DSM Project Car/Build Updates

It has been a while since I updated this as it has been very busy here and the Talon has been relentless in playing a game of chicken with a partout. ha!

The 2nd head gasket failed in the exact same way as the first. There is another thread discussing this here:
http://www.dsmtuners.com/forums/cyli...way-ideas.html...

As the title implies I just finished removing my 2nd Cometic gasket after it started to pressurize the coolant system.

The first failure happened at relatively low boost (24-25psi) and conservative timing for E100 (14* total, 7-8* @ 5000).

Both the head/deck were prepped for MLS to a mirror finish. The block deck was checked for flatness. I am using A1 H11 studs torqued...

The head is still off being repaired so I have been doing what little projects I can and collecting parts for the reassembly.

The O2 housing had a pretty large leak right at the wastegate opening so that would explain the slower-than-expected spool. I had it re-surfaced and it was pretty out of whack. I don't see why MAP won't use a 1/2" flange.

I had originally...

Well, the 2150s work great and E98 is a blast, but it started pushing coolant. After a re-torque and lowering timing it stopped but when brining the timing back up it pushed again so it was time to pop the head!

Here is the last pull before pulling the head (attached):



It was running...

I'm slowly getting to the point to see what this new combo will do. I picked up some VP110 today to see if the knock I was seeing was mechanical noise or if this thing just really doesn't like pump gas.

Turns out it doesn't like pump gas. I started turning it up a bit. My transmission is still acting weird on the 1-2 shift so I need to sort that out. With some more timing (+2) and 16psi...

I installed the IR boost control solenoid yesterday and got it set up. I made a small bracket out of aluminum stock to mount it to the radiator. It is working good, and is at about 16psi at 45% duty cycle. It is hooked up using both the top/bottom ports. My only concern is how tolerant these solenoids are to heat. I like where it is mounted to keep the hose lengths down, but it will obviously get...

Well this is not the kind of update I was looking forward to but someone rear ended me on my way to work this morning.



I was stopped at a red light getting off the highway and I stopped, then pulled forward to see if any traffic was coming to go right on red and about the same time I stopped...

I finished up a few things on Saturday. I finally moved the battery down to make room for the JMF catch can and stop dumping my crankcase evac to the ground. It is supported by a piece of 1/8"x2" angle iron. A piece of masking tape worked good to transfer the bolt holes that the charcoal canister mounts to over to the angle iron so it would sit level.

The top of the battery...

I haven't had a lot of time to drive it and sort out all of the bugs but it is running pretty good! I just switched from the Brad Penn SAE 30W to Valvoline 20w50 VR1 at 150 miles and there is just under 200 miles on it now. It doesn't smoke or burn oil and there are no leaks.

It is now time to start cleaning up a few things that were skipped in the rush to get it running while I had...

Good news, it lives!

Now, it certainly was not without its drama but I am impressed with how well it did right off the bat.

Before the first start I turned the key on to finish setting up ECMLink and I hear a loud pop and saw a bunch of fluid shooting all over the car out of the engine bay.... the damn meth injection pump came on for some damn reason and blew a hole...

Ok, taking a short break to do an update. I have been absolutely thrashing non-stop since Wednesday night to get this thing finished. My father is in town for a while so I have had a great shop hand to keep things moving along. We've been met with challenges at every single corner, what a pain in the A55 this thing has been.

I am approaching each issue and trying to do it "right"...

I picked up a Saturn alternator and modified it and the block. I also got a pigtail from O'Reilly's and started wiring it up before the motor goes in. I am going to leave the F wire unhooked and run the S wire to my fuse block for the fuel pump. The L wire will be the only one hooked up from the stock 4-wire harness. I may run a new 4AWG power/ground as well.

The stock belt was about...

I sent the throttle body off to Steve at throttlebodys.com, who did a great job and had a very fast turnaround. I had the "uber" seals installed that are tested to 40+psi. The sensors also checked out good. He also machined out a minor scrape in the inlet area. There shouldn't be any leaks...

...

I got the cams degreed in. I used a spare trigger plate modified to mount to the head to use as a dial indicator base. It actually worked surprisingly well and I had no issues with it. It looks a little funky but it works.



I was unable to find a dial indicator extension locally so...

The turbo is installed along with O2 housing and wastegate. I'm just trying to do what I can while waiting for the intake cam. I have been putting off cleaning up the engine bay as it is my least favorite thing to do.

The drain line was kind of a pain to get right as it is pretty short and the hose wants to kink. Here is the order I did it in: (1) install straight fitting onto hose...

A picture is worth a thousand words:



Well, far less than 1000, but I only have 1 cam so I will not be getting the motor done this weekend as planned. After waiting three months, GSC sent the intake cam untapped for the late 2g cam sensor after requesting confirmation multiple times that it would...

I am still waiting for cams, which doesn't surprise me much, but hopefully GSC comes through.

In the mean time I am finishing what I can. I finished the transmission last night. I ended up replacing the sun shell and kick-down band. When the transmission was new it would occasionally bind on the 1-2 shift when using full line pressure. It wasn't bad but it was noticeable. When I had...

I picked up some parts from the powder coater today, which was a few days ahead of schedule.

I am happy with how they came out, the color combination is exactly what I wanted. It is actually really close to the factory color. The red Mitsubishi symbol sets it off well I think.

...

I cleaned off the transmission and dropped the pan. I was expecting much worse but there is actually not much material on the magnets and there isn't a ton of glitter in the pan. This was with about 12,000 miles on the new build.

I was concerned as I had a rattle-type noise when free-reving in neutral. My old billet converter used to do this so I wonder if it is just the converter....

I installed the oil pickup/pan yesterday morning. I picked up some 6.0mmx1.0x30mm studs and some flange nuts to install the pan with. It made it a lot easier to get it aligned without making a mess of the RTV.



I used Right Stuff grey for the pan. The caulking gun tubes are really nice and would recommend...

I spent a while today trying to find all the front case bolts. Made a little progress and ported the OFH.

I plan to run 20w50. Rod bearing clearance is at .0028 and mains are at .0030.



I tried to find a 2g windage tray but couldn't locate one. However, I got an Evo tray and the bolts...

I think this might have been a better avenue for sharing this build then just putting it in the cylinder head/shortblock section.

I will be posting the updates/photos from the original build thread in this format.

Thanks for looking!

I won't be posting up a picture of every nut bolt and screw but I will try to make this a semi-informative thread that...