Rally Build: 1990 TSi, Roll-over ready.

[PotatoFlakeSTi]

Originally Posted by Tyeler18

Looks like quite a fun project! Ever thought about going Water to air intercooled? Don't know what you're rules are you need to follow, but the W/A will allow you to keep a free radiator and not have to worry about ruining a FMIC, quicker spool and more efficient cooling as well.

Like Kreez said, if you ever want any help let me know. I'm not too far away and this is the kind of racing I'd love to get into!

Well, as most privateer rally cars I'm trying to stay with a "Keep It Simple, Stupid" approach, so for now a chargecooler is not in the plans.

I hope to have anti-lag programmed EVENTUALLY, so spool-time will cease to be an issue at that point... Of-course I'll need to shed heat better at that point.

If you're interested in the scene, and want to get involved I'd implore you to visit the ColoradoRallyRacing.com forum. It's still pretty new, but there are some knowledgeable guys on there. (Working on setting up a NASA Rally Sprint in Steamboat, CO)
They also have information on the Colorado hill-climbs, some not too far from you.

On that note though, I will be heading to New Jersey permanently around the beginning of March, along with the car.

[ConcowTSI]

awesome thread, love the car man, what kind of coilovers are those? i recently got a 95 tsi and am really really looking forward into rallying it, first thing i want to do is suspension. could we get some pics of the rear skid plating also?

[PotatoFlakeSTi]

Originally Posted by ConcowTSI

awesome thread, love the car man, what kind of coilovers are those? i recently got a 95 tsi and am really really looking forward into rallying it, first thing i want to do is suspension. could we get some pics of the rear skid plating also?

Hey Concow,

The suspension is HotBits DT2 with Gravel valving and softish springs with helpers, 2-way adj and exterior expansion canisters.
I'm currently not entirely sure of the stiffness on the springs(lb wise), but I'll look into it.

Suspension should definitely be the first thing you do on a rally car (after safety items, ofcourse!), since you can run upgraded suspension in production class. Although I think the reason you see more 1g's on the dirt is because they have more travel available in the front.

I'll post up some pictures of the mid/rear-ish skidplating (which is actually just a few urethane sheets from the doors back)
The fuel-tank has a steel tank fitted around it, which will work well for when I decide to get a fuel cell as well.

Edit: Meant to say that I'll post pictures when the car arrives in New Jersey... Being shipped across the country atm.

[Sebba]

What about this? Better spool, and never have to worry about the fins clogging.

[PotatoFlakeSTi]

Originally Posted by Sebba

What about this? Better spool, and never have to worry about the fins clogging.

That set-up looks pretty good, any more information on it?

[Sebba]

Yeah the owner is Mike, AKA JAXWHITE1G. He is a master when it comes to metal/mechanics. He fabricated the whole thing himself, IMO that's how they should have been from the factory.

I've only ridden in that car once, but I was impressed by how well everything was done. He was running a 20g at the time and it spooled like a mofo. I think he added a draw fan under it, but I can't recall. I know he's running it with the GM-MAF on the intake like my car, but I don't know if he recirc'd it. I could be wrong, but I think he just picked up a small core off of eBay and make it work.

Unique, functional, effective, and best of all better performing.

[PotatoFlakeSTi]

Originally Posted by Sebba

Yeah the owner is Mike, AKA JAXWHITE1G. He is a master when it comes to metal/mechanics. He fabricated the whole thing himself, IMO that's how they should have been from the factory.

I've only ridden in that car once, but I was impressed by how well everything was done. He was running a 20g at the time and it spooled like a mofo. I think he added a draw fan under it, but I can't recall. I know he's running it with the GM-MAF on the intake like my car, but I don't know if he recirc'd it. I could be wrong, but I think he just picked up a small core off of eBay and make it work.

Unique, functional, effective, and best of all better performing.

So he's running his GM MAF pre-turbo?

I'm not terribly worried about spool-time, as the car won't be still much and shouldn't be low on revs often... When the eventual anti-lag is programmed all I'll have to worry about it cooling and "ease of fixability"

[PotatoFlakeSTi]

Alright, car is in NJ.

If you're in the Central NJ area come by and I'll get some beers and a pizza and we can talk cars!

Should have a welder soon!

[Sebba]

Originally Posted by PotatoFlakeSTi

So he's running his GM MAF pre-turbo?

I'm not terribly worried about spool-time, as the car won't be still much and shouldn't be low on revs often... When the eventual anti-lag is programmed all I'll have to worry about it cooling and "ease of fixability"

Yeah, pre-turbo. It'd be awesome to see another top mount setup.

[2nd Gen Mnstr]

Yeeea. im thinkin tha motor mount is dead.

[Evo3Codriver]

Here is my FMIC w/ skidplate.

[arrowhead]

Originally Posted by Sebba

Yeah the owner is Mike, AKA JAXWHITE1G. He is a master when it comes to metal/mechanics. He fabricated the whole thing himself, IMO that's how they should have been from the factory.

I've only ridden in that car once, but I was impressed by how well everything was done. He was running a 20g at the time and it spooled like a mofo. I think he added a draw fan under it, but I can't recall. I know he's running it with the GM-MAF on the intake like my car, but I don't know if he recirc'd it. I could be wrong, but I think he just picked up a small core off of eBay and make it work.

Unique, functional, effective, and best of all better performing.

Very nice would sure like to get more info and photos.

[autokid90TSi]

I have been wondering what happened to this car for some years now. I took these pictures at the Main Forest Rally in 2002. This car has got a lot of stage miles on it. How come I didn't see you at Rally New York this past weekend?


This was my first rally that I ever attended and also my first pictures. I've shot 20-30 rallies since then.

img015 by Drew84(PASCARPHOTO), on Flickr


img026 by Drew84(PASCARPHOTO), on Flickr

[Evo3Codriver]

Originally Posted by autokid90TSi

I have been wondering what happened to this car for some years now. I took these pictures at the Main Forest Rally in 2002. This car has got a lot of stage miles on it.

I was codriving that rally. Bruce Perry owned the car and I had some close championship competition against him and his usual codriver Phil Barnes. They would run on both sides of US/Canada border.

Originally Posted by autokid90TSi

How come I didn't see you at Rally New York this past weekend?

Rally NY would be last on my list to go to. Did a couple times too many.

[autokid90TSi]

We'll I meant the OP, but Rally New York was all new this year. You know who I am right ?

What was the story with your side of the car in those pictures ?

[Evo3Codriver]

Originally Posted by autokid90TSi

You know who I am right ?

I dunno, Pete Kuncis?

Originally Posted by autokid90TSi

What was the story with your side of the car in those pictures ?

Adrian Wintle was with Bruce Perry that event. Can't recall if I know what they hit. I was w/ Jon Nichols, black Subaru #97 if you can find any pics.

[autokid90TSi]

Nope, Andrew Pascarella, Drew84 on other forums. DirtyImpreza etc.

I do not have pictures of that car The only black Suby is #925

[PotatoFlakeSTi]

Whoops! Went absent for a bit as my wifes mother had a stroke, so now her parents are living with us.

Sure makes for early (3-4am) mornings!

I should be able to start working on the Talon again shortly!

[PotatoFlakeSTi]

I've got a few updates, and I'll try to get pictures in the morning.

1. Exhaust leaks... at least 3 of them. I could tell by ear that I had one, but until I had the mid-skidplate and fiberglass wrap off I didn't know of the extent.

The terrible engine mount condition likely caused all of them, the down-pipe directly off the turbo had a bit of a kink to it, which had apparently caused a hairline crack to run about 1" lengthwise, while a 1mm hole in the center of it.

The wire interior of the flexpipe had broken loose, and the pipe barrier was torn about 1/2 way around, while the outside wire was relatively intact.

The downpipe to "catback" connection had a large leak, large enough to severely soot and burn off the underbody coating, I knew of this leak from the molten hot steel 2" from my foot after racing for a while, and was the only exhaust leak I was truly aware of.

So now I need to get myself a new downpipe, I guess my only option is to go by an exhaust shop with the old torn up piece and hope they can match it, since I've yet to acquire a permanent trailer.

2. Was scouring Lowes for bits to build a boost leak tester and my total was coming to around ~$30 in parts for something shitful looking, so I ordered one from TURBO BOOST LEAK TESTERS - Kits For All Turbo Charged Vehicles, for ~$40 shipped. Would rather support the automotive community than Lowes!

3. Had a slow leak on my LF, so put my last remaining spare on... The rest of my wheels and tires are still in Colorado, along with my extra heads/turbos/subframes/diffs etc.... I hope to have 2 full sets of Medium 195-65-15 DMack gravel tires before my first race, but a single set and my used for spares would help keep costs down.

4. I still need a reasonable tuning option, but with the recent addition to the family, the budget has been tightened. I figure I'll try and pick up some bigger injectors, 560 or 650, a Walbro fuelpump, and try and tune as best as I can with the MAF-T.

5. Rear subframe woes, I suppose I'll try and get a picture of this, but I think I need some new parts, ha.

Will try and have pictures up asap... I really need to make friends with a mechanic, I want to drive. As much as I wish I knew how to weld, rebuild engines, etc I just don't have the experience yet. D'oh.

Originally Posted by autokid90TSi

I have been wondering what happened to this car for some years now. I took these pictures at the Main Forest Rally in 2002. This car has got a lot of stage miles on it. How come I didn't see you at Rally New York this past weekend?


This was my first rally that I ever attended and also my first pictures. I've shot 20-30 rallies since then.

Very awesome, and thank you for the pictures.

I've e-mailed some of the previous owners, got a few fun stories out of it.

Originally Posted by Evo3Codriver

Here is my FMIC w/ skidplate.

You wouldn't happen to have pictures of how the skidplate is mounted, would you?

[Evo3Codriver]

Originally Posted by PotatoFlakeSTi

You wouldn't happen to have pictures of how the skidplate is mounted, would you?

Here it is.



Closer up.



Bolts go thru upper/front holes and spacer w/ rubber into nuts welded into lower radiator support.

Bolts for bottom/back go thru spacer and replace a bolt that normally holds something (control arm) in the front suspension.

Its a good idea to stick your bolts thru your skidplate and configure any spacer and rubber insulator and then weld a large washer to the bolt to hold everything together as one part. Less stuff to misplace and quicker to reassemble during rushed service.

[PotatoFlakeSTi]

Can't seem to find my camera, it's gotta be in one of the moving boxes we put in the basement.

I got my boost leak tester and promptly slapped it on.

Couldn't even build 15 psi initially the BOV was leaking so bad, it appears to be a HKS knockoff. Luckily I had a stock one laying around so I put that on.
Few leaks here and there from the T-Clamps not being fitted perfectly.
The factory BoV is leaking a little, I tried to crush it to see if that would make a difference, it did not, so it must be the seal(starts at ~12psi).

Originally Posted by Evo3Codriver

Here it is.

Bolts go thru upper/front holes and spacer w/ rubber into nuts welded into lower radiator support.

Bolts for bottom/back go thru spacer and replace a bolt that normally holds something (control arm) in the front suspension.

Its a good idea to stick your bolts thru your skidplate and configure any spacer and rubber insulator and then weld a large washer to the bolt to hold everything together as one part. Less stuff to misplace and quicker to reassemble during rushed service.

Thanks, mine is two separate pieces, with a whole lot more bolts. No rubber insulators, though that would be a good idea.

[PotatoFlakeSTi]

Still been too busy to really work on the car, but I did manage to get some time to go rally.

Co-driver for Tom Barton in the RNY Summer Sprint, managed a 3rd in class in his first time driving his RHD EVO IV. Champagne was had!



Sorry for the noise, GoPro's don't have an external microphone that I could have put inside the car.
Rally New York Sprint Crystal Lake SS4 - YouTube

[arrowhead]

Nice ride.

[PotatoFlakeSTi]

[autokid90TSi]

That skid plate is nice looking.

[PotatoFlakeSTi]

Got some goodies from my Friends at Road Race Engineering.





And a much needed set of 550cc injectors from VTEC_THIS

[PotatoFlakeSTi]

Decided to tackle the Fuel Pump yesterday.

Everyone always has mean words to say about the Fuel Fitting... Mine was surprisingly easy to undo
Naturally, this being a much used Rally car the only logical conclusion is that someone's already done the hard job of undoing it for the first time.



Fuel looks clean, no debris down there



Looks like there was a Denso 150lph pump installed. Don't know how long its been in use, but I'll be carting it around to races incase the new Walbro 190lph fails.

[1gAWD92]

nice ride. any updates for us yet?

[TheMadCheshire]

Potatoe, I know you havn't updated this in a while and I'm fairly certain you're busy at Empire State Performance Rally, but... anychance I can get a pick of the mounting of that roof vent? Been thinking about dropping one into the turd before the next rx event but havn't found many pictures of people using them in the 1gs.
Looks like you guys are 2nd in class atm. Good work! Now what is this evo about on your fb page?

[PotatoFlakeSTi]

Originally Posted by TheMadCheshire

Potatoe, I know you havn't updated this in a while and I'm fairly certain you're busy at Empire State Performance Rally, but... anychance I can get a pick of the mounting of that roof vent? Been thinking about dropping one into the turd before the next rx event but havn't found many pictures of people using them in the 1gs.
Looks like you guys are 2nd in class atm. Good work! Now what is this evo about on your fb page?

Hey!

Sure I'll get you a picture of the vent mounting later today, it's pretty straight forward.

We -WERE- 3rd in 2WD Overall, but politics got in the way and a VERY DESERVED penalty got waived for a certain someone. Got a trophy for 3rd Open 2wd Heavy, so that's cool!

Here's a picture;