18/09/2026
Built by Legends Spoon EG6 Civic — Chassis Reinforcement
Episode 1: Prologue
In July 2019, I began the chassis reinforcement work on this EG6.
The original request from BBL (Built by Legends) was fairly conventional: install a roll bar and add spot-weld reinforcement.
However, because this car was intended primarily for street use, I felt it was better to keep additional welding to a minimum.
By that time, I had already reinforced cars such as the DC5 Integra and 350ZRS using a combination of OEM steel panel doubling and roll bar reinforcement. The next method I wanted to explore was carbon fiber doubling.
Before starting this EG6, I had also worked on reinforcing an S2000 with preformed carbon panels. That process required female molds, and to create those molds, the chassis side first had to be built up by the intended thickness of the carbon panel. It required an enormous amount of time and labor.
For the EG6, I therefore decided to take a different approach.
Instead of making female molds, I would lay carbon fiber directly onto the existing chassis and use vacuum infusion to draw epoxy resin through the carbon, creating a second structural layer over the original steel panels.
A production car body is a monocoque structure made from many steel panels joined mainly by spot welds. Because of that, there are countless panel seams, bolt holes, clip holes, and other small openings throughout the body.
For vacuum infusion, the area being laminated must be sealed under plastic film and held under vacuum before the resin is introduced.
That meant the biggest challenge was not simply laying the carbon fiber — it was finding a way to stop air from entering through all of those seams, holes, and gaps, and to maintain a stable vacuum over an automotive body shell.
After a great deal of trial and error, I developed a method that allowed the vacuum to hold properly, making it possible to apply carbon fiber doubling directly to the EG6 chassis.
For this first episode, I’m sharing photos of the car before and during disassembly, together with the finished carbon reinforcement on the interior floor, front chassis structure, and strut tower areas.
From the next episode, I’ll go back to the beginning and show how the work was carried out, step by step.