D16Z6 HappyJack 1978 Civic 1200 engine swap

[HappyJack]

After fitting my new rims I realized I needed to address the idea of fender flares. I did some research and read somewhere that VW Golf MK 2 (1983-1992) flare would work with some minor modification. So, I contacted a friend who is a bit of a VW guru. I asked if he had a set of Golf MK2 flares. He said he didn't, but he did have a set off a Golf MK1 (1974-1982). Actually, here in Canada it was called the VW Rabbit.

So, I grabbed the set and quickly just taped them on the car to see how they looked.

Though now that I'm looking at the flares on the Golf/Rabbit, I realized I have them on my car backwards. I have the rear on the front, and the front on the back. But once I switch them around, I think with truly little trimming they will be great on the Civic.

[HappyJack]

Yes, I'm still alive, and the building is still going. Though very slowly. Summer is racing season, so my Civic project gets put on hold. But now race season is finishing, so time to start again on Bebe.

I finally mounted up the fender flares I got from a VW Rabbit (Mk1 Golf).I didn't trim the front flares, but I noticed they had a gap at the front where the original VW air dam was supposed to fit in. So, I talked to my friend who I bought the flares from, and he also had the air dam. So, I thought I'd see how it looked as well before I trimmed down the flares to get rid of the gap.

I like it. I think I'll use it as well. I'll have to bolt it to the fender to match the body curve, but it is made of soft polyurethane.

The rear flares I had to trim an edge that stuck out to match the VW body line.

The flare on the left is before the trimming, the one on the right is after I trimmed it. The edge that I trimmed faces towards the front of the car.

The rear edge of the flare I did have to trim a little to match the Civic body line. (flare on left trimmed)

I had to tape the rear flare temporarily because I still need to add the rear body corners that were cut off. But you can see how it will fit.
TIP

So that's all for now. Flares are on for now. They will have to come off again, for painting and bodywork. Right now, I just have a couple screws holding on them, I may use some double-sided tape to help seal them closer to the body when the time comes.

[HappyJack]

Yes, Bebe is still alive. My project keeps getting shuffled to the bottom of the list of priorities, but it is still a build, albeit a slow one.

I have the motor mounts tack welded into place where I want them. I'm not a good welder, and my welder is crap, so my son who is a welder by trade will come over and weld them properly. So don't judge my terrible welds.

I have the motor on a stand. Cleaned it up, added a header, new water pump and timing belt. Replaced a leaky oil pan and replaced the coil.

Next thing I worked on was the crank pulley. I need a single belt pulley. I can't seem to find one, and I'm not sure they even exist in the factory. I searched a little for an aftermarket one, but all I could find was an underdrive one, which I prefer not to go with.

So, I took my original pulley,

and hacksawed it in half.

Now it fits, but I'm worried about the balance now.

Thoughts? Ideas? Suggestions?
Anyone have a single belt pulley? Or a place to get one cheap? Will my cut pulley be ok? (I'm thinking not, but I'm hoping someone can convince me it will be fine.

[EvoCivic]

I probably would have taken it to a machinist and gotten them to part it off on a lathe. If you are really worried about balance it shouldn't be hard to find someone to balance it (look for people who balance flywheels, crankshafts etc).

[HappyJack]

I probably would have taken it to a machinist and gotten them to part it off on a lathe. If you are really worried about balance it shouldn't be hard to find someone to balance it (look for people who balance flywheels, crankshafts etc).

I did think of that, but they won't touch it because of the rubber dampener that is in the pulley. If you look closer there is a black line around the pulley. It is like it is a 2 piece with rubber holding it together. They were concerned about the heat melting the rubber, and the age of the rubber that it may blow apart.

[HappyJack]

I was looking at those, but I was worried about it being an underdrive pulley. I ran an underdrive pulley on my racecar, (Chevy 350) and it didn't turn the alternator fast enough to charge the battery when I was at idle. Not a problem with a race car that spends most of the time at wide open throttle, but I wasn't sure how well it would work for a daily driver.

[HappyJack]

Well I came here to do some updates. The project is still alive, and still progressing slowly. But now I see all my pictures are being held for ransom by photomucket. They won't let me hot link any pics unless I pay $400 a year. Screw that. So I guess I'm looking for a new photo hosting site.

[Randy]

I don't charge for uploading pictures or holding your car hostage either.