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Old June 25th, 2014, 06:41 AM   #1
Metalball
 
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Metalball's Inspire Modulo Gen7 Build

Well, it has been quite some time since I was active on these boards, but it is well due that my project gets off the ground. I've been wanting to convert my 2004 Honda Accord EX sedan from the USDM Accord to the JDM Inspire for quite a while. I thought my dream was to also install a complete Mugen kit, but a deal came my way that I couldn't refuse. So, I am going complete Modulo instead.

Here is the current state of the car. There aren't a lot of modifications done thus far, but that will obviously be changing in quick succession. I have the following parts currently installed:

- JDM Inspire Tails
- OEM Navigation
- iSimple iPod and Bluetooth kits
- 9000k HID kit
- Comptech USA 22mm rear sway bar
- EBC USR Rotors (Front/Rear)
- EBC Brake Pads (Green front/Red rear)
- Goodridge SS brake lines (Front/Rear)
- RV6 v3 j-pipe
- Injen CAI
- Rerouted coolant lines from throttle body
- Arc Audio 6.5" coax in front
- Boston Acoustics 6x9" 2-way in rear
- 30% tint

There are several parts that I have been collecting dust over time until the big build kicked off. I'm happy to get these out of the basement and onto the car!

- Fujitsubo Legalis R exhaust system
- Neuspeed 27mm front sway bar
- RV6 v3 high flow precats
- JDM Inspire power mirrors

Now onto the good stuff and the latest round of purchases. Here is what has shown up in the last few weeks:

- Honda Inspire hood
- Honda Inspire grill
- Honda Inspire headlights with HID ballasts included
- Honda Inspire front bumper
- Honda Inspire foglights
- Honda Inspire left fender (not needed for conversion, but was included)
- Honda Inspire right fender (not needed for conversion, but was included)
- Honda Inspire rear bumper
- Honda Inspire Modulo front lip
- Honda Inspire Modulo rear lip
- Honda Inspire Modulo side skirts
- Honda Inspire Modulo front grill
- Honda Inspire Modulo spoiler (thanks MuGen7Modulo!)
- Half-cut Honda Inspire frame (includes radiator brace and wiring)

The goal of this build is a OEM+ design. It will be super clean and is intended to be a street cruiser. You won't see superchargers or turbo kits on this build, nor is it intended to see any track time. I do plan to spend some time on suspension and bolt-on power mods (as seen above) to fix a few factory shortcomings. However, I will mostly be focusing on the conversion and cleaning up the exterior by shaving exterior badges, trim moldings, etc.

Last edited by metalball; June 27th, 2014 at 03:14 PM..
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Old June 25th, 2014, 07:05 AM   #2
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Here is a picture of the crate that showed up with the Inspire parts. (That's my other ride hiding in the background, an Acura RSX Type-S.)




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Old June 25th, 2014, 02:23 PM   #3
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Same here. I was going to trade my 07 for a 14. But decided to keep it so now I'm converting it.
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Old June 27th, 2014, 02:51 PM   #4
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Congratulations and welcome to the Inspire conversion family.
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Old June 27th, 2014, 03:13 PM   #5
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Glad to finally be a member!
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Old June 27th, 2014, 03:18 PM   #6
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Here are some photos of the crate unpacked. There is some minor damage to the front lip, but I'm pleasantly surprised at the condition of these parts! Please pardon the messy garage...





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Old June 28th, 2014, 08:38 AM   #7
ER MER GERD!!!!
 
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sweet! subscribed!
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Old June 30th, 2014, 07:34 AM   #8
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Where you get the front end from?

Sent from my XT1053 using Tapatalk
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Old July 2nd, 2014, 09:20 PM   #9
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so excited.....
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Old July 6th, 2014, 06:05 PM   #10
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Quote:
Originally Posted by chrishowe View Post
Where you get the front end from?

Sent from my XT1053 using Tapatalk
I used an importer in Canada for the entire front clip.
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Old July 9th, 2014, 10:43 PM   #11
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This is the start to an interesting thread....cant wait to see more and would love to hear more about this canadian importer as I will be needing inspire parts very soon!
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Old July 10th, 2014, 05:56 PM   #12
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The name of the importer is Japan Direct Japanese Auto Parts. Here's their website: JDM Japan Direct Japanese Auto Parts JDM Engine JDM Engines JDM Part JDM Parts JDM Transmission JDM Transmissions
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Old July 17th, 2014, 11:28 AM   #13
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Thanks everyone for your patience for the next round of updates! I just got back from a bit of R&R at Lake Norman, NC and will be starting to install some parts this weekend.

I've placed an order with Eastwood for a plastic welder, some copper welding plates, and some body filler materials. There are a few minor repairs that need to take place on the JDM parts, and I'll try to do my best to document as I go along.

Stay tuned!
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Old July 27th, 2014, 06:19 PM   #14
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The JDM front clip has been stripped clean. I am pleasantly surprised that the wiring harness is almost completely intact. I only have to repair two wires.

I found a strange issue with the passengers headlight, though. It looks like one of the plastic corners has pulled away. It doesn't look like it is leaking, but I may reheat it to see if it moves.

I'm still waiting for my plastic welder and body filler materials to arrive. They should show up this week.

Stay tuned.



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Old July 28th, 2014, 04:23 PM   #15
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BTW, I don't have any need for the JDM stock airbox, AC condensor, radiator, or crash brace. Those will be up for grabs in the Classifieds soon.
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Old July 28th, 2014, 05:15 PM   #16
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Clean!!
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Old July 29th, 2014, 10:39 AM   #17
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Congrats Nate. And that grill isn't Modulo, it's just a stock grill.
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Old July 29th, 2014, 12:14 PM   #18
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Good catch, Ariel, but this one is... I can't give away all of the good surprises!

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Old July 29th, 2014, 08:08 PM   #19
▒JDM е KING▒
 
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^Nate, this is just a modified grille. Emblem area removed.
There is no Modulo grille for UC1 just the OEM JDM one.
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Old July 30th, 2014, 11:24 PM   #20
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Can't wait to see the finished product
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Old July 31st, 2014, 04:56 PM   #21
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Here is the next round of updates on this build. Bear with me, as this is going to be a massive download of pictures. After a (very) late night this week, I am starting to get some positive momentum in the build and am very happy with the results thus far.

Here are some shots of the starting point for my 2004 Honda Accord EX sedan. The afternoon deluge rain storms absolutely suck for keeping a car clean this time of year, but I think you get the point. You can actually still see the rain clouds on Pikes Peak in the background, which is pretty cool.

As you can see, it is a fairly clean donor for this project:









For those that are following along, I'm taking a little different path than the other members with (hopefully) the same end result. I was fortunate enough to source a half-cut Inspire that had a lot of the OEM parts still included.

One of the gems out of this purchase was the intact JDM wiring harness. It was a tedious job, but the end results were absolutely incredible. As a former MECP Technician, I was bracing for a battle and was pleasantly surprised! The difference between a USDM harness and a JDM harness is literally one plug, mounted behind the factory battery location.

The USDM harness is a single white/green wire, while the JDM harness is a three-wire plug (white/green, blue, and yellow). Tracing the JDM harness, the optional blue and yellow wires terminate at the lower radiator fan plug location. On this harness, that is where the importer made the cut. I'm guessing that it led to the JDM front bumper speed sensor, but it was not included with my half-cut.

Bottomline, it is really simple to use the JDM wiring harness on a USDM vehicle. Cut off the JDM plug, cut off the USDM plug, and solder (do not butt connect!) a single wire. Voila, it's done.

Enough rambling, onto more pics.

Here's a shot of the USDM grill and front bumper removed:



Front bumper - Driver's side (already removed the air filter on my Injen CAI to clean it at the same time):



Front bumper - Driver's side with headlight removed. The additional wiring that you can see in this pic is from the aftermarket 9000K HID low beam kit that I had installed. This kit will be going up for grabs on the Classified section as well, if someone wants it.



Here's where I started to deviate from the usual conversion. Since I had both JDM front fenders, I wanted to use them on the car. Little did I realize how much extra work that would be involved! There are 9 bolts and require removal of the side skirt, front bumper, and headlight to do so. Picture shows fender removed, as well as removal of HID kit.



Onto the actual routing of the JDM wiring harness. If you haven't done so already, you will need to remove your battery and intake (OEM or aftermarket) to get your grubby mitts into the crevasses. Remove the two bolts holding the fusebox and flip it over. Remove the splash cover to gain access to the harness plugs. There are 3 harness plugs that need to be removed and swapped to use the JDM harness.



Now this is the wiring difference that I was speaking about at the beginning of this update. As you follow down the routing path of the original harness, you come to a plug that is different and needs to be swapped out. In this picture, the USDM plug is on top, and the JDM plug is on bottom. Breakout some wire cutters, wire strippers, and a soldering iron to swap plugs. The car-side connection for this plug is show in the bottom right-hand corner of the photo.



I unfortunately didn't get any pics of the wire routing down the back of the radiator for the additional fan plugs and the two excess wires, but it is fairly straight forward. Just remember that the spare wires can be trimmed and mount them out of the way. Keep moving along the front of the car installing the JDM harness. Here is a photo of the passenger's side, again with the headlight removed.



Another deviation of the swap, I wanted to compare the front crash beams from the USDM and JDM models. Just for kicks, I pulled the USDM beam and decided to weigh it. The JDM beam weighs 6 pounds lighter than the USDM one! So, I elected to install the JDM crash beam for it's weight reduction. Here is a photo of each for comparison (JDM on top, USDM on bottom):



Here's a pic of the completed wiring swap on the driver's side:



Completed wiring swap on the passenger's side:



At this point, it was well into the wee hours of the morning, and I decided to button things up since this car is still my DD. Here are some pics of the first test fitment.







The headlights are fully functional right off the bat! I need to source a parking light bulb and high beam bulb that is a closer match to the HID low beam. Having the pure white HID against the yellow halogen is not going to work. If you have any brand suggestions, I'd love to get some feedback.

I didn't get a chance to mess with the foglights yet, but I'll let you know how that turns out.

Stay tuned as there is more to come!
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Old July 31st, 2014, 05:39 PM   #22
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progress looks good. i see you swapped your left fender too. you are really lucky to have landed an awesome deal for that front clip, skirts and rear. i have spent more and sourced parts in different countries to complete my build.
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Old August 1st, 2014, 10:29 AM   #23
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Quote:
Originally Posted by toinkee69 View Post
progress looks good. i see you swapped your left fender too. you are really lucky to have landed an awesome deal for that front clip, skirts and rear. i have spent more and sourced parts in different countries to complete my build.
I did swap the fender, but after taking a look at it in the daylight, I am very disappointed to find a horizontal crease running through the entire part! It must have gotten damaged during shipping, so unfortunately, that part of the work will need to be redone on the driver's side.

The passenger's fender needs to be replaced from the shoddy body work done by the previous owner. It looks like someone hit the fender and then just bondo'ed over it. When I get it off, I'll take pictures of the fender so that you can see what I am talking about.
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Old August 1st, 2014, 10:45 AM   #24
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Lucky you it comes with fenders as well. I like it when everything falls into place. Congrats.
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Old August 7th, 2014, 01:30 PM   #25
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This is sick I know someone selling inspire front
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Old August 19th, 2014, 10:57 AM   #26
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Some more updates on the build. I removed the rear bumper to fit the Inspire bumper onto the Accord. One thing that you will want to note, though, is that the foam padding on the USDM bumper has to be removed. The exhaust cutouts on the Inspire bumper contact the foam and will not allow it to be installed on the car. I also had to use my BFH (use your imagination) to massage the rear crash beam slightly upward to make the fitment correct.

Here's a pic of the bumper removed. The golf bag is a mandatory accessory!



I also took a few more moments to get the rear splash guards to attach correctly to the Inspire bumper and Modulo lip. You just have to drill a small hole for the screw locations. A small minor detail, but it will definitely keep splash guard from flapping in the wind.



Round one of test fitment of the rear bumper with lip attached.



Another minor difference between USDM and JDM is the rear bumper bracket locations. On the underside, the clip holes do not line up and will need some slight massaging to work properly.



I had some help from a few family members to put the original driver's fender back on the car, after noticing the JDM fender had a vertical crease running the entire length of the fender. We also replaced the damaged passenger's fender, passenger's side skirt, and fit the Inspire hood.

I took a calculated approach to replacing the front sheet metal and setting the correct gaps. I replaced the front fender first, aligning it to the USDM hood. Then I replaced the passenger's fender, also aligned to the USDM hood. The JDM hood was then a breeze and fit properly on the first attempt. It's amazing what happens when you properly plan before starting disassembly!

More to come on how we made the Inspire latch work using the USDM frame. I'm undecided if I will cut out the USDM frame and install the JDM frame just yet.

Here's the current status of the car:









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Old September 7th, 2014, 06:07 PM   #27
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Time for a mini update -- after waiting patiently for 2 years in my basement, the Fujitsubo Legalis R exhaust is finally on the car! I was surprised at how easy it was to remove the exhaust, without having to mess with the rear suspension. The last car that I replaced the exhaust required dropping the rear trailing arm to remove the OEM unit.

I was also a bit taken back at how heavy the stocker is compared to the Fujitsubo unit. I got a PM asking about this exhaust since it is made for the 4cyl Accord model. I can confirm that it fits just fine on the v6 model!

Here are some pics.

The brand new Fujitsubo Legalis R exhaust:




Installing the exhaust on the car. To evenly raise the car, I started with the rear tow hook and placed jack stands in their proper location. I then moved to the front driver's side and used the front tow hook to raise the remainder of the car. Always remember to put jack stands before climbing under a car!


The finished product:


Circling back, here is the reason why I had to remove the JDM driver's fender and replace it with a good one. It's a small detail, but I was not going to fight the bodywork when it comes time to paint!


The other section of damage on the JDM fender:


Now, here is the original passenger's fender. I started to notice a section of paint that was chipping around the wheel wheel. After a little investigation, I found out that someone had crushed this fender and poorly repaired it. It looks like swiss cheese and bondo. So much for an "accident-free" vehicle... Just goes to show, don't trust the word of a car dealership!
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Old September 7th, 2014, 06:25 PM   #28
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Still debating a few elements of this build. I still am undecided on the direction to go with the wheels. Since this is a OEM+ build (similar to European builds), it is acceptable to use either OEM or non-OEM wheels. I am leaning towards either 18" or 19" models to get rid of the massive tire sidewalls. However, I can't go too crazy on the sizing with the horrendous road conditions out here in Colorado. Anyone have a good suggestion?

I'm also currently hunting through the various OEM manufacturer's color palettes to respray the car. I debated using a custom shade, but that will be truly a PITA if/when I have to touch parts up from all of the rocks on these Colorado roads. Instead, I am thinking of using a OEM shade to make color matching easier.

The current color that I am eye balling is Lexus Starfire Pearl from the IS-F, which is a 3-stage paint with a brighter shade of white and a metallic pearl. What do you think? Have any better ideas?
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Old September 7th, 2014, 07:41 PM   #29
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is that exhaust made for a tsx?
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Old September 7th, 2014, 10:15 PM   #30
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Quote:
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The finished product:
Change the emblem
I like!
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