Kraftwerks build w/ lots of pics.

[AZ05DC5]

Kraftwerks supercharged 2007 Civic Si Sedan (FA5)

Hello everone! Im pretty new here but not new with the K20's.

I have an 05 RSX type S with all the major bolt ons and wanted help a friend of mine build his FA5. It started a few months ago with him going for a quick ride around the block in my car and he (Josey) was hooked and wanted more power out of his car! From there we were trying to decide what direction to go with on his car and while doing some research I came across the Kraftwerks thread in here. I showed him all the info about it and said he can still go NA or Turbo or Roots style S/C if he wants to, but we both agreed it would be pretty sweet to have him be one of the first few with the Kraftwerks kit.

He is not active on any forums and has asked me to be the one to go ahead and document everything. I will also be the one doing all the work on the car so I wanted to start this for anyone who is interested in seeing a build with this kit. I am somewhat active on Club RSX (SN: 05DC5LUVR). I will admit this is my first attempt at any kind of build thread, so please go easy on me .

I am sure there may be a few other build threads on this and Im not trying to outdo anyone or race anyone to get it done first. I want to take my time on this to make sure everything goes as close to perfect as possible. Also, we have a few parts on back order anyways so this wont be started for another week or so. Please feel free to make suggestions along the way if anything seems off.

Modification List: (so far)


Kraftwerks kit with Rotrex C30-94 Supercharger and Hondata Flashpro
Skunk2 Mega Power RR 76MM Exhaust
Skunk2 Mega Power Race Header changed to Alpha Race Header
TWM Short Shifter System
Competition Clutch Stage 4 Clutch
Competition Clutch Ultralightweight flywheel
Hasport motor mounts (70A)
JDM Front H Badge
JDM rear H badge
Excelerate Gauge Pod V2.
Walbro 255 high pressure fuel pump
99 civic CMC
Megan Racing coilovers/ roll center adjusters/camber arms/H brace/rear lower tie bar/front lower tie bar
AEM gauges (Boost, A/F ratio, oil temp, oil pressure, voltage)
Ingalls torque damper (item removed because it wont fit with aftermarket motor mounts)
Yellow stuff Brake pads
Full Race traction balls
BWR oil filter sandwich adapter
Hondata 4 bar map sensor
Skunk2 Fuel rail
Skunk2 72mm throttle body
NGK Iridium 2669 spark plugs

I will be modifying the Mod list as we add to it.

First video of the car finally starting up

You Tube

You Tube

On the dyno and a few quick pulls

You Tube

You Tube

Skunk2 exhaust (left) 85lb Kraftwerks SC box (right)

[AZ05DC5]

7/10/12 First item installed TWM SS and bushings





7/24/12 started tearing it apart today













Working on the Supercharger and getting it ready to go in...









Clutch and Flywheel going on...





Motor mounts...





Skunk2 Throttle body and Skunk2 fuel rail came in





Oil filter sandwich adapter for oil temp and oil pressure





We got the header, exhaust, and Megan racing suspension stuff on in a few days























Dyno #s are in... 371 whp and 236 tq

[AZ05DC5]

Im going to use this next section to help anyone with a few issues we ran into

okay so I found that SD card (not sim card my bad) lol. with the pics showing some of the issues we ran into. I will add all this to the first page as well.

1) Aftermarket Fuel Rail

So we saw somewhere that Kraftwerks and Skunk2 mentioned that some aftermarket fuel rails may run into an issue where they are too long at the end and will hit the bolt coming out of the SC bracket just barley. When we test fitted the S2 fuel rail we found that this was definitely the case. It comes so close to clearing it but not enough to just "make it work" so our solution after calling Kraftwerks and asking about it was to just simply add a small lock washer to the other side of the bolt where it threads into the bracket.

This first pic I circled in red where the bolt comes out of the SC bracket and clears the stock fuel rail with tons of room...



and after adding a washer you can see it pulled the bolt out just enough to clear. Also very important note to make is Kraftwerks told us to make sure the threads are at least going all the way through the bracket still after adding the washer/spacer and you can see that it is...






2) larger Throttle body

The coupler/rubber hose that comes with this kit will not fit on the S2 72mm throttle body. I believe that Skunk2 and Kraftwerks is working on making a larger hose that fits correctly for those who want to run a larger TB. We believe that the size you really need is a 3 1/4" reduced down to a 2 7/8" with either a 45* or 60* bend from what we measured but we could not find any that size so we found a 3" NON FITTED rubber hose with a 90* bend. The one we found was almost twice the size as the stock one and I believe that is why we ran into most of these issues.

Here is a side by side pic of stock (Kraftwerks) fitted hose next to our larger non fitted hose. This pic is before we cut about an inch off of the side that mates up to the TB for better fitment...



And the first issue we noticed is the stock upper radiator hose was major kinked...



and the next issue was with the shifter bracket hitting the inside edge of the IC piping...



So to fix the first problem we called a local NAPA and picked up the famous part # 7777 radiator hose...



And to fix the shifter bracket issue we simply had to turn all of the IC piping to point it closer to the Radiator fans and it now clears fine...





Also the 3" hose we picked up was perfect for the IC pipe side and went on that no problem but on the TB side we had to spray a little WD40 around the inside edge of the hose and while one person pushes the hose on a second person had to use a large flat head screw driver to pry it over the damn throttle body. The rubber was flexible enough on the NON REINFORCED rubber hose to go over without ripping. But it was a pain.

Also another small issue since we ended up with a larger hose was it pushed the IC piping further out towards the battery tray. The metal tray circled here cleared the charge piping by only about 1/2 an inch but once we put the plastic battery tray down it was rubbing really bad against the charge pipe so we had to hack up the plastic battery tray just on one side (sorry no pics of it) to get it to sit down in there flat so the battery would go in.



3) 4bar map sensor

No pics but when we added the 4bar map sensor the base map that was sent to us from Kraftwerks would not start the car. It would crank but would not fire up. We had to go into flashpro and switch something over so it would recognize the new map sensor and then it fired right up.

4) Mounting the oil cooler

I did mention this a few pages ago but if you want to mount the oil cooler using the supplied bracket the bolts that come with the bracket were about 1/2 inch too short. We originally went and picked up longer bolts that were 1 inch longer thinking that it would be perfect but the 1 inch longer bolts were so long that they were hitting the radiator. So we went back and found ones 1/2 inch longer instead and they worked perfect.

[sofakingfresh]

Cool.

[LatinFG2]

Pretty sweet!

can I get a ride once the kit is in? haha

[AZ05DC5]

Originally Posted by LatinFG2

Pretty sweet!

can I get a ride once the kit is in? haha

Hell yes! Haha!

I wanted to invite some local members over during the build process and once it is complete but its not my house or my car so I gotta talk to Josey, but he/s pretty chill so Im sure he wouldn't mind.


More pics hopefully in the next few days of more parts!

[Fat_Kid]

Sub'd

[fid3L]

sub'd for results!

[DeDonDeRosa]

sub'd!

[Pracata]

Awesome!

[AZ05DC5]

Mods can move this to the "build" section if this is not the place for it. Apologies.

[aLmk]

That thing is gonna be loud!!!! Also the stage 4 clutch might be a bit overkill. Sub'd for results!

[fid3L]

a clutch master FX350 would be good choice

[Fsrider]

Nice! need more pix.

[Excelerate]

That's a nice assortment of mods.

[kekekekevin]

God Damn...so jealous that he's got his kit already.
Mine is still....no where.....I'm running out of patience.
Anyways, good luck and have fun...lots of fun

[wannavtec]

sub'd

[HotShot]

So nice!!! Good choice!

[VtecPanda]

AWESOME, def sub'd.. and yeah i agree about the stage 4 clutch, but too each his own.

[aLmk]

Yeah you may just want to see how long the stock clutch lasts.