1996 Integra GSR Sedan

I figured i may as well post the build that is sucking away all of my funds and time. i guess rebuild is more like it. i bought this gsr back in 2003 and sold it in 2010. by dumb luck i came across it again and purchased it back May of 2014. however, it was in waaaaayy worse shape than when i sold it. been in rebuild mode since then, still not finished. now that i htink about it, i am the second and 5th owner of this car lol. i have a build thread on team-integra.net and honda-tech.com that has every little detail i worked on so far, but i'll just put up a few pics here and the work i completed so far. i'll update this thread as i continue to work too.

here she is at her prime right before i sold in 2010






and the day i purchased her back





You can see my old tacoma in this one







so here is what i have done and replaced so far.
-completely stripped the car treated rust and undercoated entire car
-replaced all metal fuel and brake lines
-replaced all 4 wheel bearings
-new ball joints, inner and outer tie rods,
-all new bushings in all control arms
-new struts
-new water pump and timing belt and all associated seals
-all new engine gaskets (except head gasket)
-new front and main oil seal
-clutch kit
-clutch master and slave cylinder
-new brakes, rotors, calipers, pads, parking cables,and brake hoses
-new axles
-new to me rear quarter panels
-new vtec solenoid
-new wires, plugs, cap, rotor, fuel filter,
-new exhaust and gaskets
-new to me rear trailing arms
-new to me abs sensors
-all new coolant and vacuum hoses
-new drive belts
-new fuel pump, fuel pump cover, and fuel meter
-new to me abs pump
-new lost motion assemblies
-new o2 sensors
-new catalytic converter
-probably $500 or so in new hardware and bolts from Honda
-new fuel filler neck


there is probably a lot more i am forgetting. i'll just post this for now and add more later.

 

i love tegs! good luck with the project. i used to have a 94 dc2. it ended up getting stolen, then i rebuilt it with a totaled 01 over a summer.

 

i can't wait to get this one on the road again. i had several setbacks, i'm probably a total of 6 months behind at this point lol. as soon as i finsih up the body work in the rear quarters, i'm going to re-install the tank and getting everything connected and try to fire her up

 

Some pics of the tear down and my original to do list. right around august 2014 i think.

 

When i started applying chassis saver to the underside of the car, and then top coated with rubberized undercoating. This is around September 2014 i think.

























Then i did the inside parts of the chassis that i couldnt get to with a brush.



then rubberized undercoated everything.

 

Sometime in December or January i put the car somewhat back together so i could push it into my garage for winter working.

 

and just some various pics of all the motor work etc..

 

nice! love the gsr sedans, you never see them. i had a 1998 hatch back in the day, great car

 

and lastly here is the most recent work



























still need to do some final "finessing" of the rear patch panel to make it fit.

 

Thanks! I plan on keeping the car for a lonnnnnnnng time after this. its going to be a brand new 1996 lol

 

unfortunately, i have a bunch of no good updates...i had to re-focus my work on the car. I remember now why I was skeptical of the driver's side quarter panel i got. I took a closer look of it over the weekend, and it is junk. Complete junk.... i really don't think i can use any of it. Which really, REALLY throws of this car's schedule... i knew it was bad, but i didnt realize how bad until i started grinding. as soon as the grinder hit it and worked through the paint, it instantly started throwing white dust around. its all body filler, it has been repaired once..and not well at that. I kept grinding through the wheel arch area to find some spot welds, and its all junk. Because of how it was repaired, its all rusted out. It was repaired with booger welds and some weird glue. it could be panel adhesive that no one bothered to finish. It's not much better than the one on my car now to tell you the truth. I'm really bummed out about this.

looks good from far, see all that white? Body filler.


There is a spot weld under here somewhere


there should be a bumper mounting tab here


JUNK


so like i said, i had to refocus my work for the weekend... i shaved off the front bumper license plate mounts and filled those in. i also sanded the bumper repair to get ready for the flexible body filler


installed my replica lip. not a huge fan of how it mounts, but i can make some additional mounts for it.


wiper cowl installed.


short strand body filler applied to where the side mouldings used to be.




after it hardened and was all sanded down, i applied a thin bit of standard body filler to smooth it out. still have to sand this out.


trying to track down an affordable outer panel replacement. waiting to hear a response from a couple of places. shipping is the killer.

 

forgot to update this for anyone that is looking lol

i was motivated to get some work done this weekend. i wont go into detail, but the wife and i had some pretty terrible stuff happen to us last week. so i dealt with it the best way i know how... i kept myself busy and occupied. so after doing a bunch of stuff with the wife, i secluded myself to the garage. friday night i primed up the parts of the car that i had worked over with bondo the weekend before (shaved door mouldings, bumper repair, antenna shaving).



then i went back to working on my ecu wiring issues. i have 3 wires that have pulled out of the ecu crimps in the individual plugs. and i see why now. i was reading up on depinning and repinning plugs and i tried a wire that was intact in the ecu plug to make sure my technique was good. check out the crimp on this wire. see all of the corrosion? i'm sure a lot of these are like this.


i am having a heck of a time getting the pins that came free from the wires to release from the ecu plug. i dont have the luxury of pulling the wire to remove the crimp. i tried turning it straight up and down in hopes that it would fall out via gravity and i had no such luck. i tried releasing the pin like in all of the depinning videos and pushing it out the back from the front, that didnt work either. i'm actually starting to cause some damage to the plug and i really dont want to do that. this is getting to be really frustrating. i want to repair it properly without causing further damage to the ecu plugs.

speaking of frustrations, i ordered up this guy to stop my frustrations with re-doing the connections to the harness for the vafc2. so now my frustrations lie with the ecu plug repairs only.



so i finsihed up the work in the garage this weekend with some painting and general cleaning. this is just rattle can paint, the same color i used for the engine bay. still needs a little clear coat. its not perfect, and the body work is not 100% final yet, but in the event i dont get the car painted next year, this will hold me over in the meantime.



re-installed the rear calipers, brakes, and most of the rear suspension on the passenger side. driver side will be installed when i have most of the cutting out of bad metal done.


also completed the re-installation of my jdm fogs and finsihed wiring up the switch. as soon as i get some new bumper mounts for the fenders, that bumper can go back on the car for good for now.

thats all for now, more to come.

 

I'm looking forward to seeing this come back to life.

I have a soft warm place in my heart for anything DC2 or DC5 and EG hatch related.

Love the Group-N RNR replicas... I had a set in silver back in the day.

 

i'd love to get some legit mugen's for this car, buuuuuuuuuuuuuut that's an expense i cant afford right now lol

 

Naw,

Nothing wrong at all with ROTAs lol...

 

gah! i forgot my other update from last week. i'm working with a member on Honda-tech that lives out in Cali where there is no rust issues lol. he is going to go to a salvage yard near him and get me a quarter panel to replace the junk one i have now so i can finish the rust repair on the car.

 

Aww man you've got me missing my old GSR. Despite the rebuilt title it was the most reliable car I've ever owned. Fast as hell too! I really wish I still had it as a daily driver.

Here she is on Kane Creek Road in Moab:

 

is that a 94-97 with the 98+ front bumper or is it the 98+ body style and you threw on the fat 5 wheels? i love the DB/DC chassis, i may be a bit obsessed lol. i got some goodies a couple of weeks ago to sort of "complete" the owner package. i'll have to snap some pics tomorrow

 

Looking forward to the progress!

Mine was an '01 with the fat fives and an LS/VTEC swap. Admittedly I didn't do the work on it but still I miss that car.

 

i forgot to post my pics of the "owner" goodies.

this manual and manual case along with the service cards and the original owner's informaiton came with the car when i bought it in 2003. i found the extra luxury care pamphlets and quick tips on ebay so i snatched them up.



i found these as a package deal on ebay also. all from 1996 so it matches the car. too cool to pass up. Do dealerships still have these things or is it all digital now? lol





i remember going to the dealership with my dad or sometimes with my friend and his dad when i was little (10-12 maybe?) and i would always look through things thing. I thought they were the coolest things lol