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95 GSX 6 year build journey

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bigal07

15+ Year Contributor
93
1
Aug 2, 2007
Fort Dodge, Iowa
This build has been going on for 6 years on and off now due to money, ambition and other projects i've done. At the beginning I didnt take many pictures and a lot of things have been changed through the years on my car so I will do the best I can.
A little about me. Currently I work as an industrial mechanic in Iowa, working half the week and making good money. I was a toyota mechanic for awhile and at that time the car didnt get much love since I was constantly broke.
The ultimate goal now for the car is to make 500-600 hp and run mid 10s down the track. Now from the beginning.
This is the car the day i bought it off ebay for $2500 with a grinding transmission and bad clutch
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The motor was completly stock. It just had the ugly body kit.
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This was summer 2007, in fall 2007 i bought my first big purchase. ACT 2900 clutch, fidanza flywheel, 1g big rods, and an evo3 16g.
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I installed the turbo on and drove it for a few months until the stock clutch sarted slipping so we put the ACT in and ran into problems. Crankwalk. The flywheel could be moved about an 1/8 of an inch so it was pretty close to junk. Time to put the stroker in.
Put in 2.3 stroker with mitsu crank, eagle rods, and wiseco pistons. At the same time i got ecmlink, brian crower 272's, fidanza cam gears, PTE 880cc injectors, greddy xl intercooler, tubular manifold, ebay bov, greddy profec spec b and other small upgraded
These pics are when I lived in Chicago building the motor in 2008.
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After this I moved back to Iowa and started to drive the car again after being down for a few months. Driving around doing logs I went half throttle at 10 psi and got 325 hp out of it. I decided to take it under the knife again and get a bigger turbo. Decided on a hx40 with mitsu housing.
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The old evo3 and hx40
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Went to a Tial 38mm external wastegate, MAF translator, and got a aeromotive afpr, and aem uego
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About this time (fall 2008) i also put 2gb from and rear bumpers on it.
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Now for the major downtime. I got my current job and moved to a new house and decided it was finally time to paint the car black. Engine bay and all jams would be matched and all body work.
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That was how the car sat for a little over 2 years as i worked on other projects like a bobber, dune buggy, snowmobiles and wasting money on fun stuff.

Spring 2012 i started working on it again. Filled holes in engine bay, fixed frame damage from previous owner, which i lost all the pictures of the finished product. And filled holes for 2gb spoiler.
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In May she started getting the paint. Went with a black called Nighthawk Black, its black with blue flake, pictures dont do it justice in the sun. My old evo3 was payment to a buddy to spray it for me as i helped with what i could.
Everything except paint.
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Now for the fun that was a 18 hour day.
 
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After we primed and sanded it was time for some color.
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This is the best picture i had of the color
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After this i changed the turbo set up to a t4 hotside and learned how to tig weld. This was summer and i started to buy a house so the car got put on hold again till the last few months. Now im going to be running e85 and doing head work and some other modifications i'll say later.
I also bought a t4 divided manifold.
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Started with making the exhaust from scratch
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I wanted a little something to make the car more fun so got an exhaust cutout to go out the front bumper and still have full 3" exhaust.
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This is the bumper exit with a plate bolted to the bumper.
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Made dump tubes for both wastegates which are kind of hard to see.
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I finally got all the body panels on except the front is back off now.
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Ran -06 AN lines and intank and inline walbro 255s
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Put battery in trunk and wired both pumps
Got a used shepard stage 3 tranny with welded center diff
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Relocated fuse box to air bag compartment and did a wire tuck, dont have finished pictures of this since i just got it done a few days ago
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Got a cheap set of 15" wheels from a friend that will be powdercoated black
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This is how the car sits right now. This week i plan on getting the fuel filter mounted, fuel pump hanger back in and pulling the head off to get sent out to get stage 3 build from dsmgraveyard.
The only things left before its ready to go are head rebuild, going with Kelford 272's, Tial bov, catchcan set up, 1g radiator, manual boost controller instead of greddy profec, alternator relocate kit, Hoosier DOT slicks and a tune.

Any suggestions to help me meet my goal are great and i will answer any questions. This car will get running and down the track... Eventually. Heck ive only got to drive my baby 300 miles in the last 4 years.
 
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Got the head off today. Sending it out to dsm graveyard for stage 3 build. Manley valves, Manly springs, titanium retainers, 5 angle valve job, stage 2 port, bead blasted
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Heres a few pics of the finished wire tuck running along the frame rails
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Holy smokes. I just read through that review. I cant say I will ever buy even the smallest part from them.
 
First things first. That job you did on the downpipe / cutout is absolutely amazing. I had an idea similiar to this not too long ago, and I really don't think I could have ever made it as nice as you did. Props for that.
Secondly, who made that exhaust mani for you? That thing is sexy looking!
Last but not least, did you ever try out that Ebay BOV? If so, was it garbage? Or did it do it's job?

Very nice car, and looks like your buddy earned that evo.
 
Thanks a lot! The exhaust was fun to build but it took about 3 days to fab and finish weld an get the side exit to fit right. Redjack racing made the manifold for me and it is great. I had the ebay bov on it for a long time and worked fine, just need to upgrade now. The paint looks great, like I said the pictures dont do it justice. I hate doing body work but it was well worth it in the end.
 
Got the head sent out today to Built Industries, I talked a lot with Mike Huml and he was a great help with choosing what I needed. I'm glad I talked to him also since he made be a better deal than what their internet price was. The set up I went with is their STG 1 port, 5 angle valve job, manley valves and springs, titanium retainers, and revised lifters. Going to be about 3 weeks before I get it back. Meanwhile I have some garage cleaning and next week there will be some pretty powdercoated parts!
 
Can you show pics of the fuse box relocation? I am much Interested in getting that ugly box out!
 
Heres how I did the fuse box relocate. You have to unplug everything out of the hole behind the drivers fender to get it all out. After that we took all the conduit off an took out abs, srs, and foglight wires. Rerouting the wires for the headlights was the worst part, i had to lengthen the pass headlight, coolant jug, and cut a few to get them out of the main harness. The actual bulb wires for the pass headlight I ran in the radiator support. When I took out the airbag I ha to cut out a lot of the plastic in there to get the fuse box to fit. Heres a few pics, ask if you'd like any others. The wiring pics are in some previous pics
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Did some stuff to the car recently, I was waiting to get the head back to get anything done. I bought my own powdercoating gun so did a little bit of that and got the head back
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Got a few things powdercoated black, will be doing some blue next week
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Havent updated in awhile, got a lo of stuff done on the car. Got all my blue powdercoated except valve cover.
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Got the motor fully assembled and back in the car for hopefully the last time
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Tried to start the car up and wasnt getting spark on 1&4. After chasing wiring around an trying different coils, ignitors and checking voltage I found a broken wire in the harness but she fired right up. I have a video but im not sure how to upload it if someone wants to help. I dont have a youtube account. I also picked up a COP setup and rewired that and removed the old coil pack and moved the ignitor and tucked some wires to clean it up a bit
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And just for fun I put on the rest of the front end. The carbon fiber hood needs some work but the end is in sight!
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Just a quick update. Got a 60mm BBK throttlebody for free so put that on. Got the thermostat housing on and coolant lines ran.
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Had to get a new cv boot and axle seal for the left side, but of course the parts store gave me the wrong seal so i had to order it online. Also put 2 o2 sensor bungs in the exhaust for my wideband and front o2
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I made the last large parts purchase this week too. Kelford 272's, Tial Q 50mm, and a used 1g mishimoto radiator and slim fan will be here wednesday. Last thing to get it running was a catch can from calan but its going to be 4-6 weeks before I get it so i'll have to improvise until then. So this thursday or friday i'm hopefully going to get it on the road for break-in!!!
 
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Well haven't had an update in awhile so this has what has been going on.
I got my last big parts purchase in, got the radiator and new Kelfords in so the motor is all done.
Heres the motor with everything together and powdercoated
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I also got it all washed up
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The car is running and loping very hard and sounds great with the new Kelfords but the idle jumps from around 1100-1400 now. I have a few videos on my phone but it wont let me post from it if someone wants to help me with that.

All that is left now is wire up the radiator fan, bleed and adjust the clutch, and new passenger axle seal to drive it.

I also picked up some FIC 1650cc injectors for after break in to flow plenty of e85!
 
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