The Pippa Project - Honda S2000 Powered Haynes Roadster - Part 3: Cylinder Head Rebuild

Welcome back to the Pippa Project. The haynes roadster powered by a honda S2000 engine. In the last episode we pulled off the S2000 Engine cylinder head and resurfaced it to get it flat and smooth. At the end of the last episode the S2000 cylinder head was flat to within 0.05mm which is within tolerance. However I have further refined the surface to within 0.025mm. In this episode it is time to rebuild the S2000 engine cylinder head. And put the rest of the engine back together.There are some important steps to this process. There are lots of bolts that have to be torqued to specific values and done up a specific orders. While rebuilding the cylinder head I also do a little demonstration of how the Honda Vtec system works. Finally with the engine back together It is time to start looking at re-configuring the cooling system to improve the water cooling and reduce the oil cooling. After all it was engine overheating that caused this problem in the first place.
Here are the previous episodes.
Episode 1: • The Pippa Project - Ho...
Episode 2: • The Pippa Project - Ho...
If you like the videos I make then please consider sharing them with your friends. There is a share button just below the video viewer. It's got loads of options for easy ways to share a link. This REALLY helps the channel to grow and enables me to bring you more videos.
For more information and behind the scenes content be sure to check out my socials
Facebook: handmadeextreme
Instagram: handmade_extreme
If you would like to make a contribution to the channel then I also have a Patreon page.
www.patreon.com/handmadeextreme
Cheers,
Rob
- Handmade Extreme -
Disclaimer: This video is meant for educational and entertainment purposes only. It is in no way meant to be a set of instructions and therefore no attempt should be made by any party to recreate what has been seen in this video. Any attempt to do so is done completely at your own risk.

[@noellwilson1273]

On placing the head back on the block while trying not to wipe the sealer off: I’ve got a toolbox drawer full of headless bolts to lightly thread in. Then I just have to get the head on the bolts - long before the head gets close to the block. I hacksaw a slot across the end of the studs so I can use a screwdriver to remove them if necessary.

[@TheAussiePirate]

Learning heaps from these videos, thanks!

[@Handmadeextreme]

Thanks Carl, Glad you are enjoying them and thanks for the continued support.

[@hzmeister9596]

8:05 dropping spark plugs in like that is an easy way to mess up the gap.

[@Handmadeextreme]

Good point, never considered that. Thanks for the advice. 👍👍

[@stephenrowley4171]

My magnetic pick up tool fell apart while changing spark plugs the other week. There was 5 minutes of panic trying to figure out where the magnetic went.

[@Merlinkatamari]

i hope you found it :)

[@Handmadeextreme]

Oh dear.. Hope it's all sorted out now.

[@stephenrowley4171]

@@Merlinkatamari thankfully found it on the floor and not fallen into the cylinder.

[@Guds777]

When the V-tech kicked in, It was at this moment, he knew he fucked up... :D

[@ColbyJohnson]

I'm loving this new series :)

[@Handmadeextreme]

Thank you. I'm glad you are enjoying the project. Plenty more jobs to do. 👍

[@britishreaction54]

Nice work. Enjoying watching your progress.

[@Handmadeextreme]

Hi Carl. Great to hear from you. Glad you are enjoying the project. How's the lathe coming along>

[@britishreaction54]

@@Handmadeextreme Going well thanks mate. I have started rebuilding the table of my milling machine, turned up some new lubrication nipples to replace broken ones. Next I have to make a new table lock bolt as the original is bent.

[@Handmadeextreme]

Sounds like it's going well. What milling machine is it?

[@japjoem4077]

I'm doing a head gasket on my 02 ap1,so you reused the head bolts ?,and did you use an oem head gasket?

[@phorestgump8149]

Hi there, how has that headgasket been holding up? what made you pick that compared to oem?

[@yohnivillarodriguez1]

Can you do a full engine rebuild on the f22

[@Umski]

Curious on the history of the engine - what happened the S2000 it came from? I was always afraid of DIY on my S2K until I needed to clean the injectors after being SORN'd for too long - not so daunting seeing you do this ;) Was that an OEM head gasket?

[@jacksat2252]

Shouldn't you replace the head bolts also? As a mechanic, I always replace the cylinder head bolts reason be nr1 they are already stretched from the factory torque up and can have micro-fractures, 2: they are weekend and can break when you re-torque them after you let the engine go to working temperature and cooldown. It always puts a smile on my face if a see like in wheeler-dealers when they put engine head bolts in a piece of cardboard to keep them in the right order, no replace them. Just use that cardboard trick for pushrods and valves if you have to remove them. Anyway, I still like your videos.

[@Handmadeextreme]

I wondered how long it would take for someone to notice that. 👍 Your right, under most circumstances yes I would replace the bolts. For the S2000 engine Honda give 2 sets of instructions in the workshop manual for the head bolts. One for reusing, and one for new. As you can imagine the reuse one does not torque as highly as, like you pointed out, the bolts are already stretched. Reuse is 29Nm (22 lb/ft) then +180deg in 2 steps of 90deg New is 29Nm (22 lb/ft)then +270deg in 3 steps of 90deg If I ever have to take it off again I will replace them though as I don't like the idea of reusing them again, and again. Great comment, thanks for sharing your experience. Comments like this are really valuable. Glad you are enjoying the videos. 👍

[@joell439]

👍😎👍

[@Handmadeextreme]

Cheers. thanks for watching.

[@Merlinkatamari]

woow this is so cool if i had the time i also would build my own buggy car out of stainless steel and put electric wheel hub Motors in it :). I Love Honda such a great company :)

[@Handmadeextreme]

I did some research into hub motors for a project a few years ago. Great idea but my main issue with them is the huge increase in unsprung weight. Take a look at the TU Delft formula SAE car. They have made good use of them. Glad you are enjoying the video. Thanks for the support.

[@Merlinkatamari]

@@Handmadeextreme yes that is still a big Problem but i think it should work when the complete wheight is not to high so the motors can be small 3KW per motor with a light frame could work so long they have enught newtons it shoudn't be a racing car ^^

[@Handmadeextreme]

Sounds like a good plan. I guess you will be looking at 4 wheel drive if it's a buggy? Stainless is a nice choice too if it's an off road car. Many £££ though haha. Have you looking into torque vectoring? AC or DC electrical system? The guys at Delft used epicyclic gearboxes on their hub motors which worked really well. Sorry I have tonnes of questions. Love projects like this. I'm actually looking at my white board now which has some sketches on it for my next 'big' project a few years away but lets just say it's topically relevant to this video series and our conversation.

[@attacklifeuk]

I want to build 1 of these with my nethews and drop my S2K engine in and then K24 the S2K, bit to low of mileage to start pulling stuff apart though, lol.

[@Handmadeextreme]

Sounds great. When you do there are a few things to watch out for with the s2k engine. The bell housing is very wide. If you are building right hand drive you will end up with not much room for your pedal box. Also it's very tall. Sump guard is essential. Good look with your project. I'd love to see some pictures when you get going with it.

[@SpartanMJO12]

So THAT'S where mayonnaise comes from!

[@Handmadeextreme]

haha. Yeah.. shhhh....trade secret 👍😂