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'07 was the year of change on my GST

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April '07


Well, at this point, my tranny is apart @ TRE. My first gear and input shaft needed to be replaced. As well as the 3-4 fork, but that's a standard rebuild replaced item. Everything else looked good. A couple days later, Jon called and we worked out the build.

- Double syncro 1st-3rd
- 11% taller 1st w/ new input shaft
- Welded center differential
- New 3rd/4th hub & sleeve
And then all of the other Basic rebuild features.....

I also bought yet another parts car and robbed the Thermal R&D cat-back from it for my '99:

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My Fidanza clutch and flywheel finally came in as well:

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So, at this point in time, this is how my shecklist sat:


Here's a quick re-cap of my original plan:


#1. The AWD swap on the GST. DONE.
#2. Pull GST engine and replace timing components, as well as install Magnus SMIM. IN PROGRESS.
#3. Eliminate cruise control and A/C. Emissions delete and vac. line delete. DONE.
#4. Have AWD tranny rebuilt by TRE.
#5. Redo black headliner. NO PROGRESS.
#6. New springs, shocks, flywheel, clutch. DONE.
#7. Finish replacing "the wing" with a more "low profile" (non-aluminum) design spoiler. IN PROGRESS.
 
tenn-gsx said:
Wait!!! I see that is a 7 bolt flywheel. How long have you ran that engine, at what hp, and how hard do you run it?
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It was the original engine in the car (read '99 block). I had been pushing 300-350 WHP out of it through 2005-06, and finally a little more in the fall of '06. I drive hard, but I maintain it well. Back then, I was changing the oil every 1500 miles and the stark plugs every 1000 miles.
 
Haha the "garage". Terrible. No wonder your spelling is so bad in this thread.

When can I move in with you guys?
 
Late April '07

The engine is mostly put back together at this point. All new timing components and water pump. Balance shafts are gone. Comp 101200's are installed along with the Fidanza gears. I also have the Magnus SMIM installed with one of those heat barrier spacer gaskets.

Engine Pics:

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earily May '07

Clutch, flywheel, starter, and tranny are bolted up and ready to rock.

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Installation:

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She fired, and we broke in the cams for 30 minutes. A small idle adjustment and we took it for a test drive. After minor adjustments with Link, it seemed to be just fine. This was the first time driving it in 8 months.
 

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May '07

Within days, I decided I didn't like the Megan springs at all, and purchased a set of Hypercoils and threaded sleeves.

7" Hyperco's on all four corners:

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I also paid off the body shop and got my hatch and new spoiler back. I had the aluminum wing removed, the holes were welded shut, the new spoiler was fitted and installed, and everything was painted.

New spoiler and Hypercoil springs:

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I put 200 miles on the car over the next 3 weeks.
 

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June '07

Well.... Lot's of updates.

I sold the Koni/Hypercoil set-up. It was a nice set-up, but the lack of shock travel at my desired ride height steered me to a different set-up. So, I picked up a brand new set of D2's.

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Now for the bad news - Car is down for a while. I over-boosted and finally lost my bottom-end. Bent #1 and #4 rods.

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And upon taking everything apart, looks like I've completely destroyed my half shaft as well.

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the next day, June '07

Well, the D2's are on. These things are bad-ass. They are completely unadjusted in these pics, but they are pretty close to where i want them to be. So, at least now, she sits lookin pretty while not running.

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June '07

Engine and tranny are back out once again. Me and Dale had it out in like 20 beers. Just kidding. It took us a little more than 2 hours with distractions.

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Me, Dan, and Dale pulled my engine apart last night. The carnage:

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Three of the four rods were bent to this extreme. #1 and #4 were actually hitting against the very bottom of the cylinder wall and chunking away at the wall, and gouging up the rod and piston skirt. Surprisingly, the head gasket never failed even though I was still only using factory head bolts and a composite head gasket.


Upon pulling the head, this is what TDC looked like:

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And this is where the side of the rods were hitting the wall:

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Cause of failure? While experimenting with a new boost controller, I accidentily left the watsegate vacuum plumbed incorrectly and tried to boost while passing a car. The wastegate never even began to open at over 30+ PSI, so it basically went infinite boost for a couple seconds. I'm not really sure how high the boost actually went, but it was probably 40+ psi.


I spent the entire month of July saving for engine parts and machine work.
 

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First week of August '07

Wiseco 9:1's, Eagle h-beams, Bored & honed w/ torque plate (.020 over), decked, SS O-ring, cleaned, and assembled:

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I painted the block with a light gray engine enamel. I also picked up a JM Fab coil bracket. I then had my head re-surfaced and had a mild exhaust port job. Then I torqued the head down, using a OEM composite gasket.

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I also studded the oil pan and valve cover:

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This is currently how she's sitting on the stand. I still need to install a few of the timing components, as well as a new Fluidampr. I also sold my 50-trim and plan to pick up a new Turbonetics 60-1 for the '08 season. I have the engine bagged up and on the stand. As soon as spring time rolls around, I'll finish assembly, order my turbo, and drop everything back in.

It's been a busy year to say the least. :)
 

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I see you got a new fully built block, what did that run to bore and hone, flatten it out and asemble everything for the block? I never have seen a average cost for a machine shop to assemble everything, bore and hone.

James :laser:
 
Auto RS T said:
Nice progress on the car, you basically went through everything! LOL

I'm glad I could help out with the Throttle Body. The adapter plate is pretty slick too. :cool:
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Yeah, I didn't plan to go through everything (and it was tough to afford it all), but this is how my cards fell. Thanks again on the TB rebuild. It's working flawlessly. :)

SBstar said:
Awesome build-up paul. I'm going to have to see this thing in person sometime this year. Who knows maybe you'll even get me to turn a wrench haha.
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Yeah, let me know if you're ever on this side of the state. I may even try to make it out to one of the Xceed or MIdsm meets this coming summer. :thumb:

VETTE_50_TH said:
I see you got a new fully built block, what did that run to bore and hone, flatten it out and asemble everything for the block? I never have seen a average cost for a machine shop to assemble everything, bore and hone.

James :laser:
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Well, here's a break-down of the majority of the machine work that I had done. As far as I know, these prices are a little on the high side, but the work was done by a very reputable shop that is very familiar with the 4G63, so I felt it was worth the couple extra dollars.

$155 - Bore & hone w/ torque plate
$120 - Deck block
$120 - O-ring block
$175 - Assemble shortblock
$25 - Check align hone
$60 - Degrease block
$50 - Assembly-clean block
$50 - Micropolish crank journals
$30 - Hanging pistons
$35 - Install new freeze plugs and b-shaft bearings

As far as parts, I got them for dirt cheap through my place of employment.
 
-LA- said:
Put the wing back on, damit. :thumb:

Car looks great dude
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Ha, you're the ONLY person in the entire World that has said that. ROFL
I liked my aluminum wing on the car, but I like the new fiberglass spoiler much better. It'll be on there for a while.

bartels903 said:
No, don't put the wing on.

Paul... Are you planning on bringing it to SO?
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Don't worry, Bart. I'm saving the wing for your Colt. ;)

Yeah, as long as it is running problem-free, I'll definitely bring it.

wishihadatalon said:
It's all like deja-vu :)
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HAHA, yeah most everything was just copied from WM. I didn't realize how long that thread was until I made this thread. :thumb:
 
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