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turning scrap metal back into a 95 talon tsi

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PROGRESS!~

only 1 pic but at this point i aint doing anything special yet. and a rundown of parts and their issues.


fidanza light weight flywheel installed. (ordered for my 6 bolt GSX, recieved a 7 bolt GST flywheel.)
clutchnet street disc (recieved 2, i have tried for 3 months to contact clutchnet, leaving voicemails, emails, etc.)
felpro rear main seal. (original seems to be for a 420a, ordered for a gst)
i ordered several aftermarket gauges (ordered sunpro round boost vac gauge, received 3 pot volt, oil temp, water temp gauge)
(ordered sunpro round volt gauge, received sunpro dash mountable flat on one side volt gauge)
i will post others as i remember, i know there was more

as for the motor install, originally i forgot it was a gsx motor and did not swap the starter alignment plate. had to pull trans and swap plate. motor was still on the cherry picker so this only lost me maybe 30 minutes.

everything else went good. went from motor on stand still needing oil pan, rear main, clutch, and trans hooked on. to motor sitting on its mounts in the car in about 8 hours casual work.
 

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my sticky notes are getting away from me so this is just a quick blast of what will be 'stage 2'. meaning after it fires and drives.

carpet
95-99 Mitsubishi Eclipse Carpet GST or GS Coupe Complete Kit 1995, 1996, 1997, 1998, 1999
intake piping, intercooler (havent decided front or side mount, have some ideas on both)
exhaust (3" down pipe, dynomax bullet in place of cat, probably no muffler or a viper if i find one used)
needs all new suspension and bushings, (energy master kit and KYB )
at some point it will also get a stereo install, nothing too fancy but no walmart or best buy crap either.

feel free to post suggestions on things that i have missed or things that you could do better/cheaper.
 
got a couple more hours in on it over sunday. just need radiator, fluids, battery, intake tubing and i should be able to test fire it. provided that goes well i will mount the front drive parts and start cruising it around. then in the summer i will start on the limited mods. most of the modding will be based on the fact that stuff just needs replaced because its old and rotten and that is a good time to upgrade things.
 
so close to firing it up... spent more time looking for lost bolts and brackets then working on it. and theres some temporary ghetto patches here and there. but what DSM doesnt have bailing wire somewhere?

i did headstuds and cleaned the crap out of the valve cover. the 14b didnt fit as nicely with the stock intake tubing as i would have liked so i used some leftovers from my 1g front mount install. provided it runs for any length of time the intake will get swapped to a vrsf kit so it just has to work for now.
 

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IT LIVES!!!! *insert Frankenstein laugh*

initially i sat in the drivers seat and turned the key over.... and nothing happened. no starter..just nothing. jumped the starter relay under where the console should be... bam, starter cranks.

no fuel. poking around checking my connections on the top of the pump, under the hood. finally try the fuel pump test connector and get nothing there. left the wire connected to the test connector while im looking for my ratchet, suddenly hear BZZZZZRRRRRRRRRR... so i unhook the wire. theory here is the stock pump relay was seized up and it worked itself loose. it has been working since. i do have the stuff to do a rewire also but the rewire isnt done yet.

hit the key, kinda tries to fire up sounds like it is hitting on maybe 2 cylinders. figure one of the coils is shot. pull plugs individually and check for spark and they all spark good. i notice that plug 1 is bone dry though. swap the injector with a different one. 33rd times the charm? turn the key and its definitely trying harder, let it rest for fear of the other cylinders being fuel soaked, and i hook up the battery charger. o.k. here we go.... key.... rumbles and clatter to life.

1 lifter is ticking... ticking is an understatement, and its odd that its literally just one. but the engine sat on the dirt in a field next to the car for years. and basically none of the sensors work, the cluster is lit up light a christmas tree with things that the ECU is concerned about.

BUT IT RUNS!!!

now the long road of making it driveable.

i promise i will actually take some pictures when i get to the interior and body stuff.


last time car was registered (JUN 2000)
 

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most of my friends think i am flat out crazy. 99% of the time a vehicle that i seriously WANT is not one that could be driven home. most of the time my friends are like "DUDE! this one comes with an ENGINE...SCORE!" in their sarcastic WTF are you doing now tone. luckily for my wife MOST of the time i do motorcycles. i can strip a crotch rocket to the frame, have it half cleaned, powder coated and going back together in a weekend. cars...especially mitsubishis out here in cattle country...not so much.

not car related but some of my other current builds. LTC mining rig. then the one on the floor is my soon to be deployed 16TB virtual host and ZFS storage SAN. the one in the rack is my current 6.5 TB raid 5 array in use, with 1500KVA UPS. this stuff runs my house, media serving, web based uploading and downloading, gateway to network management.

also i am upgrading our XBMC front ends from the random homemade boxes i have deployed on all the TVs in the house to these
Newegg.com - Foxconn Brazos AT-5570 AMD A45
i ordered 1 and tested it to make sure it works the way i want so i will be ordering 4 more next week. streaming media FTW!
 

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busted arse this weekend got the front end back under it, clutch master in. backed out of the garage under its own power. was going to cruise around the block but backed out into the street right in front of a cop...with the jun 2000 tag still on the back. i just calmly pulled back into the driveway and got out like i new what i was doing.

ive got a couple bad sensors for the coolant. and im getting a SES light. will hook up a scan tool soon and start some trobleshooting. still a long road but progress has been made.
 

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sad pictures of unibody. this poor thing was picked up with fork lifts and front end loaders. you can even see a bend in the exhaust. the car itself is not tweaked, i have always known the floorboards were bent in pretty good. just one more thing to repair.

im going to get interior (lack there of) pics and start on the assembly and dash repair soonish.
 

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flushed and did a po'man injector rebuild. i think i have the running part worked out, there are a couple of bad sensors, and a rattle n the front suspension that concerns me. but some interesting things i think are coming soon. in theory i am getting new carpet for xmas. i also have plans for a pretty crazy custom stereo built around a stock modded head unit out of a late model mitsubishi. (people keep braking in and stealing my crap so the head unit will look stock) and maybe even exterior paint this coming summer.

interior and functionality fixes coming. i found a vendor for spray on vinyl also so the dash repair is on my list some year.
 
po'mans injector rebuild guide. (i know there are injector cleaning guides but heres my way.)

pic 1. ordinary injector
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pic2. pry out filter basket with small scraper
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pic 3. pry out filter brass retainer with same small scraper
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pic 4. open injector (i used a dremel with a plastic brush bit on the inside of the injector just to polish it a bit)
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pic 5. use aircompressor with rubber nozzle to test if injector leaks
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pic 6. bottom of injector
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pic 7. slide scrap fuel line over bottom of injector (needs to be tight with good seal)
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pic 8. use small AC adapter (3 volt half amp worked well) to activate injector
IMG_20141125_193902.jpg
pic 9. fill fuel line attached to injector with solvent while injector is open and use air compressor to push solvent backwards through the injector, a couple times is good. then i put hair forwards through the injector to get all the solvent out.
IMG_20141125_193937.jpg
use a bench vise and a couple of rags to gently press the new filter basket back into the flushed injector. kits are available that come with all the seals and a new injector basket. out of the 8 injectors i had, i found 1 that leaked, 1 that wouldnt open and 1 that leaked and wouldnt open. i stopped when i got to 4 that were in good condition so i still have 1 untested injector. do not bother trying to do this with the filter basket in place. its design makes it almost impossible to run fluid backwards through an injector. if you have a good air compressor you might want to back the psi down to around 80psi.

i also got a factory 2005 lancer head unit from an infinity system. stereo rewire with amp to come fairly soon. (debating on using factory amp harness, i do not think i will as i am putting in some sound quality pieces and the stock low voltage wiring is unshielded.)
 
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goodies

yes i will be using a stock mitsubishi deck. it is out of an 05 and it is the infinity version so it has preouts to go direct to a AMP. there will be the 2 coaxials and a small hidden sub. probably an 8". these infinity decks actually have amazing sound quality, and this entire system will be extremely stealth visually. and i will be adding a GROM USB device that runs through the CD changer port for USB, MP3, and Bluetooth support. yes, i am spending way more $ on this then what a cheap walmart sony deck would cost for the same functions. BUT this system will actually sound better and look bone stock.
 

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crappy picture but new windshield.

i finally pulled the original motor apart too. typical thrown timing belt at 143,000 miles of abuse. but the original owner actually spent the time and money to change the head and belt. BUT the poor guy used all the wrong gaskets from the throttle body, intake and exhaust, and even the head it looks like. (all 1g gaskets installed on a 2g) judging by the blow by on the exhaust manifold they actually spent some time trying to get it fired up. it probably never actually started just from all the leaky gaskets, or might have started and barely ran. so at that point they parked it and it sat for the rest of its life. not sure whats more sad, that it unlovingly got abandoned, or that they spent the time and effort to change a head and got beat by the teenage kid at the parts store selling them the wrong year gasket kit.
 

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short shifter stock shifter mod

i took the stock shifter, tapped an extra 1.5 inches of thread, caut about 1.5 inches off the top. then i moved on too changing the length of the cable attachment at the bottom. i tried about 5 different times ranging from shorter then stock to way too much longer then stock. the pic on the blue chair shows the shorter (it was terrible do not go shorter on the cable side). the close up shows the final resting place. it is only about 1/4th inch longer than stock. kind of a pain to weld that small of a chunk into, and my wire feed really was not set up for this small of a project.

anyway if all you did was thread the top and cut an inch of thread off it would be a very worth while mod by itself.
 

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got 17" wheels back from powder coat shop. they look good considering one of them was broken and i had to weld the crack shut after i beat it back into a round shape. 300$ for powder coat, i dont think i paid anything for the broken set of wheels but if i did it was not much.

and an interior shot. carpet is partially installed and working on stereo with aftermarket amp wired into factory location. MMATS amp, MMATS 5.25" coaxials in doors, and a dayton 8" woofer in hatch. and a JVC media deck, no cd or anything just usb and bluetooth.

car electrical got some new ground wires added but really its in good shape, cruise works, heater works now, i got all of the vent flaps and cables for the hvac stuff moving again, and got the rest of the dead mouse innards and poop scrubbed out of the dryer, blower motor, and ducting (i think.) the wiper motors all work, heck even the washer fluid pump works, tank does not leak. overall its been in good condition. i did have to replace the drivers side door lock actuator. and the passenger side is quite slow so i will replace it too. (with universal ones via some information here on the forums. the process works well and if you take your time it does not look like a ghetto hack job)

when i get the carpet and radio finished i will charge the A/C system and start trouble shooting it. the compressor looks like it has been changed once and the system actually had a tiny bit of pressure in it when i tore it apart so i am hoping all it needs is flushed and charged.

ive actually driven the car quite a bit, boost on the 14b is set at waste gate and holds solid at 8psi. when it spools it just obliterates the stock sized crappy tires. so when i get around to putting the new wheels and tires on i will bump the boost to 16psi. that will be the max i ever run on this car as this is to be my DD. the AWD 1g with the 16g will be the racecar. it was pushing 30psi when i parked it.

so standing projects are
finish interior/stereo/door lock actuator.
charge and test A/C (its about to be summer here)
then keyfobs would be nice. the car has the security system.
and somewhere in between that stuff will be get tires for the wheels and put them on the car.
 

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interior is in, stereo is in, small sub, components, amp.
all the weight made the car noticeably slower so i broke down and stuck the crappy MBC i had laying around on. it really ended up having 2 modes, not closed or not opened. so i pulled it apart and and crushed the spring with some pliers and managed to get it to function at 16psi. i need to get some more pics uploaded. i need to pull the headliner still too. but im about to move on to body work. (still have not got tires for the 17s either.)
 
MBC installed and running 16psi. stock intercooler needs to be dealt with. time to start the uber top secrete side mount upgrade project i guess. if this works out like i hope, it will open up some side mount aftermarket options for DSM guys that want to keep the stock theme going. the base intercooler i am going to start with should keep intake temps down all the way up through 20psi. but the real benefit comes in because once the build and fitment is mocked up, the donor vehicle has several options for aftermarket upgraded stock fitment sidemounts available. we are talking easy install hidden side mount intercoolers good to 30+psi and 400+hp. (not that my goals are anywhere near that high, but i like having options available.)

needless to say, this will not be some ghetto supra intercooler mod.
 
just realized i have done zero interior pics. heres a couple. i did end up using an aftermarket head unit, i found a JVC KD-X310bt on sale for 49$. at that price it was cheaper than the bluetooth module i was going to put in for the stock mitsubishi head unit i have.

cigarette lighter was lost in the cleaning so i put a USB socket in its place. i did mess up one small corner of the aftermarket carpet but i doubt anyone will ever see it. and i have not repaired the crack in the dash yet.

the stereo has a 4 channel amp, there are coaxials in the door and a small 8" sub in the hatch. all speakers are ran off the amp. the dash speakers are disabled and the rear 6x9 speakers are removed. however this is all professional audio equipment, the coaxials alone probably cost more than most people have in their entire system.

also i did use a small section of the stock wiring but i hid my crossovers in the doors for the coaxials and i managed to keep each section of audio cables under 6 feet, to each section or device. (it helps that this car is tiny) the head unit itself is not technically a SoundQuality component but i am not using its built in amp so that again eliminates a normally crappy sounding component in car audio.

both door panels had the handle screw cups broken out so i put a slightly longer screw in and filled in around the screw with a semi-hard epoxy to prevent any future damage. for a car that is nearing classic plates status the inside does not look too bad. and other than the bash mark in the hood and the bottom of the front bumper being broken off the outside is not in terrible shape.

i will probably replace the front bumper while working on the intercooler mods. more to come.

OH AND MOST IMPORTANTLY THE AIR CONDITIONING WORKS!!!!!
 

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