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Discussion Starter #1 (Edited)
UNCOMPLETED BUILD THREAD
IS CURRENTLY BEING UPDATED DAILY !!!

NEW PARTS PURCHASED :
10/21/20

Hello K20a.org this is the 1st time I have ever created a build thread, not just on K20a.org nut on any website. My little company is call B&B Weld and Fabrication and by no means am I attempting to sell products that B&B makes. I am simply sharing somethings as this build thread develops. Some history on this thread : I purchased this 2002 Acura RSX Type S a few years ago. It was 100% bone stock, zero modifications done, and it was a one owner of a 56 year old man primarily used for highway travel as a DD to work. The car came with the original window sale sticker, the maintenance reports from the dealership service department, original literature packets, original leather travel notebook provided by the dealership, and even an Acura pen with business card of the car's salesman.

The car was turned over to me at 142,000 miles, burned little to zero oil, and came with a strong engine. The tranny has zero pop-outs, grinds, hesitations, and shifts like butter. The dealership installed the LSD and I must say did a fine job keeping the engine, tranny, and chassis up to par. The only thing wrong with the car is the door locks have to be done manual and the timing chain has slack in it. This build thread is being done to the best of my ability and will provide as many (part numbers) as possible.

Currently the purpose of this build is to get as many miles out of this engine and tranny, providing I add some love into the build. I am REPLACING the Timing System, Oil System, most Mechanical Systems, Gaskets, O-Rings, Bolts, Valvetrain Assembly, and UPGRADING Camshafts, Bolt-Ons, Fuel System, Cooling System, Exhaust System, and Engine Management.

In the meantime, I am saving money to completely build the block for a higher compression, forged internal, and balanced set up. Keeping it in NA fashion, I will favor a stage 2 type camshaft and a CNC 4Piston head.


Modifications Done Before 7/1/20

Engine

  • 2002 K20A2 Bone Stock Longblock
  • Hasport 62A Engine Mounts Driverside & Passenger Side
Transmission & Drivetrain
  • 2002 K20A2 4.3FD 6spd, Oem JDM DC5-R LSD
  • K-Tuned Billet Aluminum Shifter Bushings (KTD-CAB-SPH)
Suspension
  • K-Tuned Rear Lower Control Arms (KTD-RL)
  • SPC Rear Upper Camber Arms (67230)
  • SPC Front Camber Bolts (81280)
  • 05-06 oem DC5-S Front Sway Bar (51300-S6M-A51)
  • 05-06 oem DC5-S Rear Sway Bar (52300-S6M-A61)
  • Hotchkis Front & Rear Sway Bar End Links (2540)
  • Megan Rear Lower Adj. Tie Bar (0788536944240)
Interior
  • Honda jdm DC5-R Shift Knob (54102-S6M-R00)
  • Honda jdm DC5-R shift Knob Backing Nut (90310-ST7-Z00)
Weight Reductions
  • Spare Tire (28.6lbs)
  • Jack & Tool Kit (5lbs)
  • Rear Seats Delete (35lbs)
  • Rear Seat Belt Delete (12lbs)
  • Rear Cargo Screen (3.5lbs)
  • All Interior Carpet (13lbs)
  • All Plastic Trim Below Windows (18lbs)
  • Oem Airbox Assembly (11lbs)
  • Rear Lower Control Arms Minus K-Tuned Arms (3.2lbs)
  • Center Console Delete (5lbs)
  • Bose Head Unit (7.5lbs)
  • Bose AMP (2.3lbs)
  • Bose Subwoofer (6.8lbs)
  • All Four Speakers (3.2lbs)
  • Oem Cat Delete (17lbs)
  • Hood Liner (3.5lbs)
  • Glovebox (3lbs)
  • DC5-S Front Leather Seats vs Cloth (12lbs)
  • Aluminum Lug Nuts (?)
Chassis Strengthening
- 05-06 oem DC5-S Front Upper Strut Bar (74180-S6M-L50)

All New Parts Purchased After 7/1/20 For B&B Build

Engine Parts
  • K-Motor Oil Pan Gasket K20/K24 (KM-OPGKK2024)
  • Honda oem PRB Oil Pump (15100-PRB-A01)
  • Honda jdm 02-06 DC5-R Oil Dip Stick (15650-PRC-004)
  • Honda oem jdm DC5-R Crankpulley (13810-PRC-003)
  • Honda oem Crank Pulse Plate (13622-PNA-003)
  • 05-06 Honda oem Intake Camshaft (14110-PRC-030)
  • 05-06 Honda oem Intake VTC Cam Gear (14310-PRC-003)
  • 05-06 Honda oem Exhaust Camshaft (14120-PRC-030)
  • 05-06 Honda oem Exhaust Cam Gear (14210-PRB-A00)
  • Honda oem Valve Cotters (14781-PRB-A02)
  • Honda oem Valve Stem Seal A (12210-PZ1-004)
  • Honda oem Valve Stem Seal B (12211-PZ1-004)
  • Honda oem Valve Spring Retainers (14765-PRB-A01)
  • Honda oem TDC Camshaft Sensor (x2) (37510-PNB-003)
  • Honda oem Crankshaft Seal (43x58x7) (91212-PNC-004)
  • Honda oem Chaincase O-Ring (91302-PNA-004)
  • Honda oem Camshaft Sensor O-Ring (15x1.9) (91333-PNA-003)
  • Honda oem Camshaft Pulse Plate (14113-PNA-003)
  • Honda oem Camshaft TDC Pulse Plate (14114-PNA-000)
  • Honda oem 14mm Camshaft Seal Bolt (x2) (14115-PNA-000)
  • Mugen SS Head Gasket K20AX (0.4 compression bump) (12257-XK5-0000)
  • ARP Head Studs (ARP-208-4701)
  • Honda oem Oil Chain (64L) (13441-PCX-004)
  • Honda oem Oil Chain Guide (13460-PNC-004)
  • Honda oem Oil Chain Shaft Tensioner (13450-RAA-A02)
  • Drag Cartel Chain Guide (DC-LWR-GUD)
  • Honda oem PRB TCT (14510-PRB-A01)
  • Honda oem Cam Chain Tensioner Arm Guide (14520-PNA-003)
  • Honda oem Cam Chain Guide A (14530-PNA-003)
  • Honda oem Cam Chain Guide B (14540-PRB-A01)
  • Honda oem Cam Chain Tensioner Bolt (90003-PNA-000)
  • Honda oem Oil Seal (43x58x7) (Nok) (91212-PNC-003)
  • Honda oem Knock Sensor (30530-PRB-A01)
  • Honda oem Oil Pressure Switch (37240-PTO-014)
  • Honda oem Block Drain Sealing Washers (28mm) (x2) (90401-PR4-000)
  • Honda oem Valve Cover Gasket (12341-RTA-000)
  • Honda oem Valve Cover Washers (90441-PNA-010)
  • Honda oem Cap Nuts (6mm) (90213-PH3-000)
  • Honda oem Spark Plug Seals (30522-PFB-007)
  • Honda oem Oil Cap O-Ring (15613-PC6-000)
  • Honda oem Coil Packs (30520-RRA-007)
  • Honda Denso Spark Plugs (SK22PR-M11S)
  • Honda oem VTC Oil Control Valve Assembly (15830-RBB-003)
  • Honda oem VTC O.C.V.A. Sealing O-Ring (15832-PNA-023)
  • Honda oem VTC Filter Assembly (15845-RAA-A01)
  • Honda oem VTEC Spool Valve Assembly (15810-PRB-A03)
  • K-Tuned P.S. Relocation Kit (KTD-PSP-204) ** Not Delivered 10/7 P.D.
  • K-Tuned K-series Side Mount Pulley (KTD-SMP-K20) ** Not Delivered !0/7 P.D.
  • Hasport Steel Front Engine Mount (62A) (HP-DC5FRM) Delivered
  • Hasport Billet Rear Engine Mount (70A) (DC5RR-62A) Delivered
Transmission & Drivetrain Parts

  • K-Tuned Billet Shifter Arm (KTD-BIL-ARM)
  • K-Tuned Clutch Slave Cylinder (KTD-CLK-KSS) Delivered
  • K-Tuned SS Clutch Line W/ Fittings (KTD-CLK-001) Delivered
  • Honda oem Shifter Cable Wire Washer Assembly (54118-S10-000)
  • Honda oem Split Pin (2.0x22) (94201-20220)
  • Honda oem Split Pin (2.0x35) (94201-20350)
  • Hybrid-Racing Race Spec Shifter Cables (HYB-SCA-01-05) Delivered
  • Honda jdm DC5-R Chromoly 10.4lb Flywheel (22100-PRC-003)
  • Honda oem Flywheel Bolts (12mm) (90011-PNA-B00)
  • Honda oem Clutch Bushing (21x24x8) (22103-PNA-004)
  • Exedy Stage 1 Clutch (KHC10)
  • Honda oem Passenger Axle Seal (35x58x8) (Nok) (91206-PL3-003)
  • Honda oem Driver Axle Seal (40x56x8) (Arai) (91205-PL3-B01)
  • Honda oem Shift Arm Cover (24479-PPP-000)
  • Honda oem Select Stopper Plate (24467-PPP-000)
  • Honda oem Trans Cap Breather (21396-P20-000)
Suspension Parts

  • BC Racing BR Type Coilovers 30-Way, Adj. Camber Tophats (01-06 Acura DC-5)
  • Energy Suspension Master Bushing Set (16-18111)
  • K-Tuned Extended Roll Center Adjusters (KTD-RCA-R02)
  • K-Tuned Adjustable Inner Tie Rod Arms (KTD-TRI-RCI)
  • Honda oem Tie Rod Lock Washer (53536-S5A-900)
  • Honda oem Steering Box Mounting A Bushing (53685-S5A)
  • Honda oem Steering Gear Box Mounting Box (53685-SL0-A00)
  • Hardrace Outer Tie Rods (8144) *** May be switching to Hardrace Reverse Thread Spherical Rods
  • SPC Front Camber Bolts (81280)
  • Honda oem Steering Box Mounting (53685-S6M-000)
Intake Parts
  • Hondata IMG (Cut Angled To Match PRB Head & RBC IM) (K20A-IMG)
  • B&B Performance Modified RBC IM (17100-RRB-A00)
  • K-Tuned 70mm TB Tapered to 74mm ID (KTD-70K-DBP)
  • K-Tuned TPS Hall Effect (KTD-TPS-HES)
  • K-Tuned RBC 70mm TB Thermal Gasket (KTG-RBC-TB)
  • Honda oem Map Sensor (37830-PGK-A01)
  • Honda oem Map Sensor O-Ring (37835-PGK-A01)
  • Honda oem Map Sensor Screw Washer (5x20) (93892-05020-08)
  • Honda oem IVAC Rotary Air Control Valve Set (16022-PRB-A02)
  • Honda oem Purge Control Solenoid Valve Assembly (36162-PNC-005)
  • Honda oem P.C.S.V.A. O-Ring (36221-PNC-005)
  • Honda oem P.C.S.V.A. Screw Washer (93892-05012-08)
  • Aluminum 2.5" Schedule 10 Pipe Bored to 74mm ID
  • Custom Aluminum 74mm ID x 3.325" ID Concentric Reducer (RC-4042-A)
  • K-Tuned 3.5" Velocity Stack Filter Combo (KTD-VST-C35)
  • K-Tuned Intake Air Temp Sensor Adapter Weld Fitting (KTD-IAT-ADA)
  • 3.5" Aluminum (1/8" wall thickness) Intake Tubing, 24" long
  • 3.5" Aluminum (1/8" wall thickness) 180deg Extra Long Radius, 24" length
  • Mishimoto 3" Coupler black (MMCP-30SBK) Delivered
  • 2017 Honda Civic Type R Hood Air In Assembly (74160-TGH-A00ZD)
Exhaust Parts
  • K-Tuned 421 RSX 409 Race Header (B&B Performance Modified true 2.5" collector) (KRH-RSX-409)
  • Honda oem Header Gasket (18115-PNB-003)
  • Vibrant SS 2.5" V-Band Clamp (VPE-1490)
  • Burns Stainless Megaphone 2.5" In, 4.5" Out, 14.5" OAL, 8deg 304SS (MEG25045SS) *** It is being cut at 3.5" DIA in length4
  • Burns Stainless Short Transition 304SS 4" to 3" (RD-300-16-304-S)
  • Vibrant 3" x 6" Long SS Flex W/ Braided Liner (VPE-63006)
  • Summit Racing 3" SS Premium V-Band Clamp (x2) (SUM-697300)
  • Summit Racing 3" 409SS by 48" long Exhaust Tubing (SUM-640130-1)
  • Summit Racing 3" 180deg Bend 6" Radius, 10.75" Legs Tube (SUM-622005-SS)
  • Vibrant 3" SS Ultra Quite Straight-Thru Resinator (VPE-1142)
  • Vibrant 3" SS Stealth Straight-Thru Muffler (VPE-1147)
  • Vibrant 45deg Oxygen Sensor (x2) (VPE-1193A)
  • Summit Racing SS Exhaust Hanger Hardware (x8) (WLK-35411)
Fuel Parts
  • Acura RDX 410cc Fuel Injector Assemblies (16450-RWC-A01)
  • Acura RDX Injector Clips (16451-PLC-000)
  • K-Tuned RDX Injector Clips & Pigtails (KTD-RDX-CB)
  • AEM 340lph Fuel Pump (50-1000)
  • Fuelab Fuel Filter, 40 Micron SS Element, -6AN Inlet/Outlet (81811-1)
  • Vibrant Inline 3pc. Fuel Filter Set -6AN (VPE-16736)
  • Vibrant -6AN Check Valve (VPE-11187)
  • Vibrant Alum -6AN ORB Slimline Port Plug (VPE-10992)
  • Vibrant -6AN Flare x -6AN Straight Cut (x2) (VPE-16826)
  • Vibrant -6AN 90deg Swivel Hose End (x4) (VPE-21906)
  • Vibrant -6AN Straight Swivel Hose End (x7) (VPE-21006)
  • Vibrant -6AN Union (x3) (VPE-10702)
  • K-Tuned -6AN to 1/4" Female EFI (KTD-14-EFI)
  • Vibrant -6AN (0.34"ID) 10' Black Nylon Braided Flex Race Hose (VPE-11966)
Cooling System Parts
  • Mishimoto Inline Water Temp Sensor Housing 32mm (MMWHS-32-BK)
  • Mishimoto 32mm Radiator Cap Housing Aluminum Weld Fitting (MMFN-S)
  • Mishimoto 1.3 Bar Radiator Cap (MMRC-13-SM)
  • Speed Factory Tuck Radiator (SF-06-TuckedRad)
  • Speed Factory Tuck Radiator -16AN Hoses (SF-04-048)
  • K-Tuned Swivel Neck Thermostat (KST-UNV-16A)
  • K-Tuned Coolant Temp Sensor Fitting Port (KTS-GF-307)
  • Summit Racing EPDM Silicone Radiator Hose 90deg 5" legs (SUM-294040)
  • Summit Racing EPDM Silicone Radiator Hose 90deg 5" legs (SUM-295040)
Brake Parts

  • EBC Ultimax Front Rotors (RK1473)
  • EBC Premium Rear Rotors (RK7128)
  • EBC Green Front Brake Pads (DP21254)
  • EBC Yellow Rear Brake Pads (DP41193R)
  • Stoptech SS Front Brake Lines (805890389774)
  • Stoptech SS Rear Brake Lines (90540502)
Mechanical System Parts & Fittings
  • Autometer Oil Pressure Gauge, 0-100psi, Ultra-Lite (105-4321)
  • Autometer Water Temp Gauge, 100-250degF, Ultra-Lite (105-4337)
  • Odyssey PC680 Battery Metal Jacket (0769-2017)
  • Odyssey Universal Terminals (3217-0006) Delivered
  • Honda oem Water Pump (19200-PRB-A01)
  • Honda oem Water Pump Gasket (19222-PRB-A01)
  • Summit Racing -16AN Male Aluminum Weld In Bung (SUM-220064)
  • Earls -10AN Male Aluminum Weld Fitting (x7) (EAR-997110ERL)
  • Earls -6AN Male Aluminum Weld Fitting (x2) (EAR-997106ERL)
  • Summit Racing -6AN Male Steel Weld Bung (x2) (SUM-220023)
  • Vibrant 3/8" ID Hose Barbed Weld On Bung (x2) (VPE-11181)
  • Moroso -16AN ORB x 1.25" Hose Aluminum Fitting (63521)
  • Moroso 3/8" NPT Female Aluminum Weld Bung (68900)
  • Summit Racing -10AN 45deg Twist-Tite Barb Hose (x2) (SUM-220708-N)
  • K-Motor -10AN x M14x1.5 PCV Delete Fitting (CS-60AR-4SZD)
  • Honda oem PCV Valve (17130-PRB-A01)
  • Aeroflow M14 x 1.5 Aluminum Weld Bung (x2) Delivered
  • Honda Drain Plug Washer (14mm) (94109-14000)
  • Vibrant -10AN Push On 90deg Swivel Barb Hose (x3) (VPE-22910)
  • Vibrant -10AN Push On Straight Swivel Barb Hose (x6) (VPE-22010)
  • Vibrant 3/4" ID Barbed Hose Aluminum Weld On Bung (x3) (VPE-11184)
  • Vibrant -10AN (0.56"ID) 10' Black Nylon Braided Flex Race Hose (VPE-11970)
  • Honda oem Power Steering Oil Tank Bracket (53777-S6M-000)
  • Speedmaster 2.20" dia x 0.7" depth Push-In Air Cleaner (PCE104-1090)
  • Wildside Composites Carbon Fiber Sheet (26" L x 14.5" W x 0.09" T) (WSO-WS9033)
Weight Reduction Projects
  • Odyssey PC680 Metal Jacket 15lb Battery (8lbs)
  • Honda jdm DC5-R Aluminum Front Control Arms
  • B&B Performance Aluminum Hood Brackets w/ Ti Bolts
  • B&B Performance Aluminum Hatch Brackets w/ Ti Bolts
  • Honda oem DC5-R Aluminum Front Bumper (7lbs)
  • Honda oem DC5-R Aluminum Rear Bumper (9lbs)
  • Honda A/C Condenser & Lines (19.2lbs)
  • B&B Performance Hood Lightening Service
  • B&B Performance Front & Passenger Door Lightening Service
  • Sound Deadening Removal
Mechanical System Upgrades
  • B&B Performance Valve Cover Breather Box
  • B&B Performance Closed PCV Oil Catch Can
  • B&B Performance Ram Air Intake Box
  • B&B Performance Upper Coolant Swirl Tank
  • B&B Perfofrmance Air Cooling Duct Work
Planned Future Parts

I am modifying the radiator bulkheads vertical and horizontal. The front end of the car will be tied in far beyond better from factory.
  • Front Splitter
  • Rear Diffuser
  • ASP Custom Header
  • Some DC5 Type R parts
 

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Discussion Starter #9
That is quite the list ! In for some pics ✅
Brother I am getting the pics up slowly. Things are going to take off fast, I have a 400A Miller gasoline welder/generator coming over to play with and power my 200A Tig welder. I will be able to weld complete all of my aluminum parts and SS parts.
 

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Discussion Starter #12
9/26/20 Progress

Today I am working with my extra PRB head. I have been using it for practicing porting and polishing and learning the apex's and concave pockets of the intake and exhaust ports. I am planning to hand PNP the PRB I am using in this build. My intentions are not to wildly bore the ports, I want to mildly accent the existing ports by hand and some machine. My goals are to do better than the RSP head and still keep a strong baseline platform. I want to see the difference the modified RBC IM makes, improve the intake and exhaust ports some, supply a lot of air from a ram air system, and keep the Z1 (PRC) cams. I am not after huge gains from the jump, keeping velocity while making cfm gains is my goal. I am more interested in seeing how well all of the intake and exhaust improvements work together that I have designed.
 

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9/26/20 Progress

Today I am working with my extra PRB head. I have been using it for practicing porting and polishing and learning the apex's and concave pockets of the intake and exhaust ports. I am planning to hand PNP the PRB I am using in this build. My intentions are not to wildly bore the ports, I want to mildly accent the existing ports by hand and some machine. My goals are to do better than the RSP head and still keep a strong baseline platform. I want to see the difference the modified RBC IM makes, improve the intake and exhaust ports some, supply a lot of air from a ram air system, and keep the Z1 (PRC) cams. I am not after huge gains from the jump, keeping velocity while making cfm gains is my goal. I am more interested in seeing how well all of the intake and exhaust improvements work together that I have designed.
Taking notes. I have a 06 PRB head on the shelf that i would love to be able to do some work on but as far as porting goes my experience is 2 throttle body openings 🙄😂
 

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Discussion Starter #14
Taking notes. I have a 06 PRB head on the shelf that i would love to be able to do some work on but as far as porting goes my experience is 2 throttle body openings 🙄😂
Throttle Body boring is a good start to get a feel for removing cast aluminum and learning how different burring bits feel, how certain grit sandpaper feels, etc. When I TB bore, I also taper the bore.

The next step is doing the rest of the intake manifold. Many people underestimate the task, they ruin the important balance between air velocity and cfm improvement. Too much stock is removed in the wrong places that hurts velocity. Too much stock removed in certain areas cans hurt the beginning stages of fuel atomization. And of course at the end of the runners where they meet the head's intake ports - what is port matching ?

Believe me I am not getting on K20a.org and talking like I know this and I know that. There are plenty of pioneers in this business that have figured out how to do this kind of work. However, they had to start some where and had to start on gut feelings, practicing, and finding out if I do this the result is this. I am one of those people that is starting. I have only ported and polished one K series head and I have ported and polished (4) RBC IM's, (1) PRC, and (2) PRB IM's. I prefer to port match RBC IM's to PRB heads b/c once the plenum is removed I can see down the 75% of the runners and use feeler gauges to find out if there is something that needs to be smoothed out. It really helps lining up thermal intake manifold gaskets which disrupt the the meeting angle of IM to cylinder head port.
 

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Throttle Body boring is a good start to get a feel for removing cast aluminum and learning how different burring bits feel, how certain grit sandpaper feels, etc. When I TB bore, I also taper the bore.

The next step is doing the rest of the intake manifold. Many people underestimate the task, they ruin the important balance between air velocity and cfm improvement. Too much stock is removed in the wrong places that hurts velocity. Too much stock removed in certain areas cans hurt the beginning stages of fuel atomization. And of course at the end of the runners where they meet the head's intake ports - what is port matching ?

Believe me I am not getting on K20a.org and talking like I know this and I know that. There are plenty of pioneers in this business that have figured out how to do this kind of work. However, they had to start some where and had to start on gut feelings, practicing, and finding out if I do this the result is this. I am one of those people that is starting. I have only ported and polished one K series head and I have ported and polished (4) RBC IM's, (1) PRC, and (2) PRB IM's. I prefer to port match RBC IM's to PRB heads b/c once the plenum is removed I can see down the 75% of the runners and use feeler gauges to find out if there is something that needs to be smoothed out. It really helps lining up thermal intake manifold gaskets which disrupt the the meeting angle of IM to cylinder head port.
Areading your post it got me curious, so I went and looked at my thermal intake gasket against the rbc I have, and my rbb-2 head. The first pic is on the rbc , second the tsx head. I thought it was strange to see that it looks like the rbc ports are a bit smaller.
15238926-FB96-4EEF-BAC3-4E9F876AC08C.jpeg
A06767B9-598B-4DCB-A7DB-58F40431ECAB.jpeg
 

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Discussion Starter #16
That won't fly. What thermal IMG do you have?

See this is where having the plenum off of the RBC IM would work to your advantage. You could bolt it up with the IMG and see how the bolt play works out before going any further. And be able to get a good mock up.




I
 

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Discussion Starter #19 (Edited)
20200927_190705.jpg


I am not into extreme polishing when it comes to working on these manifolds. As far as blending for smoothness down the runner's path, yes I blend smoothly and I don't worry about polishing away the working marks completely. I aim to keep as much wall thickness, which is something I consistently check during the work.
 
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