djzt's 91 GS da9 (re)build restore.

djzachtyler

Looking for my next Teg..
This is a direct copy of the build thread I have going over at G2IC. Too lazy to re-write everything... ALso I just copied and pasted all of my posts from there to here, so chronologically speaking from start to end you see my build progress over a period of several months

Additional info on my teg not listed in my other thread... chassis has approx 361,000 or so miles, Current motor is a B18A1 stock LS block with 151,000 on it and running strong.

well it seems everyone has a build thread... seeing as I am completely hooked on this car and already into it for more than it will be worth.. may as well go all the way right?!?!?!

In a nutshell last may I finally got my license back afetr losing it for hot rodding a 1st generation 300ZX (1984 Shelltop.. a very rare 300ZX at that I almost cried at my stupidity) into a light pole at warp speed, I collected a nice check and started looking for a new car. I have owned a few different flavors of japanese cars including a 1st & 2nd gen Preludes, 2nd gen accord, 1st gen civic (yes the little booger box ones from the 80s) and the 300ZX I totaled.

One car I had never owned but had several friend absolutely have a blast with was the Acura Integra. I had always wanted one, but was more particular to the Gen 2 as I did not care for those 2 round headlights, and the gen 1's were not quite as sharp as later models IMHO. I thus hit craigslist in search of something and came across a guy selling a DA with clean title for 2650. upon seeing it I immediately picked him apart on the numerous screw holes and mis matched fenders and drove off with it for 2k flat. At the time it had under 150k on the odometer, had a 90 LS b18A1 motor, LS A1 transmission as in it's previous life it was a LS/Vtec swap with full race skirts etc etc... the last owner pretty much parted it our and put it back to stock. The upside was aftermarket sway bars and tokico shocks... so suspension wise it rode solid. Another plus was that the engine was nice and smooth running and the car had 0 alignment or drivetrain issues whatsoever. Combine that with a clean title I guess I did alright.

here's the pics from when I bought it.







ROll the clock forward I soon after driving around realized I had slightly been duped on how well the car ran. new water pump,timing belt,all kinds of maintenance done... yea guy was full of it once I got around to tearing stuff down I saw the work done was that of an amature. I felt almost defeated and that I was stuck with a lemon.... At that point I decided since money was tight at that time I was going to start a budget build.

Shortly after that I picked up an extra contract and had extra cash, but decided to stick with a slightly budget build that incorporated returning the exterior to an almost stock look while lightly modifying other areas... First things first was to diagnose and resolve my over heating issues I was having.

As it turned out I realized the guy before me had a OEM radiator that has so much stop leak run thru it the top was completely crusted. at that point I decided I was going to just replace the entire cooling system. Found a deal on a 2 core Aluminum radiator with 3 ply silicone hoses (In red cause my engine bay is red and that is the theme in there) ordered a aftermarket cooling fan & Gates thermostat de and took a weekend to slap it all together.




I had also attempted to purchase and subsequently got burned on a purchase of an AEM intake by a guy I met at another forum :(... but as good fortune would have it I found a guy just north of the bay area selling the intake arm for 40 buck.. I then contacted AEM and had the install kit shipped, ordered a new AEM dry flow filter and hydroscopic filter cover bag from Amazon and also happened to fins a new set of Matrix 9.3MM plug wires. I had also through the help of Welfare diagnosed that I was having issues with my coil unit & possibly my distributor... this led to discovery that I also had a bad o2 sensor. so thus began the next phase which led to installation of the AEM Intake, new ingnition coil , plug wires and some fancy new Red Silicone vacuum hose to tie everything together :)




project stopped at this point while I worked on saving up more cash under the impression I may have had a bad head gasket. After I got enough together to pay my mechanic to deal with it & had ordered the master gasket kit, I had it sputter to a halt down the street from my place... thinking I had a fuel ssue after seeing spark (but not turing it over long enough to see my new coil was shot) I waited till the following monday to have it towed to the shop... that trip resulted in it passing all tests & ruling out a head gasket, and replacing the entire distributor. I was quite thrilled as this freed up money for something else.. like.. new... SHOES!!! (Akita Racing AK77 16x7 +40 rims with Forceum Hexa 205/45 ZR16 tires)



I also had ordered and installed a 2nd cooling fan with a shroud to attach to my fancy aftermarket radiator. I finally found it in red and swooped on it quick. did the install myself... I also over the course of the last couple weeks found a DC sports street header (CA Legal) DC rear Strut bar, OBX/Forza Front Strut bar, custom ordered a Powder Coated GLoss red B18a1 Valve cover, and managed to have the driver axle start clicking.

That all said Teggy is in the shop today getting the new goodies installed and her Driver axle repplaced. Once I pick her back up, I'll post more pictures as the mechanical work is done on this build (For Now) in the next 2 months she is going to Marty's Chop Shop in Campbell, CA to get the body work started in preparation for a new paint job next spring in time to start showing her off at locl meets and shows. at this point I can equate her to being a pretty girl in an ugly dress haha.. soon tho very very soon that shall all change for the better...

If anyone has ideas for paint, I want to do something that says Classic G2, but also have custom flavor. I really am diggin the red/black/minimal white idea, but my head is full of ideas. either way when I'm done I'm quite sure she will turn a few heads :)

More Pics coming soon!
 
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djzachtyler

Looking for my next Teg..
here is a pic of the aftermarket shroud.



After installing the new Strut bar I had a clearance issue with one of the vacuum lines (the 9mm one connected to the dashpot).. by the time I got home I had alot of hissing going on and found that the strut bar had destroyed a vacuum line. This resulted in having to Tweak the fitting. also should not that the cruise control valve doesn't have much clearance from the back of the bar... on occasion you may get a clunk if it taps the bar on a rough start... otherwise the clearance seems to not be an issue with that one.



used a 17mm wrench to carefully tweak it to the side... stock it points straight up and runs right into the strut bar.



all put back together and tightened down and you can see there are no more clearance issues

 
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djzachtyler

Looking for my next Teg..
And to highlight the rest of todays project work...

DC Sports header :)


DC Sports rear strut bar :)


engine bay shot with the new valve cover & STrut bar etc...



Probably going to go grab a jug of simple green and give it a good rinse down sunday to try and clean up some of the dirt in there and make it look super clean. then to start setting aside to start the body work and get her ready for paint :)
 


djzachtyler

Looking for my next Teg..
Teggy got some thump added...

Alpine SD series 12 powered by a Rockford/Phosgate amp bridged to 550 watts @ 4 ohm



sound system sounds really great... considering I got it all set for under 400 bucks... the sound is pretty damn good & I am normally picky about sound...
 

djzachtyler

Looking for my next Teg..
thanks for the props guys..

I'm basically just going for a goood DD for now.. long term goal is a hybrid DD / weekend track car as I have some buddies that run their cars at Laguna Seca & Thunder hill every month... they have been lovign my project teg and keep bagging on me to bring it out. I'll also take it to the Honda meets once it is a little more presentable & I get the kill switch hardwired into the security system.

not looking to do much more mechanically a sit is good enough for now. Planning on body work and paint next then going to get rid of the Tokico blues and coilovers and swap for some descent adjustable coil & dampening shocks... torn between the D2, Skunk2, oor K-Sport setups for that but that won't be till much later on.. also going to be replacing the LCA's and add a rear subframe brace, Traction bar up front. ALready came with aftermarket sway bars so I'm good there I think. I also am going to change the exhaust to a Tanabe Medallion setup after the body and paint are done... (Love how the Tanabe system maintains an OEM look) Oh and let me not forget some Skunk 2 front and rear camber kits :) May or may not swap over to a Skunk 2 intake also.

For now tho I am happy with my N/A all motor build.. longer term I'm toying with the idea of boosting the hell out of it when I get to where the motor is in need of a rebuild, but not sure on that yet or not.

I'm definitely not in any rush to get some of this stuff done, but do have a short and long term plan for this car. 1 thing I do know is I will never get rid of it. :) after I can no longer get it to smog, and I finish paying off my mazda 6 (currently mom is using it) this car will be used for the track and whatever fun I can get out of it.. Hands down one of my favorite cars of all time, right up there with my old Mustang GT :)

I also just replaced my tail lights with some fresh OEM ones after I bleached the pink lines out. replaced the tail light gaskets as well after the last rain hit I had a redneck swimming pool forming in my trunk hahaha. That was a project as I found the driver side light frame was slightly bent in... so I spent an hour tapping and bending everything back into place, then sanded, primered and painted over the damage to get rid of and prevent future rust.

All said and done I have no more swimming pool haha. you cannot really see the cracks in the before photo on the driver tail, but they were there along with holes I had drilled to drain the excess of water from them as the gasket was missing a part and allowing water to fill up the lens

before


damage repaired


after


Neat tidbit... is my original OEM donurt wheel.. with painted rim... wouldn't rely on it for anything other than having an OEM donut for shows. Trying to find a OEN jack to toss in there and complete the package.


Note to others about bleaching the lines out... MAKE SURE YOU RINSE THE LIGHTS OUT GOOD... otherwise you end up with severely corroded light bulb sockets... Just Sayin..
 
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djzachtyler

Looking for my next Teg..
Charly[horse];1160261 said:
Nice lookin car! I like the red/black theme, thats what I am goin for too
Yeah some have said too much red under the hood... I personally like it... When it goes for paint I am going to go back to a red body with some black race stripes. some may bag on me about it but IDC... this car was a red car originally, and I cannot see why anyone would ever paint a beautiful red car black...

definitely going to stay in line with the red/black theme, and keep the White JDM "A" badges.


I also forgot to mention that the guy I bought my tail lights off of hooke me up with a GS emblem so I have all of the OEM emblems for it.
 

djzachtyler

Looking for my next Teg..
just to update... in the last month the latest progress on my build was after the first heavy rainfall in Cali finding that my trunk had become a redneck swimming pool.

bought a set of OEM tails locally and bleached the pink lines out, then ordered some new gaskets and set to work on replacing my old tails... as it would turn out the gaskets were shot, and missing sections hence the water buildup in the trunk.

I also discovered that the driver side tail light fram was slightly smashed in and starting to rust...


bent the frame back in place, sanded down the rusted areas and hit it with some rustoleum to seal up the bare metal & prevent future rust... installed the new tails with fresh OEM gaskets and called it a day.



next couple of rains there was no water, however whil on my 10 day trip to Chicago... I guess the bay area was hit with monsoon type rain storms and my trunk once again had water in the corners... last couple days with moderate rainfall hasn't yielded any flooding, but I am guessing I'll need to check my sunroof drains a little better, and also pull out my back seat and trim so I can also check my pressure vents & gaskets next.

I hope and pray that one day I will finally get all these little issues resolved LOL...
 

djzachtyler

Looking for my next Teg..
Latest update... had my crappy temporary speakers (Pyles of s**t lol) blow up front so I forked out 212.00 to amazon and scored 2 sets of Polk DB6501 component speakers for the front and rear.

Why the rear you may ask??? well previous owner had holes drilled on my C-Pillar molding for some components, so it seemed to reason I should just put some components back there to at least cover those damn holes versus buying new molding. Alternate reason is I will eventually be amplifying these speakers to get better sound out of them and there was a slight wattage difference between the DB 651 and the 6501 component counterpart. With all components I only need to seek out a 4 channel amp that is pushing 100W x 4Ch x 4 Ohm :)

End result is with the Alpine SD series 12 & my Pioneer deck my car sounds ridiculously good!!! when I get the amp and run it it will sound even better at higher volume. That however is on hod as I want to get my body work started. Only reason I did speakers was having no fronts & crappy rears was making me crazy...




Targeting beginning to mid february for the body work. Want to get the external transformation started so when the Bay Area meets start kicking off I'm not looking like an eyesore amongst the others :p
 
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djzachtyler

Looking for my next Teg..
been awhile since I updated this... then again I haven't done much work to the old girl in awhile...

Today's adventure was to San Jose Pick-N-Pull to get new window switches... Passenger side never rolled up, and recently the driver side controls were getting fussy as the contacts were worn out. I was lucky enough to find them for both passenger and driver sides between the 3 trashed tegs on the lot... almost grabbed a magnaflow exhaust kit, but found rust holes in the welds for the muffler and passed on it. had also grabbed a power mirror for my driver side and a mirror control switch as I was unable to even adjust my driver mirror... issue was the switch so I was able to not have to replace the mirror & returned the one I pulled for a store credit...

Also took time to get missing parts from my dash cowl, and other odds and ends to continue getting my interior back together.

little by slow she is coming along. next up is to diagnose my hazard lights... found out they don't work & after looking at a wiring diagram I now know what the loose green/white wire in the engine bay I saw (when installing the CAI) was for LOL.. I hate electrical crap... :p
 

Novice

New Member
Looks good man, Junk yard runs are always a fun, lots of parts on the cheap, kinda like treasure hunting LoL
 
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