Metrics
Weight
Performance
K20 Swap
Disassembly
Cooling
HVAC
Firewall
Fuel System
Electrical
Engine
Mounts
Exhaust
Misc
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Air Intake
A 3" tube was made to draw air from the left hand side scoop.
Clutch
Simple. Remove 10mm line from the Toyota slave cylinder (an ugly cast iron piece) and screw into the Honda slave cylinder (a nice aluminum piece).
Trunk
I cut out the intrusion into the trunk, created to clear the Toyota stock exhaust manifold. Since we're building a tubular exhaust, there will be room to extend the trunk floor to full size.
Shifter
I removed the Lotus reverse lock out. I then spent a lot of time getting the shifter central - in the end I removed the bell crank pivot shaft, made bushings and bolted it back together. I also cut and re-welded the bell crank arm.
The eyelets on the end of the shifter cable had egged out, since they are only cast aluminum. I replaced these with oil filled bronze bushings.
Wheel Studs
The Lotus wheel bolts were replaced with conventional studs and lug nuts.
Suspension
The stock suspension was replaced with Penske shocks. Major problems with the Penske shocks - the shocks themselves are great, but poorly specified. The front shock travel is insufficient. The front shock is way too long - I have moved the upper shock mounting point 0.500" upwards and the shock is still just off the bump stops at rest. The springs are too long both front and rear to allow a lowered ride height. The front springs could be a standard 2.25" size rather than a custom 1.9" size. The front springs are rubbing the shock body to death. The front remote reservoir hoses are too short, and the rear far too long.