D16Z6 HappyJack 1978 Civic 1200 engine swap

[Layspeed]

Jack, just a heads up, the positive camber problem is one of the main reasons why most just don't swap in 2nd gen knuckles/hubs/brakes. Since you have almost everything needed to do a proper 4x100 conversion other than caliper adapters, that's what I would suggest. As far as the front crossmember goes, I'm curious to see the finished product. I know with very careful engine placement and re-routing of the exhaust around the crossmember, you could keep the swaybar. I just choose to run without one.

Pics are great, no such thing as too many pictures. Whether people plan to do a swap or not, I'm sure everyone gets excited over pictures. :D

[HappyJack]

Yes, the project still lives on. After a year or two of procrastination, I'm back at it.
I decided to deal with my fuel tank issue. Since I'm going with a modern motor, I knew I would have to go with an electric fuel pump. The easiest solution seemed to be use the fuel tank from the 93 Civic donor car. But it is roughly the same dimensions, except for the thickness. It would hang down too low.

So I stripped out the 93 tank, to see if I could get the pump to work in the 78 tank.

The 93 tank had 2 holes, one for the pump, the other for the fuel gauge sending unit.

The 78 Tank just has one hole, and it is too small for the electric fuel pump.

Not wanting to cut up the 78 tank unless I had to, I started looking at my options.
I noticed the hole in the 78 tank was the same size as the hole in the 93 tank for the fuel gauge unit. I decided the best way to go was to use an inline electric fuel pump, and then I could use the modern fuel gauge unit in the 78 tank and it would just plug in because i was using the wiring harness from the 93 as well.

I just had to cut a small notch in the unit to fit in properly.

It fit in like it belonged there!

A fresh coat of paint to keep the rust at bay and it is ready for install.

I can mount the tank, and then worry about the fuel pump later.

Then I realized my mistake. By using the hole in the 78 tank for the fuel gauge sending unit, i had no way to get fuel out of the tank! Doh!! :oops:
I guess I have to dig through my parts to see if I have an original 78 sending unit and use it. I didn't get one with the tank, but I've stripped enough parts cars I'm sure I have one around somewhere.

So this is my non-progress so far. At least the tank is shiny.

[HappyJack]

Ok, after my last post I feel really stupid. But remember when I bought this car, it was already in pieces. :roll:

I had assumed the fuel pick up, and the fuel gauge sending unit were in the same spot. And since I didn't have one readily available to compare I just went with that assumption. So yesterday I did dig up a spare gas tank and pull the gas gauge sending unit out of it. This is what I got.

I tore it apart hoping to...well I don't know what I was hoping for.

So I tore apart the one from the 93, figuring maybe I can use parts or swap then or something.

Identical inside, might just shorten up the arm. Then I realize I can probably use it as is, since I did have it in the tank anyway. Then it dawned on me, the old unit doesn't have a fuel pick up either. Never said I was quick. :oops:

So now the stupid question. Which of these 3 small tubes is the fuel pick up?

[HappyJack]

Ok, small update, more for me than anyone else. So this wont seem like anything much to most of you. Got the fuel tank in and sorted out. I ran the wires for the fuel pump and fuel gauge through the rubber drain plug under the back seat.

I have now started assembling the interior. Back seat is in as well as the seatbelts.

Next I installed the trunk latch.

On one of my latches, ( i have a couple as spares) there was a cable attached for a remote trunk release. It looks like it might of been added, not factory. Anyone know if this was a factory option? If so, where would the release lever be? Beside the seat?

Next is the dash.

I have already stripped out the old wiring and am going to use the 93 Civic wiring harness. Hooking it up to the original controls ( heater motor, radio, lights etc.) and gauges as much as I can. I have a couple spare dashes, so I'm picking out the best of what I got.

Including the centre mounter fuel and temp gauges.

Thats it so far, now it looks like I'm off to shovel snow before I continue on.

[HappyJack]

I'll be fabricating a crossmember too. My son is a welder, so I'm waiting on him when he isn't busy. So, I decided to work on the interior etc.

[HappyJack]

Ok, I picked the best of my 3 dashes. I had to swap the VIN number off the original to the one I'm going to use so it matches the ownership, and the number stamped on the firewall.

I plan on using the deluxe gauges, so I had to peel back the fake wood grain to get at the panel behind it.

Removed the panel

I set the gauge pod in to see how it would fit.

I noticed the gauges themselves were dirty, so I took them apart and cleaned them up.
Fuel gauge cleaned, temp still needed to be done.

Re-glued the fake wood sticker with the section removed for the deluxe gauges.

Gauges set in place, now I got to find the mounting screws.

Slow progress, but it is progress

[HappyJack]

Actually I didn't take it down that far. Someone else did, I bought it this way. It was a shell, and several boxes of parts. Which makes it harder.to reassemble since I didn't take it apart. My wife calls it the world's biggest jigsaw puzzle.

[HappyJack]

I think I should rename this thread "Here is what NOT to do".
After peeling off the fake wood grain off the dash to install the deluxe gauges, I glued it back on.
Well, a couple days later I went back out to the garage to find this...

I think it was the glue I used. I just grabbed the closest stuff I had; ABS cement. You know, the yellow glue you use for plumbing pipes.

It either reacted to the vinyl, or it didn't stick to the dash and as it dried it curled up the vinyl. So don't use that!

So, I debated trying to find a match for the wood grain vinyl somewhere, then decided I had a spare dash with good wood grain. So I removed the cover plate to install the deluxe gauges without removing the wood grain.

Now I just have to swap everything over from the dash I was going to use. It's a bit of a pain, but I think it's easier than trying to find the vinyl and trying to install it without messing it up.

Started filling the holes in the firewall. Installed the throttle cable, clutch cable, speedo cable, brake booster, hood latch cable. I'll have to find a rubber grommet to fill the hole for the manual choke.

Installed grab handles on both sides. I was going to ask if anyone had the little plastic piece that covers the screws for the grab handles, but I found one after I took the picture.

Also went through what I have for letters and badges etc. Not great shape, but I should be able to clean them up. The fender badges are the worst, not sure about them. I guess I'll see what a little paint will do. I won't be using the Hondamatic badge, and the one Civic badge is from the 93-donor car I got the engine from. Probably not using that either. I also managed to find a local dealer badge. I pulled it off a second gen Civic I found at the wreckers, but the logo is about the same vintage for my 78.

Getting ready for a dash install next.

[HappyJack]

Not too much to update. Been busy with Christmas, family, and life in general. But what I have done has been minor. About installing the dash but making sure everything behind the dash is ready first, since doing it now instead of after would be easier. Also soldered the old plug for the heater motor onto the new wiring harness, so now it just plugs in.

I installed the radio, which is the right vintage, if not completely correct for the car. But first I made sure it worked. It was a small mystery at first since it only had 3 wires to work with. But it still works. Hooked it up to a speaker and had glorious mono-phonic sound.

Took the gauges apart and cleaned off 37 years of grime. The speedo had been apart before, someone added an NGK decal to it. Debated scraping it off, but I was worried about damaging the face. So, for now, it stays. I will be using the original cable driven speedometer, even though the computer will be looking for a speed sensor for the v-tec. But I know someone who can get into the computer and have the computer not look for the sensor. He has done it on his 1st Gen CRX with a B18 in it.

My latest obstacle is finding a replacement bulb for the dash light that is behind the heater controls. I have stripped 4 cars, and everyone is blown.

It is a 12 volt/1.2-watt bulb. The local Honda dealer is useless because they can only look back as far as 1980 on their computer. I found a couple online, but they are 2-watt bulbs, not sure how much brighter that would be. I did find some in India on a vintage motorcycle site, package of 10. But I was hoping for something closer, and I don't need 10. Unless I sell the rest here.
So, does anyone in Ontario have one, or know where to get one before I order some? Seems dumb to pay $5.99 for shipping on a 39-cent bulb.

So that is my progress so far

[HappyJack]

I believe the bulb is only for behind the heater controls, but then again, I didn't check the speedo and tachometer, I just ran power, and they lit up. Now I must go check.