Honda
Engine & Gearbox
Low mileage Honda k20A2 i-VTEC type
engine complete with Honda 6 speed, close ratio gearbox.
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Baffled Sump
It is important to protect the main bearings on your engine from
oil surge. Pulling anything more than 1g on acceleration
deceleration or cornering will create oil surge and leave the
engine vulnerable to oil starvation, and at 8000+ rpm this can
be very quickly catastrophic. Our specifically designed baffled
sump has four trap doors to alleviate this and has been tested
to short bursts of up to 1.8gs under race conditions with slick
tyre compounds. Laser-cut & CNC folded, it’s the lightest
baffled sump on the market and is included at no extra charge
within our conversion.
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Exhaust Manifold
This ultimate exhaust manifold has evolved through several years
of design & development. It’s simply the lightest and most
beautifully fabricated exhaust available. Crafted from high
grade 304 stainless steel it’s mandrel-bent tubing is then back
purged and TIG welded for strength and durability. Slip joints
have been strategically placed to alleviate vibration and
cracking.
Hundreds of hours of rolling road and Dyno sessions have enabled
us to achieve genuine torque and BHP figures well in excess of
inferior manifolds. |

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Exhaust Fitting Hardware
The standard car uses mild steel nuts and bolts which are
prone to rust. Spring washers lose their "spring" when heated
and Nyloc nuts will melt.
It includes 6x Stainless Steel M10 bolts, 12x Stainless steel
M10 washers, 6x M10 Stainless Steel full nuts and 2x new Exhaust
Gaskets. |

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Nuts, Bolts & Washers
All the nuts, bolts, washers and fixings we use are of the
highest quality BZP (bright zinc plated) cap head variety. All
our nuts are BZP Nyloc’s and our hose clamps are top quality
stainless steel..
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Engine Mounts
Designed to be lightweight yet incredibly strong, strategically
placed gussets folds and holes achieve the best and lightest
mount possible. Laser-cut and CNC folded,. The rubber flexible
“shock absorber” has been improved over OE to alleviate
vibration yet keep the engine from “rocking”.
All the mounts are first Zinc coated to repel corrosion then jet
black powder coated to keep them looking good for years to come.
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4th Mount
Only our kit has this bespoke 4th engine-chassis mount. We have
found it beneficial mainly on supercharged cars, but we now
supply it as standard fitment on all conversions. Each mount is
minimally designed, nothing superfluous is added just simple
design and function. The rubber bushes are all specially made
for us right down to the CNC machining process on each rubber
giving it more elasticity which in turn alleviates vibration
felt through the chassis.
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Air Induction System
We use an 80mm encased cotton Twister filter connected to the
throttle body via a 3-ply silicon hose. The filter itself is
placed discreetly within the air-flow from the left-hand air
intake. We use a high grade flexible silicon tube to flow the
air into the throttle body.
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Wiring loom
Completely bespoke to us, our engine loom manufacturer has many
years’ experience in the race car industry and this shows in the
quality of the looms produced for us. There are 6 different
designs required as each model of vehicle is different; S1, S2,
340R, Exige, EU & JDM engines etc. The highest quality wire and
terminals are used furthermore we are the only company to have
invested over £10,000 on OE terminals thus creating a loom which
is even better than the original equipment.
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Gear Cables
Brand new OE spec gear cables are used within our conversion,
this enables precise fitment and longevity. Our rod ends are of
the highest quality and the cables are maintenance free being
internally greased for life.
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Temperature switches
We provide new temperature sender switches with all our kits and
because we can program the ECU, we are the only company that can
switch the fans on and off through the ECU. |

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Silicon Hoses
All our hoses are bespoke, they are manufactured from our own
tooling specifically designed for the purpose not simply various
bends cut down and joined to fit. |

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Aluminium pipe work
Expertly crafted using CNC mandrel forming tools, then clear
anodised externally and internally for longevity. Each end is
bead formed to ensure the hose fit is leak free and tight
fitment. We also black powder coat the hoses which not only
helps dissipate heat better it keeps them looking good for many
years to come. |

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Gear Linkage
We have constantly improved this area over the past 4 years (and
200 conversions). It is now the pinnacle of gear change
mechanism being precise and well engineered. It has built-in
adjustability for those that want a longer or shorter throw gear
change. The brackets are laser-cut and CNC folded for accuracy.
We then zinc coat the unit (to alleviate future rusting),
finally they are black powder coated to keep their looks for
many years.
The tube bosses are CNC machined to a 1 thou tolerance as are
the brass top hat spacers. The kit is put together using hi
tensile BZP cap head bolts & nyloc nuts.
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ECU
£25,000 and many hundreds of man hours were invested in the
correct tooling and mapping of the Honda original ECU.
Because of the complexity of the iVTEC engine and the several
variations we offer i.e. JDM, EU, normally aspirated,
Supercharged, MK1 & MK2 Elise, 340R, Exige etc., all of these
variations require slightly different mapping. We have
alleviated the need for you to endure a long and expensive
Rolling Road session to map your car by doing all this work
early on within the project. Over the years, we have learnt and
updated the maps where we have found improvements could be
possible. We now have dozens of maps that have achieved more
genuine power from the engine install than any other company.
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Fuel
Regulator & Braided Stainless Steel Fuel Lines
We have designed a bespoke fuel system that not only looks good
and performs well. The Fuel regulator is a high quality fixed
pressure item in an anodised aluminium housing. All our fuel
lines are of the highest quality Teflon lined and steel braided
type. The lining will take temperatures of 200° and pressures of
over 250 PSI which is far more than your fuel pump will ever be
required to achieve (runs at less than 60 PSI).
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Fuel filter
Because fuelling is of the utmost importance, we supply and fit
a new fuel filter with every install, it is false economy not
to. |

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Water reservoir
An old coolant tank can spoil the look of your investment, so as
a matter of course, we replace the old yellowing plastic bottle
with a brand new clear item. |

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Junction box
The only way to safely join the battery power to the
starter/engine wiring is through this top quality junction box.
It is neatly installed on the aluminium bracket already on your
car so it looks OE. |

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Brackets & fittings
Only through experience can these be perfected in the way
they are. Designed for ultimate strength yet still lightweight.
Each item serves its purpose perfectly. All steelwork is
laser-cut, folded, zinc coated then powder coated. All aluminium
bobbins, spacers, sleeves etc are CNC machined from HE30 alloy
then hard anodised for longevity.
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Belt
It is false economy to use an old alternator belt or
supercharger belt so all our kits use a top quality Gates item
(Goodyear). Manufactured to last, 3-ply non slip 7 groove belt. |

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Oil, oil filter, antifreeze, brake & clutch fluid
All our approved fitting centres use top quality synthetic oil.
Your system is refreshed with OE spec antifreeze and the clutch
system is replenished and bled with the highest quality DOT 4
clutch fluid.
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Heat shielding
Our kit comes complete with brand new top quality Nimbus twin
ply heat shielding. As you can imagine, an engine producing
220-300bhp needs to rid itself of a lot of hot gases and
although our exhaust system is superb, protection is required
around vulnerable areas such as centre bearings, boot floor and
sub-frame, low mountings.
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Clutch hosing
We use a rubber hose for flexibility attached to a copper bundy
tube. |

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Driveshafts
Probably the most important part of the conversion. So many
“issues” are caused if they are not perfectly correct in several
areas. Firstly they need to be the correct length to within 1mm
and there are not only differences between the S1 & S2 lengths,
it is even important that the ride height is taken into account
too. Ours are made only for us and ALL our parts
are new – nothing is reconditioned.
Because it has taken a lot of time and effort to design and
develop these, we will not go into fine detail, we will simply
say that the material we use is the strongest steel available
then induction hardened, the splines are cold rolled (best
possible), Our joints are bespoke and made specifically for us
with built in speedo ring gears, they are much more robust and
stronger than OE. The bellows are neoprene not the “cheap”
rubber type, even the grease we use is the best (and most
expensive) available.
All this has been achieved through many years of trial and
testing on the race track predominantly and also with the
experience within the fitment of 200 or so conversions.
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Lightweight Flywheel
Optional Upgrade
OEM flywheels are heavy parts designed for optimum street
drivability by soaking up some of the power from the engine and
putting it in storage in the form of inertia, unfortunately this
comes at the expense of engine response and acceleration. Our
light-weight flywheel keep less inertia in storage but the
lighter rotating mass providing significantly improved engine
response and acceleration characteristics, an excellent
modification for road or racing use, exactly what performance
enthusiasts need.
Made from precision chrome-moly forgings that have an induction
hardened integral ring gear, which weighs less than 4kg.
Designed for faster revs, quicker engine response, improved
drivability and provide quick throttle response exiting corners,
a proven product used by Japanese race teams worldwide.
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Oil Cooler
Optional Upgrade
Although the original engine has an oil cooler as standard we
have found for prolonged track and race use, an upgraded cooler
is advised (also recommended for Supercharged cars).
The oil cooler we use is a Mocal water-oil exchanger unit. All
the oil hoses are of the highest quality Teflon lined and steel
braided type. The lining will take temperatures of 250° which is
far more than your oil will ever achieve. The cooling pipe work
is bespoke 3 ply silicon and aluminium pipe work (see pipe work
section)
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Clutch Optional Upgrade
EXEDY performance clutch uses only premium friction
materials that are resistant to slippage and burst. Increased
clamp loads give the necessary capacity to handle highly tuned
and modified engines. The drivability is similar to a stock
clutch although pedal efforts will be slightly higher due to the
higher clamping loads.
All of our clutch discs have high capacity spring centre dampers
to reduce the drive train shock and impact. The result is
maximum torque capacity and durability, while maintaining good
release clearance for fast, clean gear changes.
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Flexible Sports Catalytic Converter
Optional Upgrade
Built by the same craftsmen that build our exhaust systems. No
others are back purged and TIG welded 304 stainless steel, we
use 304 grade stainless steel laser cut flanges.
The best quality FIA certified 100 CPI platinum catalyst is used
which is so free flowing it does not reduce power output even if
compared to a straight through bypass pipe.
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Super charger Optional Upgrade
For superb throttle response, linear power delivery and top
end performance.
Boosting power by around 80+BHP, whilst providing a consistent
level of torque across the entire engine rev range. Based on the
Eaton M62 Roots type Supercharger, with our custom mounts,
injectors, and mappings, you have options for over 300Bhp and
over 200Ft/Lbs
The supercharger install components include a cast aluminium
intake manifold, mounting brackets, gaskets, spacers, pulleys,
belt tensioner, and all the fuelling hardware you see below.
The supercharger option can be added at the time of conversion
or at a later date
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High output Fuel pump & Swirl Pot
(These are only required on the
Supercharged Conversion.)
This is only required on the supercharged version as the OE pump
is fine running at 3 bar and flows plenty for 225BHP. This Bosch
unit is the best we can buy. It acts on the process of the OE
pump being a simple “lift” pump. The fuel pump is a top quality
Bosch unit that can flow enough for 500 bhp
The swirl pot/fuel reservoir is beautifully crafted from
lightweight aluminium, TIG welded connections and fixing points
have been strategically placed to ideally position the fuel
lines once mounted, thus keeping the hoses to the minimum
lengths which not only looks neat it saves weight too. |

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Injectors
(These are only required on the Supercharged Conversion.)
The standard injectors are fine for 225bhp but on engines giving
more than 250bhp, larger injectors are required. The type we use
have a perfect spray pattern for good emissions and can flow
well over 400bhp.
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Road testing
Every completed install is rigorously road tested. After all, we
will be giving a 12 month warranty on everything and the
installers/garage reputation is paramount so it is in our
interest to ensure all is perfect before you collect your car.
If for any reason you do have future concerns, we can offer a
free on-line enquiry service, please note this is for our
customers only and not for any other install. |

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