ROAD LEGAL HONDA CIVIC TYPE R BUGGY PROJECT

Thread in 'Project Cars and Builds Threads' started by Cornishmechanic, Jan 16, 2019.

  1. Cornishmechanic

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    Here's my road legal 240bhp 500kg Honda civic type r powered buggy.
    Its mostly built now so I'll be uploading alot of pics up.
    Thought I'd make a build thread as alot of people as asking to see it through the build process so here it is.
    Enjoy ;)

    20170723_104941. 20170723_144931. 20170723_144942. 20170723_144909. 20170723_120118.
     
    #1 Cornishmechanic, Jan 16, 2019
    Last edited: Jan 17, 2019
  2. Cornishmechanic

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    Found a very clean low mileage ep3 type r with 80k on the clock.
    Engines removed and ready to see if it'll fit into the buggy :/

    20170107_115145. 20170107_115116. 20170107_145345. 20170109_110602.
     
    #2 Cornishmechanic, Jan 16, 2019
    Last edited: Jan 17, 2019
  3. Cornishmechanic

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    Got some more pics of the buggy today before I start the strip down.

    Screenshot_20170721-160917. Screenshot_20170721-170359.
     
    #3 Cornishmechanic, Jan 16, 2019
    Last edited: Jan 17, 2019
  4. Cornishmechanic

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    Got the 1.1 Engine out now, it's guna be a tight fit getting this 2.0 in it for sure.

    Screenshot_20190116-225103_Gallery. Screenshot_20190116-225111_Gallery. Screenshot_20190116-225123_Gallery. Screenshot_20190116-225131_Gallery. Screenshot_20190116-225142_Gallery. Screenshot_20190116-225412_Gallery. Screenshot_20190116-225431_Gallery.
     
    #4 Cornishmechanic, Jan 16, 2019
    Last edited: Jan 17, 2019
  5. s13silvia

    s13silvia doughnut muncher

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    How compact is that gearbox!! Man I might swap out my SR20 for a K20 in the micra. Looks like it's even smaller.

    Such an awesome project by the way!
     
  6. Cornishmechanic

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    Funny you say that I've just bought a 89 micra k10 to kswap lol

    IMG_20190116_185154_597.
     
    • Like Like x 1
  7. Cornishmechanic

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    Got the engine in now, bit tight but it fits ! Using some custom made billet alloy engine mounts with polly bushes. I've mounted the engine as low as I can and so that both driveshafts are the same length. The engine is also perfectly level in the chassis.

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  8. s13silvia

    s13silvia doughnut muncher

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    Awesome progress already!
     
  9. Cornishmechanic

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    Made up the exhaust now all outof 3" stainless steel and a £700 ktuned big tube manifold.

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  10. BreadBin

    BreadBin Rough Tonguer

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    That's pretty sweet.
     
  11. Cornishmechanic

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    Moved on to improving the steering rack now so i bought a custom made stronger quick steering rack.
    Screenshot_20190116-231112_Gallery.
    Screenshot_20190116-231437_Gallery. Screenshot_20190116-231430_Gallery. Screenshot_20190116-231453_Gallery. Screenshot_20190116-232500_Gallery. Screenshot_20190116-232714_Gallery. Screenshot_20190116-232721_Gallery. Screenshot_20190116-232729_Gallery. Screenshot_20190116-232741_Gallery.

    Had to make these steering tie rod extenders made up as the corsa d inner tie rods arnt long enough.
    Screenshot_20190116-233009_Gallery.
    Honda civic ep3 track rod ends fit perfect into the original buggy hubs. Screenshot_20190116-233015_Gallery. Screenshot_20190116-233021_Gallery. Screenshot_20190116-233212_Gallery.
    Big chunk of steel in the lathe making up the new front hub stub axles for the mk2 mazda mx5 1.6 hubs to fit onto the original buggy hubs.
    Screenshot_20190116-233505_Gallery. Screenshot_20190116-233514_Gallery.

    Also had to machine off some material from the buggy hubs.
    Screenshot_20190116-233523_Gallery.
    Pressed the new stub axles into the buggy hubs and tig welded them on. Screenshot_20190116-233701_Gallery. Screenshot_20190116-233710_Gallery.
    Now the mx5 hubs and calipers bolt onto the buggy hubs. To my amazement the front mazda mx5 caliper carrier bolt holes where exactly the same as the original buggy calipers ! So no modifications were needed there, just had to made some alloy spacers up and jobs done.
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    Very good steering lock on it now, from the centre steering point full lock is just half the turn of the steering wheel.
    Screenshot_20190116-234112_Gallery.
     
  12. Cornishmechanic

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    As im lowering the buggy alot ive had to modifiy the suspension arms and flip the bottom ones upside down so that the angle of the rose joints is correct.
     
  13. s13silvia

    s13silvia doughnut muncher

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    I find it absolutely disgusting how quickly you are making serious progress on this.

    Major dedication and skills there bud :thumbs:
     
  14. Cornishmechanic

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    Made a start on the wiring loom.
    I used a complete honda civic eg wiring loom with a kswap wiring adaptor loom.
    Every single light is led. Screenshot_20190126-231403_Gallery.

    Cutting out what wiring i dont need on the buggy like heater electric window wipers etc
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    Trying to work out where to mount everything :/
    Got the civic eg clocks now mounted.
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    Fuse boxes mounted.
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    This is the loom ive gota fit :/
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    Reverse light, fog light, numberplate light and tail lights now fitted.
    Screenshot_20190126-234718_Gallery. Screenshot_20190126-234723_Gallery.

    Kpro 4 ecu fitted.
    Screenshot_20190126-231352_Gallery.

    This was honestly the worst part of the whole build no joke ! Trying to make a single pole hazard switch into a twin pole switch was a nightmare ! Everyone i spoke to didnt have a clue how to do it and neither did i at the start ! Ive had to use 3 relays inc a switching relay to make it work and it now works perfect so all these wires here are just for the hazards to work !
    Screenshot_20190126-235002_Gallery. Screenshot_20190126-235645_Gallery.

    New wiring loom now all made and tidied up with loom tape.
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    The whole buggy loom.
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    Hazard switch, fog light switch and horn switch mounted.
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    New led headlights with built in sidelights dip and main beam fitted.
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    Made a headlight bracket up. Screenshot_20190126-235534_Gallery. Screenshot_20190126-235547_Gallery. Screenshot_20190126-235555_Gallery. Screenshot_20190126-235600_Gallery. Screenshot_20190126-235606_Gallery.

    Honda civic eg indicator stalk mounted.
    Screenshot_20190126-231423_Gallery.

    Kswap loom.
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    Civic eg ktuned temp switch mounted. Screenshot_20190127-221016_Gallery.

    Civic eg ignition switch mounted.
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  15. Mr.Booz

    Mr.Booz New Member

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    this is awesome mate! keep it going.
     
  16. Cornishmechanic

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    Mounted the obp pedal box now.
    Had to cut off the throttle pedal and move it so it would fit better.
    Had fun and games finding all the right brake fittings as they was all american sizes.

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  17. Cornishmechanic

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    Got a mk2 toyota mr2 gear selector unit after spending many hours working out what to use ! Innovative make a conversion kit for the mr2 to the k20 engine so it seemed like the right thing to use.

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    Mounted the mr2 gear selector unit and the civic eg handbrake lever.
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    Made up the centre console piece to hide all the wiring and water pipes at a later date.
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    #17 Cornishmechanic, Jan 29, 2019
    Last edited: Jan 29, 2019
  18. Cornishmechanic

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    Made a start on the nightmare that was making up all the water pipes.
    Found that the civic eg rad was the smallest one i could get that kindof fits into the buggy frame.
    This of course had to be modified though. Bottom pipe outlet had to be cut off and moved at an angle and the bottom mounting pegs had to be moved.
    I also mounted the ktuned lower temp fan switch in the bottom hole which used to be the drain plug.

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    Fitted an inline water joiner with a ktuned water temperature sensor and an air bleeder valve.
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    All water pipes are held to the chassis with stainless p clips.
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  19. Cornishmechanic

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    Sorted the fueling side of it today. I had to modify the original buggy tank by welding on some alloy an fittings.
    All stainless braided fuel hose and anodized an fittings.
    Has a ktuned fuel rail, ktuned high pressure regulator, bosch an fuel filter and a 255ltr walbro inline fuel pump all mounted on rubber mounts.

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  20. Cornishmechanic

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    Made the rear wishbones up now using 3mm thick steel tube.
    Made some threaded inserts up to weld into the tubes.
    Bought the best heavy duty rose joints you can buy.
    All arms are now full rose jointed to adjust camber caster angles.
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    Made up some wooden jigs so that every arm was excatly the same.
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    Im using mazda mx5 mk1/2 rear hubs with calipers etc
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    Rear upper shock mount made up.
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    Stainless steel rose joint spacers made up.
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