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91 TSi AWD 400AWHP street/rally build

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jofe4

10+ Year Contributor
50
0
Mar 13, 2011
St. Peters, Missouri
It all starts with an ok looking 91 talon tsi awd that runs GREAT.
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So I buy the car. Drive it from North Adams, Mass. to here in St. Peters, Mo. with really no problems.

Start driving it around and start noticing the smell of fuel whenever I’m walking away from it. So I starting looking for a fuel leak figure out that it back by the tank and that the tank is leaking a little and all the fuel lines are rusted to hell!
So the next day I drive the car up to school at Ranken tech collage in st. Louis(33miles from my house to there) and it started missing on the way there. I pull the spark plugs and found that cylinders 2 and 4 were missing the porcelain. I also put new tires on the car that day as well as attempted to align it and found the rear adjustments were rusted and seized.

I drove it home and put new spark plugs in her (NGK platinum) and went to drive it to school the next day to attempt the alignment again and was getting on the highway and lost all power held boost and smoke was everywhere I pulled of the highway and she died...

Once I pulled over I popped the hood and there was oil and coolant everywhere!

My first guess was the head gasket went.... I was wrong................
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She leaned way out!
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So I've always seen car problems as a chance to upgrade! And upgrade I am!
Boring .020in over stock, full forged bottom end, new valves, 3in turbo back, tubular exhaust manifold, new fuel lines and tank, new rear suspension (cradle and all), repainting the roof, and assorted gauges the are very much needed, clutch CC stage 4, VRSF FMIC, and evo8 injectors till I get link.
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After .015” is boared ^

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old^
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new^
 
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Old gas tank^
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Will post more pictures and updates as they come.
 
What turbo will you be running?

I plan to a fp ball bearing of sort not sure how big yet. Right now stock td05 14b getting a new turbo will be one of the last things I do unless my 14b fails
 
Looks like a great start! What type of rally are you planning on doing and have you considered classes? That should always be taken into account before starting the build.
 
I plan on American rally once a year at the 100 AW rally in Salam MO in open class as well as scca rally cross in awd modified and scca solo 2 (auto cross) in SM which means I can do just about what ever I want LOL
 
Consider using a smaller turbo if you're going to be doing stage rally, since you will be running a 34mm restrictor (limiting you to around/under 300whp).

Who will be building the rollcage? Yourself?
 
You have a good point I just really want a ball bearing turbo and most ball bearings I have found been rather large

And i'll most likely have izzy's custom cages do it here in the st. Louis area
 
almost street ready
end up getting dsm link in march so here we go cant wait to get her out on the road
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will post a runing vid when the time comes
 
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