Muckman’s High Compression Super Build

I decided to start a build thread but my “build” has been ongoing since 2003 so forgive me since I won’t be starting at the beginning. This is my 5th engine rebuild for my 2000 GSR. My engine build for 2013 is a continuation from 2012. I’m running the same turbo and high compression setup. Highlights are 13.5:1 compression, E85, GT3076R, Hytech manifold, Dart head, and GSC T1 cams.

In 2012 these were the original goals and myths to disprove:
1.) You can’t safely run high boost with high compression without race gas. Im running E85 ethanol available from my gas station.
2.) Turbo Honda’s don’t have any low end torque under the curve. We’re all well aware of this.
3.) Only big turbos don’t suffer from torque/boost taper at high rpm. I hate seeing the big turbo hump in the middle which turns into a 100ft-lbs dive of disappointment.

The goal was to build a responsive high efficiency engine with high compression, a high flow ported head and big cams. I am going to reuse my current turbo setup which consists of a Hytech manifold and a GT3076R-13. I’d like to make at least 500hp observed with lots of torque that is linear and smooth.

I achieved my goals last year. I made 597whp (STD correction) with a 13.5:1 compression engine. It made fantastic low end torque 150ftlbs at 2000rpm (no boost, low cam). And I was very pleased how the cams carried peak torque all the way to redline. I do not care about midrange torque because it’s the easiest place to make torque. I am trying to build up torque on both ends of the rpm range which is very difficult to do.

Here is the base pull on wastegate spring pressure - 5.5psi = 350hp observed. Absolutely nuts for such low boost on a medium sized turbo. Look at this torque curve; it looks like a N/A motor! 150ft-lbs is made at 2000rpm, off boost. Compare the torque to any other B series Honda under the curve, most are around 100ft-lbs off boost. The torque plateau is gradual and unrelenting all the way to redline.



On pull 10 we made 408HP observed on only 10psi.

On pull 29 we made 539HP observed (597HP Standard correction) at 8500rpm on 18.3psi (peak 20.2 psi).

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Pull11 - 444hp observed @ 8300 @ 13.5psi (peak 15psi)
[youtube=444hp observed @ 8300 @ 13.5psi]8RVCbUklcPk[/youtube]

Pull14 - 395hp observed @ 8200rpm @ 17.6psi (peak 18.1psi). Crap power because of the heat but this one has a nice flame shot out the dump at the end.
[youtube=395hp observed @ 8200rpm @ 17.6psi]1ZIN8qe87A0[/youtube]

Same pull as above but different angle from the GoPro. Notice the puff of smoke that comes out of the turbo at the end.
[youtube=395hp observed @ 8200rpm @ 17.6psi]hCzvgfb_fxI[/youtube]

Another one of pull14 but I love how this sounds with the tunnel affect.
[youtube=395hp observed @ 8200rpm @ 17.6psi]aWT5w3xR9rk[/youtube]

Pull16 - 480hp/300ft-lbs observed @ 8300rpm @ 17.3psi (peak 18.8psi). Small flame out the dump.
[youtube=480hp/300ft-lbs observed @ 8300rpm @ 17.3psi]gVcuFlfMolo[/youtube]

Pull18 - 498hp/315ft-lbs observed @ 8300rpm @ 18.3psi (peak 21.1psi). This is my favorite video from Friday. It has all the elements - stalling, hooning, boost cut, random pipes falling, big HP and high fives - all in one take.
[youtube=498hp/315ft-lbs observed @ 8300rpm @ 18.3psi]Y09VedxzC6E[/youtube]

Pull19 - 502hp/320ft-lbs observed @ 8300rpm @ 17.5psi (peak 19psi). Big flame out the dump.
[youtube=502hp/320ft-lbs observed @ 8300rpm @ 17.5psi]AsnJTuwkl9E[/youtube]

Pull26 - 536hp/330ft-lbs observed @ 8500rpm @ 19.7psi (peak 23.3psi). This was terrifying to watch my camera nearly vibrate off the platform.
[youtube=536hp/330ft-lbs observed @ 8500rpm @ 19.7psi]TEmlp-cVJlk[/youtube]

Same pull from the GoPro.
[youtube=536hp/330ft-lbs observed @ 8500rpm @ 19.7psi]eKtTSEqTZXA[/youtube]

Pull29 - 539hp/340ft-lbs observed (597hp STD)@ 8500rpm @ 18.3psi (peak 20.2psi)
[youtube=539hp/340ft-lbs observed @ 8500rpm @ 18.3psi]LEvEzPwkBjE[/youtube]

However at the end of my dyno session several minor engine issues emerged. As I invested they turned into bigger issues. Fortunately these issues were caught before catastrophic engine damaged occurred but still required a full rebuild.

The 2012 engine issues were:
-Bent wrist pins *caught before piston exploded
-Broken middle piston ring on #2 * scratched cylinder wall
-DART head had worn valve guides * causing poor valve seal and oil contamination
-Oil squirters were contacting piston skirts *Debris in oil
-Debris scratched up bearings

After the dyno session I did a compression test and found #4 was lower than the others. I found the reason to be poor valve seals due to loose valve guides. This is rubbing alcohol used to visualize leaking air as the cylinder is pressurized.



This is a video of the valve seal testing I did. Remove cams or point lobes away from valves, fill ports with alcohol and simply compress air into cylinder.



When pulling the pistons to swap the wrist pins I found the middle ring on #2 was broken. Installer error - only myself to blame.



The broken ring scratched the cylinder wall. This will need to be bored out to remove.



The bent wrist pin is a badge of honor though. 8)

The rebuild highlights for 2013 consists of:
-Custom pistons with thicker wrist pins
-Bored and Oringed block
-New valve guides and valve job for DART head
*Switch to Hondata and coil on plug

The goals for 2013 are the same but this time do it reliably.



Full build list:
http://www.clubintegra.com/board/garage_vehicle.php?do=view_vehicle&id=767

Love seeing a real ass, proper, myth busting build... badass s*** man, staying tuned for sure. I always love when people say you can boost with high compression lmao.

Love the Hytech manifold. Subscribed.

Finally you post it. Been wondering how long this was going to take. That hondatech thread isnt satisfying.

I didnt want to simply copy and paste what I had on HT plus I cant start at the beginning because it would be too long and boring. So what Im going to do is go through the latest engine rebuild in great detail. Everyone loves pictures, and I have lots.

Sounds good man. By the way, the valve cover is sick. Me wants.

I read through your build on HT from page one. I'm glad to have it here though lol.

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wow

Sub'd

Damn. Subscribed.

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Man I sure will be watching this build

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