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DSM4LIFE-AWD JDM GSR-4 91 Build Thread

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Time to post some pics :)

Rear GoodRidge brakes lines :
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Plate to block the abs hole :
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Here's last weekend update:
This is what I found this morning ...

FUUUCCCKKK !
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I knew the boost was pushing a bit but never tought the wideband too ... It was cold this morning in the garage in f*ucking canada where winter never ends. Clear cover was just prying a bit since I finished last week but looking sweet ! I toutched it than it started: tik tik tik ... TAK a big nice crack right in the middle ...

Don't know what I'll do. Maybe run the cluster without the cover untill I can afford the other gauges I would need ... Got a spare clear cover that I could shim and kind of glue around if that makes sense ...

Update from yesterday:
Here's what I installed today, polished for now but I'll paint it black this summer.

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Overkill Fabrication bumper kit installed but still need a bit of adjustment ...
 
Gotta get some made and i will summer is near and mines is coming together every week, ways to go but im about 95 percent done for the year.
 
This is probably the coolest 1G build I have seen. Your attention to detail is amazing!
 
Can't believe I never updated my build here ...

4 bolts axle done rebuilding with new greace and boots.
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Old bearings and seals out of rear wheel hub/shaft :
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New goodies installed, I removed the ABS ring for weight saving (1/4lbs) :rofl: :)
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I know it's not a big update but it's something I want to keep in my build.

The 2 bolts on the diff cover broke when I tryed to remove the mustache bar. Got one out after some work and welds but the other broke 2 other times ... Decided to give up when I remembered that I might have a spare one.

Indeed the all 1gen diff cover are the same. Took 2 minutes to get my spare one off. Didn't knew what I would find since there was some little metal rocks on the magnet in my lsd diff. I don't know if it's the cold that made this to the shockproof oil but it was more like greace than oil ... I also found a little spring where the axle goes in. It doesn't come from the diff that's what made me wanting to invetigate a little more. Here are pictures to show the vent in the cover and the difference between open and lsd 1gen rear diff.

My open diff was like new after two summer. Nothing on the magnet :)
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Now the lsd one, it's a different housing I'm not swaping parts ...
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Here you can see why it's a good idea to add the deburing option on a tranny or diff or x-case ...
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Brake cleaner wasn't really cleaning anything so I used diesel fuel than rince with brake cleaner.
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The only thing I've found while looking for damage ...
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LSD back in, should get my cover from the powder coat tomorrow after work :D
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Here's a small update of what I worked on yesterday ...

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I need to buy a TIG this week ... Getting sick of waiting for my welder ...

And yes I'll trim the rod of the FlameRiver big cut off switch, you can already see a black line. It's made with a shaft and not a tube so I'll modify on the lathe this evening.
 
Worked on the wiring yesterday ... Still not done, man it's boring I hate wiring so much ...

Now the good news, I love my kill switch rod. Looks badass as hell :D

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BOUM ! :)

Lincoln Precision TiG 185
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The only welds I've done on this car are the stich on the subframe. This morning I'm practicing with my TiG to get this sh*t done LOL ;)

Here's what I did yesterday:
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Bouya :)

After 5 hours of praticing back:
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Dump tube completed :D

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Just need to add a support bracket and cut the exit at the right angle ...

Now I needed an other 1/0 wire for the alternator and the kill switch. I always use bulkhead connector so here we go :)
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And one for the postive jumper post:
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The new alternator wire:
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Had to grind behind this bracket to make enough space for the wire. The abs ecu and wires are also gone. Had to unpin some at the front, was a piece of cake after the 2gen ...
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Distribution block for the front:
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Igor always there:
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It's almost 1am here and I'm finally ready for powder coat. Decided to pull the trigger and weld the control arm. Truck is full of parts that I need to go unload in my friend's car ... It was about time if you ask me ... ;)

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Got my parts back from powder coat. :)

My friend forgot to plug the ball joint holes and some fume went where the bearings goes ... Damn I've been cleaning it with some paint stripper since yesterday evening ... Got one done so far ... At the price he charge me I can't say anything but I'm getting tired wasting my time because of other's errors ...

Anyway it's saturday so lets be happy :D Here's a teasing:
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Now today is my best friend' birthday and there's a surprise party. I told his wife that I'll be there but the thing is that I'll only be thinking about my parts ... Life's a bi*** LOL
 
Man it was long cleaning while taking care but I'm happy because it's done :D
I guess it was good memories ;)

Here's what I'm staring with this evening:
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This week I have no help at the garage so it took some time to bolt it back up alone yesterday ... My dog Igor wasn't really in the mood for helping :rofl: Anyway no scratch nor nothing so I'm happy :)

I gave RTM Racing a call about some protective boots for the JayRacing heims but up to now the supplier want way to much for shipping so it's on hold. He'll find something it's just a matter of time ...

I also need to buy new brackets that hold the parking brake cable on the subframe, will see if I can find some ...

Now here's a picture, I know quality suck but it's all I have:
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Found some energy to work yesterday evening after 12 hours at the shop ... Getting used again of sleeping 4hours/night. Nothing is free in this world ...

Decided to not put back the rear brake dust shield, the front one are gone too ... Bearings and everything assemble:
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Putted clear where it's shinny and on the heim to be sure that I don't start to rust ...
 
Haven't found any other way yet ... ;)

Trailing arm, upper and lower arms are on. Rear bumper + cover is on and adjusted. 0ga wire for battery jumper are installed. SS bolts everywhere I could. 0ga done in the trunk, interior installed back in ...

This is just a teaser since my phone was dead as usual when I finished.
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Now it looks way better than this pic but this is all I have ... I was trying to find a way so it doesn't looks like a mess ...
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Started welding my IC piping, should finish tomorow evening ...

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An other day an other pay ;)

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2 days ago I tryed to weld the brackets on the IC ... The breaker was popoing after 15ish sec. 40amp wasn't enough to weld it but at least it was enough spot welded in place. I went to see my welder yesterday and he was getting angry like I never seen before. How do you think you could keep a good temp on an aire cooler ... Anyway he did it for free because he wasn't happy with the result but I think it looks good and it's perfect for the job. ;)

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Now the piece of cake, so big and so light it's incredible :D
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I installed my transfer case Magnus cover without shimming the gears. It was just to modify my downpipe. It's an ebay one that i got for 80$ shipped. Even out of the box it wasn't perfect. It was hitting the stock transfer case cover a bit but worked for 1 summer. Decided to cut it and route it better, took a complete day of work, at least 100 swears and a pack of smoke but it's done. It's perfect and fits with my 3.5" driveshaft. Wideband bung is already added but no pics ...

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I also insalled my oil and water gauge's sensor. Wires are all hide in the stock harness. Damn I'm slow when it comes to wiring ... Anyway I need to pull back out the driveshaft and bring it to a shop to be sure that it's balance when assembled. I have to learn how to proprely shim a transfercase ... All things that I would have pass my turn.
 
Yesterday I started to rebuild my driveshaft, it was super easy but I manage to hit myself right on the nose while pulling the first cap off the u-joint. I than started to bleed like crazy LOL ...

I don't know why I putted my face right where I was pulling but it would have make a cool video ... ;) I'm lucky I have no black eye today, my nose still hurt every breath I take even if I only have a small cut on the outside.

I think it still straight but it's bigger :rofl:

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Buying a TiG is probally the best move I've done so far ... Already saved me a bunch of money ... The day I'll build a top mount exhaust manifold, that bi*** will be paid :rofl:

Worked a bit on the car last week-end, I ordered the yoke kit from mitsubishi because you can get a stock u-joint for 50$ + a stock yoke instead of 125$ for only the u-joint. I disassemble it last friday than installed it on my new unit. For 75$, 15 minutes of work is worth it ! I also pressed a new bearing carrier. You need to phase the drive shaft before assembling it !!! Took me something like 7 or 8 try to get all the yoke align because of the splines and loblro joint.

Now I let the drive shaft at a shop named Mr. DriveShaft. He's one of my customer and said he would balance it perfect for 50$ so that's where I putted the saved money on the u-joint LOL.

It'll be ready tomorow, now I need to mess with the Magnus TC cover. It hits the oil pan just a bit (Marco also said it could happen) ... Don't know if I'll dent the pan or grind the cover, will see how I feel toninght LOL

Then it's just shimming the TC and I'll be almost done :tat:

Not much but here's something new to show :)
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BouYa :D

Took 20 minutes ... Now try to do yours LOL ;)
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Just turned the key on ! Everything seems to be working, no fire so it's good :)

Switched fuse block for gauges and acc.
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I tryed to shim the TC during 2 evenings and still not so sure ... Damn ... :(

There's still oil on the top of my transmission ... I don't know where it's coming from. Looks more like motor oil than transmission (tranny is out of oil). It can't really comes from the CAS as I see no oil there. It's right after the bell housing on the joint when you split the transmission appart. I think I'll try to isolate that spot to investigate ... I wipe it, 2 days later it's there. I putted 1qts in the engine before putting the vc on and it's been there since last summer ...

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Plugs Bpr7es 0.028", heavy weight Shockproof oil in rear diff everything torque to spec. Stock cold air installed back with MAF, temp catch can setup. SS 4an line for bov and boost controler done. Inner fender back on. Just need some other little stuff, should be done this evening :D

I found a guy who wants to teach me how to shim the TC. Will see how it turn out since it's the last "big thing" that needs to be done.

Wrapped the dump and added a gusset to give it a chance. It still needs to dry so I can paint it ...
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BouYaa
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Temporary catch can hose and intake pipe before I switch to SD.
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New o-ring for the CAS since the stock one cracked when I removed the cap ... It's not exactly like the stock one but I'm pretty sure it'll get the job done and it's already installed.
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First road test yesterday ! :)

The car really needs an alignment ... I hope the steering get better because it's special with the depower mod but I'm sure I'll like it.

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Alignment time :)

Guys here love my car haha they started working 30 minutes late LOL
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Ok the 1gen is back in the garage. I was hoping to switch to SD in one evening but I started with a boost leak test. I'm still trying to fix that leak 3 days later ... At first it was leaking between the intake and adaptor flange. Between adaptor flange and throttle and the elbow !? OEM gaskets everywhere except on the intake ... As you can see in the pic, the threads for the 1gen TB interfere with the chamfer of the adaptor plate. That's where the leak was coming from. Really stupid design from Magnus is you ask me ...

Putted some rtv in the threads and only used rtv as seal. It worked but the throttle was now leaking from the shaft seal ... So here I'm now rebuilding the throttle.

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Here's the cake ;)
Drill 15/64" than tap 1/16 NPT. You can drill 0.410" deep so be careful.
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I also decided to remove the ISC for now ... I'll use the stock gasket again between the Flange/TB/Elbow but with some RTV on both side. I hope it wont leak after that.
 
Back on the car waiting to get tested ...

It was super easy to rebuild the throttle it's incredible. Just follow this vfaq: http://www.ca.dsm.org/faq/tb-shaftseals.html

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Now it's time to wire the IAT and MAP, I'll use the wires from the MAF.

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IAT Wiring
It doesn't matter what wires goes where coming out of the back of the IAT sensor, both can go to either a ground or signal wire.
- Cut the GRN/ORG wire at the MAF connector pin 8 (IAT signal).
- Cut the GRN/BLK wire at the the MAF connector pin 6 (sensor ground).


MAP Wiring
-Cut the GRN/RED wire at the MAF connector pin 4 (5v power)
-Cut the GRN/YLW wire at the MAF connector pin 7 (Baro signal)
-Cut the GRN/BLK wire at the MAF connector pin 6 (Ground)

Fond those instructions on Tuners and other sites. Yes I could buy the cable from Link but who wants an other cable in a wire tuck ... ;)


Seriously I don't really want to buy a PR o2 + Tial mvs and modify my dump pipe ... I'm starting to get short on cash, time and my Cummins also need some love ... I could buy a tial and modify my o2 housing, that would be easy enough and not too pricey ;). I decided to give a try porting the 16g and o2 housing flange.

Here's the progress so far, still not done:
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