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Boston's - 2003 HONDA CHALLENGE - Build Thread

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Old 03-24-2023, 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 and future engine build.

I purchased this Suzuka Blue AP1 in 2017 completely stock from the 2nd owner.
Had 103k miles and an excel sheet of maintenance going back to the 1st buyer in 2002.
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 and I wanted to keep building the car to compete in Time Trials with NASA.


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










Interior/Chassis-
  • 2,480lbs light fuel without driver
  • Gutted chassis, no AC, no heat, no airbags, no windows, no passenger seat, gutted doors, 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
  • Cartek GT battery isolator (Kill switch)
  • Racequip mesh window net 15"x18"
  • Sparco Circuit II halo drivers seat
  • Sparco Circuit II 1 piece seat cushion
  • Sparco lumbar cushions
  • PCI fixed mount seat base
  • Schroth Flexi 2x2 harness
  • Race German cage harness collars
  • Sparco R330 suede steering wheel
  • Battlecraft Hyper Quick Release
  • Splin Mota Shift Knob
  • AEM oil pressure gauge
  • SOS gauge mount panel
  • YAGI dry carbon fuel pump cover
  • Joes Racing 17" wide angle mirror kit
  • Modifry Shift beeper
  • AIM Solo2 w/ 3D printed dash mount
  • GoPro 11 black
  • NAUS Brake pedal riser (0.5")
  • SRP aluminum 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
  • Zunsport mesh grille
  • Cartek 3 mode Rain Light
  • OEM tow hooks

Suspension-
  • Karcepts MCS 2way non remote w/ 800lb front & 700lb rear Hyperco springs & Hyperco helpers
  • Karcepts spherical top hats
  • Karcepts Swaybars front and rear
  • Origin Fab UCA offset bushings
  • Origin Fab UCA gussets
  • Spoon Compliance bushings
  • Power Flex bushings on all control arms
  • Splin Mota Rear Toe Eccentric Lock Out Washers
  • P2M rear spherical toe arms
  • P2M front V brace
  • Splin Mota Rear subframe stiffener
  • Spoon rigid collars
  • Spoon steering rack collar bushings
  • Sakebomb FP spec front bumpsteer spacers

Wheels-
  • Apex VS5RS Anthracite 17x10 +48 w/ Toyo RR 255s - Dry Race Tire
  • Enkei RPF1 Black 17x9 +45 w/ Toyo RA1 235s - Wet Race Tire
  • Volk TE37SL Matte Blue Gunmetal 17x9.5 +45 w/ Michelin PS4S 245s

Brakes/Hubs-
  • OEM calipers
  • 2-piece Girodisc front rotors
  • 2-piece URGE rear rotors
  • Titanium pad shims
  • Baero ap1 brake ducts
  • Hawk DTC70 front pads
  • Carbotech XP10 rear pads
  • Project Mu stainless brake lines
  • LHT Master brace
  • 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-
  • Stock unopened F20C (125k miles) Oil labs every oil change - perfect health
  • Rainh8r modded valve cover
  • AP2 retainers intake/exhaust w/ new valve stem seals
  • NGK 7772 plugs
  • Blox racing TCT
  • PLM Js racing rep header - Calico Coated
  • Origin Fabrication Titanium Full 3" exhaust (9lbs)
  • HKS single exit exhaust w/ 70mm Test pipe for track sound limits
  • K&N FIPK + AEM Dryflow airfilter (21-2039DK)
  • Fluidampr crank pulley
  • CSF Radiator w/ oem fan - Removed AC fan
  • Dual Saikou michi catch cans
  • NA Toyota supra PCV
  • Izze Racing Air pump simulator
  • Izze Racing air injection Block off plate
  • Izze Racing Evap simulator
  • RRP Anti-starve fuel baffle plate
  • Innovative 75A engine mount kit
  • Ingalls ETD
  • Karcepts AP1 Tune on Greddy Emanage Ultimate
  • PC680 battery
  • Amsoil Dominator Racing Oil 10w30

Drivetrain-
  • AP1 trans
  • SOS 8.5lb flywheel
  • OEM Pressure plate
  • OEM clutch disc
  • Puddymod stg2 AP1 differential / 4.30 gear (shot peened and cryo treated)
  • OSgiken LSD with OSG custom tune and OSG 80w250 fluid
  • Innovative 75A trans mount
  • Hybrid racing detent springs
  • SOS SS clutch line
  • Motorcraft XT-M5-QS Trans Fluid
  • Hardrace Rubber Diff mounts
  • Hardrace axle spacers

Coming Soon...
  • Link ECU G4X
  • Link Can lambda
  • Link Splitter connection
  • Link Extension for JST4
  • GM IAT


Here's some photos from the first race weekend January 2023.




Last edited by .Boston.; Yesterday at 05:26 AM.
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Old 03-24-2023, 08:13 AM
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Old 03-24-2023, 08:13 AM
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Old 03-24-2023, 08:14 AM
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Old 03-25-2023, 04:44 AM
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this gonn' be good
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Old 03-25-2023, 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?
Old 03-25-2023, 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 06-20-2023, 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.; 06-20-2023 at 02:16 PM.
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Old 06-20-2023, 01:07 PM
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Insane! Loving this. Keep the updates coming
Old 06-20-2023, 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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