VTEC-E in custom built car....

[rkcarguy]

I'm planning on having the components of a unibody structure made from laser cut plate and rectangle aluminum tubing. I don't expect to be spending more than $1200 on materials as aluminum is running in the $2.25/# range and I don't see needing anywhere near 500#'s of it.
Carbon fiber and fiberglass is beyond my skills although I have a general knowledge and and worked with them before on a limited basis.
I was commenting that at a later point I may opt for composite sections of body, but to begin with I will use the aluminum for ease of making changes as things progress.
Most small car unibodies are manufactured from 1mm steel stamped sheet, it's the shapes that give them their strength. I don't see where using .080 or .090 alum sheet with an occasional square tube here and there will yield any less stiffness.
I'm not rich and not looking to set new records(you never know though), but I'm pretty sure that with a bunch of Civic parts in a small aerodynamic and lightweight car I can see the mpg gains to be proud of along with performance I'll like.

[theunchosen]

You definitely can see advantages doing that. And I see where you are coming from with the changes over time with aluminum being. . .MUCH more giving on the subject than CF monocoque.

The problem with it is it takes a ton of time spent checking and re-checking everything to make sure it fits, because once its molded there is very little changing that can be done.

I'm not very capable other than bolting things together of construction so the least amount of welding and fab the better for me. CAD and CF and someone else molding it for me sounds best. I'm good with cad especially only as much as this would need it, but forming the panels by hand is out of range for me.

[rkcarguy]

Originally Posted by theunchosen

You definitely can see advantages doing that. And I see where you are coming from with the changes over time with aluminum being. . .MUCH more giving on the subject than CF monocoque.

The problem with it is it takes a ton of time spent checking and re-checking everything to make sure it fits, because once its molded there is very little changing that can be done.

I'm not very capable other than bolting things together of construction so the least amount of welding and fab the better for me. CAD and CF and someone else molding it for me sounds best. I'm good with cad especially only as much as this would need it, but forming the panels by hand is out of range for me.

CAD isn't that hard, I took a few weeks of it in school and learned the rest as I went along in the workplace. I'll know how much the bare body will weigh before any shavings start to fly. Handforming is something I can do well and have done before building radar masts for boats. Sometimes you just build to a certain point, get out the cardboard and start fitting templates by hand....
The front is going to be an exercise of that trust me...

[theunchosen]

lol Kudos to ya. I am stuck in the CAD CF realm because I can't do it by hand.

It should be an amazing boost in FE.

Did you have a trans in mind?

CVT would be good considering. . .its a honda and you might get lucky and be able to find a CVT from an 07-08 thats wrecked. Manual is almost as good if ou set the gear ratios just right.

[rkcarguy]

Transmission in hand at this time is a 4.08 final drive .701 5th gear LX sedan tranny. I can find a 92-95 CX/VX tranny easily though that has a 3.25 FD and is much better for pretty cheap, many people change them out.
I won't do an automatic of any kind sorry. I like shifting and also just don't believe that converting mech motion to fluid motion and back again is the efficent way to do things. A properly geared manual will always give better results imo.
Also honda's CVT requires a myriad of wiring and weighs over 200#'s compared to the 75#'s of the manual tranny. My spare D15B-VTEC has one still on it it huge!

[theunchosen]

Since you are building this bad boy ground up. . .I would recommend a different engine now that I think about it.

You could step over and grab a GDI and lean burn your way to massive MPG. I dunno what the laws are for WA but for alot of places custom builds don't have to meet EPA which means the GDI's standard no cat emissions are much lower than GII.

As you stated about the CVT though it (GDI) also requires some tech to go along.

Although the convenience of already having the engine is hard to overcome.

The new Lincoln MKSs and Cadillac STS(might have wrong model I don't keep tabs on caddy) have them as standard if you wanted to get one from a dealer.

[rkcarguy]

I thought about it but it's kinda a run what you brung for me, I still have an "in" with the guy that bought my business and therefore have access to all the honda parts and computer chipping/tuning. Not only do I have the engine but I have several computers axles disc brakes aftermarket suspension stainless brake lines etc.
I guess "the" engine doesn't even apply because I've stashed away a D16Z6, 2ea 3-stage VTEC's, 2ea D13B's, and a B16A2 swap. I pretty much have everything I need except a few things as far as the oem parts being used.
Yes it's true I only have to meet basic state regs for a custom build, it will be emissions exempt and safety exempt. I think it entails just working lights, wipers, horn, windshield, and a few other simple requirements.

[theunchosen]

I don't actually think you need a windshield. . .although I most certainly would not go out without one after watching an 18 wheeler spider-glass my windshield with a rock. . .

I had an open design thread for new manifold design for GDI and I am definitely in the boat of waiting until someone drops one in an econo car and it gets wrecked

[rkcarguy]

I live in Washington, windshield is a must have as well as door seals etc. An open roadster turns into a bathtub here
Drawings are in the works autocad arrived wednesday.

[evolutionmovement]

Not that I'm anti-pollution control, but emissions exempt would open a lot of doors. I don't know how extensive the mods required are for stratified charge injection, but if a piston redesign would do it, that would be pretty cheap and allow ridiculous lean mixes. They were essentially outlawed ages ago due to, obviously, high NOx. The Honda CVCC (Controlled Vortex Combustion Chamber) used SCI. There's probably some kind of trickery with the cams and head design also, but I've never torn one apart.

It also allows free reign in regards to importing foreign engines from small TDIs to GDI, though I know you said you're not interested in that. I guess I'm just thinking for myself. The Subaru 2.0 diesel would be interesting.