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Discussion Starter · #1 ·
June, 2014
Car Build Part 1

I shortened this version down a bit, for complete build click on here http://www.checkerdsports.com/....html

(Sorry most pictures are crappy cell pictures)

Built by: Ansel and Raul
Written by: Raul

When reading this you have to remember this didn't happen over night. We literally made most parts of this car by hand. This has been a long project that tells many stories. The project is far from done, but with the chassis being on the ground it will be a huge accomplishment to us. I didn't want to show the project because I knew I would feel pressured to finish it faster with people asking for updates. We just work at our own pace. We have put tons of work hours and ate lots of pizza. We knew what we were getting into, but damn not sure if we knew exactly how in depth we were getting. Fuck it we did it anyway.

Rewind a few years back, I meet Ansel White. (Early 2010 ish)
Checkerd Sports was still new at the time. I had a few CNC aluminum pieces, couple brands, and of course my s2000 push button kit that started it all, but I wanted to add more unique race parts. After building a few Hondas, I wanted to take it to the next step with my EG4. I needed a cage that would be mean, functional, and also daily driven. I drove up the hill to Lake Tahoe to meet up with Ansel, to get a quote for the cage. He checked out the car and was impressed with the engine bay, and the work done to the car. Few weeks later cage was done, I picked up the car and drove it home with no dash, no speedometer or anything since it had to be removed for welding.

Rewind a few years back, I meet Ansel White. (Early 2010 ish)
Checkerd Sports was still new at the time. I had a few CNC aluminum pieces, couple brands, and of course my s2000 push button kit that started it all, but I wanted to add more unique race parts. After building a few Hondas, I wanted to take it to the next step with my EG4. I needed a cage that would be mean, functional, and also daily driven. I drove up the hill to Lake Tahoe to meet up with Ansel, to get a quote for the cage. He checked out the car and was impressed with the engine bay, and the work done to the car. Few weeks later cage was done, I picked up the car and drove it home with no dash, no speedometer or anything since it had to be removed for welding.



Few months passed and Ansel was telling me that he might be moving to his own shop. I told him that would be cool, and we could possibly work together since I always have ideas in my head and I liked his fabrication work. You have to also know Ansel is a Subaru guy, My Civic was the first one he’s ever caged, he normally builds rally cages. First idea I brought him was a K-Series coil cover that would have dimples all the way down. We made a prototype and I rocked it on my engine for a while (still somewhere in the shop), never went into production. We also made an aluminum rear strut tower bar, which also never went into production. I know somewhere out there someone has that bar, sold it on NWP.





Couple months later, after making a few pieces that actually went into Checkerd Sports production, the EG4 was featured in Honda-Tuning. I learned a lot at Ansel’s new shop, Monzo Speed; bending, cutting, notching, welding, etc. One time I told Ansel we should make our own car, just an open wheel car, street legal, raw and mean looking. He just said yea that would be rad, not really taking it seriously. I always thought it would be bad ass to build my own car, isn’t that everyone’s dream? When I saw the Ariel Atom, it reminded me of all the dune buggies that you see on the street here with plates. I live in Nevada so I can pretty much build anything, throw lights on it and call it street legal. That’s when I decided to start doing research.



More months passed and I didn't hear from Ansel, nor did he reply to my messages, just assumed he was busy. Then I got a message saying “I’m a live, Rock and Roll”. Only thing I could think was, what the fuck is he talking about. That was it, and then I didn’t hear from him for another week or so. He then explains to me that he got ran off the road and crashed his Ducati, he was in a coma for a while. He said I moved my shop also and will be moving my stuff if you want to cruise by, but with his brain damage he couldn’t remember his address. I arrived and the first thing I asked him was if he could still weld, he said, “Yea that was the first thing I tried, check out the welds”. It’s like first nature to him, welds of art. Couple months went by, his speech and movement got better and his memory was back in business. I asked him again if he wanted to build a car. He said sure if you got the money. We sat down a few weeks later and talked about a few ideas, browsed a couple books of different suspension and steering designs.

The build begins! (2012 ish)
I knew the heart of this build had to for sure be a K20A Type R. Went home pulled the K20 out of my EG4 for mock-up of the engine mounting. You know pull your engine out of your car to do a “quick” mock up and put it back in, people do it all the time right?



We started by putting the K20 on the table and leveling it out.



Started to build a frame for the engine.



While all this was going on I was also collecting a bunch of S2000 Parts.



The Floor and wall came next. Tacked everything down to the table.



Making the main hoop felt like a huge accomplishment at the time, to us it was starting to come to life! I think we sat back and looked at this main hoop for a while after we made it and tacked it down.








Took all the S2000 knuckles and put new wheel bearings and ARP studs on them.



Next was connecting the rear to the mid section, which would also be used for A-arm mounts.



It was easy to use the Hasport EGK1 Mounts for the sides, but we needed to make a rear one. I also wanted it to match the other billet aluminum ones.



Side mounts no tacked, just chillin, but you get the idea.



Bottom A-arm tabs tacked on. Making the A-arms I think was the part that took us the longest. I left this part mostly up to Ansel, he knows all about roll centers, geometry, etc etc.



Contacted Tracy at PSi. He helped us a lot with the build of the shocks. Remember we are building a car, we can't just buy shocks off the shelf. After a couple days of talking to Tracy we came to the conclusion of getting some Penskei shocks. He sent us a dry shock to use as a mock up to get some specs.



Making the A-arms we needed some ball joints. I took some factory Honda ball joints and had some cups made for them so we can press them in and make A-arms with them.



Looking for location for shock tabs. Old s2000 wheels pictured.




Now pictured with the real wheel we are using.
Gram Lights



New Toyo 275/45/17 mounted up.




Now here is were we get crazy. Making a one off billet aluminum engine mount by HAND, no mill. Cut and drill. Yep took me a full day to make this, but it came out pretty good.






We put the top A-arms to the side after making one set and not liking the clearance of them. We started working our way forward.





One of my favorite pieces from this build is the Tilton pedals. After making a mock up of the first set of pedals we received, we realized we had the wrong pedals. Cut that off and started over. With the right pedals this is the first place we put the pedals, eventually you will see why they had to be removed and re-located.



This is pretty much the point where we are not exactly sure what happened, but we stopped working on the chassis for about 6 months. The "chassis" was welded together and removed from the table.



During the down time I messed around and made a few things.
I made a 7.3mm spacer to place behind the rotor of the s2000 knuckle and BAM, DC5 Brembos bolt on.



Skip to next year (2013ish)

I decided that this thing needed to be rolling soon. We re-arranged the shop and pulled the chassis out of the corner and picked up were we left off. (Rear A-Arms)

Finished the top rear A-arms, but decided we didn't like the clearance of these either. We left them on there for now and decided to move to the front in the meanwhile.



With the shock mounts being done, we were able to send all the vehicle dimension specs to Tracy so he can custom build the rear shocks for us.



For the steering rack we had planned on using a S2000 rack. The thing about that rack is, ITS HEAVY. We put it off to the side and decided to look for a lighter rack. The goal of this car is 1500 pounds or less.

Then I decided to check out a spare Civic rack I had in the garage. Seemed like the rack was just too crappy for how much work we were putting into this car. Did some research and decided I wanted a Lotus Elese steering rack. Got really lucky and actually found a person selling it locally, what a crazy find.



Front end being built.



Front wheels and tires 245/45/17



Front wheel mock up, measuring up where the wheel will go to build A-arms.





Building the front lower A-arms



Jig to duplicate the other side



Ansel's weld porn





Top A-arm mounts and steering rack mounted.











Child Labor with Enzo



Notice anything different in this picture? Oh yea we had to convert the car to right hand drive. Since we originally planned on using the s2000 steering rack, it's a front steering rack. Well the Lotus Elese rack is rear steering rack so we decided to flip the rack to work with front steering knuckles, making the car right hand drive now. Which brings us to our next do over. We had to cut the nice pedal mounts we made the previous year and start over and make them on the right side.



New pedal mounts and rack completed on the right side. Third time is a charm for the pedal mounts.



Couple weeks later front shocks arrived from PSi.



This is pretty much were we are at. Chassis is ready to be put on the floor just waiting on heim joints for the rear A-arms. Thanks to Summit Racing, should of had them yesterday, but they forgot to ship them :/



The chassis will be displayed at the Checkerd Sports Summer Meet, June 28th. Come check out all the hard work we have done so far.
The DC5 donor car will be here soon so we can use the engine from it.



FAQ:

Q: Will the car be street legal?
A: Yes

Q: Will the car have body panels
A: Only a few up front to cover electrical and to prevent debris from flying up and hitting us.

Q:Will it have 2 seats?
A: Yes 2 Status Racing Ring seats

Q: What engine will be in it?
A: Stock K20A Type R.

Q: Will it have windscreens?
A: Not sure yet, will probably just wear a Guy Manuel helmet when I drive it around.

Q: What is the weight goal?
A: 1500 pounds or less with full tank and groceries.

Any other questions just follow us on IG or FB and ask
 

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Discussion Starter · #2 ·
If you went to the Checkerd Sports Summer 2014 meet you might of seen this car rolling around, please post pics if you have any. I will update this soon.
 

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Penske shocks!? You guys are definitely ballers... aren't they around $1000 each?
 

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Discussion Starter · #4 ·
Close but not quite that much, plus my shop discount helped a bit. The price added up because they had to be custom made to our specs, that adds to the price of the shocks as well. We only got a single adjustable as well to keep cost down.
 

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Discussion Starter · #6 ·
Here are some recent pictures of the car on the ground at my shop. Checkerd Sports and Monzo Speed have merged shops since we are always working together anyway. So if anyone needs cage work done lmk.



Had time to finally lower the front suspension, when we first put it on the floor it was too tall up front.

 

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Here are some recent pictures of the car on the ground at my shop. Checkerd Sports and Monzo Speed have merged shops since we are always working together anyway. So if anyone needs cage work done lmk.



Had time to finally lower the front suspension, when we first put it on the floor it was too tall up front.

looks fun
Definitely does look fun
 

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Discussion Starter · #10 ·
Is the rear narrower than the front? Or is it just the angle?
You know since we dropped it on the ground it was hard for me to tell with the naked eye I keapt going back and fourth looking at it from front and back and couldn't tell. This weekend I will have time to measure it. If it is I will just take the Brembos off the front. In order to put those Brembos on I did a conversion which was 7.3 mm spacer behind rotor so rotor lines up and 10mm in front to clear the wheel. So that is 17.3mm on each side I can take off. I'm sure the stock s2k calipers will be enough anyway, I just had these laying around and thought it would be cool to put them on. In this picture I also didn't have the rear rotors on which also make the back wheels go in a bit more.
 

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You know since we dropped it on the ground it was hard for me to tell with the naked eye I keapt going back and fourth looking at it from front and back and couldn't tell. This weekend I will have time to measure it. If it is I will just take the Brembos off the front. In order to put those Brembos on I did a conversion which was 7.3 mm spacer behind rotor so rotor lines up and 10mm in front to clear the wheel. So that is 17.3mm on each side I can take off. I'm sure the stock s2k calipers will be enough anyway, I just had these laying around and thought it would be cool to put them on. In this picture I also didn't have the rear rotors on which also make the back wheels go in a bit more.
Tow plates should give a pretty accurate reading
 

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Looks cool. Narrow the back more it can be like the T-Rex or Can am's style :)
 

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Discussion Starter · #13 ·
Had some time to check it yesterday, its pretty dead on. Just an illusion when looking at it. If I decide to take off the brembos, which I'm leaning towards then the front will be a bit narrower.
 

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Also let me know if that subie is for sale :)

I cant quite tell, but if its an aspen white bugeye I'm definitely interested. Either complete or rolling shell. THnx
 

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Discussion Starter · #17 ·
Also let me know if that subie is for sale :)

I cant quite tell, but if its an aspen white bugeye I'm definitely interested. Either complete or rolling shell. THnx
Sorry that was a customers car.

No updates as of now. I posted a few pictures on my IG and Fb if you follow you will see the engine mounted up almost. @checkerdsports
 

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This is an awsome build i happy to know somebody out there is chasing their dreams. I was actually think you was going to make this rear wheel. The welding is amazing i kind of wish you made parts for an fa5 civic or even an ek hatch.
 

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Discussion Starter · #19 ·
We left off last time having a meet at the shop. Thanks for everyone who attended.
Really good turn out for our area, I think a lot of people were surprised how many people came out.

Back to the build. I started ordering hardware to replace the random hardware all around the car.
Also lowered the front a bit, might still need more low.



A few months ago I had ordered an Integra DC5 Type R from Japan as a donor car. Please don't ask if we
can import you a car and register it, not going to happen. Car arrived and right away I went to pull the heart out.

Here is a picture of the car before it left Japan.





Parts all over the shop.



The removable top X bar that we made makes it very easy to mount the engine.
Speaking of mounts, we still had to complete the welds on the engine mounts, they were only
tack welded on, still enough to hold the engine in.
Since it's been so long since we last dealt with the mounts, we had lost one of the engine mount
pieces. Called Hasport and was shipped the next day.



I remove the heater core hoses on all my engines, so this one was no different.
R Crew Racing K20 heater hose block off kit, in stock.

Before



After





Found this modified RBC manifold in my office. I started working on it a few years ago and had plans of putting it
on the EG4, but never got around to finishing it. Might finish it and put it on the slayer.



I started messing around with some RBC manifolds, shaving the un-used sections.
I stock RBC manifolds so it's nice to be able to grab one off the shelf.




Started doing some shopping for radiators and realized the Rywire tucked radiator dimensions are exactly
what I was looking for.



Perfect Size!



We originally had planned on making a gas tank to place behind the passenger seat. After mounting
the engine we realized we needed everything else up front for weight distribution. Change of plans made
us decide to put the tank up front. I found an Aeromotive 6 gallon tank that was perfect for where we
were placing the tank. The tank is a great buy, built in baffles, and fuel pump. After doing some math
making our own tank would only save us a couple hundred dollars, so it was easier to just buy this one.

We made some mounts for the tank and welded them to the tank.



Radiator and fuel cell mocked up, kind of :/ .



The next task I wanted to tackle was the floor. The floor turned out to be more work than I thought.
I spent almost three straight working days on it. I welded the tabs that were already tapped for bolts.
That's when I realized we still had lots of welding that had to be finished from the bottom of the chassis.
Ansel cruised down finished the major welds and also brought his wire feed, since my old yeller Miller
decided to start acting up. The day after I spent most of the day grinding all the welds on the bottom so
the floor plates can sit flush on the metal.

For the front compartment and driver/passenger floor I cut out 1/4" aluminum, everything else behind the
seats was .080" aluminum to save weight, no one will be stepping on those sections.







Random cool pic of Ansel cleaning up the edges on the harness bar.
We had a few late nights at the shop since we wanted to show the car at Eibach "The West
Coast Collectives: One" meet.



Harness bar welded in.



Next obstacle we faced was the steering column. We had to finish the support of the column. We planned
on using a heim joint for the rod, but they didn't make a heim joint the size we needed. We had our
machinist make a spacer that would press into the heim joint and slide perfect on the rod.



I finished boxing up the column mount on the top for support.




Then built a box to bolt the heim joint to.



We finished mounting the radiator and fuel cell.



We wanted to add the headlights to the car before we took off to the meet. The headlights really set
the car off and make it look more like a car.



We bent some tubes for the supports, the next day I made the top plates and Ansel finished off the welds of art.



Of course we added some dimples to it.
#dimplecity



Headlights mounted up. The lights might have to be mounted on top of the supports for inspection.
According to NRS they need to be 24" off the ground.



Grabbed a battery and quickly hooked them up to see how they would look lit up.



Few last details and we were off to Corona Ca. for the meet.



Long trip.
8 hrs one way, stayed for the meet, ate dinner and drove right back home.
Had a few people that told us they came to the meet just to look at the car, which was awesome.
Brian from Hasport gave us kudos on the car, pretty cool coming from Brian.



A few pictures Joey took.
It was nice to catch up with a few people I haven't seen in a while. The original Eibach location meets
are always the best. Last time we were there was 2010 I think.







Until next time, follow me on IG if you want to see faster updates.
We also release sneak peaks of upcoming product sometimes.
@checkerdsports
 
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