550whp 1990 AWD

[Mickey6]

So as the title says, my final goal is roughly 550AWHP on a 1990 GSX 5 speed manual. The car has 202,000 on the chassis and 120,000 on the engine with a freshly rebuilt head and some minor cosmetic exterior damage to the passenger side door and quarter panel. I got the car with a nasty idle surge and thanks to an air compressor narrowed it down to a leaky BISS, throttle body gaskets, and ebay waste gate. Theres various ebay and half assed parts on the car, but I suppose thats nature of the beast with a car as old as this one. I plan on running on pump gas, as E85 is sold at one gas station out of the way in these parts.

I've been reading and reading and compelling data and pretty much have the plan laid out finally. I do appreciate the vast knowledge on this forum and the very intelligent individuals that seem to grace the different topics.

So far I've started out with the basics. Changed all the fluids and checked all the belts, wiring, and vacuum lines. Spark plugs went after I ran some sea foam for good measure. As I go through I am replacing any worn stock components with performance related ones.

Now on to the "meat and potatoes", as they say.

Already on the car is a Thermal R&D cutback with an Apexi 3" Downpipe, some ghetto electronic boost gauge that reads 20psi....yes psi and not vacuum at idle. A home depot MBC, ACT Clutch (not sure what stage), ebay ghetto waste gate that leaks like a sieve, and an ebay 16g with tons of shaft play

I have a roadmap setup and roughly in the 13,000-15,000 range for a reliable 550-600hp car.
I've already spent a little over 4,000 on maintenance and procuring the parts listed below.

Like I stated above, after compiling a list, here are the parts that I have already purchased:

Forced Performance DSM Race Manifold
TIAL 38MM Wastegate
ECMLink V3(lite)
ETS Race FMIC with 3.5" core
TIAL Q BOV
1150cc FIC Injectors
-6 AN fuel tank to rail with Fuel Lab filter
-6 AN fuel rail return line with Fuel Lab FPR
Autometer mechanical boost gauge
Punishment Racing 02 housing
Calan catch can with necessary push lock lines for valve cover PCV delete.
Genuine 16g to suffice while I save for more parts
Autometer Electronic oil pressure gauge

For future parts I've compiled as follows:

JAM Stage 2, 2.0 block
Curt Brown ported head with Keegly Beehive springs and retainers
Kelford 272 cams
TMZ Stage 3 trans, cryo and shot peened
FP 4" Intake with welded bung for Valve Cover catch can vent
4 bolt diff with driveshaft shop axles and 4 bolt cups
twin disc clutch (still decided on brand for best setup)
Hx40 (hopefully 6 blade with a .55AR exhaust housing by BEP, as I'm not too worried to make huge numbers on a dyno, just something more street able)
All drain and supply lines necessary for hx40 (-4 supply and -12 return)
Speed Density Setup


I'm still up in the air for a good braking system as well....cause of course with all that power one would need to be able to bring it to a stop.
Also looking at replacing the stock beat up radiator with a mishimoto and two 12" slim fans. I don't honestly see the point in having crazy amounts of gauges b/c I'm not auto crossing or trying to set records, plus a data logger pics up multiple parameters .

I'll get pictures up tomorrow, as the ones I just took are pretty worthless in the fading light.

 

[dsmdeliveryboy]

Steer from the HX, I can point you in a better direction of a turbo for your goals with less modification to install. The list so far looks good though, looks like your on the right path and have been hitting the forums to see the best of the best. Good to see someone that still knows how to research haha.

 

[Mickey6]

Steer from the HX, I can point you in a better direction of a turbo for your goals with less modification to install. The list so far looks good though, looks like your on the right path and have been hitting the forums to see the best of the best. Good to see someone that still knows how to research haha.

What turbo would you suggest? The 6062? Thanks for the feedback . I thought everyone researched, haha. I spend half the time on the forums frying my brain with tech stuff.

 

[dsmdeliveryboy]

PM'ed

 

[canada4g63]

You can easy make 550whp off a HX40 +E85=your goal.

 

[BIGMIXX]

(outta the tech pages today myself).... very nice set up... looking to do about the same .. just at a slower rate. working on a 92... looking to refresh from the ground up. good luck, can't wait for pics. *subscribed*

 

[TSITurbo95]

Mod list looks good to me. Go with the holset, it's cheap and proven.

 

[slow91]

6262 is s very awesome street turbo man, i made 575@34 power band is very nice!!

 

[dsmdeliveryboy]

You can easy make 550whp off a HX40 +E85=your goal.

Yeah with a 6 blade, his is 8. Big difference.

 

[Archer Fabrications]

Yeah with a 6 blade, his is 8. Big difference.

it says right there... he is looking for a 6 blade HX40.

 

[TSimage]

Yeah with a 6 blade, his is 8. Big difference.

Doesn't matter because a 6/7 blade is a 6-700+ whp turbo. He can still easily achieve his goal with an 8 blade HX40.

 

[Archer Fabrications]

Doesn't matter because a 6/7 blade is a 6-700+ whp turbo. He can still easily achieve his goal with an 8 blade HX40.

OP's on the right track, let him get the 6 or 7 I just Bought up an HX40 Pro 7 blade from justin, hes shippin it out monday and im stoked! it sure as hell looks purdy anyway

 

[Mickey6]

Sorry its taken a few days to get these up. Went to test and tune last night and finally getting around. GOing to install the front mount today and look for a good place to mount the catch can.

As I said, its got some minor cosmetic damage, and in dire need of paint. I'm not trying to go all fancy on it and happy with the bone stock silver paint scheme.

^^ quarter panel and door are dinged up. looks like the door frame is bent.

^^Hood needs a good sand and paint

^^trim work on window seal is shot. prob just going to paint it, since it looks like you have to take the door completely apart to get to it.

^^The engine bay is extremely dirty so I'm going to degrease and wire tuck when I pull the engine and trans out.

^^ghetto ebay wastegate. Have the turbo housing off to drill and easy out a sheared bolt.

OP's on the right track, let him get the 6 or 7 I just Bought up an HX40 Pro 7 blade from justin, hes shippin it out monday and im stoked! it sure as hell looks purdy anyway

Totally sweet and I'll do say, I'm a bit jealous right now, haha. Did you get the Hx40 pro or stick with the normal compressor wheel?

 

[Mickey6]

Just got a few more parts in. Installed the FMIC and just have to trim up the bumper a bit. Also Installed the throttle body. Thanks to Justin for the Hx40 and Steve for the throttle body cleaning and seal replacement.

^^^ 6 blade Hx40 new to a can of V8.

^^^ Hx40 and throttle body

^^^ front view of FMIC

^^^ another FMIC view

^^^ bumper back on and just needs to be trimmed

 

[david9291]

You can get the door trim off with the door all together, just use a plastic trim tool to push it straight up and off.

 

[Mickey6]

You can get the door trim off with the door all together, just use a plastic trim tool to push it straight up and off.

I did not know that, thanks for the advice . Do you have to roll the window down as well to help take some pressure off it? I suppose google would be a good source to start with that.

 

[Mickey6]

After a long hiatus, I'm finally back to it again. Recent additions include:

1. Bought a 94 AWD transmission that was taken apart. I assembled it to be sent to Jacks for the 2.2HD rebuild.

2. Pulled the engine and transmission last weekend, along with the head.

3. Just received a DW300 fuel pump today along with my Ross 8.3:1 pistons and Eagle H-beam rods.

4. Put together the Hx40 drain line and welded a bung onto a spare oil pan.

This thursday I'm making the trip down to English Racing to have the block machined and head ported. While all of the machine work is being done I plan on doing a good wire tuck and getting rid of un-needed wires, as well as cleaning up the engine bay with a degreaser. This week I also plan on running the fuel lines and installing the new pump.

I'm also planning on ordering some Kelford 272 cams as well as new misc. hardware for the new front case, water pump, OFH, a Fluidampr harmonic damper, BR8ES (recessed plugs), new spark plug wires, and a transmission temp gauge.


Stripping down block

Head off of the car

Building the spare transmission

 

[Mickey6]

I know this is going pretty slow and the build is taking time, but I figure thats the way it needs to be. Do it once, and do it the right way.

Just ordered a whole slew of parts again and got an update from Myles at English Racing. So far they have been extremely helpful and definitely blew my mind when talking in depth about the build (thanks Aaron ).

We re-evaluated the build and the following parts are the "meat and potatoes" of the build.

Head:
New Seals
GSC S2 cams
Kiggly Springs
Kiggly HLA
Street Port
Magnus A1 headstuds
Cometic head gasket
Calan catch can

Bottom End:
Wiseco 1400HD .20 over
Eagle rods
ACL tri-metal bearings
Kiggly main girdle
ARP main studs

Turbo/Intercooler stuff:
Hx40 6-blade
-4AN feed line with restrictor
19mm drain line
16cm^2 twin scroll hotside
ETS "race" FMIC
ETS intercooler piping
TIAL BOV
JM Fab "race" intake manifold

Fuel:
DW300 in tank
Walbro 255HP inline
-6AN line from tank to rail with fuel lab filter
1150cc injectors
Fuel Lab FPR

Electronics:
DSM Link V3 full
Speed density
Autometer electric oil gauge
" " mechanical boost -30 to 45psi boost gauge
LC-1 wideband

Drivetrain:
Jacks 2.2HD
4 bolt conversion
South Bend SS Pressure Plate Combo w/ TZ/B-Series Disk
ACT Streetlite flywheel

Misc:

Mishimoto "race" radiator
A/C delete (who needs A/C in washington)??
Jay Racing alternator relocation
Full 3" turbo back exhaust
Redjack Racing divided T3 with twin 38mm MV-S wastegates (external dump)


So with all of this, we shall see what kind of magic the gentlemen at English can work up. Possibly move to a PT&E 6266 if the hx40 isn't wild enough.

Anyways, stay tuned for pictures and a thanks to anyone who has been following (new factory color paint job and rims update to come). - Mike

 

[Mickey6]

Few updated pictures. Removed sound deadening material (really pain in the a$$), also pulling out the steering column and clutch assembly to bust rust/paint. Wiring up the boost/oil pressure/wideband tomorrow and going to start assembling. Bought a 91-94 shift base and cables as well.

Mess on the driveway, washed the suby today too .

Sound material out and in process of pulling out pedal assembly

Before sound material was removed

I hope this might help anyone who wants to pull the dash out to show them how it is all put together. I have tons of other pictures and will put them up and write a full report as soon as I get this beast (soon to be) back together.

 

[xxNocturnalxx]

Awesome to see a local car being built, keep up the good work

 

[Mickey6]

Awesome to see a local car being built, keep up the good work

Thanks . Its good to see local guys around still that are into these cars.


More work and progress being made.
I got the engine harness out and working on stripping it down to only the essentials. Theres a lot of crazy wiring (wires looping back to other ones, and random crimps). Been reading more aboutt he plasti-dip and seems pretty legit for a sleeper car vs a 2k paint job. I bought a can of black today from the home depot just to see what it would look like....and i'll say, isnt very shabby at all.

Just pulled the engine harness out

Starting to separate the different groups of wiring, i.e. injectors with TB stuff, and coolant sensors. I'm going to bundle the groups together to make less of a headache of the engine bay.

Part before plasti-dip

After plasti-dip

More pictures to come in the next few weeks now that I'm in between quarters at school .

 

[907dsm]

If the holset isn't wild enough are you still going to try and run the t3 ts manifold?

 

[PotatoFlakeSTi]

Nice cars :]

With great taste, comes great responsibility.

 

[Mickey6]

If the holset isn't wild enough are you still going to try and run the t3 ts manifold?

I'll most likely switch over to a T4 manifold if the holset doesnt excite. The BW and PTE turbos I have seen are all divided T4. Should be pretty impressive to see what the divided holset housing holds.

Nice cars :]

With great taste, comes great responsibility.

Touche' sir! It looks as though you rally your DSM as well?

Tried some matte black plasti-dip just to see what it would look like on the car, and so far very impressed with it for as cheap as it is. Nothing beats 5.98 a can

Plasti-dip test run with 1/5 of the can

Finished arranging the wiring harness today. Planning on tucking it when I re-install the engine.
Got the MPI/MAF wiring on the far left, the coolant stuff is bottom center, and the injector connectors/resistor pack is on the far right.

Extra wires pulled out. Blue is cruise control, A/C compressor clutch wire is orange, and EGR wire is the one with the green tag.

I'm also expecting to get the block back from the machine shop in two weeks. They have been extremely backed up apparently. All coming together, slowly but surely!

 

[dkalfop]

Amazing build! I just put in a real 20g turbo opposed to eBay junk, but I wanted a holeset hx35. Your build is extensive. I'm excited to see what that hx 40 will do. All the hard work and especially the research on this site will pay off. Like you said do it right with the right parts once and you'll have a car that will last. So much eBay kaka out there and really think if you cheap out on parts it will cost you more in the future if not a catastrophic failure of some kind. I wanted to say how much these members have helped with questions and guidance they have given to you and everyone else. Keep at it and waiting for some more updates.