Daily Driver 2004 Civic Type-S "EV Roller"

7th Generation (2001-2005) vehicle added by BB Baboonface, Tuesday 17th Nov, 2015

  1. BB Baboonface Valued Contributor ★ ★ ★ ☆ ☆

    United Kingdom James Chesterfield
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  2. rimmo Premium Member Club Supporter

    United Kingdom Charlie Brigg North Lincs
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    Very nice :Niceone:
     
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  3. BB Baboonface Valued Contributor ★ ★ ★ ☆ ☆

    United Kingdom James Chesterfield
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    Hey all, still getting used to the site so perhaps a few errors here and there, the "owned by..." thing being the first boo boo so far!

    Got some work ahead to get things up to speed with how the project is progressing, but must first say thanks to all those who have been so welcoming and complimentary.
    (Please forgive the lack of return input so far on all your fine cars and projects, there is so much to see it is difficult to know where to look first!)

    Suppose the beginning is a good place to start this thread at least :Laughing:

    As stated in my intro thread, this all began in 2012 with the purchase of a 2005 Cosmic Grey Type-S VSA. This was inspired by a good friend who also owns one.
    The space and performance seemed to tick all the boxes and be a perfect compromise for someone with family who also still enjoys the odd B road blast.

    Wanting to explore the "sleeper" element the EV1 then led to looking for ways to up the power output.
    Won't go into mega detail here, but after months of researching and emailing round the world, the dream was halted by the problem of finding remappable engine management that was legal and did not compromise the cars factory functions.
    (I do have some info and VSA EV1 specific wiring diagrams, so if anyone wants to take the research further then drop me a line)

    All seemed lost until looking for parts one day, i stumbled on the fact that some facelift models were produced without the electrical systems that stood in the way of fitting aftermarket engine management.

    After a little soul searching the savings were raided, a non VSA model sat outside the house, and the much loved Cosmic Civic was up for reluctant sale.
    Here are some photos of the day she arrived:

    P1020590.JPG
    P1020627.JPG P1020594 01.
    Being on a tight budget meant that the mileage was pretty high at 97K, and there were a few battle scars and other cosmetic issues.
    However, a pretty comprehensive Honda service history was a reassurance when making the purchase.

    The first thing was sorting the usual crusty headlight issue:

    P1020593.JPG

    Some work with the DA polisher saw them looking a little better:

    P1020597.JPG

    Before anything else could happen, someone decided to push past the car with sacks full of garden rubbish scraping them down the roof and passenger side.
    The damage was pretty extensive, so out came the DA again. Below are some before and after shots:

    P1020610.JPG P1020614.JPG

    Above shots are the roof, below are some of the side:

    P1020611.JPG P1020618.JPG

    While looking better over all, the damage has impacted into all the paint layers and remains visible in some light which is beyond the scope of polishing to fix :Frown:

    Despite the setback some trips to the scrapyard provided some bargain bits to help spruce things up.

    P1020694.JPG P1020696.JPG
    P1020692.JPG P1020693.JPG

    Was not to keen on the gear knob that came with the car either:

    P1020699.JPG

    So picked up a slightly worn one from an EX model for a fiver:

    P1020700.JPG

    The main cosmetic issue was hidden under a rear seat belt, they were clipped in place by the seller of the car and i stupidly did not check under them. When i did, was pretty dismayed to find this:

    P1020631.JPG
    P1020637.JPG

    Will come back to that later (if you have not fallen asleep from boredom!)

    The biggest change was the pleasant task of banishing the dinky and crusty 15" OEM wheels:

    P1020592.JPG

    Thanks to a loan from my awesome Dad, some new wheels were ordered.
    Was worried that they might be a little OTT looks wise, and some outlets stated they would not fit the Civic.
    In the end i told the company that they were for a BMW MINI which has the same PCD and centre bore as the non VSA EV1!

    Next was the problem of the locking wheel nut key being missing.
    Ordered a new one from Honda using the key code card from the cars documentation, only to find that though the part number was the same the design had been changed.
    You can see below the difference between the newer key from that of the Cosmic Civic on the right:

    P1020642.JPG This rendered it useless (Grrr!)

    In the end a 19mm socket and a hammer were employed to remove the old lock nuts, and a test fit of the new rims was possible:

    P1020644.JPG

    With the 5 spoke design of the wheels, the grotty calipers would be on show, so a lick of paint was in order:
    P1020655.JPG
    A bit of a crappy brush paint job, but better than before. (the car had been SORNed for while at this point pending sale of the other Civic which explains the rust on the discs)

    Finally, after 4 months of waiting on the driveway she was free, yet more pics from the first trip out: P1020767 No Plates. P1020768.JPG P1020769.JPG

    Sorry for the mahoosive post there, more detail than strictly necessary but hopefully fleshes things out in a pleasant sort of way.
    More to come yet!
     

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  4. BB Baboonface Valued Contributor ★ ★ ★ ☆ ☆

    United Kingdom James Chesterfield
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    Yes, that was just the beginning... ("oh no!" i hear you say lol)

    The next mod was something i had seen on forums in the US, upgrading the wiper switch to that of an Acura RSX (US spec DC5)
    Ordered a switch from US ebay and terminal pins from Honda long before buying the Silver Type-S, just never dared to fit it!

    You may be able to spot the difference between this and the standard Civic switch in this pic:

    P1020589.JPG

    To clarify, this switch has the little collar to change the speed of the intermittent setting.
    It took a long while to find the part numbers for the terminal pins needed, and after tracking them down they took 6 months to arrive from Japan!
    The switch requires two extra wires to be run to the connection on the multiplex unit and allows you to vary the "signal" to the built-in intermittent wiper relay.
    For anyone with electronics know how it is technically easy to fit, physically, it is a pain to access the relevant connectors.

    Having very little experience of any of this kind of thing made it pretty challenging, ended up going the scrapyard to play around with wiring in a car there as a dry run.
    Was over the moon to finally get it fitted, here is a spud cam vid to give you an idea of it in action:


    (Did also make a fuzzy guide to the process which perhaps may fit in the relevant section on HK at some point)

    Gave the engine bay a quick clean too, no before pics but it was coated in brown dust from the yard the car was purchased from:
    P1020969.JPG
    Not great but the flash photo is not very forgiving, and i still find cleaning bays scary!

    The local friend with a Type-S decided to swap to full leathers from an EX model and sold me his entire interior for £60!
    No more burn! :Grin:

    P1020972.JPG

    Also took her to TDI North for a much needed 100K service. They did a fine job of going over the car, and apart from routine maintenance also noted a few defects that needed attention.
    Was already aware of a leaking front shock, and a goosed front engine mount. TDIN noticed a knackered ball joint boot with the beginnings of play in the joint itself, and advised some new brake discs for the front.
    Defects aside, having fresh filters and fluids and the valve clearances adjusted made the engine seem to run much more smoothly.

    Ordered a Powerflex front engine mount and booked into a local garage to get that, brake discs, ball joint, and a new shock fitted.
    Ended up without the car for 4 days and later discovered the ball joint had not been done either (More Grrr! :brickwall:)

    This also ate up the budget for winter wheels and tyres, and despite a good coating of sealant and regular cleaning the lips of the ZCW's got a bit tatty from salt damage :Frown:

    Saved up over winter 2014, and after some indecision, these arrived:

    P1030003.JPG

    They also waited around for a while too.
    After the local garage episode and a few false starts finding a local specialist to fit them, the inner Macgyver that got the wiper switch sorted took over...
     
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  5. legend-ary Moderator Staff Team

    United Kingdom Legend The Big Smoke
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    Fantastic bit of progress. Looking forward to next batch of updates. tbh other than the 3 door I didn't really think much about the 5 doors but after looking at @RogerH69 's and yours I am thinking I won't mind upgrading to one of these from the Jazz.
    What I can't seem to understand is, why are the pre-facelift 2002-2005 so cheap? 100s of them under £1000 which is weird.. I know they suffer from the same dreaded input shaft bearing issue like Jazz from the era but must be some other reason..
    What do you reckon?
     
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  6. BB Baboonface Valued Contributor ★ ★ ★ ☆ ☆

    United Kingdom James Chesterfield
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    Thanks for your kind words bud :Smile:

    Difficult to say why the 5 door seems to go for that kind of money, makes for a buyers market at least which could be to your advantage if you are looking out for one.
    As you stated the 1.4 and 1.6 D series petrol models have the issue with gearbox bearings, also heard the 1.7 diesel can suffer various issues too.
     
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  7. RogerH69 Premium Member Club Supporter

    South Africa Roger Oxford, UK
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    Nice updates. keep them coming :Smile:

    Lucky find on those seats as well. Whole set for £60... not bad at all, especially if they'e all in the condition of the rear seat you showed.
     
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  8. BB Baboonface Valued Contributor ★ ★ ★ ☆ ☆

    United Kingdom James Chesterfield
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    Here we go again... :shock: lol.

    Have to confess now that before painting the calipers i had only jacked up a car a couple of times for the odd wheel change, so fitting coilovers was a pretty big step up from there.

    Decided to start at the rear as generally things looked a bit simpler at that end.
    Annoyingly, the 5 door requires most of the boot trim to be stripped out to gain access to the top of the struts:

    P1030007.JPG

    This done, work started on the drivers side and things generally behaved themselves when detaching the knuckle and camber arm.
    The lower strut bolt was rather more stubborn and it took a couple of hours and plenty of Plusgas to get it moving.

    Fitted all the new bits, torqued them to spec and turned in for the night, here they are in situ before getting coated with Dynax UC:

    P1030039.JPG

    There is also a fair bit of surface rust about which will need attention at some point, but on with the current saga for now.

    As before, the upper fittings on the second side were pretty well behaved, but the lower strut bolt proved to be the stuff of nightmares!
    After an eternity trying to shift it the damn thing went from hex to round, and left little option but to start cutting.

    Problem was, there being no space to bring my angle grinder to bear, so ended up sawing through the base of the strut by hand and pulling it out to gain access!

    P1030026.JPG
    P1030035.JPG

    The bolt seemed to be fused both inside the control arm and the bush on the still attached shock base. It took a ridiculous amount of hours and night was setting in before the last remains of the bolt and bushing finally came free .

    Had ordered two new lower strut bolts from the local dealership the day before, so they were fitted with liberal application of copper grease as the new suspension went in.

    After that debacle the drivers side front corner went pretty well, during the job:

    P1030020.JPG

    The only snags were, first the threads on the track rod end getting mashed up when separating it from the strut.
    After a quick trip to the motor factors and a google crash course on fitting a new one it was sorted.

    The second error was making the rookie mistake of letting the weight of the hub assembly pop one of the drive shaft joints out of its seating, after much wobbling and cursing it was reinstated and everything put back together:

    P1030022.JPG

    Last off was the passenger front corner.
    This had been making a rather annoying knocking sound for some time and the shock absorber fitted by the garage had not fixed it.

    On loosening the pinch bolts attaching the old strut to the knuckle, the source of the noise became scarily apparent.
    The top mount had completely died, and the spring was not held in place as it should be. On removing the first bolt bolt the whole strut shot downwards propelled by the wayward spring, pivoted the knuckle downward, and disconnected the drive shaft on this side too :facepalm:

    Without spring compressors, no available car, and available time running out, it was a tough call. Legged it indoors and fetched a welding glove to protect the CV boot from damage and hoped for the best.
    Mercifully, it came out largely without incident. The drive shaft was a real pain to replace, but after fitting a new track rod end on this side, everything was finally back together. It was a great feeling to beat all the challenges and get the job done :BooYeah:

    Only a subtle drop in height, but here are before and after pics:

    P1020676.JPG P1030040.JPG

    And though the car was mucky, yet more:

    P1030048.JPG P1030049.JPG P1030051.JPG P1030053.JPG

    Right! Will stop bludgeoning you poor souls with this for the moment.
    There is more to update, but my daughter wants to borrow my computer as her tablet has died!

    Cheers!
    - - - Updated - - -
    Sorry not to reply sooner, bit slow at typing! Thanks though Roger, kind of worry this is rather dull for you guys to read.

    Was really happy with the seats at the price, even if most of them are hanging around in the basement at the moment.
    Replacement covers for that part of the seat from Honda are 10 times what i paid, even if available!

    Cheers again, James.
     
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  9. K24 CL9 GUY Premium Member Club Supporter

    United Kingdom Guy Gloucester
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    Loving the build so far and fair play for getting stuck in and doing the coilovers yourself as not sure if I would be so brave. Excellent write up and plenty pitures which makes it a good read, look forward to seeing more. What a difference those wheels make to the look of the car, suits the car really well and looks epic :Smile:
     
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  10. SpeedyGee Administrator Staff Team

    England Speedy Birmingham
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    Great work there buddy, good job on the suspension, especially considering you hadn't done anything like this before.

    Loving the thread so far. I recon your car could be candidate for Car of the Month award :Grin:

    So keep it going buddy :Thumbup:
    - - - Updated - - -
    That amount of drop looks perfect !
     
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  11. RogerH69 Premium Member Club Supporter

    South Africa Roger Oxford, UK
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    I'll second that :Smile:
     
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  12. K24 CL9 GUY Premium Member Club Supporter

    United Kingdom Guy Gloucester
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    Gets my vote too :Smile:
     
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  13. BB Baboonface Valued Contributor ★ ★ ★ ☆ ☆

    United Kingdom James Chesterfield
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    Wow guys! Again, thank you so much for taking the time to read through all that, and the positive feedback after having done so.

    Generally things have moved slowly due to constraints of time and money, but guess it all seems quicker when writing up a years worth of progress in a few days.
    The poor girl is scruffier in flesh than the photos can convey so not really worthy yet for car of the month but your support is humbling, so thanks again.
    Hope to get more updates sorted to match where things stand currently very soon, all the best to all!
     
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  14. K24 CL9 GUY Premium Member Club Supporter

    United Kingdom Guy Gloucester
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    It's all about the effort you have put in to make it at its best for me with going to the lengths of changing the plastic trim etc which is something I'm in the process of now to get rid of all the little things that let her down. Top work keep it up :Smile:
     
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  15. SpeedyGee Administrator Staff Team

    England Speedy Birmingham
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    No cars are without scars :Grin:

    And :whathesaid: (@K24 CL9 GUY)
     
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  16. BB Baboonface Valued Contributor ★ ★ ★ ☆ ☆

    United Kingdom James Chesterfield
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    It is satisfying getting those little things done, definitely adds to the little glow of pride from knowing things are juuust right! :beach:
    Something we all share as enthusiasts for our motors.

    Picking up tools and having a go really opened up a world of possibilities and added a new positive dimension to life. Great to finally share in that element seen from watching other peoples projects for so long.

    Promise to have a detailed look at what everyone else on here has been doing with their projects once the updates are up to speed, so many mouthwatering cars! :dribble:

    Cheers bud
     
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  17. SpeedyGee Administrator Staff Team

    England Speedy Birmingham
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    :Grin:
     
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  18. BB Baboonface Valued Contributor ★ ★ ★ ☆ ☆

    United Kingdom James Chesterfield
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    Haha! Thanks bud.
    Sure most of us agree it can be a bit tough with a daily driver that we care for, life can be a bit rough on our poor old motors!
     
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  19. RogerH69 Premium Member Club Supporter

    South Africa Roger Oxford, UK
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    Sorry, I just noticed that you were replacing interior plastic trim. I've had to do that on a couple of pieces on my EV1 as well. I dunno if they get brittle after a while, but they do seem prone to breaking, especially the clips on the back of them.

    As the guys above say, CotM doesn't have to be a shining example of buffed and polished perfection putting out 500bhp. The idea behind CotM is really to show appreciation for people that have put a lot of effort into their cars (with no real matter the level/type of work being done) and show pride in their cars. We also appreciated the effort it takes to properly document progress on your car, so like it when people take the time to update their project logs and share information on how / why they're doing what they're doing.
     
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  20. BB Baboonface Valued Contributor ★ ★ ★ ☆ ☆

    United Kingdom James Chesterfield
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    Thanks again Roger, and also to you other guys too!

    Agreed on the trim clips, they can be a bit of a pain at the best of times. Not sure on longevity of the trim material, some parts probably do suffer fatigue from long usage, maybe sunlight and other temperature extremes can also have an effect on such bits.
     
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