Project Scope: This project involved the complete resurrection of a neglected JDM import. My goal was to transform a "forgotten" chassis into a modern, high-performance street machine. The restoration covered every major system, from "engine-out" maintenance and drivetrain repairs to advanced ECU calibration and custom chassis geometry.
Phase 1: Engine & Drivetrain Restoration
To establish a reliable foundation, I performed an engine-out service to address long-term neglect.
Engine Service: Replaced the engine mounts, oil pan gaskets, and rear main seal to eliminate leaks and stabilize the rotary powerplant.
Drivetrain Repair: Diagnosed a failing input shaft bearing within the transmission. Resolved this by sourcing and installing a replacement transmission and high-performance clutch.
Fuel System: Performed a comprehensive refresh of the fuel system to ensure the high-flow delivery required for the upgraded power goals.
Phase 2: Forced Induction & Exhaust Fabrication
With the foundation secured, I modernized the forced induction system for increased efficiency.
Turbocharging: Installed a new turbocharger and integrated a high-response blow-off valve (BOV) into the charge pipe.
Exhaust Geometry: Collaborated on the design and re-fabrication of the exhaust system, specifically focusing on a revised header geometry to optimize scavenging and thermal management for the rotary engine.
Phase 3: Digital Calibration & Driveability
Transitioning from 1992 analog controls to modern digital management was central to this build.
Haltech Integration: Installed a Haltech Engine Management System (EMS) to replace the dated factory ECU.
Dyno Tuning: Spent extensive hours on a dynamometer to map the fuel and ignition curves. I achieved a 50% increase over factory power (1.5x original output) while maintaining safe air-fuel ratios and engine longevity.
Driveability Refinement: Beyond peak numbers, I focused on daily driveability by meticulously tuning the cold-start sequences and idle control, ensuring the car starts and idles with modern reliability.
Phase 4: Chassis Engineering & Precision Alignment
To handle the increased power, the 30-year-old suspension required a total overhaul.
Bushing Refresh: Stripped the chassis and replaced all suspension bushings to eliminate play and restore handling feedback.
Custom Control Arms: Installed custom control arms at all four corners, specifically chosen to provide a wider range of alignment variance than the OEM hardware allowed.
Precision Alignment: Using a professional alignment rack at Charing Cross Car Care, I utilized the increased adjustability of the custom arms to dial in a bespoke geometry setup, maximizing the vehicle's mechanical grip and high-speed stability.
Technical Summary
Software: Haltech NSP/ESP, Dyno Load-Cell Software.
Fabrication/Mechanical: Engine-out service, Drivetrain swaps, Turbo plumbing.
Chassis: Professional Alignment Rack operation, Suspension Geometry design.
Result: A fully restored, dyno-verified 1.5x power increase over stock with OEM-level driveability.