DSM4LIFE-AWD JDM GSR-4 91 Build Thread

[DSM4LIFE-AWD]

Hey guys, here's my build thread. I forgot to post it here on Tuners so here we go. Let me time to update it it's almost done but I'd like to hear your opinion.

Here it goes

1991 JDM GSR-4 with 60 000Km for 4000$

Doesn't have any rust on it, compression was 150,150,150,155 on a cold engine with barely 1/8" of oil on the dip stick.

The night I bought the car, was such a special evening for me. I couldn't stop smilling

 

[DSM4LIFE-AWD]

Here's how it rolled for the first summer, that was 2 years ago

This on was on the interior side of the driver door so I removed it, but I think it's important information for us DSMer

 

[DSM4LIFE-AWD]

Cat back is installed, wasn't bolt on since the flange didn't line up at the cat ...

Made some bushing in 6061 for the driving shaft carrier.Well after copying a set from our vendor or on ebay, I've found that they aren't enough tick so THAT'S REALLY BAD. Here's the fix, solid 7mm tick spacer :tat:

Free mod since I was broke as hell, took 1 hour to find this crap since I guess it's a JDM and the wiring is different. So my chicklet was black and 2 prong instead of 3 and white ...

End of first summer

 

[DSM4LIFE-AWD]

Last year, here's how it started

Started on the first crank, smoked a bit from the exhaust but this car has always done that on a cold start up when humidity seems to be high !? Anyway it alway stop after it warms up. First time she get out of the garage since we needed to get some car out of storage.

Took 30 minutes and she was looking so much familiar to all of us :rofl:

Now the fun parts 2 weeks ago it was about 20*c outside when it's normaly 0*c so here's what I took out of my 1gb that 2literRiceEater gave me

Here the new set I grab for a steal at a JDM shop (the one I bought my GSR-4). Here's my new Volk Racing AV3 2 pieces 17x7 ET37. Paid 100$ for 4 wheels ! They where gray and too much sleeper for my taste so I powder coat them gold. I also repolish the lip, there was a damn ceramic clear coat on the lip so it took a good 2 hours by wheels to make them new. Still need to do one wheel, anyway I'll only have my special lug friday.

Before:

Now, the lip isn't repolish on this one. Now it shine like hell seriously :

 

[DSM4LIFE-AWD]

Time to update after 3 days of weekend

Here's the last wheel with the polish lip. Done it on a buffer with 4 stage of paste, shine like a mirror

Special lug nut for the Volk AV3, should receive my lock this week:

Here's my front roll stop in 6061 made by myself. See the hole ? Right diameter at the right place

Painted my VC last friday at the job during my brake

And here's my special 90* fitting for my sealed catch can on the pcv line:

I also installed an other catch can under the K&N (a GReddy one) ... Don't really have any pictures but you get the idea with the hoses and I think you can see it in a picture of my front roll stop.

 

[DSM4LIFE-AWD]

Crazy night yesterday, haven't really sleep this week yet ... But it looks like I'll roll in my GSR this week-end so I think it was worth it :rofl:

Crappy cell phone pics but it's all I have ...

Here's my ebay downpipe, I cutted the flange and welded a new pipe to remove the cat. Why buy one when I know that the flange won't align ... First time I ever try to weld a v-band.

And finally off the jack stand ready to get wheels alignment

Already got some updates,

About the twin sealed catch can setup I was planning to run, well it runs like crap ... When you remove the baffle, do not recirculate the pcv to the intake manifold or your engine will drink 1/2 liter of oil in less than 100km. I retap the VC to 1/4" NPT and ported the fitting to the max so now it's like a -08 AN setup. Now running the 2 hoses from the VC to a vented catch can and wow it idle like a champ. Best idle my car ever had and my piping will stay clean

No pics of the catch can for the moment ...

Going to do some work tonight. I need to finish my bracket for the rear sway bar. After that I'll turn the boost up to 15psi tonight to see how it goes.

 

[DSM4LIFE-AWD]

Yesterday I was bored so I decided to install my 2gen passenger Bride seat in my 1gen since I would have never sat in it. Haven't paid that much to let them take dust for so long ... :tat:

Made a road trip to see my uncle, he gave me a new windshield for my birthday

Pictures of last summer and some about the DIY rear AFCO camber kit.
Well don't buy the Afco metal to metal heims, buy some Aurora AM12-T. Here's how they look after 10K Km ...

I swapped them on the car in less than 30 minutes but haven't drive with them yet. This is a must if you have done this mod or you'll have a play in the wheels. Like a bad bearing and it will lead to vibration.

 

[DSM4LIFE-AWD]

Been rocking and scraping all around an Home Lip half summer long haha
It was fun but now it's gone. Being on the stock suspension didn't help at all ... I think it was looking decent for 0$

I found that kit while changing the hatch strut.

That's about it for last summer, just waxed it with Turtel Black Wax before storage and wow I should have tryed that stuff before. Shine like never before !

Here's why the home depot lip is gone. Got my alumalite pannel in stock

 

[DSM4LIFE-AWD]

A single Walbro 255lph hp will do for now
Rewire with 8ga has been done the first week I owned the car.

Needed more space for the new FMIC, got tired of trying to relocate the stock one after 30mimutes as I still wasn't happy ... JMF Deluxe Overflow FTW

Here's my new ETS 5" tick Race Core, yep 5" and it weight near 30-35lbs.
Dimension of the core without end tank is 12x25x5, forget about the bumper but fog might still fit.

Got the 3" In/Out and it's unpolished at this moment but will be in the next few days. I just didn't wanted to spend 200$ on polish since I can do it for 5$ ... This part is just, well it's just pure sex ! Welds looks awesome and you can see it's quality. Nothing like the shitty 3" ebay that weight max 5lbs ...

Special thanks to lilredeclipse for is help by telling me how to install that beast !
Don't have any picture of before but look at your car and you'll see what I cutted. Still isn't 100% done installing it since I need to weld bracket under it, remember it's 35ish lbs

Ho yeah and stock latch has been removed since I'll run the Afco scirocco rad.

Also removed the stock overflow bracket.

 

[DSM4LIFE-AWD]

Like I said after last summer my coolant was all brown looking like sh*t ... My old mechanic told me it wasn't oil if I didn't see any oil floating ...It was almost sand in the overflow ... I bought a Samco hoses kit and a new rad since there was build up in the stok one. Could feel it with my finger ...

Afco race radiator, custom top bracket and stock shifter base bushing on button tabs. Fits like a glove !

Now with no hood latch the "upper radiator support" wasn't strong enough for hood pins imo ... Now it's strong more than I tough it would make it. A simple stainless tube

Now the Aeroquip hood pins, what a PITA to install ! Maybe on a carbon hood it's different, maybe I decided to put them at the hardest place, maybe I didn't wanted to drill big holes under it ... What I want to say is that on a stock hood there's a skeleton frame and to fit the new plate to make the latch sits more flush it's a pain. I really like how they turned out, had to hack them a bit ...

Stock rubber still seal all the way

 

[DSM4LIFE-AWD]

Large polished B&M oil cooler FTW

I have the 90 oil filter housing also in stock wooot wooooot

Here's what I've done this week. I was already running zebay shifter end cable brass one but they where looses so I threw them away and made new one haha

Still waiting for all the poly I ordered, this one doesn't come in any kit so it just gave me a good reason to make a solid one.

Ok here, I wanted a Bulfab cross member but decided to keep my stock one since I like way more how my solid front roll stop fit. Now those one where really cool to build, I press all those bushing on my hydraulic press.

 

[DSM4LIFE-AWD]

Now here's my Afco radiator with 2 x 1/2NPT bungs and -16AN bungs

Here's the last set of Tein SuperStreet coilover sold in America. Yep there is no more you can buy haha sorry !

Now it was time to pull the engine for time and balance shaft job. Still isn't done since I spend so many hours cleaning ...

 

[DSM4LIFE-AWD]

Ready for clean up

My balance shaft bearing removal and installation tool

Boots to protect my new heims ...

New shifter end cable brass vushing installed, man they where a pain to press in with 0.002'' of fit. It's too much but hey now it works and they'll never move so it's a success.

Tested the crossmember with solid mount, perfect fit

Rear SwayBar Poly, custom bracket because I'm running Afco lower arm. Took me half an hour for 4 bolts since the car is on stand ... damn ... At least they are done !

Now this week I'll try to clean the engine for paint than I'll be ready to re-install timing and drop it in

 

[DSM4LIFE-AWD]

Here's a small update, not everything but it's something. Now the only thing holding me from finishing my timing is the damn crown plug. I almost cracked my oil pump housing trying to loose it, also tryed with the oem tool at the dealer since we're friends after all these years but no luck it slipped. Tomorow I'll try to weld a nut on it so I can try my 3/4'' impact on it and save 300$ ...

Tonight I'm lapping stuff, it's long and boring ... It's what we use in hydraulic to bring flange as straight as possible, with both flanges like that there would be no need of gasket to hold pressure. Decided to lap avery stuff I could, thermostat housing is done, tb elbow is done and tonight it's the exhaust manifold time

Flange Q45 to 1G, thanks Marco ! :tat:

I also decided to go no power steering and depower the rack. Got my torsion bar welded, can't wait to see how it handle !

Before it become an half moon it needs to be a full one, seriously I like this part. Fits like a glove on my head !

Modified my water pipe for AN

 

[DSM4LIFE-AWD]

And now my gift from Magnus Thanks again you guys rock ! :tat:

Here's an update, don't have any pics since I was to busy working last weekend ...

- Engine is painted, tranny cleared
- New OEM seals for axles and transfer case
- Timing is done but I lost the nut for the oil pump gear ...
- SS stud all around the head
- Retap the oil filter housing to accept NPT instead of BSPT
- Retap and plug the thermostat housing (waiting after an oem thermostat to finish)
- Brake booster painted
- ABS delete custom braided line and valve installed
- Poly installed in powder coated mount
- Poly installed in powder coated subframe
- New Moog ball joint installed in powder coated arm
- Rear SS braided line installed
- Done painting the knuckle since I didn't wanted to mess with the bearing this year
- Some other stuff I forget ...

Tonight I'm lapping the DNP manifold, seriously the flange was wrapped maybe 1/8'' ...
At least I build a setup so I can go to sleep while the machine do the work for me haha

 

[DSM4LIFE-AWD]

you can't imagine how much I'm working, I've been sleeping like 3 hours/day for weeks ...

Well story of my life things aren't going like I wanted. My friend who powder coat didn't wanted to do my last parts because he know I would have whine about the result. I don't know why but when he blasted my VC, well it was looking like sh*t under the stock paint ... Little holes that would have trap aire and make a bubble when cooking the powder coat. Spent a night sanding it, now it's ready for paint ...

Now the big f*cker. Let me tell you that the Magnus V3 intake looks rough, really rough ... I don't know what they looks like when powder coated by Magnus since no one post pic that near, maybe that's why they go with satin black cause it hide imperfection. Anyway it's cast so it's kind of normal ... You can see pin hole on top of my runners, well I didn't like that so I sanded it down for like 5 hours. Then we did a small coat of a special body filler good with powder coat. I sanded it last tuesday night than I did an other coat yesterday. I hope it looks good today, will see after work ...

I also remove the AC Evaporator and made some plates to block everything, I like how it turns out

Here's when we cooked the special body filler tuesday:

And here's a pic of it yesterday after the second coat before cook:

If there's no other pinhole showing my friend should finish them today, haha will see like I said story of my life

Et voila coating is done ! Woooooooot Woooooot

Now time to go to sleep

 

[DSM4LIFE-AWD]

Rad setup almost done, I forgot my temp switch at the shop ...

New tools for aluminum fittings and adapters. I like the large one better, got more size too ! found this on ebay

All OEM timing stuff + OEM gaskets, Gates belt, ARP cam bolts, ARP ss stud for thermostat housing, ARP ss studs for CAS, ss studs for exhaust manifold + cooper lock nuts, ss bolts water neck, custom machined brass washer for CAS, ss bolts for v3 ...

I also hooked my glow shit oil sensors ... Better than nothing to start my car, I can't afford the gauge serie I want at this moment :rofl:

 

[DSM4LIFE-AWD]

Small update, just finished eating and wanted to post what I'm doing

Battery box isn't on the right side, wire will point the exrerior of the car ...

Here's my dirty bay so far, got my Moroso thru firewall installed where the canister bracket was. I painted under the car up the front, brake master leaked oil. Paint was peeling when I was washing it

Anyway I wanted to paint the car so it'll be fine for now.

I saw that my clutch master was leaking on the inside when I was installing the brake booster so new clutch master and slave. OEM for sure !

Also got my flywheel step at 0.609", should be perfect !

Here we go turbo setup is on

7cm Ported Evo3 manifold wrapped + Ported Evo3 Turbo + Ported SS o2 housing

This is me pointing the turbo to show my honda's friends what will kill there K20 setup :tat:
Decided to run it waterless since I didn't wanted to bend my 14b line.

Modified the 2g Dynatek bracket to make it fit in my 1gen.

 

[DSM4LIFE-AWD]

Made some power steering lines' cap after work.

Here's a small update, Arc-2 is installed and wiring done. Done with the f*ing steering rack wich was the biggest pain. Done with the sway bar, everything is perfect.

I made a bracket for my calan catch can but my hose ends now hit the swaybar so I have to build a new one this evening ... Story of my life ...

Here's more pics than not enough, I would have like to saw those pics before installing mine ... Wiring for the Dynatek pass in the fender than in the car where the stock hood latch cable used to be.

Made the last brackets yesterday, there's like 1/4" clearance between the hood and the 180* hose end. Et voila how it'll looks, IC piping should clear I'm not THAT worryed :rofl:

Here we go, you can see my custom bracket in the front to lift the engine. Put it in without the crank pulley and fitting on the oil filter housing, it make things way easier





[URL=http://s383.photobucket.com/user/dsm4life-awd/media/GSR-4/null_zps458ff3ad.jpg.html]

 

[DSM4LIFE-AWD]

Here's what I did yesterday, looks stange with the flash but at least you can see something. Here's my 0 gauge water proof distribution :

I've bolt this crap behind the block don't know why but no pics at this moment ...

Almost done with the wiring, it's so f*ing boring that I felt a sleep on the couch in the garage yesterday ... I deleted the ABS and cruise wiring, was super easy compare to my 2gen. As usual I couldn't resist to do some wire tuck, I just relocate the things lower on the firewall untill I do my fusebox relocation.

It'll do for now since I really don't want to start something like that this year. I want to test my self exiting 160amp saturn alternator before deleting everything I don't need. I also want to start the car and jump to SD before messing with wires.

Here's a shot of the garage, you can see my 3 DSMs

The one in the back is Veronika, a 94 ES-T who will get some love this winter. 2LiterRiceEater gave it to me maybe 2 years ago, perfect shell only missing an engine and I have 3 spare waiting to build one








Only need to build a ground to my engine, tranny and starter. Still don't know if I'll do them in 0ga or 4ga wires ... I think I'll go with the 0 one

 

[DSM4LIFE-AWD]

Wire tuck is 90% complete, yesterday everything was connected without wire loom to get the lenght of injector wiring and things like that ...

Some-one have an idea where to hide the o2 sensor wiring ?

Magnus 1000hp fuel rail with 10 ORB ports, that's the old style one with FIC 1050cc FTW. Got a speedflow special tube adapter coming in the mail to exit the fuel rail without hitting the timing cover, coming from australia

What is this ?

Huh ?

Seems to taste good so they should get the job done :rofl:

Made those brass bushings since the one from jay are for stock pulley ... 0.445" driver side and 0.330" passenger side.

Riding the smallest pulley for this self exiting 160amp saturn alternator. JayRacing steel reloc kit. Lifetime waranty from motor city ! I called them and this is what he told me to run Glad he said this cause I've heard 200amp doesn't charge well at idle rpm or something like that ...

 

[DSM4LIFE-AWD]

Wiring 99% done ! WooooooT WooooooooT

Done some plumbing yesterday after working over time at the shop ... Feels like I want to die today so no work this evening ! Throttle is on also so I could figure out my hose ends ...

-08An from filter to rail, Earl
-10AN from vc to catchcan, Aeroquip
-04AN turbo oil feed line, Aeroquip
-04AN from intake to FPR, Aeroquip

Still waiting after my special tube adapter to connect the other side of the rail. I'll do it in -10AN even if it gets in with a -08AN. I'll redo all the fuel system with -10AN so this one will be final ...

I know this pic suck but it's the only one I have, was too tired yesterday ...

Done updating, feel free to comment now haha

 

[jjw205]

Wow, insanely clean and detailed build. Very tasteful setup.

Still on stock cams? Any plans on upgrading cams or turbo down the road?

 

[DSMnoobsause]

Very clean and love the attention to detail. where would I find a lapping machine like that?

 

[DSM4LIFE-AWD]

Wow, insanely clean and detailed build. Very tasteful setup.

Still on stock cams? Any plans on upgrading cams or turbo down the road?

Yep stock everything, I'll be shopping for a new turbo, manifold and internal this winter.

Big big turbo