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Post by davefromdownunder on Nov 2, 2018 2:29:00 GMT
Hi All
I have ordered my kit from Equilibrium and have started on the donor car I picked up. The donor is a 1993 honda prelude with the 2.3l dohc non vtec engine My sonic will be powered by a Honda h23 engine coupled to an auto transmission. After discussing with my engineer I will fitting a turbo running 7 lb boost to the car straight up. I am looking for around 300 rwhp. I have removed the engine and transmission from the car and can start to refurbish both. The engine and transmission weighed in at 205kg without fluids. The engine will have cast sleeves fitted with a forged bottom end and some mild head work and cams. The auto will be fully rebuilt by a professional. I have to run a stock ECU initially to comply with Dept Transport regs. I am using a stock Integra 2000 ecu as it is the latest that will still interface with the TCU.
The kit will hopefully arrive by Feb next year and I will need to strengthen the chassis as the factory ones are rated at a torsional strength of 2700 nm per degree and I require a strength of 4000 nm nin to comply with Australian regs. The engine bay will be extended by about 150 to 250mm to allow room for the turbo and intercooler.
The engine and gearbox mounts will be interesing as there are 4 of them , 1 on each side of the assembly.
The donor came with 4 good condition Osaka race wheels, 17 x 7
I am considering using them on the front with 205 45 17 soft tyres on them and then getting the same wheel in a 19 inch for the back and running either 225 or 235 45 19 tyres on them.
I want the car to sit slightly higher at the back and will then use under body pans to assist air extraction from the radiator bay and engine bay.
I will try to updats as often as I can and will start some photos as well.
Cheers Dave
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Post by kiwicanfly on Nov 2, 2018 7:18:28 GMT
Very interesting but why automatic?
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Post by davefromdownunder on Nov 3, 2018 1:52:23 GMT
Yes I know. It is auto so the wife can drive it as well, haha. the Honda auto is lock up in 2nd 3rd and 4th so it should still be a bucket of fun. I decided not to go with the vtec as it would come on at pretty well max boost and I think would be very unpredictable at that point.
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Post by drbrian on Nov 19, 2018 19:30:33 GMT
Well Dave, It looks like you have a plan! Just check when you extend the frame in the rear that you do not extend beyond the body limits. I think I have about 15cm of clearance between the frame and the rear bumper but you should definitely check double before picking the final number on the engine bay extension.
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Post by davefromdownunder on Dec 12, 2018 5:54:21 GMT
Well Dave, It looks like you have a plan! Just check when you extend the frame in the rear that you do not extend beyond the body limits. I think I have about 15cm of clearance between the frame and the rear bumper but you should definitely check double before picking the final number on the engine bay extension. Hi Brian I am looking at cutting and extending the side body pales and glassing in a scoop on one side for the air intake to the turbo and then extending the engine cover and if required raising it up to allow for a RX7 intercooler top mounted over the engine. I have been looking at seats and spacing and have found that it will be very tight to accommodate a handbrake between the seats so looking at fitting an electric park brake. I found the rear wings over the tyres are not wide enough for the tyres I have selected so I ordered a second set of the wings and will cut and graft them together for wider coverage. Cheers Dave
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Post by kiwicanfly on Dec 12, 2018 7:41:01 GMT
I found the rear wings over the tyres are not wide enough for the tyres I have selected so I ordered a second set of the wings and will cut and graft them together for wider coverage. I widened my wings without buying a second set. mevowners.proboards.com/post/99492/threadImages are not showing but if you click on the icons they open. When I first mounted them I glassed aluminium tubes into them for mounting. When I widened them these tubes located the two halves perfectly.
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Post by davefromdownunder on Dec 12, 2018 23:55:36 GMT
Thanks Kiwi
I will use the tube trick to line up the wing halves. I am going to either 225 or 235 /35/19 tyres on the back if mine.
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Post by davefromdownunder on Dec 13, 2018 1:43:01 GMT
Thanks Kiwi
I will use the tube trick to line up the wing halves. I am going to either 225 or 235 /35/19 tyres on the back if mine.
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Post by davefromdownunder on Dec 13, 2018 2:07:34 GMT
Just had word , the kit has been picked up and crated for shipping. Hopefully it will get on the water before Christmas. Parts ordering continues. Ordered new front hubs for the rear of the car in the later 5 stud pattern as the wheels I want for the back only come in the 5 stud size. 17 x 7 on the front and 19 x 8.5 on the back. I see that Kiwi loves red and shiny and mine will be blue and shiny , haha. I did not think I could fit the handbrake lever between the seats so have ordered an electric handbrake assembly to mount between the seats on the floor. Still working on the brakes as I want bigger discs on the back and probably std on the front. Wilwood duel cyl brake pedal ordered and master cylinders to suit, I will need to fit float switches to both reservoirs as they dont have them fitted. I still have not decided between the Toyo R888 tyres or the Yokohama AD08R tyres. Both come in the sizes I want. Steering column has been rebuilt and wiper controls removed and key ignition removed and push button start fitted to the hole for the key switch. Plastic surround has had the additional holes filled and been painted metalic blue. Steering wheel and boss from Autotecnica, has to have a padded centre for ADR compliance. I have to work out how to pad the dash as well, under the design rules there has to be 25mm padding in the head impact zones. Really... I think I am very serious trouble if my head hits the dash. I have ordered the M style roll bar and have been considering fitting a front bar as well with a centre bar between them but will need to talk to my engineer for that.I did consider a bar each side but think it will be a pain to get in and out, especially as I am an old bugger.
I am using a race dash that complies with the rule as it has all the idiot lights on it as well. Also fitting some VDO analogue guages for fuel, temp, oil pressure , boost etc. Not much in the way of photos yet but will post some as soon as I work out how. Cheers
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Post by davefromdownunder on Dec 18, 2018 23:31:17 GMT
Ok so the kit has now been picked up and boxed. It will be on the water in a few days. Still looking for a donor engine that complies with au regs. Identical to the one I have but with a 2000 engine number. Parts gathering continues, new hubs and bearings, lights and indicators, carbon fibre and blue kevlar fabric to cover the dash with, Brake pedal and master cylinders, proportioning valve, etc etc etc. The list goes on. Looking forward to getting the chassis and doing the required mods and additions to get the torsional strength to over 4000nm per degree as required.
Dave
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Post by kiwicanfly on Dec 19, 2018 4:56:23 GMT
Ok so the kit has now been picked up and boxed. It will be on the water in a few days. Awsome, the forum is a little quiet at the moment so there's no better time to play "Where in the world......" mevowners.proboards.com/post/25045/threadAs the owner you need the ships id and the appropriate software and away we go. Be warned it gets a bit dicey when it exits the Suez Canal but bar that.........
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Post by davefromdownunder on Dec 19, 2018 5:19:38 GMT
Ha ha I have already looked at where the ship is and it wont be in the uk until the 22nd.
The game sounds good. Have to be called " Where in the world is Dave's Sonic"
Really looking forward to it arriving.
I have to get all the docs from Angus and the shipping co , bill of lading, fumagation Cert etc. I will start a new thread in the General Chat area. Thanks Rob
Dave
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Post by kiwicanfly on Dec 21, 2018 9:42:19 GMT
How did you (or are going to) prove the chassis has the pre-requisite torsional strength?
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Post by davefromdownunder on Dec 21, 2018 23:22:44 GMT
I am modifying the chassis with extra bars and triangulation and braces and then my engineer will test it for torsional and beaming strength.
The original sonic chassis was made with 25 x 25 tube and the new one is 40 x 40 .
The floor will be 1mm stainless steel sheet, pre-stressed and welded in place.
External side body panels may also be welded in if required.
I think the issue may be the suspension as for the torsional test the car must be supported on the rear suspension and I am not sure if they will have the required rigidity for the 4000+ Nm per degree approval.
Cheers Dave
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Post by perthwa on Dec 23, 2018 12:10:16 GMT
I will be interested to see what your final frame looks like after you get it compliant and compare it to one constructed by Southam Engineering.
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