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'91 CRX Si Rebuild (UPDATE)

18K views 40 replies 12 participants last post by  Claysonw  
#1 ·
Hey guys! I had no clue that I was going to stumble upon my dream car! A little background: I have always been into Hondas because my older brother got me into them with his 94 Honda Civic. I also got into cars because of my brother. Well, one day I was sitting down at home with my father watching top gear (sadly, we were watching the american version...because it was one of the first episodes) Anyway, on this episode (i think it was the second or third episode) all of the guys bought what were their first cars when they were kids. Guess what one of their first cars was? A CRX! I saw it on this episode and I fell in love with it. I had a '92 prelude at the time and literally right after the episode, I got on the internet to look for a CRX. I was only in high school at the time, so I didn't have the money to buy one. So that was when I initially got hooked on CRX's. So, fast forward a good 3 or 4 years, to this past summer. ( I still had my prelude at this point...) I was set to go to Florida with my Fiance and her family for vacation on june 14th (which was also my 21st birthday. haha). About 5 days before we were set to leave, I was driving to work one day and saw a white '91 CRX Si! I immediately pulled over and took a look at it. I didn't have much time left before work so I had to leave. As soon as work got done, I ran back over to where the CRX was and found the guy that was selling it. I asked him how much he wanted for it and he said "i want a thousand, and im gonna get a thousand cuz i've had way too many people stop by just in the past 2 days." So I told my Fiance all about it (she was not thrilled to say the least...) and started figuring out if i could afford it or not. So the next day, I hopped in the car with my brother and went down to take a better look at it. We looked it over and realized it needed quite a few things, but at the most (mechanically) it would cost between 600-700, IF the engine was not getting compression (it seemed fine). So i made a deal with the guy for him not to sell it to anyone else and that i would go get the money and come back the next day and get it. :) I went back the next day and grabbed that sucka and i was the happiest freaking person in the world. haha. Anyway, I started making plans as to what to do on it first...and 2 days of driving it...IT DIED. lol...ALMOST literally... Found out that I had no compression in one cylinder and low to no compression in another. (I like to say i was running on 2 and a half cylinders...haha). So, at this point i had to go to Florida. I put my prelude up for sale while i was in Florida but it didn't sell by the time i got back. When i got back, i started buying parts to pretty much rebuild the engine. I took the head to a shop to machine it and clean it up and when i got it back, the guy told me it was off by 15 thousandths!!! WTF!? I never knew it was that bad! haha. So this is what I did to the engine (with my big bro's help of course(i have never done anything this big on a car before and he taught me. haha))

I put in:
-Piston rod bearings
-main bearings
-new piston rings
-all new belts
-new radiator
-new header
-new downpipe
-new catback exhaust
-decked and machined head (replaced a valve that had a chunk taken out of it too...YIKES)
-new gaskets (of course)
-some misc. new sensors
-new oil pump (funny story here, my brother and I didn't see one of the bolts because of all the grime and we tried to "gently" smack it off...dented the oil pump and had to get a new one)
-new "ebay special" (as i like to call it :D) short shifter
-All new hoses (they were so old and falling apart...)

So, after all that, and a full weekend of work (literally took up all day saturday and all day sunday and half of monday from the week prior) it finally came to life! It was an amazing feeling to hear it and feel it start up! :D So I drove it for a few weeks having intermittent problems (knew it was going to happen, still crap to fix on it) and this is what i did then:

-new coil (first time i got a new one, it worked for 2 days fine and then intermittent problems again...i got such a headache trying to figure out what was going on and just the other day replaced the coil because it was under warranty and THERE WE GO, works great now! haha)
-new fuel tank! (thing was rusted solid through...)
-some new fuel lines
-new fuel pipe (can't remember the exact name...haha sorry. its the one in the back of the cabin, bronze looking, its literally what you put the fuel pump at the gas station into to fill your fuel tank.)

So now for pics! :D It still has a LOT of work left, with a ton of crap i want to do on it. But the best part is that everything mechanically is perfect now! (it doesnt even smoke at all anymore! It used to just BILLOW smoke)

Night i got it!
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Taking the D16A6 out! :)b
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Out now and nothing in the engine bay...
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On the engine stand.
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Sorry that I don't have any pictures of the dissasembly. :( Somehow they got lost on my phone...

Dropping it back in! (thats my brother on the right, and me on the left, he's looking at the clearance for the mounts and telling me which way to move the engine)
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BACK IN! (this was the end of Saturday night at around 9:30 pm. We had started at literally 9 am that morning...long day)
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Sorry i don't have any pics of the engine bay now! :p i feel ****ty haha. I'll take some pics later and post it on here. just wanted to get this build thread started since it's been over 2 months since this was done...haha)

This is what it looks like now! I took a drive today to hopefully find a Civic EX armrest...tried 3 places and none of them had it! GRRRR! Oh well! It was a great drive with the Rex and i got some okay pics! haha

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And this is a cool pic of a house I found that looks like a castle. haha. Sign said "Under surveillance" so I just backed up real quick and shot my pic and left. They were probably like, wtf? haha. I'll have to go back and be a little more daring next time and get a better pic. :D haha

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I'll post pics of the engine bay and the interior later on. Next major things I have on the list are:

-Windshield (fucking huge crack)
-New tires (not rims...TIRES. haha)
-CD Player
-Seats reupholstered (my dad did his own Del Sol seats so he said he would do mine. :D)

Thanks for looking guys! lemme know what you think! Also, I'm thinking on painting it silver... :D
 
#4 ·
Yea, i was super happy that it was unmolested. lol. And yea, either blade silver or a deeper silver...like the color that someone on here has. He has a build thread and his name is Quentin...he has a great, CLEAN CRX. And yes most def! Already know I pretty much have to redo the rocker panels...don't worry guys. It will be done well. :D
 
#5 ·
So a little update guys, I got my new corner lights in this weekend and installed those puppies! :D

These were the old ones:


These are the new ones:


I also cleaned the IACV a few days before this weekend, this is before:


and after cleaning with brake cleaner:


Then i buffed it a bit and cleaned the inside:






Heres the engine bay. Soon, i am going to powdercoat the valve cover. :D


Then i started tearing apart this civic seat that my brother gave me because he has new seats. I'm going to use it for donor foam for my driver seat because its crap and falling apart. :cry: Eventually i will reupholster the seats as well...


Oh, and i found out that i need two of these...one of each. For the passenger's side. :p Where can i get these?


Well, that's it for now. Big plans for this car though. Can't wait to get some paint on it and some new seats. :biggrin:

Also, i have no clue as to why the images are small like that...
 
#10 ·
Yea, and its especially helpful when he has done practically everything to his civic and can help you with yours. :D Also guys, i'm thinking about a dark silver like this GTR: http://www.google.com/imgres?sa=X&biw=1 ... 205&ty=119

Or maybe STI blue. Even though I HATE STI's with a passion, I think that blue would look really good on a CRX. What do you guys think?
 
#13 ·
Its been a while since i have done anything to the REX... I bought new quarter panels and rockers for the CRX and my brother is teaching me how to do some body work.



And i bought some cheapo rims off craigslist for $80. There's only 3 here because...



This one is FUCKED up. I bought it knowing this...And i got it fixed! A coworker of my brothers' is a great TIG Welder and he did a great job repairing it.



Here it is fixed. The sunlight is hitting the rim kind of weird and it looks ****ty right now because i'm currently using a heavy duty paint stripper to get the crappy paint off. I'm pretty sure the previous owners used regular latex paint...



This is the specific area that was jacked up...



Then, we of course tore everything out...











I cracked my dash taking it out. :oops: Next time i will be way more careful. I'm in the works of fixing it right now...I'll show pictures later on.



Found this cool Japanese writing on the headliner underneat of the seatbelt lights.



Then, we tore up the sound deadner and found boat loads of rust... This is the passenger side floor pan. Luckily this was the only BAD rust. The rest is just surface rust.



Took the sunroof off and found a lot of terrible rust.





Completely rusted rear bumper...



Took the old rocker off...





I'll keep you guys updated as everything progresses. Obviously everything will take a lot longer than thought, because of all of the effing rust. Also, a supsension overhaul is definitely going to be done soon...Hopefully sometime in July. :bounce: I also bought a new carpet from stockinteriors.com. I got the mass backing so it should make the cabin more quiet which is what im going for. I'll also probably get some dynamat from them soon too.
 
#18 ·
Well, I have started collecting parts. My carpet also came in but i don't have a picture yet. Too lazy... It is very thick though and very nice. It also got shipped very fast. Would definitely recommend them to other people.

New amber corner lights



I got a full set of these "Stagg" shocks on ebay. They were cheap and i am going to just be using them as an OEM replacement. There is another member on here who got them and said that they are actually decent. From reviews that i have read, it seems like they are good for the price. They also stand behind a lifetime warranty with the car being lowered within 1.5" I don't think i'll be lowering it on these though...I also bought these just so i had something for now, and i am saving up for the famous Koni Yellow/GC combo.



My birthday was also this past Saturday and as one of my gifts from my fiance, i got a short ram intake. Now i don't have to look at that ugly hardware store bendable duct pipe...



And last but not least, the paint off the rims are peeling off slowly but surely...

 
#19 ·
Hey guys, the build is going along nicely. Should have it painted in the next month or so. Its been very slow going but i'm nearing the end! There was way more rust on this thing than what we had thought at the beginning. My brother has been helping a lot with this build and it would have taken a lot longer without him! Just a few pics before a decent update when the car is put back together!

Some fab work cuz its FABULOUS! :bounce:
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And this is how she sits now until paint... all welding is done. Just need to finish the sunroof, do some bodyfill and prep for paint.

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#24 ·
Work on the Rex has been rolling along. It feels like its taking such a long time with the car being an hour away at my brothers garage and only getting to work on it on average one day a week. :cry: Anyway, here are some pictures of the progress made recently.

Decided to just go ahead and strip the paint completely to make sure i know whats underneath the new spray.




Then laid down A **** TON of body filler. Waaaay too much :( Oh well, its all gonna get sanded off next time.





It's taking so freaking long to sand all that off the hood. DEFINITELY going to be more careful next time. I would guess that i'm probably about halfway through sanding it right now.



And some goodies i got recently.



Went to the local pick n pull and got this from a Civic EX.



Painted it black with some of the duplicolor vinyl spray. It worked super well and came out really nice!





My rims are finally coming along too! They are being completely sandblasted and then powdercoated black. 8) They had 3-5 coats of LATEX paint on them. looks like they were originally white and then someone sprayed black over that and then another white over that. Goal is to have the CRX put together by April 1st. :)b
 
#25 ·
When I saw your post on Jan 20th or so and you said "all the welding is done so just need to body work and should get paint in the next month" I thought....yeah right I know how this goes. Let's see if this car gets paint in a month lol. Not making fun just saying I've been there. All these people that say they built their cars but didn't do any of the bodywork and just dropped it off at a shop have no idea how hard it is to do yourself. Seems like you don't have long to go but doing the bodywork for me seemed like the hardest part of my entire build! Props for you actually doing your own work on the body! Take your time. When in doubt put another coat of primer and block it out again. Bodywork makes the paint job. My bay took as long alone for the shave and bodywork as the outside of the car. You will appreciate the car so much more actually doing all this yourself. Everytime I wash and wax my car I appreciate the finish knowing that my hands went over every inch of my car over and over to finally create this finish and it really feels good. I don't undertand how some people can say "built not bought" when they hauled their car off to a bodyshop and "paid" or "bought" to have someone else bodywork and paint the entire car lol.

BTW, putting a huge skim coat of filler over a panel like you did on your hood really sucks to sand off but in the end usually saves time and is the best way to do it. If you try to just put filler on small spots at a time you will keep chasing all over the panel and doing the panel several times over(guess how I found this out). Skim coat it and block it all back out. You are doing right. It looks like a lot of filler but 95% ends up back on the floor. Look through my build and you can see when I sanded my hood off and there is a pile of filler on my garage floor lol!

Keep it up!
 
#26 ·
I totally understand man. Maybe I was too jumpy to say it would get paint by end of February. But I think it's good to have goals so that it pushes you harder. So with that said, I'm shooting for it being painted by the first week of April, which I think is doable. Hopefully I can work on it more than one day during the week which is why it's been so slow. :p and yes I totally agree. That's why I want to do it all myself. Also, that ensures that it's done right and I know exactly what is on the car. And yea my bro is helping out which is awesome because he did his civic this same way. And thanks for the advice man! Next update will be paint. I'll leave this in the dark for a while. Not too many interested anyway. :oops: haha.