Mugen Beat Refresh Project

[R@tch]

Nearly 2 years ago now me and my brother purchased our beat of a member here. It was in need of some tlc because of overheating issues. Due to other projects, work and some unfortunate circumstances it's been in storage for long periods in between the things we were doing to it :awwww:. But the deadline is to rly get it finished for summer 2015 and we would like share our project here :).

This was just after I picked it up in Banbury and after a wash:
http://i1276.photobucket.com/albums/y473/Ronjohnalex/009jelMedium_zpse65c9ed5.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/009jelMedium_zpse65c9ed5.jpg.html)
http://i1276.photobucket.com/albums/y473/Ronjohnalex/017dbtMedium_zps601baf63.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/017dbtMedium_zps601baf63.jpg.html)
http://i1276.photobucket.com/albums/y473/Ronjohnalex/022umMedium_zps4f2cc1e4.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/022umMedium_zps4f2cc1e4.jpg.html)

[R@tch]

It came with the original mugen front and rear bumper and best of all the beat specific 13" front 14" rear Mugen nr-10 wheels:
http://i1276.photobucket.com/albums/y473/Ronjohnalex/015wgMedium_zpsc6727c37.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/015wgMedium_zpsc6727c37.jpg.html)
http://i1276.photobucket.com/albums/y473/Ronjohnalex/012iat1Medium_zps5c4112bb.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/012iat1Medium_zps5c4112bb.jpg.html)
http://i1276.photobucket.com/albums/y473/Ronjohnalex/051ozMedium_zps51a12b6e.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/051ozMedium_zps51a12b6e.jpg.html)

[R@tch]

We began stripping it down inventorying all the parts and searching for rust and other probable issues.
http://i1276.photobucket.com/albums/y473/Ronjohnalex/017gv1Medium_zpsfde99d32.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/017gv1Medium_zpsfde99d32.jpg.html)
Hardly found any rust on the chassis but we soon discovered that the coolant system was in really bad condition which probably led to the overheating the previous owner had mentioned.
http://i1276.photobucket.com/albums/y473/Ronjohnalex/015zqqMedium_zps31aa083b.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/015zqqMedium_zps31aa083b.jpg.html)
http://i1276.photobucket.com/albums/y473/Ronjohnalex/014spyMedium_zpsdfb8be8e.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/014spyMedium_zpsdfb8be8e.jpg.html)

[R@tch]

The coolant pipes that run underneath the car were in a dire state, rusted through and repaired by cutting out the rusty bits and connecting the ends with rubber hose.
http://i1276.photobucket.com/albums/y473/Ronjohnalex/P1020604Medium_zpscd15e506.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/P1020604Medium_zpscd15e506.jpg.html)
The internal rust of the pipes led to rusty red coolant throughout the coolant system :awwww:. I don't know what happened in the engine bay, but at some point it has sprayed the rusty coolant water everywhere as can be seen on the subframe,drive shafts, exhaust and aluminium oilpan in the picture where we took the engine out, luckily the subframe was nice and black underneath when we washed it off :D
http://i1276.photobucket.com/albums/y473/Ronjohnalex/018cqfMedium_zps0cdd9c7b.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/018cqfMedium_zps0cdd9c7b.jpg.html)

[Gavin]

Ah I remember you saying about the pipes to me ages ago!! Mine went on the bracket right near the back, I may be getting a new aluminium radiator. Car is looking great very rare to get all the mugen parts in one go

[R@tch]

So the plan was to overhaul the complete coolant system, new radiator, waterpump, thermostat, pipes and if possible hoses. Started ordering parts from Japan and through the local honda dealer
http://i1276.photobucket.com/albums/y473/Ronjohnalex/051tjMedium_zpsb2155e73.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/051tjMedium_zpsb2155e73.jpg.html)
At the same time purchased a zebra mat set and sunvisors as none came with the beat when we got it, also got a better condition ashtray that will never be used:D
http://i1276.photobucket.com/albums/y473/Ronjohnalex/ea3jMedium_zps099189ad.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/ea3jMedium_zps099189ad.jpg.html)
http://i1276.photobucket.com/albums/y473/Ronjohnalex/5m1x_zps87076549.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/5m1x_zps87076549.jpg.html)
The radiator is a dual core item with a lot more capacity compared to the original, not bad with a high revving midship engine ;)

[R@tch]

URL=http://s1276.photobucket.com/user/Ronjohnalex/media/rimg0003iMedium_zps9bf45c07.jpg.html]http://i1276.photobucket.com/albums/y473/Ronjohnalex/rimg0003iMedium_zps9bf45c07.jpg[/URL]
We were thinking of making our own first but opted for getting a used set of pipes from Japan in the end. With only very little surface rust which they all seem to have. Next after taking lot's of pictures beforehand inventorying every bracket, nut & bolt we took a bucket full of stuff and the coolant pipes to a local company that de-rusted and galvanised everything and then added a yellow pasivation layer making it look like factory new again.
http://i1276.photobucket.com/albums/y473/Ronjohnalex/P1020598Medium_zpsc74f2ee6.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/P1020598Medium_zpsc74f2ee6.jpg.html)
http://i1276.photobucket.com/albums/y473/Ronjohnalex/P1020609Medium_zps5d1678fb.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/P1020609Medium_zps5d1678fb.jpg.html)
To further protect the car from rust I grease every nut & bolt and brush linseed oil on the galvanised bits before putting them on the beat. They look a lot better than the old pipes, you can also spot the old waterpump in the box with it's rusty inside:
http://i1276.photobucket.com/albums/y473/Ronjohnalex/P1020610_zps9a0605b9.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/P1020610_zps9a0605b9.jpg.html)

[C-Rex]

Really nice Beat! Wondered where it was now since I saw pictures of it before on the NR10s

Are the coolant pipes OEM Honda?

Where did you get the replacement Mugen bumper stickers?

http://i1276.photobucket.com/albums/y473/Ronjohnalex/P1020629_zps0c1e117d.jpg

[R@tch]

Really nice Beat! Wondered where it was now since I saw pictures of it before on the NR10s

Are the coolant pipes OEM Honda?

Where did you get the replacement Mugen bumper stickers?

http://i1276.photobucket.com/albums/y473/Ronjohnalex/P1020629_zps0c1e117d.jpg

Thanks

Yes they are, they're a used pipe set from Japan but I had them re-galvanised and yellow pasivation layered.

I found the mugen stickers on a Japanese shop's website called TY factory, unfortunately their website seems down, think they might be out of business.

I seem to have a lot of trouble posting pictures, contiuous error messages cause I'd like to post some more :confused:

[Gavin]

Yo can post pics but I think it's 3 pics max per post before error show

[Mugsee]

I love the rims and how they're labelled as made for the beat!

[C-Rex]

If your looking to keep the Mugen theme going cliov6 has a Mugen spoiler he said he would sell

[R@tch]

Ah I remember you saying about the pipes to me ages ago!! Mine went on the bracket right near the back, I may be getting a new aluminium radiator. Car is looking great very rare to get all the mugen parts in one go I would've left replies earlier but the forum doesn't allow me to post most of the time. thank you for the offer, but as you can see we went with a new dual core radiator with more capacity, they're still for sale on the Japanese yahoo auctions. The quality is really good and would definately recommend, there's also less expensive alluminium radiators on the yahoo auctions. Unfortunately the beat didn't come with all the mugen extra's but we've collected some more, the the spoiler, exhaust, exhaust manifold and side decals are still on the wishlist :D a mugen hardtop would be amazing.
@C-Rex, definately interested in the spoiler :D

More Mugen parts we collected: mugen sideskirts, mugen suspension, mugen shiftknob from Japan
http://i1276.photobucket.com/albums/y473/Ronjohnalex/P1020626_zpse3eecbc5.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/P1020626_zpse3eecbc5.jpg.html)
http://i1276.photobucket.com/albums/y473/Ronjohnalex/0hn1Medium_zpsbe722c4e.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/0hn1Medium_zpsbe722c4e.jpg.html)
http://i1276.photobucket.com/albums/y473/Ronjohnalex/e38jMedium_zpsb54717bc.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/e38jMedium_zpsb54717bc.jpg.html)

[R@tch]

I did the rocker cover in wrinkle red, sanded back the lettering and added a mugen oil cap which was a gift. I'm quite pleased with the result for a first time try.
http://i1276.photobucket.com/albums/y473/Ronjohnalex/P1020616_zps8280979d.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/P1020616_zps8280979d.jpg.html)

[C-Rex]

I went through your photobucket pics last night some great bits happening with this.. Did you use VHT Wrinkle paint for the cover? Ill be doing my one black but waiting on new seals from honda first

Im not sure why your pics wont open on the forum too? I tried to quote one in an reply and wouldnt show up

[C-Rex]

Mugen Exhaust
http://page7.auctions.yahoo.co.jp/jp/auction/g146516595

Mugen Manifold
http://page3.auctions.yahoo.co.jp/jp/auction/c462298383

Get that wishlist sorted:D

[steveinjapan]

I noticed that muffler also, but it has some problems. A NEW Legalis K got stolen yesterday for about 150 pounds on yahoo.jp. Ouch - I paid lots more for a used one.

[R@tch]

Get that wishlist sorted:D

Yes, I used VHT wrinkle red :cool:

I noticed those mugen parts too, but atm not planning on getting any more and focus on getting the car running. We're still on a budget;)

The nr-10 wheels have some curb rash and brake dust caked into the lips, the coated centre's are still in very good condition. In the weekend we'll bring them to a firm that will sort the curb rash and polish the lips.

[R@tch]

We got the swap engine as 'a low mileage in good working condition' engine (have a vid of it running fine) but we're still going to refresh it with all new gaskets including headgasket, new timing belt and ancillary belts. When we got the beat the aircon belt was off the car but we're hoping to get the aircon system working again, if anybody has tips or knowledge of what are usually the issues with the aircon system I would very much like to hear :).
http://i1276.photobucket.com/albums/y473/Ronjohnalex/P1020620_zps227b30dc.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/P1020620_zps227b30dc.jpg.html)
We're also going to install a new clutch set and release bearing
http://i1276.photobucket.com/albums/y473/Ronjohnalex/P1020621_zpsd35ffb68.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/P1020621_zpsd35ffb68.jpg.html)
And new brake discs/pads
http://i1276.photobucket.com/albums/y473/Ronjohnalex/P1020619_zps54911423.jpg (http://s1276.photobucket.com/user/Ronjohnalex/media/P1020619_zps54911423.jpg.html)

[Gavin]

re the hardtop be prepared to payout large money for it there are currently 6/7 mugen ones on the auction but very expensive

[R@tch]

re the hardtop be prepared to payout large money for it there are currently 6/7 mugen ones on the auction but very expensive

yes, the 'buy now' prices are a bit extreme :(, and the red one is the most expensive one if I remember correctly >.< they've been on there for sooo long... They go lower when they're put up as a bidding auction with low starting price. I recently saw one go for ~90.000 yen. I was also tracking one down in Germany, a silver mugen hardtop on a yellow beat, but no replies from the owner when I cheekily inquired about it =^.^=.

[steveinjapan]

Gavin - can you send links to the hardtops on the auction? Thanks.

[R@tch]

http://auctions.search.yahoo.co.jp/search?p=%E7%84%A1%E9%99%90+%E3%83%93%E3%83%BC%E3% 83%88+%E3%83%8F%E3%83%BC%E3%83%89%E3%83%88%E3%83%8 3%E3%83%97%E3%80%80&aq=-1&oq=&ei=UTF-8&slider=0&tab_ex=commerce&auccat=0&x=13&y=26 guess that's about all of them at the moment. All but one being sold by the same seller, wonder if he's ever going to lower the prices, some have been on there for well over a year...

This one went relatively "cheap" :D http://page11.auctions.yahoo.co.jp/jp/auction/n142251382

[Steve_M]

if anybody has tips or knowledge of what are usually the issues with the aircon system I would very much like to hear :).

Most common issues are normally either:

1) A lack of Gas
2) Burnt out/shorted compressor mag coil.

[Gavin]

yeah those are the ones, they must have been up for at least 1 year now for the price I went for a RS-Mach one in the end

[Steve_M]

For Mugen exhaust, you really need this version. Mmm all things shiney, pity to hide it away under the car.

[R@tch]

Yea it's a pity, but gives peace of mind;). I do like the stainless mugen exhaust a lot more than the gen 1 mugen exhaust, on the other hand it'd be neat to have our Beat fully resemble the one on the original mugen beat brochure :D Not sure yet.

[R@tch]

The beat is on jack stands as the nr-10 wheels are away to get the curb rash repaired, the lips will also be re-polished, I took off all the brake discs and found that the front right wheel bearing needs to be replaced. Has anyone on here done the job before?

[Steve_M]

the front right wheel bearing needs to be replaced. Has anyone on here done the job before?

Its basically just like a normal FWD wheel bearing with driveshaft, but the nut is on the inside of the hub.

1) remove knuckle from car. (Caliper and disc off, track rod, bottom ball joint and damper clamp)

2) remove hub nut cover and hubnut.

3) with a press push out the hub.

4) remove circlip retaining bearing and press out bearing.

5) Pull outer race off hub shaft.

6) push new bearing in and fit circlip.

7) Install hub, supporting the inner race of the bearing.

8) tighten hub nut to 200 Nm (20kg m) and stake in nut.

9) fit new hubnut cover.

10) assemble knuckle back onto car.

[Steve_M]

This is the layout.

[R@tch]

Awesome!! Thanks Steve.

[R@tch]

I received a few pictures of the people restoring the NR-10's the first one was done today. Here are some before/after pictures:
Before with some curb rash and caked in dirt shown.
http://i1276.photobucket.com/albums/y473/Ronjohnalex/rechtsvoorMedium_zps4b7c51b3.jpg
http://i1276.photobucket.com/albums/y473/Ronjohnalex/remstofinrandvoorMedium_zpsed0e6597.jpg
After, material was welded on where the worst curb rash was in the end the lips will look brand new.
http://i1276.photobucket.com/albums/y473/Ronjohnalex/foto2_zps2d3fa7f8.jpg
http://i1276.photobucket.com/albums/y473/Ronjohnalex/foto1_zps0c7ab9dc.jpg

Currently in the market for some new tires :D, we want to fit summer tires for dry grip as the beat will probably be used as a summer car and not see rain or snow. The really good stuff in the right sizes seems to be only available in Japan. Any recommendations?

[bigB]

I'd recommend stick-on inside weights when balancing for a cleaner look.

[Gavin]

a few mugen manifolds and exhaust systems on the auctions at the moment

[R@tch]

We ended up going for sporty Yokohama A539 tires
http://banden.autoweek.nl/images/400/4/7b6dd116ae9ab4fb19fd59956b3392b4.jpg
175/60 r14 for the rear and 175/60 r13 for the front.
Not the original sizes, but was the closest I could find for a sporty summer tire. just a little bit wider but will fit fine :)
The wheels were balanced with stick-on inside weights like you recomended bigB

Will post some pictures soon.

Some nice mugen exhausts for sale indeed, you have pm Gavin :D

[R@tch]

Just won a mugen exhaust for the beat on the yahoo auctions. The dual tip powerflow exhaust that came with the beat will be available for sale.

[Gavin]

It's ready check messages ;)

[R@tch]

We decided to give the beat a professional respray in the original colour. Some pictures of the progress

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[R@tch]

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[R@tch]

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[R@tch]

And a final teaser :p We're going to pick it up this saturday.

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I also gave the front and rear lenses a recon, brushing them clean, some wetsanding with 2500grid sandpaper and polishing made them look like new again. Also looking to order new emblems and having copies of the original mugen side decals (that are unfortunately imposible to come by :( )made up.

[Dickiecrx-vt]

Very nice!


Like to do a photoshoot with our Beat!
Are you at the Japan Car classic day on 5 July?

[R@tch]

Hey Dickie, unfortunately I don't think we will have it ready before that time. I have my summer holiday coming up and will be away for 2 weeks + I can only be in the gagare in the weekends. Though I'm sure we'll do that photoshoot one day;)

Some pictures from saturday, must say i'm not entirely pleased with the paintwork, the bonnet and mugen rear spoiler will need to be redone.
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