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Benny's UKDM BA2 Prelude - Project Shakotan.

49K views 319 replies 35 participants last post by  cboutilier 
#1 ·
Hello everyone! I'm Benny and I've just taken ownership of one of my favourite Honda's so far!

Give you an idea of my Previous Honda's Here's my DC2 (USDM Style)





And my most recently completed and Mag featured HellaFlush CRX del sol









Now onto the good stuff!

1987 BA2 Mk2 Prelude 2.0i-16

One of the last Mk2's made it has a non-VTEC B20 engine, Cool as fark factory single wiper, Shagpile carpets, SUPER comfy seats, optional amazing squidgy spoiler and . . . . . FLIPPY LIGHTS!!!!! Haha

Actually LOVE this car already. It drives like new, no really, it does.

54K on the clocks and it's pretty much the definition of immaculate.



Plans are:

To lower ASAP

Source an HKS Windmaster exhaust

Find some temporary track wheels

Source some old skool Deep dish SSR wheels 15x8 ET's in the minus's

Then get them to fit lol


Time for some pics!










Retro wheels!



Single wiper! + weird bonnet spoiler thing



LOOOOVE the spoiler





Interior is IMMACULATE



Woot! :D





My questions to you lovely people are:

Will 3G suspension fit?

As BC Racing make a Coilover Kit for the 3G and not the 2G.

How can I avoid the UCA Fouling the body without cutting the struts up?

Thanks in advance!
 
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#161 ·
Head

Hey matey yeah I noticed it after nothing appeared out the back! lol!
Done a full strip down and inspection of the head, I can't believe how clean the inside of that head was such a shame it's full of debris and metal particles, gonna have to get the machinist to line bore and repolish the cam bearings as they are marked but fortunately not too badly my main concern is getting all the bearing crap out. So will see if the machinist can chemically wash it couple of times and blast out all the passages. (sorry dude gonna cos a bit more for this) You must have had a oil filter failure as even with the big ends going it shouldn't have dumped bearing material into the head!! Not sure if the shot blast that gone in the head did the damage or not but it could be quite likely at this point especially if the oil filter had failed and it had dumped it all into the oil passages. If you get the oil filter off can you cut it open and have a look see what happened to it!! Also the oil pickup has a fine wire mesh that takes out anything big too can you see if this was damaged or missing?? Very very odd what happened to it!! Real shame as it looked like the engine was a real good one before you killed it off! lol!
 
#162 ·
There is some progress!

I've taken the engine out now to find the oil filled with shot blast material gutted. At least I know what was the problem now! Onwards and upwards!





The RJudgey has written a list of stuff that is happening/needed for the build.

Chemical cleaning both block and head, cylinder rebore and hone, repair damaged camshaft bearings, cylinder head skim, and block decked.
Donor block

Piston Rings
ACL Race Engine bearings
Head gasket Kit
Block gasket Kit
Water Pump
Timing Belt
Champion Oil filter
Dizzy cap and rotor arm
Spark plugs
Ignition wires

Extras are

Big bore throttle body
FSE fuel pressure boost valve
Adjustable Cam pulleys

Rjudgey head work will be:

matching the inlet manifold, porting out the plenum intake to the larger throttle body polishing the inside of the inlet manifold, reworking the inlet and exhaust ports, reshaping the valve guide ramps and guide ends, polishing chambers and deshrouding around the valve seats.

Rich says:

With the headwork adjustable cams, exhaust manifold, exhaust system, bump in compression ratio from 9.4:1 to 10.5:1, adjustable fuel pressure regulator we should get a nice output of around 180-190bhp maybe more with excellent torque low down as well probably around 155-170lbft which would certainly make your car very lively!!

Excited!


Also found a shot I took and edited just before then engine farked out.

 
#163 ·
Mean looking pic!

Well some updates:

I have pulled the block out of storage from my spares stash, It's all fully stripped and inspected and looks good!!

As suspected the crank is good, the rods and pistons look good too. Block is in good shape considering it's been sat for a few years. Gonna give it a clean in diesel and send it off packing to the machinist for some cylinder work, decking, and a full chemical strip to get it really spanky clean!! Then the head will be getting ported and flowed then that too will be getting skimmed and the cam bearings line honed to smooth them out again from the debris caused by the shot bearings in the rocker cover. Then that will also get a doubly good washing to make sure no more crap is left inside it!!
When I get all the bits back will be time to put it all back together in the kitchen with nice new oversize rings, ACL bearings, refaced rockers, another set of cams, and hopefullky Benny will have sorted out the Throttle body, exhaust manifold and system!!

BTW benny don't junk the old engine you'll be needing the mounts and other various bits of it just in case I can't find them for mine or forget.
P.S. still haven't shown us the picks of the devastation your brought to this poor little engine!! lol!!

I'll start posting some pics up of the stripped parts and progress as we go along, as you all know I'm off for nearly two weeks to NY so probably won't be finished till the weekend I get back from Holiday. So Benny soon as you get those parts you ordered post them over to me no huge rush but before I leave would be good as when I return I'll be working on this 24/7 and the week before I go as well just hope the weather is ok as I'll be doing the porting work outside and the lousy weather as stopped me from doing this for the last couple of weeks!!
 
#164 ·
Well some updates:

I have pulled the block out of storage from my spares stash, It's all fully stripped and inspected and looks good!!

As suspected the crank is good, the rods and pistons look good too. Block is in good shape considering it's been sat for a few years. Gonna give it a clean in diesel and send it off packing to the machinist for some cylinder work, decking, and a full chemical strip to get it really spanky clean!! Then the head will be getting ported and flowed then that too will be getting skimmed and the cam bearings line honed to smooth them out again from the debris caused by the shot bearings in the rocker cover. Then that will also get a doubly good washing to make sure no more crap is left inside it!!
When I get all the bits back will be time to put it all back together in the kitchen with nice new oversize rings, ACL bearings, refaced rockers, another set of cams, and hopefullky Benny will have sorted out the Throttle body, exhaust manifold and system!!

BTW benny don't junk the old engine you'll be needing the mounts and other various bits of it just in case I can't find them for mine or forget.
P.S. still haven't shown us the picks of the devastation your brought to this poor little engine!! lol!!

I'll start posting some pics up of the stripped parts and progress as we go along, as you all know I'm off for nearly two weeks to NY so probably won't be finished till the weekend I get back from Holiday. So Benny soon as you get those parts you ordered post them over to me no huge rush but before I leave would be good as when I return I'll be working on this 24/7 and the week before I go as well just hope the weather is ok as I'll be doing the porting work outside and the lousy weather as stopped me from doing this for the last couple of weeks!!
Wow awesome, I was going to email you tonight actually to ask how you were getting on.

My buddy is so busy he just needs to get time to order the parts frustrating tho!

The water pump is here though.

I've not even attempted to open up the engine, I doubt I will just gonna make a mess lol I'll just take what I need off and scrap it.

Stupid eBay seller just isn't answering my emails about the OBX-R B20A5 Mani! I've sent like 3 emails now asking about postage costs to the UK. Struggling to find a UK Supplier.

Throttle body is still with me, I know a guy that owns a milling shop and I'm going to see if he'll do it as it'll be better someone local doing it.

The rest of the system will have to be made once the engine and manifold is in and fitted as it'll be tacked up on the car then welded up off the car.

I'm missing driving it SO much, I've been to so many Honda meets since Japfest now and it's killing me being one of those guys that talks about a build they have at home and people not too sure if your just being a bullshitter or not lol

Thanks Rich tho! :D
 
#165 ·
car meets

And where did you find dry weather to go to these! lol!
The trouble with boring it out is you need a larger diameter throttle plate unlikely you'll get one here best to send it over to someone that knows what they're doing. The labour prices in US is so much cheaper than here you could end up paying more here and get a bodge job. I've researched already for TB boring specialists in UK and come up with nothing.
I can use my gasket kits for now and you can send me the replacements to replenish my stock.
Going to order some parts soon for the build as well to make sure I get them when I return will also need some dremel parts as well for the head work.
I'll PM you when I need some dosh.
 
#166 ·
And where did you find dry weather to go to these! lol!
The trouble with boring it out is you need a larger diameter throttle plate unlikely you'll get one here best to send it over to someone that knows what they're doing. The labour prices in US is so much cheaper than here you could end up paying more here and get a bodge job. I've researched already for TB boring specialists in UK and come up with nothing.
I can use my gasket kits for now and you can send me the replacements to replenish my stock.
Going to order some parts soon for the build as well to make sure I get them when I return will also need some dremel parts as well for the head work.
I'll PM you when I need some dosh.
A bit of drizzle and cloud doesn't put us off meets! Still great fun and loads of people still turn up.

It was south Mimms 2 last last weekend and started out a little wet but the day went SO damn fast. Honda people are the best people! lol

It wouldn't be bodged, the CNC guy is very good at what he does. He has a 2500Bhp drag Willis that he makes parts for all the time. I'm sure it'd be an easy job for him. Just gotta see what he says, they were away racing it last weekend.

Yea no problem at all matey still very excited about it all!



So my willwood prop valve turned up today



Really have NO idea how to plumb it all in after removing the ABS System.

If anyone knows or can draw me a diagram that'd be awesome :D
 
#167 ·
I have converted from ALB to non ALB before, you need

master cylinder, and hard lines to prop valve
front hard brake lines from the prop valve in engine bay to soft lines by calipers
proportioning valve.

the above gets rid of all of ALB then just plumb in the adj brake bias control as per standard instructions I have no idea where they are connected into.
 
#168 ·
brakes

Can you not pair them off to front and rear the brake cylinder should be even pressure on both channels correct? Then get a pipe fitted from each channel from the master cylinder going into the brake balance and use this for the rear brakes, then run another single pipe to a T piece block where you then split into two channels which you connect upto the rear brakes, then the other channel goes to another T piece block which you then run into the front brakes which need the full pressure and doesn't need a prop valve.

Does that make sense I can't see why this wouldn't work this is what was proposed I should do when I had my custom brakes made up if I wanted adjustable braking in the end I felt it was fine as it was and left it alone.
 
#170 ·
Well I got my SSR's back from having a little polish up, taking some curb rash out and the tyres and valves mounted.

Soon as I got home I tried them on!

Front camber is more than enough:





How it should sit once on the floor:





And GOT POKE? lool I have no idea how to get more rear camber with the old suspension setup I have, But damn I need a few degrees!





Am now sending the Superforma adapters back to get longer studs as the SSRs faces are 23mm thick! so that combined with the extended RAYS nuts I want to run then I'm having some 65mm studs fitted instead of the 25mm ones.
 
#178 ·
Wow!
That looks huge now! It's amazing when you say 4mm I think to myself it doesnt sound like much but when looking at the old butterfly (even though it's not aligned) it's defently a decent improvement.
Do you know what the standard diameter was and whats the new diameter?
Did they use lock tight on the screws?
 
#180 ·
Was 55mm now 59mm, and that's one question I'd better ask! Cheers!

Good size increase loving it! Although the fitment looks bad it may not be so bad if the plate has a nice thick and correct angle. Put it up to the light and see if there are any light creeping through the gaps. Worse case scenario will have to completely seal up the idle screw but we'll see how it goes have a stock spare one if it's an issue or we'll just run a higher idle speed like 1000rpm should be fine.
Howmuch did that set you back?
There is a little light. Is that bad then?

Hope it's OK :(

Was £120.

I have:

Water pump
Oil filter
Dizzy Cap
Rotor arm
Head Set
Cam belt
Tensioner

Ready to be sent you you Rich. So I'll need your address.

I got all that for £150 which I thought was pretty good :)

Just need an alternater belt and all the fluids for the start up.
 
#179 ·
throttle body

Good size increase loving it! Although the fitment looks bad it may not be so bad if the plate has a nice thick and correct angle. Put it up to the light and see if there are any light creeping through the gaps. Worse case scenario will have to completely seal up the idle screw but we'll see how it goes have a stock spare one if it's an issue or we'll just run a higher idle speed like 1000rpm should be fine.
Howmuch did that set you back?
 
#183 ·
Throttle body

Well Benny has sent me all the parts he managed to get cheap as well as the throttle body, the machining on the body is good but sadly the butterfly is well as most noticed pretty poor which is a great shame, I don't even think it was the right size as it has two flat spots at the top and bottom of it which leaves two gaps the rest of the plate is ok real annoying!! But we'll give it a try first before throwing it back at the machinist!! I have a spare stock one just in case we can't get it to idle reasonably!!

Anyway as you gathered I'm now back I've picked up the parts from the machinist and the block and head are now 20 thou shaved off each, and the bores are honed cylinders look perfect no wear what so ever and the water that had sat in them hadn't even got through the oil I'd sprayed all over the engine! yay! I've spent a good part of today just cleaning off corrosion and making sure the pistons and rods are spotless which they are now just awaiting new bearings and rings which I'm sourcing this week, sadly the over size rings are only available from Honda if anyone knows of a supplier that can get 81.5mm rings for a reasonable price (honda wanted £245!!!! ouch) then let me know asap before I get the std size hastings rings.

Here's a couple of teaser pics when I've finished scrubbing the block it's going to be painted silver so I'll take some pics then!!





These are UKDM/EUDM market B20A pistons they have 9.4:1 CR ratio but the 137bhp engine we have has smaller wrist pins 21mm the pistons also have a black phosphate coating on the lower half of the pistons not seen that before on A20/A18 not sure if B20A5 or B20A1 JDM market have that either. But the rods and pistons have cleaned up nicely will weight check them to make sure they're not too far out from each other!!
 
#187 · (Edited)


These are UKDM/EUDM market B20A pistons they have 9.4:1 CR ratio but the 137bhp engine we have has smaller wrist pins 21mm the pistons also have a black phosphate coating on the lower half of the pistons not seen that before on A20/A18 not sure if B20A5 or B20A1 JDM market have that either. But the rods and pistons have cleaned up nicely will weight check them to make sure they're not too far out from each other!!
Rjudgey, measure wrist pin diameter one more time, there is no way that 21mm is correct, EDM B20A's (B20A1,B20A2,B20A8) have 20mm or 22mm WPs.
If I see well, these are PH3 rods so there are 20mm. Too bad B20A's wrist pins are not 21mm, then we could easily swap B16 pistons for higher CR which would make huge diffrence.
 
#184 ·
Awesome dude, SO SO good to see progress! :D

So annoying about the piston rings tho! How much of a difference will the .5mm make?

I'll take the TB back to the machinist and get him to redo the butterfly I think, just have to see how rough it idles.

Is it just rings, head bolts and bearings left to get?

OBX-R B20A5 Manifold is on it's way from America so I'll get the top half sent to you once it turns up. Not looking forward to the import taxes :( Barstewards!
 
#185 ·
parts left

Yes I found a spare conversion set for the block yesterday so were good for that I have two sets that I forgot about! lol! The bearings I'm ordering this week from my supplier will be ACL duraglide big ends and ACL race series for the Crank.

As for the rings would have been nice to have the .5mm so I can hand gap them generally worth about 5bhp over stock engine as the compression when done correctly can be about 20-30psi more than std creates a better seal which creates better suction etc. But this will only last about 15-20k miles then will drop gradually. But at £245 it's a tough call as the cylinder walls are unworn std rings will be ok should still get a nice healthy 180-190psi all round, pistons came up great managed to clean out all the landings on the ring areas and the phosphate coating is worn that much. Just a shame that I can't balance them properly but hopefully they're all pretty close to each other anyways!

Head bolts you don't need Honda don't use crappy once only jobs you can reuse them safely again and again!! So I hope you haven't binned them! lol!
 
#186 ·
Awesome can I buy one from you then if that's alright?

They are in the scrap pile to be binned lol Luckily they haven't been binned yet tho!

They aren't in any order though!


Ahhh I'm feeling it now, it's all coming together! Just need to get the brake system piped up and working and make a template for my engine mount spacers and then get the exhaust system piping ordered and it should all come together in a few weeks! :D
 
#190 ·
Engine build

It will be higher compression than stock as I've had the head and block 20 though saved off so that's 1mm in total gone. As for valves sadly as Benny's in a bit of a rush were sticking with stock ones as lets face it they're pretty big as std anyway!! lol!! But I will be doing a full Rjudgey head job which will include matched throttle body to plenum, matched inlet manifold to head, inlet manifold ports polished up, exhaust ports reworked and polished, inlet ports reworked, inlet valves swirl polished also backcut, inlet/exhaust seats worked on, chamber roof blended into valve seats, exhaust manifold matched to head ports.

Will be bumping up fuel pressure a little to compensate but as Benny is running stock cams this should be enough to keep fuel mixture rich enough. With the exhaust manifold and system that will be made for the car and a nice Cold air induction kit, with the head and inlet mods should see some nice power figures if the big bore throttle body idles ok then we should get something around 160-170bhp with a nice big fat torque to boot. Can't wait to get it up and running!!
 
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