EM1 Long term build (sideline EG track build)


Thank you Sir.. The EG is very rough to be fair, it's had panel work done before where it seems hopes and dreams were used instead of welds. But it's got all the right bits on for a base car and it'll give me a chance to be a bit free on the build, vs the em1 where I want everything to be exact.
 
Brilliant! I will keep me eye out for that build ,
I enjoy going through your posts as they are very
Detailed and informative .
Good job .
Thanks Lee.. Things should happen pretty quick with the EG, hoping to get a shake down before winter sets in
 
Dont really want this turning into an EG build thread, but a small update on the rusty track shed; one of my priorities for this car is lightness, so I managed to sell the SiR boot lid and with the money raised bought a friends carbon bonnet and boot he had going (worked out pretty much flat cost for the deal).

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Need to reinforce the aero catches as they're a bit weak and figure out quick releases for the boot.

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I've also managed to pick up an unwanted full set of plexy windows, but likely wont fit these until I tackle the rust and sort the bodywork out.

Collected everything I need now for the engine swap, including a fuel tank and pump as the car was a 1.3 DX carb - plan to swap it in on the 18th
 
Added some carbon mirrors that were laying about unneeded on a mates build, not the prettiest but go well with the rest of the worn carbon parts, and fixed in the latches for the rear hatch.

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Yesterday I made the most of the amazing weather and got most of the swap done, but not running yet as need a couple of connectors for the new fuel system (fuel injection replacing the current carb system).

First I changed parts over on the b16; alternator, mounting bracket (2 to 3 post), p/s/ pump and loom. The head looked perfect for being sat for a while.

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Then it was time to start converting from carbed d-series to b; here's pretty much the full loom laid out prior to swapping in - most of this will be unneeded so I'll strip it right back, but ant to check everythings working first, as its a bit of a Frankenstein made of EG4 lsi, EG6, and mB B18c4, going to a p28 ECU. The Lexan rear sceen is fitted in this picture too, I'll be doing the rest of the glass at a later stage.

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Then fast forward a few hours and the transformation was looking much better,

Before:
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After:
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Looks so much more proper with the correct engine in. The intake is an AEM filter on a Silicone arm - I'll be addressing the cold feed element at some point

Hoping to have it fired up over the next couple of evenings
 
give me mechanical work over electrical any day of the week! Full loom replaced though, just need to sort fueling now - a large proportion of the loom is unneeded so will be getting stripped out, but I just want to make sure everything's working first before then.

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I like what your doing with this eg,
Low budget builds put together from stuff that was lying around are always the most fun, It can be hard to not get carried away and turn it in to a full rebuild though!
 
I have to say it has been a lot of fun, whereas the EM1 build can get a little stressful and serious at times, this has been a bit of light relief.. I can certainly see how builds like this snowball, but for now I just want it to be cheap, safe and fun.

I accept having to pay out for the right parts for the EM1, but just paid £34 for 2 fittings for the updated fuel system on the EG which I wasn't overly impressed about! Only big expenses really will be safety based, so seats and cage. Then it's just consumables.

Although I do need to tackle the arches soon, it keeps proving to be a good base. Whilst fitting ek9 gear linkage last night I noticed the the steering rack was a DC2 item to go with the ARB. Likely a full DC2 subframe.
 
Nice EG, my brother used to own an EG6 Sir2, import from Japan, had a buddy club spec 2!
 
^^ hows his hearing now?? :D

so got round to sorting the fueling system out, adding a fuel injection tank donated form a breaker friend, then uprated lines and an inline fuel filter
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Fitted the Lexan side windows, reusing the original runner tabs - the rear side windows wont be getting changed until I address the bodywork.

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Can't wait to be rid of the EP3 seats, but not sure how quickly that will happen cost wise..

Had a few teething problems and a little bit of cryptic puzzles to get our heads around with the frankenstein wiring and different locations of sensors for b16 vs c4, but the engine was running spot on after being sat for a year.

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little video clip:
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Next jobs are to tidy up the loom, change all fluids, fabricate a b-pipe to mate the J's racing back box with the J's racing 2.5" manifold (on loan from my EM1 build for now) - I'll be putting in a silencer as it needs to be compliant for track use.

Still hoping for a shake down session this side of Christmas
 
I wanted a headlight intake duct for the EG, given that it wont be a road car anymore this seemed like the best route for a cool air feed. I didnt fancy paying good money for a pre-made one, so set about fabricating one myself.

I had a spare headlight, so removed the glass and used a strip of double glazing edging, with a little heat, to form the rough shape of the headlight - I've seen people use just the backing before, but I personally think it looks a bit unfinished.

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I also kept the reflector in place as wanted to keep some detail on the inside of the duct

After some shaping and fiberglassing in place

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I wanted the air flow to run flush over the bumper and into the duct, so next I needed to form the shape of the surround the headlight fills

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I had some spare piping so used this to create the exit of the duct

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Then it was down to the lengthy task of sanding and shaping..

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First layer of high build primer..

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I like the small details inside the duct

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and first test fit of the final shape

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Little bit of extra work to remove a couple of marks before I finish the priming and paint satin black, it's also still a fair bit lighter than the original headlight unit
 
the duct needs a little refinement to get it perfect, but I've been side tracked with brakes.

The EG came with 242s on non abs hubs. I've got the 262s off my em1 with good discs and pads and braided lines, all with very little mileage. I've decided that the em1 will be getting treated to something a bit nicer when it touches down, so for now I'm going to donate the old setup to the EG.. Only problem was that the 262s don't fit on the eg non abs hubs.

Luckily a friend of mine has a facelift ek4 he's breaking so donated the hubs. They've got good bearings and balljoints in them, so I swapped them over last night.

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the koseis are no longer on, I would have needed extended studs to run these safely so they are up for sale. Making use of a friends Dunlop Direzzas for now (trying to persuade him to sell them to me as they are incredibly light!)

Should be more than enough stopping power for now given how light the car is. We pick up the trailer the day before testing day, so it'll be off for alignment first.

(Hub nuts not locked in yet as leaving them as a final indicator once bolt checks complete)
 
I knew I was going to have to add a silencer to the b-pipe as the current setup was a bit rowdy with the j's racing manifold and back box, don't want to be getting called off track for noise issues.

I had this Honda silencer donated to the project.. No idea what it's off but it's perfect for what's needed.

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I also had a spare 2.5" flange and some stainless pipe in the unit so set about getting every thing to the right size..
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Took the flange down so the pipe could just slide through.

Then tacked it all up for a test fit - amazingly it fitted on the car perfectly first time.

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Finished the welding and then fitted it.

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Not the prettiest but functioning well. The sound is much better, not much change in tone but a lot less rowdy.
 
Got round to finishing the duct last night..

Bit more sanding of the last imperfections
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Then more high build and satin black
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and just a shot I liked whilst stood there last night - a lot of work in progress...

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Liking this little eg! Was thinking of doing a budget build with my mate! Looks like lots of fun.
Keep it up man :nice:

Can't wait for some track footage
 
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