[CafeRoaster]

Hello everyone! I mistakenly was posting updates to my welcome post, so I thought I'd start moving stuff over to a proper build thread.

My goal with this vehicle was originally to keep it pretty stock, as I have with most of my vehicles. However, my plans have changed - pretty drastically. Keep reading to find out.

Original Post from May '21:
Hi, folks!

Just scored this beautiful, well-maintained '05 EX for $6,000 with 171,431 miles (here in the PNW, that's a steal). The PO had it for 14.5 years and had all the records. Replaced the windshield several times, a brake master cylinder, head gasket and timing belt, etc. Very well taken care of. I hope to do the same!

You can't tell super well from the photos, but this beaut has running boards and the rear spoiler. I've already got an Aerogenics cage on the way, the shop manual, LED fog lamp bulbs, I'll be needing to replace the tires in the next year, and perform all the fluid flushes before summer is out.

We have an '09 Fit Sport as well. Her name is Betty Beep. Meet her big brother – Henry Honk! As you can tell, our kiddo loves him!

 

[CafeRoaster]

June '21

Finally got around to installing the catalytic converter shield, and changing the oil and filter. I haven't changed the other fluids yet, but they all look good, even though the coolant is the green type. I forgot how stupid difficult these oil filters are to change - I helped my friend change the one on his CR-V before, but we were able to jack it up and get to it through the wheel well. Not so with mine because we don't have a paved driveway and thus my jack doesn't get it high enough. No tire rotations for me either then. >.<

Always install Fumoto drain valves on my cars!

Managed to bust off the tailpipe. Went to roll over a curb thinking I was in an actual truck. Busted off the tailpipe, smashed the forward-most mounts of the running boards, and made the passenger side airbag deploy. >.<

 

[CafeRoaster]

Upgraded the battery earlier than intended. I was working on the fog lamps and killed the battery after just a couple minutes of using them.

EverStart Max 35N 640 CCA. First time shopping WalMart in over 10 years. >.<

 

[CafeRoaster]

August 8th, 2021:

Just a quick update. Henry Honk has some goodies on the way! Doing a full suspension rebuild and putting some new wheels and tires on, as well as lifting 2 inches.

Here's the parts list:

• Rocky-Road 2” lift kit (GR-2 struts, Dobinsons springs)
• Aerogenics Billet rear control arms
• Aerogenics front and rear camber kit (bolts and arms)
• 4x CV axles
• front & rear sway bar bushings
• front & rear sway bar end-links w/ bushings
• tie rod ends inner and outer
• 235/75/15 Toyo Open Country A/T III
• Mayhem 8303 Voyager (Bronze) 15x7 5x114.3 w/ hub centric rings

 

[CafeRoaster]

August 16th, 2021:

Replaced the engine air filter today with a Wix brand, and gave the engine a nice wipe down with Tub O Towel.

Filter looked pretty great for being 50,000 miles in.

 

[CafeRoaster]

This is a fantastic thread, keep it going! And welcome to EOC! Henry Honk is a handsome box with a lucky owner.

Thank you! This guy is great. Almost all the parts have come in for the suspension rebuild and lift, and tires and wheels just came today! See next post for those.

 

[CafeRoaster]

Happy mail day to Henry Honk and myself! Wheels and tires came. All parts for the suspension rebuild have arrived, and just waiting on the lift springs and struts now.

 

[CafeRoaster]

I've been accumulating some small items for setting out on the trails, while awaiting all the parts for my lift kit. Everything is on-hand, except my dang Dobinsons springs. My garage smells like a tire shop, which I'll miss when the new shoes go on.

I grabbed a cheap cargo basket to tide me over until I feel I need something actually heavy duty. It rusted on the first rain, despite filling all the gaps with silicone, so I picked up some Plasti Dip and got to work.

I also picked up a large Plano case to put most stuff in - first aid kits, bottle jack, deflator, compressor, etc. I'll also be adding Quick Fist mounts for my shovel, once I get around to drilling out holes for them.

We're getting into the rainy season here, and at this point I'm unsure if I'll be able to get out before the next year. Holidays are crazy at work, and I'm most likely unable to get away. But, hey, at least I'll be ready!

 

[CafeRoaster]

Made the dash pretty.

Replaced the bulbs in the center console as well, but they're actually dimmer now, and the fan speed bulb still doesn't work. Can't seem to get the new bulbs to make contact in that spot. Already busted three while trying to.

 

[CafeRoaster]

Good color choices on the dash lights. Those Mayhem wheels like nice. Will be good to see it all lifted. Please list the part numbers for the struts and springs when you get a chance - I am looking at doing a similar height lift next year.

Went for this height so I don't have to deal with subframe stuff - whatever that is. Hah!

Just waiting on my springs from Dobinson. Chose the wrong time to try to get anything from oversees. >.<

Here are all of the parts I got, pasted from my spreadsheet.

HondaPartsDirect:

Item	Part #	Quantity	Amount
Rubber, Front Bump Stop	51722-S7A-014	2	$57.76
Bolt, Flange (16X62)	90119-S6M-Z01	2	$18.86
Rubber, Shock Absorber Mounting	52725-S5D-A04	2	$8.68
Rubber, Rear Bump Stop	52722-SCV-A02	2	$20.26
Bolt, Flange (14X77)	90181-S7A-000	2	$16.50

RockAuto:

Item	Part #	Manufacturer	Price EA	Quantity	Total
Tie Rod End	45A1328	ACDELCO	$14.71	2	$29.42
Tie Rod End	45A5649	ACDELCO	$35.79	2	$71.58
Stabilizer Bar Bushing	45F2134	ACDELCO	$6.86	1	$6.86
Stabilizer Bar Bushing	45F2286	ACDELCO	$5.07	1	$5.07
CV Axle	HO8436	APWI	$44.79	1	$44.79
CV Axle	HO8437	APWI	$44.79	1	$44.79
CV Axle	HO8378	APWI	$53.99	1	$53.99
CV Axle	HO8377	APWI	$63.79	1	$63.79
Stabilizer Bar End Link / Bushing	MK80466	MEVOTECH	$15.38	1	$15.38
Stabilizer Bar End Link / Bushing	MK80465	MEVOTECH	$15.38	1	$15.38
Stabilizer Bar End Link / Bushing	MK90454	MEVOTECH	$18.40	1	$18.40
Stabilizer Bar End Link / Bushing	MK90455	MEVOTECH	$18.56	1	$18.56
Air Filter	42188	WIX	$10.58	1	$10.58
Strut Mount	KYB	SM5400	$11.69	2	$23.38
Strut Mount	MOOG	K90649	$37.79	2	$75.58

CarID:

Item	Part #	Quantity	Amount
Mayhem 8303 Wheels	3196489921	4	$696.71
Toyo Open Country AT3 Tires	3631450152	4	$559.00
Security Wheel Locks	351590	1	$19.95
COYOTE Balancing Kit	4306295	1	$0.00
Black Installation Kit	1808103285	1	$49.95
Hub Centric Rings	3412606099	4	$20.92

Rocky-Road:

Item	Part #	Quantity	Amount
Dobinsons + GR2 Lift Kit	Rear springs C23-105 Front springs C23-104	1	$833.64

AeroGenics:

Billet Rear Lower Control Arms		1
Front & Rear Camber Kit		1

 

[CafeRoaster]

Woohoo! Tomorrow, Henry is off to get the suspension rebuild, lift, wheels & tires all done. Delivering him an hour and a half away to Hiro's Hotrods in Bellingham. He's the gentleman that created and sells the swivel seat. I feel extremely fortunate to be able to have him work on my E.

 

[CafeRoaster]

Just got Henry back from Austin Hiro of Hiro's Hotrods in Bellingham, WA. He did an outstanding job and it only took him a day. Suspension rebuild + Dobinsons springs, AeroGenics rear lower control arms, and adjustable uppers all around.

The Toyo Open Country AT/III tires feel amazing! I sized down an inch for wheels, and sized up an inch for tires, giving me roughly two inches more of meat to work with. In hindsight, I could have sized up the tires without sizing down the wheels, but at least it doesn't look wonky. Hah.

Today, I started playing around with some boxes we received from a friend that used to own an Element. These boxes all open up, and form the base for a sleeping platform. I'm happy to say that they also fit disassembled for traveling with the kiddo and pup, so I think I'm set for a platform! I don't love the setup, but free is free!

All in all, I'm extremely happy. I think this will really help prolong the life of the vehicle.

 

[CafeRoaster]

Are these the crv dobinson springs?

They are Dobinsons. I believe they’re the same ones for CR-V! Purchased through Rocky Road Outfitters. They sell them with the GR-2 struts.

 

[CafeRoaster]

How has the ride quality been with the new KYB struts and the upgraded springs?

The ride honestly surpasses my expectations, and I had pretty high ones. It rides like a new CR-V or Rav4, or perhaps better. The springs really show when traversing rough terrain. Way less bouncing around, lots more stability.

 

[CafeRoaster]

Thats awesome, thanks for the feedback. Getting ready to dive into some suspension overhaul my 2004 w/ 240k mi, been feeling pretty harsh for a while. Trying to figure out if I just want to refresh oem or maybe upgrade. Good to know how things have worked out for other people. With the crv struts you didn't have to do anything with spacers or modify axles right?

Nope. The whole reason I went with this setup is because there were no spacers or subframe dropping involved. Just struts and springs. My parts list has literally everything I needed.

 

[CafeRoaster]

We took Henry out to Snoqualmie National Forest yesterday - technically Clearwater Wilderness. Our first attempt was FS-75 to Lonesome Lake, but halfway up, I decided it was too deep for Henry, so I back out. We tried a few more spots but they were all closed. Our last ditch effort was to hit up NF-7720. This proved to be more more gradual of a climb. The entire trail is 4,800 feet in 15 miles, while FS-75 was going to be about 5,000 feet in 15 miles, and many more turns.

For the first 10 miles of NF-7720, it was mostly wide packed dirt and gravel, with lots of potholes. Plenty of bouncing around. I aired down from 35 PSI to 15, mostly for comfort. The views are fantastic along the way, especially from noon and on where the sun is coming through the trees. Since a lot of the second half is higher up and receives more shade during the day, there was plenty of deep snow to tread. The deepness of the snow is very gradual and there are ample opportunities to turn around if you don’t feel comfortable.

Despite this road being more washed out than FS-75, and the snow being deeper, I felt more comfortable on it. The shield around the catalytic converter scraped the snow in the middle of the trail quite a bit, as the snow was 8-10 inches deep. There were parts where I felt that a higher clearance vehicle was necessary, but went for it anyway. Choosing the right line and having the tires aired down proved to really allow Henry to shine. Throughout the entire trail, we didn’t slip once, and I only felt AWD kick in maybe once. There were plenty of obstacles - such as severely washed-out portions, fallen trees, etc. - but nothing a standard 4x4 with appropriate tires and a capable driver should have any issue with.

At 4,000 feet, we encountered someone with an old beat up Ford Explorer that had gotten stuck on the north side. I don’t have a winch, so I wasn’t entirely sure how to help. We backed a couple hundred feet down the trail and stopped at a turnout to have lunch and take in the amazing views of the Olympics, Tacoma, and Olympia. As we sat, a gentleman in a heavily modified Jeep TJ pulled up and exclaimed his impression of our little Element. He proceeded to help out the stuck individual. We made the decision to head back home rather than heading to the top, as midwinter doesn’t lend to being able to explore much, and limits what sort of activities you can do on an overnight trip.

All in all, I am immensely impressed with our Henry. Not once did I feel unsafe or underprepared. There were definitely several points where I felt challenged as the driver, which is just what I could ask for. I think this trip really helped me learn what Henry is capable with a full load, in pretty challenging conditions.

Photo dump to follow.

 

[CafeRoaster]

 

[CafeRoaster]

 

[CafeRoaster]

 

[CafeRoaster]

Did some fluid changes I meant to do right after purchase, but since they’d been done not long before, I let it slide for a bit.
I changed the transmission fluid over to Honda ATF and holy cow did it make a difference! I already thought it was the smoothest transmission I’d ever felt, but now I can’t even count in my head the gear shifts because I can’t feel them at all! Did the same with my wife’s Honda Fit (notorious for having a laggy transmission) and it is noticeably smoother.
A week ago, I wasn’t able to start Henry up, after having to use the mobile booster on it twice already that day. While waiting for a tow, I picked up an AGM battery, but that didn’t help. I had just had the existing battery load tested, and it tested fine.
After a couple hours I realized it was the positive cable connection. Now it starts up like brand new. At some point I’ll replace that connector.
It 100% seemed like the starter motor was going out. Thank goodness it was only the connection. But now I have two good batteries and nothing to do with the lead acid one. 😆