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Boston's - 2003 HONDA CHALLENGE - Build Thread

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Old Mar 24, 2023 | 08:03 AM
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Default Boston's - 2003 HONDA CHALLENGE - Build Thread

I've been on this forum a long time and always told myself to make a thread to keep track of my AP1..
Time to share my Honda Challenge H1 build.

The car has been through a lot over the last couple years. From getting in a serious on track accident to almost being completely parted out and scrapped.
Most of that has been shared on the Racing and Competition thread, so I won't go into the details on that.. Wrecked AP1 by E36 @ CMP
This thread will keep track of my w2w progress, modifications and maybe a future engine build.

I purchased this Suzuka Blue AP1 in 2017 completely stock from the 2nd owner.
The original plan was to keep it a fun street car while I rebuilt my Time Attack/TT subaru STi. Well 3 ej25 engines and a fire at Road Atlanta persuaded me to start tracking the S2000 lol.
I did a number of DEs and quickly realized how amazing the S2000 was to drive at the limit. The Honda reliability sealed the deal.

I drove the ap1 for a full year doing monthly hpde events. The following year I said why spend all this money if I can't win anything? NASA contingencies are pretty solid for TT and Racing. So I progressed to time trials trying to chase free tires and brakes. Did TT for 2 years and then had the incident with the bmw...
I've always wanted to get into racing wheel to wheel. The added peer pressure from friends who race Honda Challenge and the incident with the E36 really pushed me over the edge.
Fast forward a couple years, now I have my competition license and have built a wheel to wheel racecar!


This is currently where the S2000 is at. Full w2w race trim.















Interior/Chassis-
  • 2,455lbs light fuel without driver
  • Gutted chassis, no AC, no heat, no airbags, no windows, no passenger seat, gutted doors, gutted headlights, removed some factory wiring, etc.
  • Removed all emissions equipment, air pump, charcoal canister, lines, solenoids, etc.
  • Full 6 point NASA spec cage done by Wilson Racing Chassis in NC
  • Fire Sense - AFFF Fire System 4L - 2 nozzles in the engine bay & 2 in cabin
  • Element handheld Fire Extinguisher
  • COMPCOOLER racing chiller system w/ cool shirt
  • Cartek GT battery isolator (Kill switch)
  • Racequip mesh window net 15"x18"
  • MOMO Daytona XL containment seat
  • Sparco 1 piece seat cushion
  • PCI fixed mount seat base
  • Schroth Flexi 2x2 harness
  • Race German cage harness collars
  • Sparco R330 suede steering wheel
  • Battlecraft Hyper Quick Release
  • Works Bell 15mm wheel spacer
  • Splin Mota Shift Knob
  • SOS gauge mount panel
  • YAGI dry carbon fuel pump cover
  • Joes Racing 17" wide angle mirror kit
  • Ecliptech Shift P2 rpm gauge w/ 3d printed mount
  • Modifry Shift beeper
  • AIM Solo2 w/ 3d printed dash mount
  • GoPro 11 black
  • NAUS Brake pedal riser (0.5")
  • SRP aluminum grid style clutch, brake, and throttle pedals
  • Doryoku front crash bar w/ added tow points

Exterior-
  • RSG Amuse rep carbon hardtop
  • Izzy's Hardtop brackets
  • 9 Lives Racing rear 68" chassis mounted wing
  • 9 Lives Racing CFD endplates
  • 9 Lives Racing front splitter chassis mounted
  • Professional Awesome splitter side support rods
  • Craft Square Carbon Mirrors
  • Track Spec hood vents
  • Track Spec hood wickers
  • SOS Hood Pin Brackets
  • AeroCatch flush mount hood pins
  • Zunsport mesh grille
  • Cartek 3 mode Rain Light
  • Doryoku front tow strap
  • OEM rear tow hook

Suspension-
  • Karcepts MCS 2way non remote w/ 800lb front & 700lb rear Hyperco springs & Hyperco helpers - RE suspension trimmed 1/2" rear bumpstops 45G white
  • Karcepts spherical top hats
  • Karcepts Front Swaybar
  • Karcepts Rear Swaybar
  • Karcepts spherical adjustable endlinks
  • Origin Fab UCA gussets
  • FDF RaceShop Green V2 Front Upper Spherical Control Arms
  • Kingpin Machine Front lower arm spherical bushings, Tig welded in place
  • Megan spherical bushings in rear upper and lower arms
  • Splin Mota Rear Toe Eccentric Lock Out Washers
  • Nagisa Auto rear adjustable spherical toe arms
  • Splin Mota Rear subframe stiffener
  • Rigid subframe collars
  • Spoon steering rack solid bushings
  • Ford steering rack limiters
  • Sakebomb FP spec front bumpsteer spacers
  • EPS mod (removed VSS wire at module, goes to 20% assist) better feedback and consistency.

Wheels-
  • Apex VS5RS Anthracite 17x10 +48 w/ Toyo R 255/40 or Maxxis RC1 255/40 - Dry Race Tires / +3mm front spacer
  • Enkei RPF1 Black 17x9 +45 w/ Toyo RA1 235/40 - Wet Race Tire

Brakes/Hubs-
  • Honed Developments Brake Booster Delete
  • OEM EK civic 13/16" Brake master
  • URGE AP Racing BBK CP8350 w/ 299mm J hook rotors
  • URGE 2-piece rear rotors
  • Hawk DTC60 front pads
  • Carbotech XP12 rear pads
  • Project Mu stainless brake lines
  • Endless RF650 brake fluid
  • New OEM front hubs
  • Karcepts Billet rear hubs
  • MSI extended wheel studs
  • Core4 Motorsports floating 17mm lugs
  • New lower and upper ball joints
  • New NSK wheel bearings

Engine/Supporting Mods-
  • HMO JDM K24A RBB3 engine
  • Powder coated Red valve cover
  • Radium press in valve cover vent
  • OEM Honda Type R FD2 oil cap
  • Powder coated Timing cover
  • 50 degree VTC Gear
  • K20 upper chain guide
  • NGK 7746
  • Penzoil Ultra Platinum oil 5w30 or 0w40 (Uses about 8.5 qts)
  • PLM timing chain guide
  • Kpower timing chain tensioner cover
  • Fluidampr K series crank pulley
  • Track Tuff RBB rwd k swap water neck
  • Track Tuff rwd t stat billet housing w/ OEM T stat 19301-PNA-003
  • Moroso Steel Kswap Race black oil pan 6.5 qt
  • Kpower k20 oil pump conversion for k24 & ported
  • Kpower RWD Intake manifold
  • Kpower IACV block off plate
  • Skunk 2 Alpha 70mm B Series throttle body
  • B series TPS
  • Honda MAP
  • DC sports cold air intake 06-09 S2000
  • Kpower ep3 idler kit
  • USDM water pump housing
  • New gates water pump
  • ASM modified S2000 header
  • RBZ engine mount brackets
  • Megan OEM S2000 style engine mounts
  • Origin Fabrication Titanium Full 3" exhaust (9lbs)
  • HKS single exit exhaust w/ 70mm Test pipe for track sound limits
  • CSF Radiator w/ oem fan - Removed AC fan
  • Saikou michi custom 10an single VTA catch can w/ Radium ANs
  • RRP Anti-starve fuel baffle plate
  • Holley Hyrdramat 3"x8" (Part# 16-125)
  • Walbro 255lph pump
  • 52mm 3D printed dash pod by DeoxedSolutions
  • SOS E85 Flex Fuel system w/ Continental ethanol sensor
  • SOS Fuel pressure sensor line extension
  • SOS Oil pressure sensor line extension
  • SOS accessory power block
  • AEM 100psi ss fuel pressure sensor
  • Syltech oil pressure and temp sensor
  • Radium Fuel Rail w/ plumbing kit
  • Radium Fuel pulse damper
  • Radium Adjustable fuel pressure regulator
  • ID1050xds injectors
  • ASM K swap LinkECU wiring harness
  • LinkECU G4X
  • LinkECU Can Gauge
  • Link Can lambda wideband
  • Link Extension for JST4
  • Link xs expansion looms
  • PC680 battery
  • Password JDM billet aluminum PC680 battery mount

Drivetrain-
  • AP1 trans
  • Clutch masters steel K swap flywheel 15lbs
  • EP3 flywheel cover
  • 2NRS adapter plate
  • B series flywheel bolts
  • ACT Pressure Plate
  • OEM clutch disc
  • Puddymod stg2 AP1 differential / 4.30 gear (shot peened and cryo treated)
  • Puddymod larger capacity diff cover with improved cooling fins
  • OSgiken LSD with OSG custom tune and OSG 80w250 fluid
  • Innovative 75A trans mount
  • Hybrid racing detent springs
  • SOS SS clutch line
  • Torco RTF Trans Fluid
  • Hardrace Rubber Diff mounts
  • Hardrace axle spacers



Most recent update! K24A is in and running strong!





Last edited by .Boston.; Mar 16, 2026 at 04:37 AM.
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Old Mar 24, 2023 | 08:13 AM
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November 7th 2017
Paid $11,700 for this 3 owner w/ 104k miles.
Came with every receipt and an excel sheet of maintenance going back to the 1st buyer in 2002.
Suzuka wasn't my first choice but it was affordable and extremely well kept. Within my budget while I fixed my subaru "track car".

Here's the FS post from one of the long term owners. I purchased the car from the gentleman who bought it off user Redlineracing.
https://www.s2ki.com/forums/cars-sal...2k-sc-1166054/

Interesting to keep the history of this car on s2ki. It has come a long ways..




Didn't get to take it to the Dragon until the following April. Only changed out tires which were still stock size but 200tw. Might have added a whiteline front swaybar and some hawk pads by then.



Last edited by .Boston.; Nov 23, 2025 at 09:28 AM.
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Old Mar 24, 2023 | 08:13 AM
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reserved 2
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Old Mar 24, 2023 | 08:14 AM
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reserved 3
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Old Mar 25, 2023 | 04:44 AM
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this gonn' be good
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Old Mar 25, 2023 | 11:14 AM
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Yep. Looking forward to it.

Any reason why you haven't gone BBK up front? Do HC1 rules not permit a BBK upgrade? need to retain OEM calipers and rotor size?
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Old Mar 25, 2023 | 08:32 PM
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Originally Posted by Bullwings
Yep. Looking forward to it.

Any reason why you haven't gone BBK up front? Do HC1 rules not permit a BBK upgrade? need to retain OEM calipers and rotor size?
​​​​​​A few reasons why I haven't moved to a BBK.

​1st - H1 rules allow you to run any brake setup but I plan to jump into ST4/ST5 or TT if there aren't numbers in HC (free tire money). ST/TT is a points hit for a BBK.
2nd - I haven't ran into any brake issues with 2 piece rotors f/r, good race compound pads and titanium shims. The girodics last a whole season and then some. OEM calipers are cheap and everyone usually carries spares, myself included.
3rd - initial cost.. I've already spent a lot on this car for a true grassroots w2w build. The AP racing BBK is definitely on my to-do list. Right now I'd rather save for a diff regear and plated LSD which there's more of a benefit vs BBK.
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Old Jun 20, 2023 | 10:08 AM
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Update -
I ran Hyperfest at VIR in May. Epic time hanging with all the Honda Challenge OGs. Lots a very fast drivers and cars. Quickly realized I was far from being optimized for H1 class.. Another S2000 in H1 had a J35 swap.. He had to weigh a minimum of 3,220lbs or something around that but it still pulled hard on me on all the straights. I was A LOT faster in the corners but I'm also overweight by almost 300lbs for running my F20. Went home after the race weekend with a car in all one piece and a list of parts I need lol. Now trying to find weight to remove around the car.
Currently down to around 2,480lbs without driver. Per HC H1 rules, minimum weight is 2,392lbs with driver.
Planning to cut the rear trunk pan out and gut more of the body panels next weekend.


Some clean shots from the weekend











And a couple new items for the racecar in order.
  • MRacing carbon side mirrors for weight savings and reduction in drag.
  • OSG LSD finally came in from Japan. Next day I sent it out to OSG USA for custom tuning. Waiting on that to come back and then counting down the days to send off to Puddymod..
  • Cartek FIA Rain light, need to wire this up next weekend. I'm now legal for rain races.
  • I picked up a used Origin Fab Titanium 3" exhaust. This is a 1 piece with vband at the header. Its a pain in the ass to install and get just right. Only weighs 9lbs or so.. Super light and LOUD.






Last edited by .Boston.; Jun 20, 2023 at 02:16 PM.
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Old Jun 20, 2023 | 01:07 PM
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Insane! Loving this. Keep the updates coming
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Old Jun 20, 2023 | 01:30 PM
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How much did you weight at hyperfest? What have you removed to get you down to that number?
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