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Which box first? (Refer to post #154)

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Eunos Roadster V-Spec Maruha 2.1L BUDDY's Build

90K views 277 replies 72 participants last post by  iRoadster 
#1 · (Edited)
So after a not so-responsive thread I decided I should start another one in the correct section of CR. If interested you guys can have a quick look on my previous thread here: http://clubroadster.net/vb_forum/20-exterior-sponsored-r-speed/64690-buddys-new-look-thread.html

I have a 1992 Eunos Roadster V-Spec (i.e. RHD). Below is an overall outline of the things I plan to complete:

- Maruha 2.1L stroker upgrade with ITB kit (power)
- lowered and stiffer than stock suspension (handling)
- wheels
- cosmetic stuff to go for the vintage-style look
- minor transmission mods, engine cooling, etc. etc.

Anyhooo, the build starts with the engine upgrade. In search for a reliable tuner, I came across Maruha where they seemed to be quite internationalised with their English/US version of their website. A brandname parts manufacturer with quality products was very important to me. I was sure many manufacturers out there offered quality products. However, the brand was equally, if not more, important. I didn't just want a high-end modification giving me superior yet reliable performance at an economical price. For me as a Miata owner, I hoped to keep most of my mods as JDM as possible (yes, there is some insensible JDM fanboi thing going on here).

So, I came across Maruha and RS Aizawa, with Maruha being what I wanted. From a bit of searching I found out that Chikara was the authorized dealer. So I contacted Ocean and everything started from there.

One very challenging issue about this story is that I live in Hong Kong but I'm from Vancouver. Meanwhile, Chikara/Ocean is based in Vancouver while Maruha is in Japan. Although it makes more sense to work with Maruha directly according to my proximity to Japan, me and Ocean are both Canadians and we communicated very well. Hence, the engine upgrade part of the build starts with me committing to Chikara.

In a nutshell, the engine will be built by Ocean@Chikara, shipped halfway across the world to Hong Kong for my Roadster.

So far the engine is coming together. Maruha parts were ordered in two shipments previously.
Here's the first shipment which includes the 2.1L stoker kit (pistons, rods, camshafts, crankshaft, etc.)



Mahle Pistons, Maruha Racing camshafts, connecting rods, and other bits ordered from Maruha via Chikara










While this batch of parts arrived Chikara, Ocean had been working on my engine base. More pictures of his work will be posted in the next few days. Those would be more interesting than the parts pics I think....
 
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#115 ·
Allllright, please allow me to update some of the progresses on bootjai's 2.1L build. While there are many on-going projects at Chikara, the main focus is still completing this engine. We wanted to start the block preparation/assembly as the cylinder head is almost done with the CNC porting. This way, we can minimize the possible exposure time for the block before the head is all ready to be bolted on and sealing the whole long block together.

As some of you may remember, Chikara already had a CNC profile made about 3 years ago. This new profile is an updated and improved version. The heads literally just got back this past weekend and we haven't gotten around to get some decent photos taken. Once we do, Ocean will fully release the details!


Back to this build.. as usual, we began with the most important part of and engine build - A thorough clean-up. After some vigorous hand wash and air dried, it was brought into the assembly room where we installed the Maruha 2.1L kit specific oil jets.



One thing that we can really appreciate is Maruha's tremendous quality that is evident in even their packaging!



SST for installing the locating pin of the jets.



how it works, quite self-explanatory ;)



Installed


Next up, torquing up the main caps for main bore measurements





With our favorite torque-wrench, we can get perfect torque every time!



Done! here's another peek of the cylinder and the oil jet.



Setting the "zero" for the bore gauge.



Ocean at work



Next are the rod journals measurements



Bore-gauging again



Last but not least, a very important step - Crankshaft measurements!



A special stamp for a special crank :D



All parts are clean during the process. Then we weighted the whole rotating assembly.







When all is said and done, we gathered up all the specs and measurements from the day and type it all into our spec sheet as our data. (And so that we have a clean record instead of our hand writing only. Later this spec sheet will also be printed out for our customer's own reference.)

Hope you've enjoyed reading this update as much as we enjoyed our second 2.1L build. Next we'll be covering the actual assembly process, thanks for checking back!
 
#122 ·
Sorry for not doing the write-ups often enough here. It's not that we're stalling with this build, The block is all done and sealed up. In fact, the work I'm about to post was done a week ago. Next will be finishing off the head assembly and have it ready to complete the long block.

As some of you might know, we have been multi-tasking many things at once. Such as our many in-progress projects and our newly launched Facebook group/Youtube Channel. Be sure to check those out as there are plenty of unseen documentation of our work in the past and also video entries for up-coming dyno sessions, trackdays, and other events.

_____________________________________________________________________________


Maruha 2.1L stroker crankshaft


Checking thrust endplay


Rear-main seal installed with shiny new bolts (high grade) used


Our own SST for oil pump installation


Again, new bolts are used for the oil pump here. (Bolt kits are actually available from us. This is perfect for those who want to DIY but not bother with the exhausting cleaning and the possible risk of re-using the OEM ones. These will provide solid and stable torque every single time. One can actually feel the difference when tightening them!)


Rods, pistons, and pins. All weighted and matched with best balance.


Piston-pin clips can be a painstaking task for some but nothing faze our thick-skinned fingers now.


Completed!


Next is checking and adjusting ring-end gaps


Another SST


Checking with feeler gauge


Grinding the rings for the proper gap


No ring compressor used, it's a designated tapper shaped SST tool


Torquing down the rods


All installed and torqued


An essential for every build - Maruha oil baffle


Our new bolt kit covers everything!


...even for oil pick-up!


Completed with the oil pan bolted on. Looks good as (or better than) new now!



There you go, our block assembly process documented in detail. Hope it was informative enough while entertaining for you all. Thanks for reading!

Have a great weekend! :)
 
#125 ·
Shouldn't be extremely hot, normal operating temperature can still be hot after a few seconds. That said, you are getting the Maruha heat exchange type oil cooler right? This should be perfect for Asian traffic patterns as it does not require continuous incoming air.
This engine is gonna be better than new, I guess u really can't resist to touch it. ;)
 
#131 ·
Goddamn I'm in NYC with my jaws to the ground with this build thread. Everything is done so properly, unlike mine haha. I sat in training not studying, hanging on to each post for like an hour. Keep up the work.
Maybe I can see this car in person next time i come to HK :D
I've walked around HK and have seen countless garages, but not many look as clean and professional as the ones you go to. I've only seen maybe 2 in To Kwa Wan where my uncle lives that are decent. Sucks that there's no space for any DIY kind of work for a car enthusiast in HK.
 
#133 ·
Updates!

So the next task was the head assembly. After receiving the head back from the CNC machine shop, it was time to install the parts and components onto the head including the valves, valve springs and related parts, cams, lifters, shim bucket, etc.

I must say I'm very impressed by the attention to detail, professionalism, and workmanship at Chikara. All the new parts they receive they clean them and check them carefully. I am sure there are builders out there that just lube and install without a detailed inspection and/or cleaning, or maybe casual inspect and cleaning. But knowing the guys at Chikara, we are talking about Asian-level inspection and workmanship (lol, but seriously).

Cleaning of the valve stem seals.




Lube before installation



Yes, they actually clean every valve lock, not just the big/major components.



And lifters as well...



Valve springs. Guess what brand...



Installation/assembly. The stains you see are from the lube. All the parts were test fitted first and prolly some lube from the pre-fitment of the valves and springs/seals also dripped a bit. Anyway, its good stuff...



Then, it was time for the main course...



And of course, cleaning and inspection before anything!



As documented before, these are a pair of non-overly-aggressive racing cams in order to strike a harmonious balance with the climate issue in Hong Kong.




While the cams were being prepared, Maruha injector plugs were installed to block the OEM injector holes located on the head. The aftermarket injectors will then be re-located onto the ITB.




Here are the (already cleaned and inspected) under bucket shim. Pay attention to the different plastic pockets. Each shim is measured and then grouped into the plastic pocket with the designated size.



As you can see from this table (no of course you can't see it, don't even try. Its just for illustration purposes), each shim is delicately measured to fit into its respective position to make sure the clearance is enough, AND the clearance is standardised. Asian workmanship yo~



Now you see 'em. Now you don't.




You will see from this picture the Maruha injector plugs all in, and the lifters in place.




You put your in-cam in, you put your in-cam out, you put your ex-cam in, and you shove it up your @$$~





And there you have it, the head assembly of the Maruha 2.1L stroker build with ITB.

Hope you all like this update. Stay tuned for more! The project will be concluding very soon so frequent updates will be done! :phillyb:
 
#136 ·
On the previous update yesterday, the post was maxed out in terms of images. So as a teaser post, here is what the block looks like.




Water pump and such installed, waiting for the head.



The block just needs the gasket before the head gets installed.



And here, just to let you guys take a peak at the inside of the port and polished head.




Cheers!:icon_cheers:
 
#137 ·
Have been collecting some special (some rare) items to dress up the car while the engine was being assembled. Going for the vintage look, so here goes:

Nakamae goodies



Original OEM V-Spec carpets



Need to do something to the badges. Any guidance appreciated!


Been always wanting to get a decent camera to take pics. One purpose of course is to get some good images of the build and also the parts that I intend to give to Buddy for a vintage look.

What can be more perfect than a vintage styling 4/3 camera? The newest/trendiest technology with a vintage design.



(taken with iPhone 4)


(taken with iPhone 4)


Couldn't decide which effect was best:






So this rare piece arrived in the mail...:ibtl:



Time to pull out my new camera!



Genuine OEM M2-1001 oil cap


Original image @ 4608x3456



Original image @ 4608x3456



And that's another update!:phillyb:
 
#139 ·
I love this build and completely agree with your theory. Lots of folks here want to make the Miata a race car instead of appreciating the much more rare (and difficult to achieve IMO) roadster qualities. A reliable car with better torque and a little more power... Perfect.

I love the engine. I'd love to have an engine built up by these guys!
 
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