Cyborg's Hondas

  • Thread starter CyborgGT
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GTP_Cyborg
Somehow I never created a thread for either my daily RSX or my project CB Accord.

First, the big project. This is what's currently ruling my life. My first car was a '92 Accord LX sedan. I did some minor mods, but after a while the original single-cam F22A1 engine finally gave up the ghost. Rather than diagnose and get it running again, I took it as an excuse to do the common swap with these things: a Prelude H22 DOHC VTEC motor. The castings of the two engine blocks are extremely similar, so aside from some minor electrical work it was a direct bolt-in - stock Accord mounts and axles, even! After about a year of smooth driving, an electrical issue came out of nowhere (in hindsight, probably a short resulting from my noob attempt at tucking the wiring harness), so again... "hey, an excuse to go harder!" In October of 2012, I pulled the H22 back out, got rid of the sedan, and spent the next several years collecting parts for more power, but this time in the wagon variant that had stolen my interest.

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After leaving the sedan, I needed a new car to daily in while I collected parts for the next Accord. I set out to find a 5th-gen Prelude Type-SH, but after being let down multiple times by what was on the local market, I saw for sale a 2002 Acura RSX (base model, semi-auto transmission). I had somehow forgotten these things existed, despite badly wanting one when they first came out in my teen years. In my haste to end my dependence on bumming rides from a friend, I failed to research the RSX, not realizing that they came with two fairly significantly different trims. But as it turned out, the base model was still a fun way to get around... especially the more I upgraded the handling. Who needs power when you don't have to slow down for corners? This car's biggest problem actually turned out to be my inability to resist modifying it. I've put quite a bit into handling and appearance changes, and all at the expense of focus taken away from collecting parts for the H22 I have sitting around. 200,000 miles later (300k on the odo as I re-write this intro post coming into February 2023), I've managed to leave the RSX's powertrain untouched to maintain reliability, but that will certainly change after I've got an Accord to drive again. The car is certainly feeling its age these days, and will become a proper project itself.

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Eight whole years after pulling the H22 from the sedan, all of my engine parts were in hand and I was finally ready to go shopping for that wagon. As it happened, the first car I went to look at in January of 2020 was too good to pass up. It was an automatic, but that's easily remedied and the body was straight, with not a speck of the rust that '90s Hondas are known for. Faded paint on an old car is to be expected, but if there's one thing I've learned by now, it's that I do not want to deal with serious body work if I can help it. In what I thought was a calculated move, I took out a loan thinking I'd knock this thing out in a few months. I don't regret the loan itself, for paying the interest was well worth it to me to get this finished up sooner rather than later, but the scale of the work still to be done was larger than I could have known. The wagon has now spent a hair over three years inside a storage unit as I work on it, and the 'end' is only now in sight.

To summarize my intentions, what I'm putting together here is a fun road trip car. I have fond childhood memories in the rear-facing third row of my mom's late-'80s Pontiac wagon, trekking back and forth between California and South Dakota, and I want to experience that as an adult. I want something to see the 49 continental United States in, but it has to be enjoyable for those thousands of miles as I hunt down this country's great driving roads, and above all it has to be... me. I'm not interested in something that anyone else can go out and buy, or I'd have just bought a newer car that most people would consider "nicer." I have certainly poured enough money into this build by now that I could have done that.

The engine is over-built in hopes of reliability, but the power will be modest. I'm aiming to be roughly on pace with the faster modern turbocharged four-cylinders - just without the turbo, because I love a good naturally-aspirated screamer. The handling will of course be improved, but not to the point of making the car physically draining to drive long distance in. Other measures will be taken to make the car comfortable to be in, even if they're at a slight detriment to performance. I'm not building a race car, after all.

As of January 26th, 2023, the car is technically drivable (has been for over a year), but not road legal and not properly tuned. I have an appointment set at one shop for the end of February to have the custom intake and exhaust tubing welded up, and then after that I'll be talking to another about the dyno tuning...

How it started:

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How it's going:

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Nice work. The Accord looks like a great project and I've always found the DC5 a really attractive shape. Like you, I've wanted one since it first came out - mainly thanks to its appearance in GT3, and then in subsequent GT games as a full Type R Integra. Unfortunately, they sold neither in the UK - and Type Rs have only come in as grey imports.

What wheels are you planning for the Accord?
 
I don't have an Accord chassis at the moment. The plans for that are to build the H22, get the car, then put together a suspension & brake upgrade including a 5-lug conversion. That's when the wheels for that car will come. *ED. - wheels are undecided. Going for a 'sport luxury' theme, though.
 
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Detailed spec on the engine, for those who might be familiar with the Honda aftermarket...

ENGINE:
Closed-deck JDM H22A

Electrical:
  • Hondata S300 V3
  • RyWire VTEC sub-harness

Air:
  • K&N Apollo enclosed air filter
  • Custom 70mm O.D. aluminum intake tube
  • Professional Products 68mm Power throttle body for ITR, polished
  • H22 Euro-R/Type-R intake manifold prepped by Rosko Racing (68mm port match), DIY polished
  • Hondata thermal intake manifold gasket

Fuel:
  • Walbro 255lph pump w/install kit
  • Rosko Racing rail
  • Acura RDX OE injectors
  • AEM pressure regulator

Spark:
- NGK BKR7EIX/2667 iridium plugs (might not be permanent, but this is where I'm starting)

Head:
  • ARP head studs
  • New OEM '97-'01 spring-style lost motion assemblies
  • Supertech machine hardened valve locks
  • Supertech titanium spring retainers
  • Supertech 79lb valve springs
  • Supertech valve seals
  • GSC Power-Division valve guides, at machinist's recommendation over Supertech
  • Supertech black nitrided, dished valves
  • New OEM valve spring seats
  • Skunk2 Pro 2 cams
  • Skunk2 Pro Black Series cam gears
  • Skunk2 cam seal
  • Skunk2 "Skunk2 Inside" VTEC solenoid cover

Bottom End:
  • Rotating assembly balanced
  • Wiseco 11.5:1 pistons (re-sleeve, of course; one of my stock bores was scratched)
  • Eagle H-beam rods
  • ARP main studs
  • ATI street damper
  • OEM S2000 oil filter (larger body maintains oil pressure past 8k rpm)
  • OEM block heater
  • OEM balance shaft seal retainer added
  • KS Tuned manual timing tensioner & walk blocker
  • K-Tuned oil pressure sensor adapter
  • Powder coated oil pan w/DEI gold heat tape above downpipe
  • Skunk2 magnetic drain plug

Exhaust (100% stainless steel, down to the hangers):
  • PLM 4-2-1 header (needed modifying to fit better) w/bungs for EGT and wideband sensors
  • Spoon Sports header primaries (needs 2.5" downpipe; one day I'll compare it on the dyno)
  • 2.5" Vibrant Performance flex pipe
  • 2.5" Catco cat
  • 2.5" x 18" Vibrant bottle resonator x2
  • Summit Racing V-bands to make system removable in pieces
  • 2.5"-to-3" Vibrant expansion
  • 3" Kteller mandrel-bent piping
  • 3" Vibrant Street Power muffler, dual 3.5" out

Long-term Plans:
  • Weld in factory manual trans bracket so I can put a softer mount in there
  • "Real" header
  • Debating full 3" exhaust, if I feel it can be made quiet enough
  • Skunk2 Ultra Street K-series intake manifold w/larger throttle body & intake
  • Coil-on-plug conversion

Longer-term Plans:
- Turbocharge to ~350 whp, inspired by FK8; ideally I'd like to find a Jackson Racing supercharger, if not go custom with a roots blower for that whine



TRANSMISSION:

  • Manual conversion
  • M2K4 gearbox (pulled from an H23A1 4WS Prelude; not sure if it's the 4.0 or 4.2 final drive. No LSD.)
  • 4th gen Prelude shifter/cable assembly
  • Cheddas Auto 4th gen Prelude Delrin shifter bushings (... two of them, anyway.)
  • MTEC Industries shift springs
  • Speedfactory Racing HD detent springs (both of these springs listed here are to tighten the shifter feel)
  • Valex Racing stainless clutch line, master-to-slave
  • Exedy Racing Stage 1 clutch
  • Competition Clutch 11.56 lb flywheel
  • ARP flywheel bolts
  • Skunk2 magnetic drain plug

Plans:
- Shorter-geared Prelude trans w/LSD and 4.6 final drive. An Accord 5th gear should lower my RPM at freeway speeds.
 
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I'm just curious what you guys think of these aero bits, sans the canards (little wings just under the headlights - and actually, they're growing on me the more I stare at these photos). I know the RSX is just a daily driver, go-to-work and run-the-errands machine, but I'm seriously in love with this look. I do go up into the canyons fairly often, at least. Front splitter, side splitters, and rear diffuser:

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H22 progress update: the exhaust system is complete!

Forgot to add the 2.5"-to-3" expansion in the photos, but from the block out:

> Spoon Sports header primaries
> EGT sensor bung will be welded to cyl. #3, just off the head flange
> OEM downpipe (for now; looking for an aftermarket dp that might bolt to stock primaries, just for the looks)
> Vibrant 2.5" merge collector
> Vibrant 2.5" flex pipe
> Vibrant bungs for factory O2 sensor and wideband A/F gauge sensor; placement to be determined on-car
> Summit 2.5" V-band clamp #1
> Catco 2.5" cat
> Summit 2.5" V-band clamp #2

> The middle section is where some experimentation will be going on, looking for that perfect sound. At the moment, I have two 2.5" Vibrant resonators to try: their standard bottle res, and their Ultra Quiet. If neither is to my taste, I'll start by finding a longer bottle resonator, and go from there.

> Summit Racing 2.5" V-band clamp #3
> Vibrant 2.5" to 3" pipe diameter expansion
> Kteller 3" mandrel-bent tubing
> Vibrant Street Power dual-tip muffler (I really hope I can make the exhaust sound nice with this on, it is such a beautiful piece!)

Everything is stainless, and everything will be polished, all in keeping with my desire for longevity on this build.

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The new focus is the head. I've been sitting on some things, I'm waiting for a few more minor pieces in the mail as I type this, and the rest should be in-hand by the end of December; January at the latest.

One idea I sort-of scrapped is using the RSX Type-S intake manifold I purchased off Craigslist. Explicit Speed Performance recently released a low-profile rear mount bracket that allows clearance in Preludes/Accords for the 8th gen Civic Si's RBC manifold that everyone swaps onto every K motor out there. I picked up one of these brackets, so after the H22 is driving, I'll be on the lookout for an RBC to compare to the Euro-R on the dyno.
 
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H22 progress update: the exhaust system is complete!

Forgot to add the 2.5"-to-3" expansion in the photos, but from the block out:

> Spoon Sports header primaries
> EGT sensor bung will be welded to cyl. #3, just off the head flange
> OEM downpipe (for now; looking for an aftermarket dp that might bolt to stock primaries, just for the looks)
> Vibrant 2.5" merge collector
> Vibrant 2.5" flex pipe
> Vibrant bungs for factory O2 sensor and wideband A/F gauge sensor; placement to be determined on-car
> Summit 2.5" V-band clamp #1
> Catco 2.5" cat
> Summit 2.5" V-band clamp #2

> The middle section is where some experimentation will be going on, looking for that perfect sound. At the moment, I have two 2.5" Vibrant resonators to try: their standard bottle res, and their Ultra Quiet. If neither is to my taste, I'll start by finding a longer bottle resonator, and go from there.

> Summit Racing 2.5" V-band clamp #3
> Vibrant 2.5" to 3" pipe diameter expansion
> Kteller 3" mandrel-bent tubing
> Vibrant Street Power dual-tip muffler (I really hope I can make the exhaust sound nice with this on, it is such a beautiful piece!)

Everything is stainless, and everything will be polished, all in keeping with my desire for longevity on this build.

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The new focus is the head. I've been sitting on some things, I'm waiting for a few more minor pieces in the mail as I type this, and the rest should be in-hand by the end of December; January at the latest.

One idea I sort-of scrapped is using the RSX Type-S intake manifold I purchased off Craigslist. Explicit Speed Performance recently released a low-profile rear mount bracket that allows clearance in Preludes/Accords for the 8th gen Civic Si's RBC manifold that everyone swaps onto every K motor out there. I picked up one of these brackets, so after the H22 is driving, I'll be on the lookout for an RBC to compare to the Euro-R on the dyno.
You're lucky you can get manifold-back systems for your car. I've been looking for a system like that for my car but haven't got £2500 to spend on an exhaust system!!

Damn nice car by the way!
 
^ That's just picking away at it, piece by piece over time. I can't blow a couple grand on anything at once either, unless I've taken a significant amount of time saving up for it. This engine's a very long-term build. The car as a whole will take many years to get it where I want it. And thank you!

Right now I'm working with a fellow RSX enthusiast to create a custom emblem for this wagon project. It's something I thought up a long time ago and only recently, by chance, came across someone who was capable of actually making it real. As heavily modified as the car will be, I want to give it my own one-off name. Inspired by the Accord Type-R and Euro-R, and the badging of the older wagons as "Aerodeck" in other parts of the world, I came up with a new trim level I call the "Aero-R." We've been going back and forth critiquing the concept in 2D, and now 3D, and so far have ended up with this.

OEM Accord Euro-R (CL1) emblem that I took the styling inspiration from:

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Final 2D concept:

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Current 3D concept:

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The step in the R I'm not feeling; the OEM's R looks to instead have a slight indentation to gap the chrome and red areas, so I'm hoping that can be replicated. Down the road, I'd like to have decals made for when I upgrade the brake calipers, and have it stitched into the backs of whatever seats I end up with.

*EDIT - First low-resolution print. I didn't notice in the 3D rendering that the R was significantly thicker than the rest of the badge, so that has been thinned to match. I'm liking this, so we're going to get a smoother finish and have it chromed...

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The emblems are finally being mailed out to me in the morning! They're not completely finished, they still need to be fine-sanded and chromed, but I have a critical eye for detail so I'm glad I am overlooking that part myself. I was sent these photos today, and I gotta say I am loving how they look against paint!

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This definitely means I am committing to purchasing a wagon once the engine is built, though. I'm terrible at making up my mind sometimes, and every now and then my taste will fall more towards the coupe or sedan. But now, with a decent amount of money being spent on an Aerodeck-inspired emblem, I can't very well stick it on anything but a wagon.
 
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Mail time, mail time, maaaaaiil tiiiiiimme! Here's the mail, it never fails, it-

Sorry.

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Can't. Friggin'. Wait... to finish building an engine, then buy a car, then paint the car, then stick these badges on.
 
Cams came in recently (Skunk2 Pro 2s), finishing off the parts pile for the head.

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> OEM gaskets & seals
> ARP studs
> S2 cams & adjustable gears
> Supertech valves, guides, springs, retainers, locks, & valve seals

Had fun mocking up the gears on an "assembled" head:

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Got some literature for the RSX: an owner's manual complete with window sticker; brochures; and a pre-release press kit for the "RS-X Prototype." The CD-ROM that came with the press kit shows off 18" BBS wheels and a complete Integra Type R interior that the American market was originally supposed to get :(

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And I hit 200,000 miles!

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My hood's clear coat keeps getting worse, so I finally tried to DIY it. It's not perfect, but considering I attacked this thing with sand paper, rattle can clear, more sand paper, and two stages of soft compounds, I'm pretty proud of the hours I put in. It's still looking a bit dull around the lock shown, so that could do with going over with the soft compounds again.

Note that I only worked on the driver side of the hood, just to see how well I could do. You can see the radiator vent is still rough; I went over everything from the bottom of that vent lip over. I'll get around to the rest later now that I know I can actually improve it and have it hold out until I can afford a real Mugen hood.

Here's the passenger side, to show how bad the flaking is. The same body line on the driver side was just as bad, as well as the edge of the hood running along the driver side fender:

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Driver side as it sits right now:

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I'm also aware of how the chassis is tweaked, causing the headlights to not line up properly with the body panels. That'll be fixed with the eventual respray.
 
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Found some stuff.

First, factory parts book microfiche for 1991-1993 Accord wagons and 2002-2004 RSXs. They look to be the exploded diagrams found on OEM parts stores, showing part orientation and OEM part numbers for every single part of the car. I should be taking them somewhere to be scanned on Monday, obviously for personal use but also because I'm working with a guy on the Accord forum who's compiling as much fourth-gen Accord literature as he can find.


by D.Flinn, on Flickr

Second, JDM power folding mirrors for the wagon... I guess the JDM switches were in English? At the rate I'm going, this car will be complete before I even have the chassis :lol:


by D.Flinn, on Flickr
 
More H22 goods came in the mail! Feels like things are finally heating up lately.


by D.Flinn, on Flickr

- Vibrant "U-J" scrap mandrel exhaust bends (2.5", stainless)
- Walbro 255 lph fuel pump with install kit
- ARP main studs

I made a slight change in build goals recently, so something really cool will be put on order in a couple weeks...

*EDIT - Almost forgot (I think it was posted in the 'what have you done' thread, at least), I filled out the glove box gauge cluster recently as well, with some fuel and oil pressure dials:


by D.Flinn, on Flickr


by D.Flinn, on Flickr
 
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It's looking like this is "all" I have left to do on this build to get driving. Small list, but after the parts collection is complete, things get pretty expensive.

- Different header; decided the Spoon manifold won't be used even to just get driving
- Pistons & connecting rods
- Banjo adapter for the fuel rail
- Fuel pressure regulator
- Probably don't need but would like new OEM valve spring bases
- Probably don't need but would like new OEM oil pump - gotta figure out what to get for a JDM OBD2 block, since there are some annoying differences on the American engines
- Crank damper - not sure if this will come now or after it's driving; depends on ease of install

- All parts in hand, then buying the wagon (I've been seriously thinking about getting a RHD car, now that they're 25 years old, but it would cost up to three times as much)

- Machine work on block and head, including re-sleeve
- Talk to my tuner about what ECU/software to get; Neptune's my first choice, even though I know this shop does a lot of Hondata work
- Dyno tune

- Decided to wait on the cooling system upgrade until first thing after the car's driving. It's not needed immediately, so it'll save me money to get the build done sooner.
 
JDM convert a US! I can definitely help with that. This stuff is plentiful.

Really love this build. The extra notch you take with each detail is awesome and so interesting to watch. Like the badge!
 
^Thanks! The details are what make a build, in my opinion. Not that the Accord's a common choice to build on, but especially with anything mainstream, you've got to find unique ways to put yourself ahead of everyone else. I go to 'tuner' car shows, and there are too many cars I walk right past. But are you offering to help me out sourcing JDM parts? There are a couple I still want, I may have to take you up on that if I don't go through with importing a full car.

And the ugly car's just getting more and more presents. Finished up the fuel system when the FPR came in the mail today.


by D.Flinn, on Flickr

- Rosko Racing fuel rail 'for Euro-R manifolds with Acura RDX injectors'
- Said RDX injectors
- Walbro 255 lph pump
- AEM pressure regulator
- AEM electronic pressure gauge, as seen in my last post.
- Golden Eagle banjo fitting (in the mail - the one that came with my rail is too long, making me believe the seller had it in a Civic/Integra?)
- Golden Eagle rail end plug (should be anodized black; also in the mail with a spankin' new O-ring)

- Not related to fuel, but those new OEM valve spring bases I wanted are on the way as well. Not really worth posting a photo of them, though.


Sorry, RSX, you'll get yours one day :(
 
But are you offering to help me out sourcing JDM parts? There are a couple I still want, I may have to take you up on that if I don't go through with importing a full car.

It'd be my pleasure. 👍
 
That's too cool, I'll keep you in mind :)


I'm giving myself a bit of a project. When I originally pulled the engine and stripped it down - this was way back in late 2012, if you can believe it; pretty sad to think about what little I've accomplished in five years - I took tons of photos documenting disassembly. Well, something happened to whatever I was storing the photos on and I lost everything quite a while ago now. Since the timing side of the block is pretty complex with all the little pieces involved, and now that I'm reaching the end of my new-parts collecting, I'm finally getting around to a sort of mock reassembly. I did my best to organize and label everything as they came off, so between that and the factory service manual, I'm hoping to put together another photographic reassembly guide for myself while double-checking that I still have everything.


by D.Flinn, on Flickr
 
:cheers:

Another part I've wanted for a while popped up for sale on the RSX forum, and I couldn't pass it up - I was planning on changing up my H22's header to something 'real' this month, but that can wait.



Mugen ITR intake. Got it a few days ago and it's already installed. Needs some more fiddling, though, because it was designed very specifically for the RHD Integra that doesn't have brake components on that end of the firewall. I've done as much customizing to the box itself as I am willing (between the brand name and its discontinuation, it was STUPID expensive for an intake), but it's still rubbing against the bmc reservoir. It's made to utilize the stock box mounting points, and it's just not happening unless I want to put up with a vibration in my brake pedal - that might have damaging effects in the long term.

But anyway, these engines are absolutely pathetic in the low RPMs. It's not a huge difference, but I do feel a bit more punch down low. I'm reading that the fiberglass it's made from is better against heat soak? The bottom half of the box is wrapped in heat-reflecting tape, anyway.

That scoop is placed to work with Mugen's own front bumper:

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My stock grill piece isn't ideal, but when I get around to giving my car the makeover I want for it, it'll be getting a BackYard Special front bumper, which has a similar scoop - personally, I don't like the way the Mugen bumper makes the car look like it's got a stupid grin on its face, lol. From the side-profile, that lower section actually juts out quite a bit too, so it looks like its lower lip is pushed out.

The BYS bumper:

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The BYS bumper comes with a carbon fiber lip molded onto it; people usually leave it unpainted to show it off. It looks like that owner attached ARC Magic winglets to the corners.
 
I'm taking a couple weeks vacation from work in October, and am planning some excellent mountain drives (one example - Autumn should be in full swing, so hopefully the leaves are golden in a few weeks for some nice photos!). The RSX really needs new brake fluid, and while the lines on the car look fine, I decided to upgrade:



I'm going to have a shop handle the work for me. Brake fluid isn't something I care to mess with.
 
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I'm taking a couple weeks vacation from work in October, and am planning some excellent mountain drives (one example - Autumn should be in full swing, so hopefully the leaves are golden in a few weeks for some nice photos!). The RSX really needs new brake fluid, and while the lines on the car look fine, I decided to upgrade:



I'm going to have a shop handle the work for me. Brake fluid isn't something I care to mess with.
Probably best if you aren't confident but I'm fairly surprised about that. I assumed you did your own fluid bleeding and new pads etc?
 
I usually do everything. Brake fluid is just something I haven't attempted before. The bleeding has always had me nervous, and I did the coolant so many times on my old Accord (bad radiator on the first engine, then changed again for the Prelude engine swap, then another radiator failure after the swap) that I just hate fluids at this point. But I've been watching and re-watching DIY videos on YouTube for a complete brake flush. I would like to get over that nervousness. I think I will go for it. Not until the first week of October, though. I just ordered inner and outer tie rods today as well, to do at the same time. I'm hoping for the RSX to be all brand new underneath by Spring.
 
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