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  1. #1
    Silver Member Seismic's Avatar
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    Seismic's Boosted Bluetop Build Thread

    Wow, this has been in the making for some time now so I've finally got around to doing something with the long-promised and long-awaited pics and details ...

    The History:

    You may have heard mention of an H23A engine with VTEC - there IS such a thing! Over the years there have been many doubters but it is well established now that between 1997 and 2001 Honda in Japan produced their own H22a/H23a "frankenstein" hybrid motor with a blue rocker cover (hence the term "Bluetop") for release in the CH9 SiR Accord Sport Wagon. This wagon was only released on the Japanese Domestic Market.
    Several years ago I researched and not only found this mythical engine to actually exist, but also found some impressive specs! So, after 3 years of hunting I imported this fine specimen:



    There was a bit of a saga attached with the import but I won't go into details here. Sufficed to say that this little beauty sat on the warehouse floor for 5 months before we started pulling it apart.




    Here is a closeup (2megapixel camera phone, so clarity < perfect) of the engine code stamp:

    And the barcode. Note that the H23A does not include a suffix in either of these pics. In the AuDM and USDM models, H23A1 defines a non-VTEC H23A, but the H23A with no "1" as a suffix is the real deal baby!


    Also, the dizzy uses an external coil:


    Eventually, disassembly began...









    As you can see, the internals are VERY clean - this was certified as only having done 23,000 kms and from its condition this was a pretty realistic lifespan so far. But ... the goal here is to push some serious boost so she had to come apart to make way for:

    Sleeves




    In a closed deck block, the bores are simply widened to make way for the sleeves. Such sleeves are called "dry" sleeves because they press hard against the remaining parent bores. Cooling is achieved by the transfer of heat between the sleeves outwards to the parent bores (ie the rest of the block) and the water jacket is housed in the block, coolant absorbing the heat and carrying it to the radiator for heat exchange with the atmosphere. Dry sleeves are much less tolerant of block warpage because machining imperfections become exagerated, creating spaces between the sleeves and parent bores where no efficient heat transfer can take place.
    These Darton MID (Modular Integrated Deck) sleeves are "wet" sleeves. This means that they come into direct contact with coolant and therefore become part of the water jacket because they are designed for an open deck block. So, they have been designed with spiral outer walls so that as coolant flows between the sleeves and the parent bore through the holes at the top, it spirals down around the outside of the cylinder walls drawing heat out of the whole length of the cylinder, rather than just the bottom where it would otherwise pool.

    Here is the block sitting like a patient on the operating table, waiting to be machined:


    The original cylinder bores are removed sequentially:





    Eventually, all bore material is removed right down to the crankcase:


    Next, the sleeve seats must be machined:


    Now the upper register of the parent bore must be machined to make sure that the tops of the sleeves seal properly:


    The finished block:



    The sleeves are now o-ringed and lubricated before sequential fitment:


    Now, back at the workshop:


    For anyone questioning the authenticity of this project, note my beloved lude in the background - PAQLD members will verify that this car with the chrome gas bonnet struts courtesy of AdReNaLiN, chrome 17" wheels to match and JDM folding mirrors is indeed mine. I'd put a picture of me in there too but I'm just not as photogenic as Steve



    That will do for now, to come ... some more internals - watch this space!
    Last edited by Seismic; 14th July 2009 at 11:33 AM. Reason: Updated sleeving process
    The path of Honda is beset on all sides by the iniquities of Mazda and the tyranny of Nissan. Blessed is the Honda owner who in the name of handling and performance shepherds his Honda through the valley of darkness, for he is truly his Honda's keeper and the finder of lost kilowatts. And I will strike down upon thee with great acceleration and furious VTEC those who attempt to overtake and destroy my Hondas. And you will know my name is PRELUDE when I lay my VTEC upon thee.


  2. #2
    Gold Member peejayy's Avatar
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    wtf.

    you are the most annoying person around! as if have such great news and interesting pictures and post thumbnails.


    m:0432 699 951 e:pujitha115@optusnet.com.au msn:peejayy@hotmail.com

  3. #3
    Silver Member Seismic's Avatar
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    Haha, I hear ya! I'm gonna fix it soon - keep an eye on it!
    The path of Honda is beset on all sides by the iniquities of Mazda and the tyranny of Nissan. Blessed is the Honda owner who in the name of handling and performance shepherds his Honda through the valley of darkness, for he is truly his Honda's keeper and the finder of lost kilowatts. And I will strike down upon thee with great acceleration and furious VTEC those who attempt to overtake and destroy my Hondas. And you will know my name is PRELUDE when I lay my VTEC upon thee.


  4. #4
    Gold Member WEAPON-R's Avatar
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    OMG about time lol

    now i wanna see you and Steve line up! hahaha

    Then i'll visit when my car is finished
    STUFF FOR SALE!

    4G jdm fog lights $80
    Had a prang? Front and Rear bumpers $50 each!!
    TANABE rear muffler brand new in box $250
    Thinking of going K series in your 4th gen?? I have the HASPORT BBK mount kit brand new for $400
    H22 intake manifold $50
    Brand new 65mm K series Throttle Body $100


    PM me for details!

  5. #5
    PA Resident SAKI's Avatar
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    Wow nice project! Whats the ETA on the completed product assuming all goes as planned? (Which i know it never does but hey, it can't hurt to have something to aim for).
    Quote Originally Posted by brash22 View Post
    You sir are mad. Like lock you in the nuthouse mad.
    Quote Originally Posted by Manabir View Post
    You sir are a prelude obsessed freak.
    Quote Originally Posted by hiru View Post
    you sir, are a prelunatic.

  6. #6
    Silver Member Seismic's Avatar
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    Okay - pics fixed, no more thumbnails!
    The path of Honda is beset on all sides by the iniquities of Mazda and the tyranny of Nissan. Blessed is the Honda owner who in the name of handling and performance shepherds his Honda through the valley of darkness, for he is truly his Honda's keeper and the finder of lost kilowatts. And I will strike down upon thee with great acceleration and furious VTEC those who attempt to overtake and destroy my Hondas. And you will know my name is PRELUDE when I lay my VTEC upon thee.


  7. #7
    Silver Member Seismic's Avatar
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    Quote Originally Posted by WEAPON-R View Post
    OMG about time lol

    now i wanna see you and Steve line up! hahaha

    Then i'll visit when my car is finished
    Haha, I'll say!
    Neither Steve's nor mine (nor yours) are on the road at the moment. So I vote we do a "virtual car race".

    We have them lined up at the lights with our windows down and we make revving sounds vocally. Then, when the light changes, we all jump out and leg it!
    The path of Honda is beset on all sides by the iniquities of Mazda and the tyranny of Nissan. Blessed is the Honda owner who in the name of handling and performance shepherds his Honda through the valley of darkness, for he is truly his Honda's keeper and the finder of lost kilowatts. And I will strike down upon thee with great acceleration and furious VTEC those who attempt to overtake and destroy my Hondas. And you will know my name is PRELUDE when I lay my VTEC upon thee.


  8. #8
    Senior Member Cam's Avatar
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    looks fantastic mate! what sort of power are you aiming for?

  9. #9
    Silver Member Seismic's Avatar
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    Quote Originally Posted by SAKI View Post
    Wow nice project! Whats the ETA on the completed product assuming all goes as planned? (Which i know it never does but hey, it can't hurt to have something to aim for).
    Hehe, assuming all goes to plan the ETA for this was about 14 months ago!!!!
    I was saying to Steve just the other day that I've had no progress on it for 7 months now. I have a pile of parts waiting to go into the engine bay but it all inges on a fully assembled engine so that I can start doing pipework and fabbing the manifold etc. At the moment I'm having a "tense discussing" with a supplier over the valvetrain components, exacerbated by the exchange rate drop to the US and more difficult freight conditions but I hope to have a resolution to that situation (after 10 months) in the next couple of weeks.
    All going well after that, and assuming that the cash keeps flowing, I'd like to say that it will be ready in November.
    The path of Honda is beset on all sides by the iniquities of Mazda and the tyranny of Nissan. Blessed is the Honda owner who in the name of handling and performance shepherds his Honda through the valley of darkness, for he is truly his Honda's keeper and the finder of lost kilowatts. And I will strike down upon thee with great acceleration and furious VTEC those who attempt to overtake and destroy my Hondas. And you will know my name is PRELUDE when I lay my VTEC upon thee.


  10. #10
    PA Janitor Bob's Avatar
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    I take it that this engine is OBD2 then. Interestingly they have taken the H22A open deck of that era to produce the H23A block and not the earlier closed deck H23A.

  11. #11
    Silver Member Seismic's Avatar
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    Quote Originally Posted by Cam View Post
    looks fantastic mate! what sort of power are you aiming for?
    Hmmm, this will start some sh1t. The goal is to push past 500 ponies at the wheels. I've said this before and got blasted for it, but that's my goal. It will be running around 31 psi to hit that mark and I'm building the internals accordingly. Yes, that is the target figure on an Australian dyno, not a US one. And yes, I know that kind of power is *almost* impractical on a FWD. Enter the Quaife ATB diff (details to come).

    This is more of a proof of concept for me now than anything else. I know it's going to be a b1tch to drive in a straight line, but that's not the point. She may become a dyno queen rather than a dragstrip monster
    The path of Honda is beset on all sides by the iniquities of Mazda and the tyranny of Nissan. Blessed is the Honda owner who in the name of handling and performance shepherds his Honda through the valley of darkness, for he is truly his Honda's keeper and the finder of lost kilowatts. And I will strike down upon thee with great acceleration and furious VTEC those who attempt to overtake and destroy my Hondas. And you will know my name is PRELUDE when I lay my VTEC upon thee.


  12. #12
    Regular Member
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    Damn!!

    Nice....very nice. I think Steve's gonna be hella jealous of the Bluetop! Even more rare than the H22a LSD. Crazy!

    How much does this thing make in stock form?

  13. #13
    Silver Member Seismic's Avatar
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    Quote Originally Posted by Bob View Post
    I take it that this engine is OBD2 then. Interestingly they have taken the H22A open deck of that era to produce the H23A block and not the earlier closed deck H23A.
    Hey Bob, yes it is OBD2 so I will have to convert the injectors and harness etc to OBD1 to run with an aftermarket computer. And yes, all my research pointed to a closed deck block so I was quite surprised when we lifted the head off to take a peek!
    It certainly changed my choice of sleeve but I'm much happier in hindsight with the sleeves we're using now so I guess everything works out in the end.
    The path of Honda is beset on all sides by the iniquities of Mazda and the tyranny of Nissan. Blessed is the Honda owner who in the name of handling and performance shepherds his Honda through the valley of darkness, for he is truly his Honda's keeper and the finder of lost kilowatts. And I will strike down upon thee with great acceleration and furious VTEC those who attempt to overtake and destroy my Hondas. And you will know my name is PRELUDE when I lay my VTEC upon thee.


  14. #14
    Silver Member ludecrs's Avatar
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    QLD - Home of Boosted Hondas and pwnr of PA's Boost Sub Forum.


    Prelude: Sold.
    S2000: Sold.
    NSX: Sold.
    F355: Coming...

  15. #15
    Gold Member hiru's Avatar
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    wow freakin awesome mate! i will be watching this thread intently.

    also i think you should put it up on preludepower and show the americans it does exist... and that we have some looney people willing to do looney things to their preludes over here too

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