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PostPosted: April 25, 2013, 12:27 pm 
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Location: Santa Maria, CA
March 12, 2013

Trimmed the 'back' chunk of engine casting off of the VFR engine so I could drop it in between my frame rails.. This is the portion of engine where the VFR's swing arm pivot was, so it was a useless chunk anyway.. Set the 149 lb. monster down into it's new home.. It is a tight fit on all sides.. biggest concerns are having the driveshaft (bike's countershaft) sit high enough to clear the Miata rack.. it will clear by about 1/4"... Also fitment issues with VFR water pump clearing steering rack.. it clears.. all issues clear so far, but most by less than 1/2"... these tolerances are so much more difficult to work with than the old 50's street rod stuff I'm used to working with :shock:


Attachments:
VFR engine on its temp legs for placement.jpg
VFR engine on its temp legs for placement.jpg [ 177.15 KiB | Viewed 3090 times ]
little V4 in its little car home.jpg
little V4 in its little car home.jpg [ 182.7 KiB | Viewed 3090 times ]
another shot as it will sit in car seen from front of car.jpg
another shot as it will sit in car seen from front of car.jpg [ 158.7 KiB | Viewed 3090 times ]

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My '72 Honda N600 build log (bike engine in a microcar)...
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My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: April 25, 2013, 1:05 pm 
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Joined: October 10, 2010, 10:26 am
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Location: Santa Maria, CA
SPRING 2012

With the engine roughly in place, I could start solving fitment issues and dealing with the 793 details needed to move forward..

Changing over from the bike's hydraulic clutch (cast into the countershaft cover), do a cable clutch was a challenge- the arrows show where the clutch rod goes through the motor; and how tight clearance was at the pivot at the top of the clutch rod.. Although the 2 pics I have of this aren't great, you can see where I made a long arm that pivots just under the countershaft flange.. it's impossible to see, but there is yet another pivot up under the arm/anchor that allow the long black arm and clutch rod contact point to travel in different arcs/angles.. Too tedious and make-specific to explain, but it took me a few days of head scratching to solve this one...

Also, found a somewhat recent pic of the T5 between the seats.. the angle makes the driveshaft flange look closer to the driver's seat than it it (in reality there's at least 5/16" in there! :lol: ). For reasons stated the T5 has since been pulled..

**btw- the 3-legged spider looking thing will be the engine side anchor point for the morse shifter cable..


Attachments:
clutch fitment diff angle.jpg
clutch fitment diff angle.jpg [ 197.81 KiB | Viewed 3087 times ]
clutch to countershaft clearance issue.jpg
clutch to countershaft clearance issue.jpg [ 190.74 KiB | Viewed 3087 times ]
driveshaft flange made from old sprocket.jpg
driveshaft flange made from old sprocket.jpg [ 186.8 KiB | Viewed 3087 times ]
T5 just before I pulled it out.jpg
T5 just before I pulled it out.jpg [ 163.11 KiB | Viewed 3087 times ]

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My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: April 25, 2013, 3:59 pm 
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Location: Santa Maria, CA
Out with the old, in with the new..

The Miata diff was just too steep for freeway use at 3.9, so out it came.. In it's place went a Ford 7.5 IRS from an early 90s T-bird... my donor 7.5 came with 3.73 gears, so I swapped them out for a 2.73 R&P.. I'm just hopefull I didn't go too far the other way.. It took a lot of trimming to fit the pumpkin in the narrowed subframe, but it works.. Pulling the T5 took about 70 lbs out of the car, while swapping the little Miata diff out for the comparatively big 7.5 brought at least 20 lbs back in... Ideally I'm minus 50 lbs or so for having done this.. (looking for the silver lining here :roll: )


Attachments:
another shot of rear clip with 7.5 diff.jpg
another shot of rear clip with 7.5 diff.jpg [ 201.11 KiB | Viewed 3066 times ]
miata diff and T5 pulled from car.jpg
miata diff and T5 pulled from car.jpg [ 154.43 KiB | Viewed 3071 times ]
7.5 irs bolted into narrowed miata rear clip.jpg
7.5 irs bolted into narrowed miata rear clip.jpg [ 180.3 KiB | Viewed 3071 times ]
7.5 diff squeezed into miata clip narrowed 9.5 inches.jpg
7.5 diff squeezed into miata clip narrowed 9.5 inches.jpg [ 177.47 KiB | Viewed 3071 times ]

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My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: April 25, 2013, 5:53 pm 
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Joined: October 10, 2010, 10:26 am
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Location: Santa Maria, CA
Spring/ Summer 2012

Motor mounts completed means fabbing exhaust.. this is a pretty low-buck approach: I bought some swap-meet headers with 1.5" primaries and cut them up for my needs.. they went together pretty nicely all considered.. it was tough to match lengths, but I finally ended up with all 4 at 28.5", which may seem long, but I tuned them for torque.. The secondary pipe is 1.75".. maybe overkill on size- don't know.. later I would add a 2nd inline 'flow through' type muffler to further quiet the car.. still tweaking on how I want it to sound.. VFRs have a unique rumble, and I don't want to lose it..

I included a pic of the VFR stock exhaust for comparison- note how long even Honda made the primaries- mmmmmm, torque :lol:


Attachments:
VFR stock exhaust.jpg
VFR stock exhaust.jpg [ 147.49 KiB | Viewed 2999 times ]
early work on exhaust.jpg
early work on exhaust.jpg [ 175.5 KiB | Viewed 3063 times ]
exhaust headers done.jpg
exhaust headers done.jpg [ 181.19 KiB | Viewed 3063 times ]
exhaust to flow under and beside driveshaft.jpg
exhaust to flow under and beside driveshaft.jpg [ 181.88 KiB | Viewed 3063 times ]
exhaust from headers to diff area.jpg
exhaust from headers to diff area.jpg [ 155.68 KiB | Viewed 3063 times ]
exhaust almost complete out of car.jpg
exhaust almost complete out of car.jpg [ 140.48 KiB | Viewed 3063 times ]

_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"


Last edited by ccrunner on April 26, 2013, 2:39 pm, edited 1 time in total.
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PostPosted: April 26, 2013, 11:48 am 
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Location: Santa Maria, CA
MAY / JUNE 2012

Assembled shocks/coils (150# front and 125# rear).. / started cutting out N600 oem inner fenders-front sheet metal in prep for custom inner fenders and engine bay detailing.. had to change inner fenders for wider tires and wheels and to accomodate lowered stance. // took out so much Honda sheetmetal it looks like swiss cheese up front! // placed front coil barrels (pass throughs) and proceded from that as a reference point.. (not sure how tall they'll need to be yet- will cut down as ride height is set later) / split and re-arched a new trailer fender to act as new inner fender base.. / Went to Pomona swap meet and picked up a good 67 Camaro rear bumper to cut down later- also got more POR15 for the floors (it is THE BEST rust preventative coating- period!)


Attachments:
more gutting oem sheetmetal.jpg
more gutting oem sheetmetal.jpg [ 192.89 KiB | Viewed 3024 times ]
drivers seat view of cutout.jpg
drivers seat view of cutout.jpg [ 199.95 KiB | Viewed 3024 times ]
pass seat view of cutout.jpg
pass seat view of cutout.jpg [ 209.48 KiB | Viewed 3024 times ]
the unfun dirty work.jpg
the unfun dirty work.jpg [ 176.92 KiB | Viewed 3024 times ]

_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: April 26, 2013, 11:56 am 
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Location: Santa Maria, CA
More on the hack job..


Attachments:
cutting and more gussetting of frame area.jpg
cutting and more gussetting of frame area.jpg [ 205.34 KiB | Viewed 3022 times ]
drivers side front cutout.jpg
drivers side front cutout.jpg [ 167.85 KiB | Viewed 3022 times ]
cabin inner fenders go too.jpg
cabin inner fenders go too.jpg [ 196.05 KiB | Viewed 3022 times ]

_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: April 26, 2013, 12:00 pm 
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Location: Santa Maria, CA
Going from removing to replacing...


Attachments:
cut down trailer fender will become n600 inner fenders.jpg
cut down trailer fender will become n600 inner fenders.jpg [ 186.27 KiB | Viewed 3021 times ]
coilspring barrels tacket in.jpg
coilspring barrels tacket in.jpg [ 202.8 KiB | Viewed 3021 times ]
cut out n600 oem inner fenders.jpg
cut out n600 oem inner fenders.jpg [ 193.47 KiB | Viewed 3021 times ]

_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: April 26, 2013, 12:12 pm 
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Joined: October 10, 2010, 10:26 am
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Location: Santa Maria, CA
JUNE 2012

Lots of progress over the next few months as I'm a teacher with summers off... These pics show a bit of the always time-consuming panel replacement/ reconstruction... To this day I'm surprised at the lack of rust on this car.. I really just got lucky.. however, I did find a bit in the driver's floorpan, so I cut it back and replaced the damaged section.. later on a came back and stiffened this area up with an OEM stamped rib..


Attachments:
detail on new spring pass through.jpg
detail on new spring pass through.jpg [ 178.14 KiB | Viewed 3018 times ]
stitching spring pass through into firewall.jpg
stitching spring pass through into firewall.jpg [ 203.1 KiB | Viewed 3018 times ]
drivers floorpan r and r.jpg
drivers floorpan r and r.jpg [ 209.94 KiB | Viewed 3018 times ]

_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: April 26, 2013, 12:35 pm 
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Joined: October 10, 2010, 10:26 am
Posts: 1227
Location: Santa Maria, CA
JUNE 2012

More panel/nose work.. The interior shot shows the oem floor rib I was talking about... floor is also in POR15 with seam sealer where apropriate..

The engine bay shots have the inner fenders/metalwork about 1/2 done... It took a bit of trial and error to learn how wide the inner fenders had to be, and how to have them clear the VFR head, particularly on the driver's side where things get especially tight.. eventually it all fit..


Attachments:
interior floor with seam sealer and por15.jpg
interior floor with seam sealer and por15.jpg [ 206.95 KiB | Viewed 3016 times ]
wideshot with nose almost back together.jpg
wideshot with nose almost back together.jpg [ 168.76 KiB | Viewed 3016 times ]
engine bay shot with metalwork about half done.jpg
engine bay shot with metalwork about half done.jpg [ 180.75 KiB | Viewed 3016 times ]

_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: April 26, 2013, 12:41 pm 
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Joined: October 10, 2010, 10:26 am
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Location: Santa Maria, CA
JUNE 2012

The engine went in and out several times as I had clearance issues on all sides.. I smoothed the firewall and did a bunch of detail work at this stage (although I didn't go too crazy with the detailing; this is not intended to be a show car).. In the end I just want it to look nice and clean and still be DD functional..


Attachments:
overhead shot of engine in place to check clearances.jpg
overhead shot of engine in place to check clearances.jpg [ 193.8 KiB | Viewed 3016 times ]
engine with exhaust and mc and inner fender arches in place.jpg
engine with exhaust and mc and inner fender arches in place.jpg [ 207.86 KiB | Viewed 3016 times ]
prepping finished engine bay for paint.jpg
prepping finished engine bay for paint.jpg [ 177.17 KiB | Viewed 3016 times ]

_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: April 26, 2013, 1:36 pm 
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Location: Santa Maria, CA
Engine bay paint.. Some guys will work to make their firewall perfectly smooth and into a mirror finish- and I can appreciate all that hard work.. In my case though, I'm just trying to make this car's engine bay look tidy and clean, stopping short of ever needing a toothbrush detail to make it shine.. Having said that, I chose to paint it with a paint I love that you can find at Lowe's or Home Depot... It's Rustoleum "Hammer Finish." You can brush it on, and it's very forgiving if you have minor surface imperfections.. If I had shot this with a gloss it would have looked pretty bad, unless I was willing to spend the time to really smooth it out.. The hammer finish paint looks pretty good in my opinion, and as I still have a bit of welding/finishing to do under the hood, touch op is a breeze. Some will not like it I'm sure, but I'm not building this car for them anyway :wink:


Attachments:
motor ready to be set back in for more fitting.jpg
motor ready to be set back in for more fitting.jpg [ 165.95 KiB | Viewed 3002 times ]
wideshot painted engine bay.jpg
wideshot painted engine bay.jpg [ 185.49 KiB | Viewed 3007 times ]
another nose wideshot.jpg
another nose wideshot.jpg [ 189.84 KiB | Viewed 3007 times ]

_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"


Last edited by ccrunner on April 26, 2013, 2:11 pm, edited 1 time in total.
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PostPosted: April 26, 2013, 1:51 pm 
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Joined: October 10, 2010, 10:26 am
Posts: 1227
Location: Santa Maria, CA
JULY 2012

Even with it's stock engine, this is a buzzy, noisy car.. To combat this, I did a couple of different things.. Instead of Dynamat or Lizardskin (two great products I can't justify paying for), I went with a low-buck appoach to each..

With all of the modding/welding I've done to this car's sheet metal, I've gone over the entire floor with POR15.. I've used it for years and love it. Money very well spent from my experience..

I read quite a bit on Lizardskin over on the H.A.M.B. forum and found many guys were mixing their own, so I thought I'd give it a try-- If I don't like it or it doesn't work I can always chip it out later.. You can read up on it and try for yourself- I don't have enough time in the car with it to tell one way or the other yet (and I still have too many gaping holes and uncovered panels bouncing sound around in my car).

The Peel N Seal is found at Lowe's, and at best it might be called the poor man's Dynamat... I put it in on a hot day (helpful) and I have not experienced the smell that others complain about... again, I'm taking the try it and see approach.. I think I 'm pretty safe having it stick well to the floor (others have said it does not stick well to verticle surfaces). Time and trial and error will tell on both.. ideally somewhere around late 2013/ early 2014 I'll know more about how these work out as my car will be driven more by then..

Threw in a pic of the ealy paddle shifter pivot/design.. still using this setup although cleaned up a bit now..


Attachments:
homemade lizard skin.jpg
homemade lizard skin.jpg [ 172.22 KiB | Viewed 3006 times ]
floor with sound deadener over por15.jpg
floor with sound deadener over por15.jpg [ 168.25 KiB | Viewed 3006 times ]
peel n seal over microbeads over por15.jpg
peel n seal over microbeads over por15.jpg [ 194.25 KiB | Viewed 3006 times ]
paddle shifter version 1.jpg
paddle shifter version 1.jpg [ 190.46 KiB | Viewed 3006 times ]

_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: April 26, 2013, 9:27 pm 
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Joined: October 19, 2010, 11:57 am
Posts: 488
Location: Waterloo, WI
Wow! This is such an incredible build. Great info and pictures!

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PostPosted: April 29, 2013, 12:56 pm 
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Joined: October 10, 2010, 10:26 am
Posts: 1227
Location: Santa Maria, CA
July 10-17 / 20012

Closed up firewall and finished all undercoating / Finished exhaust engine to diff / trimmed pass side steering rack for boot fitment issue / Final install of brake lines, adjustable proportioning valve, line lock, and master cylinder / Finished interior floor w/ POR15 and 2 coats of Henry's Roof Sealant (added microspheres) / covered floor with Peel n Seal- 2 layers at firewall and front floorpan and 1 layer under front seats and rear of car / fabbed seatbelt mounts (front only).. / modded all 3 OEM N600 pedals as needed to work with new/ altered geometry / finished paddle shifter cable 'spider' bracket at engine (this took 3 attempts to get the correct angle for the cable.. / fabbed paddle shifter at column / cleaned front and rear window flanges and painted w/ POR15..

July 18-21, 2012

Went back ant had to cut slots into firewall where clutch and throttle cable go through so a cable can be changed/serviced later.. / painted all small enine mount bits / finished clutch linkage arm / Fitted pedals for install height.. For grins swapped motor #2's instrument cluster into the VFR... very surprised to learn this motor only has 17,000 miles on it!! :D I knew it was clean from having it opened, but I had no idea it would only have 1/3 the miles of my bike... hoping it runs well- if so, it is definately the 1st choice motor to use for this car.. / sealed up engine #2 (had the covers off of both sides) and preparing it for 'final' install to run it (I've had it in and out of the car at least a dozen times for fitment)..

7-20/21, 2012

Stripped VFR completely.. I didn't want to do this (as motor #2 looks so good), but I needed the bike's harness, starter, and some other odds and ends... Once it's all parted out I will have all that my N600 project needs, and although selling/shipping stuff is a hassle, I'll eventually get all $$ back that I spent on the VFR originally..

7-21-2012

Installed motor #2 for final time.. Installed driveline.. Finished fabbing clutch linkage..


Attachments:
bike being stripped down.jpg
bike being stripped down.jpg [ 191.23 KiB | Viewed 2893 times ]

_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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PostPosted: April 29, 2013, 4:05 pm 
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Joined: October 10, 2010, 10:26 am
Posts: 1227
Location: Santa Maria, CA
JULY 25-27, 2012

Mounted radiators and started plumbing them.. No small affair placing these radiators.. there is very little room to fit any type of radiator (I wanted to use just one larger radiator but short of having a custom unit (like from Griffin), I'm going to try and use the bike's own radiators- it will just require some creative mounting and a shoe horn- (will need to switch VFR fan over to the bike's 'other' radiator) / Learned the only logical space for the oil cooler is down low in the driver's front engine bay pocket to keep it in the airstream.. / eliminated the VFR PAIR system and the intake flapper- capped all vacuum lines and eliminated all smog..

7-28, 2012

Mounted and plumbed oil cooler into pocket.. still need a few rubber 90 degree bends for the radiator plumbing.. started to fav a mount for the right bank coils... Seems I'm about down to fuel and electrical to make it start..


Attachments:
radiators and oil cooler plumbing.jpg
radiators and oil cooler plumbing.jpg [ 176.5 KiB | Viewed 2890 times ]
bad pic of radiators in place.jpg
bad pic of radiators in place.jpg [ 168.76 KiB | Viewed 2890 times ]

_________________
My '72 Honda N600 build log (bike engine in a microcar)...
http://www.locostusa.com/forums/viewtop ... 36&t=14452

My '63 Volvo 1800 with a turbo inline 4 build log (LNF Ecotec compliments a Svelte Swede)
http://locostusa.com/forums/viewtopic.php?f=36&t=16309

My '59 Berkeley SE492 build log (bike engine in a microcar)... "A Berkeley With Bite!"
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