them piecemeal, when it would be possible to make another perfectly good original spec. CR-X SiR of sorts instead.
 
#7 ·


New 187 bhp (dyno'd / 9,500 rpm rev limit) engine and Route 6 close ratio box with 1.5 LSD and 10% higher final drive is now installed with a few upgrades bolted on.
Just need to finish a few bits (4 wire O2 sensor, EK9 type R ROM chipped ECU & Fujitsubo exhaust) to get it running. Will fit a newly repainted cover later, this one will do for now.

Planning to fit Ohlins shocks, H&R springs, a mix of NSX & Civic Type R rear calipers with large discs and braided hoses over the next 2 evenings...
Large CTR booster and master cylinder was fitted before the engine went in. Work Equipe 03 wheels are also sitting there looking pretty, waiting to be bolted on once the brakes & suspension are all done.
Had all the pin dents removed earlier today. It's taking shape albeit slowly.

Off on holiday Thursday morning, so the CRX will be left alone for 10 day or so. Looking forward to getting more work completed, but no rush.
 
#9 ·
@JMZ401 - By "Tin Top" I mean an EF6, or a 1.5X, since they're usually examples with no sunroof or glass top in Japan, I think... Need to find a good clean one first though. Might take some time.

Went into the workshop & did a bit more this evening after dinner...

Wanted to avoid coilovers since this will be a daily driver, not a track car, so I fiitted H&R (30mm lower than standard) Springs to Ohlins adjustable C-ring shocks using original rubber top mounts.



Out with the old and in with the new. Rover 282mm discs, NSX front calipers and Project Mu hoses.



I love the attention to detail & quality of these Project Mu hoses. As they're a JDM performance brake parts specialist, these are the best I know of. Will be using Wedsport fluid, which has a boiling point of over 230 Deg C.
Brake booster & master cylinder are from an EK9 Civic Type R. These were fitted whilst the engine was out.



Aside from a little bit of trimming of the dust shield where the caliper brackets bolt on, it all went on easily enough.



I then test fitted the 15" Work Equipe Wheels. Inner diameter clears the calipers fine, but being 2-piece wheels the bolt ends just touch the caliper. I'll either have to trim off the ends of the bolts, or fit a 3mm or 5mm slip on spacer. Will probably do the later. Easier and reversible. Not sure these are the wheels that'll stay on the car yet, will decide when it's ready to use.
I have others in mind, but they'll do for now... It'll have Poject Mu 7-sided anodised steel security nuts.



I don't much like the US spec. orange markers after all. Too much orange, so I'll be refitting the original clear JDM ones, I think.



Will try to fit the front right side driveshaft, suspension & brakes tomorrow if I get a chance. Leaving for Europe the next morning, so I might not find the time. Will continue after I get back. No rush.... still much to do.
 
#11 ·
signalpuke said:
Excellent build!

I'll take the orange markers if you are willing to ship. My EF8 needs new markers.

Are the seat rails aftermarket of custom? I've been looking for some, but I have not been able to find any for the SR7 Recaro.

Workshop looks great too! Loving this build log.
Seat Rails are made specifically to fit Recaro to EF6/7/8. I won't need mine for a while as I have still to find one more used SR3 seat, then have them retrimmed over the summer, together with door cards. Can sell you my (still unopened & boxed) pair and order another set of you're stuck. I can sell the new orange markers too. PM me if you really want them and we can go from there.
 
#12 ·
Having come back from a short holiday on Tuesday of last week once I got settled back in, I finished a bit more work when I had some spare time this weekend.



It's now on it's new brakes (front only for now, EP3 calipers on their way as I think the now spare NSX rear calipers would be overkill and besides, they'd lead to a softer than desirable pedal, which I wanted to avoid, hence the 1 inch master cylinder now on the car.



Unfortunately I got sent the wrong 260mm discs for the rear, but that means no more than a little delay - no rush.

Still much to do, but it's taking shape. Ohlins shocks with H&R springs all on & it sits well - not too low.



The Intake combined with Fujitsubo exhaust sounds good.



It started first time once I connected up the ROM chipped EK9 ECU. Also tried the spare Power FC and that worked fine, so I disconnected it and put it away for now.



A few more wires to attach to complete the OBD2 conversion; Maz at Hond-R suggested I call him when fitting their OBD0- to OBD2 harness. It's pretty simple so far. The 4 wire )2 sensor connections were easy enough to figure out. I just need to ask him how best to attach 4 wires to the engine harness. Will call him shortly and pick his brains if he's not busy - super helpful guy (http://hondaperformanceparts.co.uk)!

Still to fit a slimline fan for the aircon (As the original would foul the Mugen manifold, then and all the engine bay's work will be done for now...



I felt like a kid in a sweet shop after hearing it run for the first time yesterday and have moved it about a new times since, albeit momentarily as I still haven't plumbed in the radiator, whilst awaiting just 4 fan mounting cables to arrive from HK.
Also ordered a 2 1/4 adjustable decat, to use once the car's passed inspection here in Japan.

Interior is the next to be perfected. Lots to do there, to make it more comfortable and presentable. Also some work to do on the exterior, just decals and changing some of the trim for new. Not 100% sure on the design of these wheels yet. Might change to something else...

 
#13 ·
Short video of the first attempt starting it, yesterday evening. Spoke to Maz at www.hond-r.com a couple of hours ago and found out I only have to attach 2 more wires to complete the OBD0 to OBD2 harness & ECU swap.
One to the knock sensor and one to the V-Tec, which is done inside the car on the original loom.

Nice & easy. Thanks Maz!! :D

 
#14 ·


Some wheels I really wanted have been found & bought today.
Mugen (forged alloy) MF8 wheels, 16 x 7J + 52 size in perfect condition.
They'll fit nicely within the arches, without need for rolling, or anything like that.

The work Equipe 03 wheels (15 x 7.0 + 38 size) that are on the car with NS-2R tyres that are nearly new will be up for sale once I get some new tyres fitted to these Mugen rims.

Rims are like new with no corrosion, etc. If anybody has serious interest I'll let them go for what they cost me (which would be only £950 GBP + shipping).

I can arrange cheap shared container freight to UK, but can also arrange inexpensive shipping worldwide.
 
#16 ·
Thanks Geoff. The workshop was something I dreamt of having at home for adecades and took 6 years of home ownership before we built it, so now it's finally come to fruition, I intend to keep it well.

It was designed so it would be easy to keep clean. Floor is domed and has a lot of drainage grates, so I can jet wash the floor, pit and walls down with very hot (solar heated & therefore free) water. There's also an outdoor shower & bathroom around the corner with a fridge...

I actually find myself grinning sometimes at how much easier it is to work on a project now... Like using a pneumatic gun to remove bolts, or change suspension springs and not having to wear a head torch any more, at night. :mrgreen:

Being 50 next year, I don't want to keep getting under jack stands any more. Had more than enough of that...

Every car enthusiast's garage at home should be built with a solid counter top, great lighting, a pit and a good stove for cold winters at the very least.
 
#18 ·
Finally found a quiet evening yesterday & now I'm finally done with the work under the bonnet....



Engine is all running perfectly now. No leaks, Check Engine Light has no fault codes, TPS reset & timing checked, OBD2 EK9 ECU tidied away and once I've bled the brakes, there's nothing more to do in there but refit the bonnet & connect up the washer jets.



Also fitted a Designs 42 (http://www.42draftdesigns.com/) oil catch can yesterday evening - It fitted perfectly by the left turret.





Noticed as I was finishing that the alternator's not charging; some bearing noise from it - could have failed, I guess. Checked it and it's duff. Ordered another. Better it fails now than on the road somewhere...

Defi gauges are in and working perfectly along with the heater, a/c needs recharging, but should work fine - incl. a smaller puller fan, which clears the Mugen headers without a problem. Tested it & it worked as planned.



Mugen MF 8 wheels and new tyres arrived. Now I know they're all good - I'lll need to get some PCD adaptors, as I don't want to mess about trying to find & fit 114.3 hubs, then source the right brake discs, etc. all over again.





These Mugen MF8 rims are slightly too inset at 16 x 7J + 52, so some good quality 10mm steel (plated) Hub PCD adaptors / changers (4H100 to 4H 114.3) will make the new wheels sit just right, I think...
Lots of Civics seem to run 16 x 7J + 42... Maybe the tyres will turn out to be too wide, but I can use them on something else I have in mind, if so..



Have now bought a pair of SR3 seats. One - a Le Mans edition, the other a red one out of an EK9. Will send both + spare set of door cards, gaiters for retrimming with black Alcantara and double red stitch by Robson Leather over the next month or so. Hoping that EK9 seat belt clips will work in place of the badly faded CR-X originals. Will know for sure when it arrives in the nexf few days...

Not sure yet if I'll get the existing Nardi wheel also retrimmed, or change for a brand new red stitched Momo Tuner wheel... One in the post to arrive tomorrow for someone else's car - maybe it'll be nice. I'll see when it turns up.

Stopping progress on this project for the summer - from the end of this week and will resume in September sometime. I'll be day dreaming about finishing it till I return to this project from mid Sept...

 
#26 ·
For some reason, my account here was locked for a few months with no explanation given at all, even after sending e-mails... So I set up another, but never used it... (Was kinda repulsed by being banned for no apparent reason... :closed: ).

But as @Sloshed mentioned in an e-mail that he was following this thread (Thanks again for the replica visors! 8) ) So here I am again...

The car's nearly finished now, but I'll post some pics here for those who may not have seen them elsewhere.

Taking the car to Tokyo tonight, for it's first proper run.

Suspension work all done (Actually has Mugen springs now, instead of those H&R ones):

IMG_0540 by Miguel Varella-Cid, on Flickr

Fitted front:

IMG_0559 by Miguel Varella-Cid, on Flickr

IMG_0561 by Miguel Varella-Cid, on Flickr

Rear:

IMG_0786 by Miguel Varella-Cid, on Flickr
 
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