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The Kakabox Build


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#1006
kakabox

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QUOTE (1gcvcb18 @ Aug 19 2007, 06:09 AM) <{POST_SNAPBACK}>
Can this part be cut off instead of making holes, i know the two holes a each end are to cover the screws that go to the spoiler but i think it could be done.

Sure, good call...funny, I didn't see that when I first laid out the holes blink.gif

Here again, not much weight, but it takes 16 ounces to make a pound...


Thanks!

#1007
87crxdx

QUOTE (kakabox @ Aug 12 2007, 10:38 PM) <{POST_SNAPBACK}>
Thank you.

I have and I will...except, this time the 1g will be a roadster w/a 6 pt. roll bar!

Stay tuned for further developments on the 1g front. If the deal is for real, I will start a seperate build thread. The 1g build will be even more radial than the Kakabox!


wow can't wait to hear your plans for the 1g! good luck.

#1008
Biscuit

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This thread is amazing!
Is that an AEM Civic-D16 fuel rail? Is the engine a ZC? It looks like it has a blacktop ZC intake manifold because the plenum looks larger than a D16A1 manifold.

#1009
kakabox

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QUOTE (Biscuit @ Aug 21 2007, 07:04 PM) <{POST_SNAPBACK}>
This thread is amazing!
Is that an AEM Civic-D16 fuel rail? Is the engine a ZC? It looks like it has a blacktop ZC intake manifold because the plenum looks larger than a D16A1 manifold.

Thanks!

'89 'teg D16A1 w/a JDM ZC intake mani and cams, adjustable cam gears, ported head slightly shaved for a tad more cr.

lxndr built the engine...he knows all the specifics.

#1010
lxndr

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QUOTE (kakabox @ Aug 21 2007, 11:04 PM) <{POST_SNAPBACK}>
Thanks!

'89 'teg D16A1 w/a JDM ZC intake mani and cams, adjustable cam gears, ported head slightly shaved for a tad more cr.

lxndr built the engine...he knows all the specifics.


Head:
Rebuilt 88/89 D16A1
Street port & polish
3-way valve grind
Shaved .050
ZC cams
88-91 Civic ZC intake manifold
Megan Racing F22 (Prelude/Accord) adjustable cam gears
'95 Civic fuel rail
AEM fuel pressure regulator
DC Sports header

Block:
Rebuilt 88/89 D16A1
Bored .5mm, decked, honed
Resized rods
Unorthodox pulley

Tranny:
Refurbished D16A1
Lightened flywheel
ACT clutch
'88 Accord 5th gear
OBX LSD

Basically, it's better than a ZC!

Edited by lxndr, 23 August 2007 - 03:03 PM.


#1011
Biscuit

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Thanks for posting the specs lxndr.
What do you mean by "resized rods"?
Was the stock flywheel machined or is it aluminum?

#1012
kakabox

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QUOTE (Biscuit @ Aug 23 2007, 02:45 PM) <{POST_SNAPBACK}>
Thanks for posting the specs lxndr.
What do you mean by "resized rods"?
Was the stock flywheel machined or is it aluminum?

The rod and caps were machined to fit the polished crank. The flywheel is an oem 'teg flywheel machined from ~20 lbs. to, IIRC, ~12 lbs.

#1013
D Jaws II

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QUOTE (kakabox @ Aug 27 2007, 12:54 AM) <{POST_SNAPBACK}>
The rod and caps were machined to fit the polished crank. The flywheel is an oem 'teg flywheel machined from ~20 lbs. to, IIRC, ~12 lbs.


J.

BTW, thanks for the refresher on the install of the torsion bars. The index DOES come in veddy veddy handy.


Cheers,


Donnie


"YOU SHOULD NEVER UNDERESTIMATE THE PREDICTABILITY OF STUPIDITY"

#1014
kakabox

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Relocated Battery

I decided to shift the car's cg slightly aft by relocating the 11 lb. battery to behind the passenger seat. I made a cardboard box the size of the Heel Toe mini battery to better help me find the best spot, the flattest position, on the floor to mount it. I didn't want to take the battery out from the engine bay just yet and use that, hence, the battery sized cardboard box.


I decided to run a live 12v cable from the battery pos term to the firewall; in effect, making a remote positive battery post on the firewall. To do this, I used a power post:


It is an insulated post that you can connect other wires to. I found the ideal locn: the old charcoal canister mount. As luck would have it, there is a factory hole just below it, perfect for the battery cable to go through! I stuck a rubber grommet in the hole and mounted the power post:



I then turned my attention to fabbing a new Kakatray for the new battery position. Using my favorite material, Home Depot mild steel, I cut some .75 x .75 x .125 angles for the base of the mount and made some mounting tabs from some left over angles I had in stock. I welded the whole mess together and positioned it on the floorboard to mark the mounting holes. When I was finished, I mounted the battery and weighed it; total weight 12 lbs. (the tray weighs 1 lb.):







...continued next post...

#1015
kakabox

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Battery Relocation, Part II?

Now that the battery was mounted, I turned my attention to the re-wiring. Basically, everything connected to the oem positive terminal of the battery, is now relocated to the power post on the firewall:


That means the cable to the starter, the hazard fuse, and the white wire to the engine bay fuse links.

Seattle being a seafaring town, it's no surprise that I live close to a marine hardware supply store that sells high quality, marine grade electrical wire and supplies; I buy all my electrical hardware there. Here's all the hardware for the battery relocation:


For the positive battery cable, I used 2 gage. Is because the cable run grew from ~1 ft. to ~6 ft. I wanted to use 1 gage, however, not only was it $2/ft more, it was, of course, noticeably heavier. Here's a comparison of the oem Honda positive cable, on the left, and the 2 gage:


The new 2g cable is of a higher quality than the oem cable. It is much more flexible and is constructed using fine strands of 'tinned' wire. At $5.29/ft. it's not cheap, but it's the good stuff:



Here's how I made the battery cables. First drilling a hole in the cap of the ring terminal:


...inserting the wire and crushing the terminal on the wire w/the vice:


Then using a propane torch, I fill the cavity w/solder (the molten solder wicks into the cable strands making a strong electrical connection):



I then cover the ends w/marine grade shrink tubing (it has heat activated glue inside that bonds and seals the connection)...


...and it's done!

...wait, there's more...continued next post!

#1016
kakabox

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Battery Relocation, Part III?

I used battery terminals that had separate studs and wing nuts to connect the cables (yeah, yeah, we know, Coast Guard approved, marine grade, blah, blah, blah! wink.gif )...makes it easier to R&R the battery or disconnect the ground:



The passenger seat belt mounting point is the locn for the battery ground, but I retained engine bay battery ground cable, I just snipped off the now useless battery connection portion of it.


I used the existing welded nut inserts along the shifter linkage tunnel to attach the clamps holding the battery positive cable (inside split conduit):



...all the way to the firewall, where I used another existing factory bracket to hold the cable as it goes through a factory hole in the firewall:


On the other side, the power post is wired w/leads to the starter, the engine fuse links:



...and the lead to the hazard fuse (which I mounted on another unused factory bracket):


Everything still functions like it did before...before I move 12 lbs. seven feet to the rear!


Cheers! cool.gif

NOTE: Updated wiring for battery-in-car...go here: http://www.redpepper...e...st&p=357203

#1017
rollz87civic

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nicely done rolleyes.gif
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#1018
DEIVIONCRX

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Looks great, are you going to do anything about a battery cut off, im sure the autox guys dont give a crap, but if you ever go to a real track they usualy look.
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#1019
Screech

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Did you put a fuse between the battery and the firewall and I missed it, or is there none? Aside from not seeing a fuse or quick cutoff between the battery and the firewall it is all great work as normal. Using the rear seat or e-brake bolt would be a great mounting location for a fuse at a glance. I'm a fuse freak as I've seen unfuse wiring through a firewall burn a car up, granted they were crappy installs, but the chance of a mishap still exist in a great install IMO.

#1020
koshir

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I have the same opinion as Screech it's perfect but you could use one fuse before engine bay terminal...
and other thing more important in car electronic is to have good - (minus-ground) than good + so I'd do another terminal like one for + and wire all ground there so those would be all conected directlly to battery...

Great things like always, keep it going !

cool.gif cool.gif cool.gif