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Autocross Build 1996 TSi AWD - Restore/Autocross

llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
Hello,

This build log is for my first DSM, a 1996 Eagle Talon TSi AWD.

Update 5/25/2016:
When I started this build I had the intention of driving it daily in the summers. That plan has definitely changed as I have gone further with the car than I had originally expected. This car will be a weekend only car. Taken to events and shows almost exclusively.



GOALS:

Current-
  • Prepare Car Safety (Seats/Harnesses/Rollbar) and Cooling System (oil cooler/shrouding/ducting) for Road Racing Track Days
Past-
  • 300whp On 93 Pump <-- Complete, 304whp
  • Street drivable < -- Complete
  • Full Interior <-- Complete
  • Ready in time for Bushur's Sport Compact Shooutout in May (2013) <-- Missed
  • Ready in time for the DSM Shootout in August (2013) <-- Missed
  • Mobile by the first snow fall in Cleveland (2013) <-- Complete
  • Compete in at least 1 autocross/road race event in 2015 <-- Missed
  • Car tuned and ready for events by June 2016 <-- Missed
  • Car tuned and ready for Porsche Club autocross / DSM Shootout in August 2016 <-- Complete (September event)
  • 450whp (w/ Flex Fuel) <-- Complete (448 whp, August 2019)
  • Mid 12s 1/4 Mile (Current best E/T is 11.9 @ 124 MPH, 1.82 60', June 2020)

CURRENT MODIFICATIONS:

ENGINE-
Built 2.0L 6-bolt bottom end/2g head:
  • OEM Crank
  • 8.5:1 JE Pistons
  • Eagle H-Beam rods
  • Ferrea SS Valves
  • Crower Springs
  • Titanium retainers
  • BSE
  • New OEM Oil Pump and Timing Components
  • IJ Oil Scraper
  • ARP Rod bolts/Main studs
  • NGK BR7ES Plugs
  • MSD Plug Wires
  • Walbro 450 re-wired
  • -6 an fuel feed line
  • Fuel Lab 818 filter w/ 10u stainless filter
  • FIC High Z 1650cc Injectors
  • Magnus -10 Fuel Rail
  • Aeromotive AFPR
  • Mishimoto X-Line radiator w/ fan shroud kit
  • SPAL 12" Puller (Main) and SPAL 12" Pusher (Secondary)
  • JMFab Catch Can
  • JMFab Coolant Overflow
  • -8an valve cover
  • B&M Oil Cooler

TURBO/INTAKE/EXHAUST:
  • 7-Blade HX35 with Twin Scroll 12cm non-wastegated turbine housing
  • 3" Turboback, SRS muffler/resonators
  • 4" Intake tube
  • ETS Street 7" Intercooler
  • ETS 2.5" Intercooler Piping
  • Tial Q BOV
  • Tial MVR Wastegate
  • Morrison Fab Small Runner Twin Scoll T3
  • ECMLink Electronic boost control
SUSPENSION/BRAKES/CHASSIS:
  • Dennis Grant coilovers (700/300 lbs Hypercoil springs)
  • 3000GT VR4 Front Calipers
  • EVO 8 Rear Brembo Calipers
  • Carbotech XP8 brake pads
  • 13" DBA Mustang Cobra Front Rotors / DBA Evo 8 Rear Rotors
  • 3G Eclipse Master Cylinder
  • 3G Eclipse Brake Booster
  • Braided SS brake lines
  • Prothane Motor Mount Inserts
  • Tubular front upper control arms
  • Tubular front lower control arms
  • Bump steer correction tie rod ends
  • Tubular rear toe arms
  • Tubular rear upper control arms w/ Prothane bushings
  • Tubular rear lower control arms
  • Tubular trailing arms
  • RM Front and Rear sway bars
  • Bulfab Crossmember
  • Bridgestone Potenza RE-71R 245/40/17
  • Evo 8 OEM Enkei's

DRIVETRAIN:
  • South Bend SS/B
  • ACT Flywheel
  • B&M Short Throw
  • STM Stainless Clutchline
  • Strictly Performance rear axles

INTERIOR/ELECTRONICS
  • ECMLink V3 Full
  • Innovate Boost/Vac
  • Innovate MTX-L Wideband
  • GM style MAP sensor
  • GM style IAT sensor
  • GM Saturn Alternator with Jay Racing relocation kit
  • GM Flex Fuel Sensor
  • Center vent gauge pod
  • Alpine CDE-133BT Head Unit
  • JL 2-way 5 1/4s (525CXi) - Doors
  • JL 3-way 6x9s (690TXi) - Rear

FUTURE MODIFICATIONS:
  • Built Trans/Driveline
  • Harnesses
  • Cage



UPDATE #1 - 4/8/2013: Interior/Engine progress

UPDATE #2 - 7/15/2013: Interior Progress

UPDATE #2 cont. - 7/15/2013: Interior Progress/Custom Spark Plug Cover

UPDATE #3 - 7/22/2013: Engine Assembly/Spark Plug Cover

UPDATE #4 - 9/3/2013: DG Assembly/Engine Install

UPDATE #5 - 9/11/2013: Wiring Harness/Transfer Case/Exhaust/Intercooler Piping

UPDATE #6 - 11/25/2013: Trans Mount/Wiring/Susp.

UPDATE #7 - 12/1/2013: First Start/Drive

UPDATE #8 - 2/2/2014: Interior/Gauges

UPDATE #9 - 5/23/2014: First Street Drive

UPDATE #10 - 10/29/2014: Current Progress/Valve Issue

UPDATE #11 - 1/5/2015: Brakes/AFPR/Paint

UPDATE #12 - 1/14/2015: Paint/Body/Catchcan/Launch Control Test

UPDATE #13 - 6/15/2015: TD06SL2 20G

UPDATE #14 - 12/8/2015: Suspension and Finished Paint

UPDATE #15 - 5/25/2016: Turbo/Manifold/Wheel Bearings

UPDATE #16 - 6/2/2016: Gathering parts/Axle assembly/Turbo Install

UPDATE #17 - 7/6/2016: Rear hubs/suspension install. Front hub assembly. Rear Axle install

UPDATE #18 - 7/17/2016: Wheels cleaned/Tires mounted/Brake Progress/Boost controller

UPDATE #19 - 8/1/2016: Car is running and "complete"

UPDATE #20 - 9/11/2016: New Radiator/First Autocross Event

UPDATE #21 - 12/2/2016: Wiring Harness Rebuild/IAT Install/Winter Work

UPDATE #22 - 2/16/2017: Wiring Harness Rebuild

UPDATE #23 - 2/25/2017: Wiring Harness Rebuild/Battery Relocation/Valve Cover

UPDATE #24 - 3/14/2017: Battery Relocation/Engine Bay Wiring

UPDATE #25 - 3/28/2017: Lower radiator hose, rear upper control arms, vented valve cover

UPDATE #26 - 4/11/2017: Rear upper control arms, catch can install, interior re-install, downpipe wrap.

UPDATE #27 - 4/25/2017: First Autocross of 2017

UPDATE #28 - 5/13/2017: Lifter Tick

UPDATE #29 - 6/9/2017: Bearing Failure

UPDATE #30 - 2/9/2018: Upgrades/E85 conversion

UPDATE #31 - 4/3/2018: Harness cleanup/Fuel Filter/Turbo Coating

UPDATE #32 - 5/1/2018: Motor re-install, coolant overflow modification, alternator relocation.

UPDATE #33 - 5/15/2018: Sway bar and front cross member install, cooling fan setup upgrade, miscellaneous interior updates.

UPDATE #34 - 5/15/2018: Dyno Tuning

UPDATE #35 - 9/27/2018: Fuel Rail / Tail Lights / Muffler / Intake piping / Autocross / Shootout

UPDATE #36 - 1/17/2019: FIC 1650s/Walbro 450/Flex Sensor

UPDATE #37 - 2/1/2019: Turbo Setup Changes/New Clutch Prep

UPDATE #38 - 3/9/2019: Suspension upgrades/New Clutch Install/Manifold Test Fit

UPDATE #39 - 3/10/2019: Turbo and Down pipe Test Fitment

UPDATE #40 - 4/22/2019: Secondary Fan Install / Heat Reflective Tape / Rear Sway Bar

UPDATE #41 - 4/30/2019: HX35 Final Install

UPDATE #42 - 9/17/2019: Dyno Tune and First Autox on the HX35

UPDATE #43 - 6/27/2020: First 1/4 Mile Runs on the HX35

UPDATE #44 - 10/4/2021: Engine Failure (again), rebuild, and "retirement"

UPDATE #45 - 4/25/2022: Oil Cooler Install

UPDATE #46 - 5/27/2022: Fuel Pump Rewire

UPDATE #47 - 8/12/2022: Return to Autocross

BUILD LOG BEGIN

The car was purchased January 2012. I had been looking for a replacement for my 3G Eclipse GT.

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I wanted to move to something faster but also wanted a c̶a̶r̶ ̶t̶o̶ ̶d̶a̶i̶l̶y̶ ̶d̶r̶i̶v̶e̶ . I also wanted something to run 12s, g̶e̶t̶ ̶d̶e̶c̶e̶n̶t̶ ̶g̶a̶s̶ ̶m̶i̶l̶e̶a̶g̶e̶, be at least somewhat competitive for autocross, and most important be fun on the street.

I found an ad for this 1996 Eagle Talon.

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What sold me on the car, other than price, were these pictures.

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Finding a car in the Cleveland area that is as old as this car is and still have intact strut towers is nearly impossible. My number one goal when looking at all of the DSMs for sale was to find a nice, clean body. I decided this one was what I was looking for and purchased it.

The car did not have an ECU or front o2 sensor when I bought it. I purchased a used ECU and a new narrowband front o2 to get it running. The car fired and was mobile, but it leaked oil like crazy. Attempted a few "quick fixes" but nothing stopped the massive leaking. I had to decide whether to get the car running as best I could and dump it or to pull the motor and build it. So the engine came out...

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After pulling the motor and handing it over to my dad's friend for building, the car was taken home to have the interior completely torn apart. The paint was pretty good except for the hatch. The only real issues were the faded hood and spoiler.

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Engine build progress

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llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
UPDATE #1 - 4/8/2013: Interior/Engine update.

Ripped the interior apart and began cleaning each piece. Pretty happy with how all the parts/body look.

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Transmission cleaned up nicely

Before:

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After:

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Engine is nearly done

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Last edited by a moderator:

llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
Update #2 - 7-15-13 - Interior Progress and Custom Spark Plug cover

Been awhile since updated. Fell behind schedule and missed my goal of being ready for the Sport Compact Shootout in May, hoping to be ready for the DSM shootout. Made decent progress on the interior and started work on a custom spark plug cover made by a friend of mine.

Before replacing the rear bumper, I cleaned up some rust spots and painted over them.

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The bumper reinforcements were pretty dirty so I cleaned those as well.

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I also worked on debadging the rear bumper, looks like the letters had been cleared over along with the bumper so that will have to be repainted at some point.


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The headliner had been painted, but I found some cheap headliner fabric at JoAnn fabrics so we decided to take the headliner back out and upholster it.

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llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
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The center license plate section of the back of the car had been painted all black covering the "Talon" lettering and just did not look great. Luckily that all came off with some lacquer thinner.

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I also got some of the panels back in as well as finished wiring the rear speakers.


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Deleted the antenna, just plugged for now. The car will be in a body shop in the future.

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I asked a friend to make a custom spark plug cover for me. I didn't like the stock plastic one.

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When it is finished, it will have "Talon" written in the center and be black anodized. The Talon letters will be filled in with the same red paint from the valve cover and intake manifold.

This looks awesome!

Glad you like it! Thanks for taking a look!
 

RussianMax

5+ Year Contributor
111
0
Feb 27, 2013
Renton, Washington
Definitely liking it so far! I have my fingers crossed that you won't go GSX look. Going to be a great build!
 

llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
Do u have a picture of that plug cover done i was gonna do the same thing but have tsi on it instead. :thumb:

That is as far as we got on Saturday, so it still looks like that. I will absolutely get a bunch of pictures up once it is complete.
 

llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
Made quite a bit of progress since the last update.

Cleaned the mounts and put the prothane inserts in. Forgot to add these pictures last update.

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The new rear speakers mounted nicely in the stock housings. All the speakers and head unit are wired and ready to go.

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The spark plug cover is just about done. Waiting on the black anodizing then I will paint the "TALON" lettering red to match the rest of the engine.

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Finally assembled the Dennis Grant coilovers I got in the group buy.

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I am very happy with the build quality on all of the pieces. These will be mounted in an update sometime this winter. Until then, they will be stored away.

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Cleaned and painted the thermostat housing and the water neck.

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Dragged the engine and trans back out and bolted them together. Also installed the MSD plug wires.

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Next step is to finish the wiring and accessories on the engine and have the intercooler cleaned out before starting the car. I am hoping to fire it up for the first time this coming weekend. Check back for first start/drive videos.
 

llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
UPDATE #5 - 9-11-2013 - Wiring Harness/Transfer Case/Exhaust/Intercooler Piping

Was able to work on the car again this weekend.

First thing I took a look at was the wiring harness. I was not happy with how it was taped or the poor shape of some of the connectors.

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Those will all be soldered and rearranged to ensure I don't run into any electrical issues.

I also wanted to verify the fuel pump and tank were in good shape. The walbro 255 was installed in the car as the previous owner had said, but the rewire on it needed to be redone.

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One of the previous owners also decided to torch the 2 transmission mount studs. I have them on order at the local Mitsubishi dealership.

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The transfer case and exhaust went back on nicely.

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Got the B&M short throw installed.

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ECU is in.

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I started mounting some of the intercooler piping. The rest will go on after the wiring is complete.

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The valve cover got a few chips unfortunately. Luckily it is only VHT and not powder coat.

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Next step is to get the harness rewired and taped. Car should be firing in the next couple of weeks. Videos to follow.

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llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
Excellent build so far man, love the progress!

Thanks! I just picked up the parts from the dealership. I now have everything I need to start and move the car. Update in a week!
 

llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
Made some progress over the past few weeks. Though the car has still not been run. Getting close.

Got the trans studs/bolts in and the mount on with the Prothane insert.

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Had to bring the DG Coilovers back out to put some grease on the torrington bearings and install them in the car.

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I also put the new boot on the clutch slave cylinder rod.

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I then replaced some of the broken/missing harness connectors.

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Car is getting close. Just have a short list of tasks to complete and it should be ready to run and move.
 

llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
The car has started and moved under its own power for the first time in 2 years.

Before starting I had to get some hex bolts for the j pipe.
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Rewired the Walbro 255.
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Filled the transmission and transfer case.
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I also finished running some vacuum lines and checked that everything was connected.
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llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
UPDATE #11 - 1/5/2015 - Brakes/AFPR/Paint

Made some progress on the front 3000GT VR4 Brake calipers

The calipers came with red spray paint on them.
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A few minutes in the sandblaster and the old paint and corrosion disappeared.
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The set came out quite well and are ready for flat silver caliper paint and reassembly.
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Aeromotive AFPR with -6an fittings.
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Drilled the bracket out slightly to accommodate one of the stock brake fluid reservoir bolts to attach the regulator to the firewall.
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Mounted and plumbed.
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The car has now been disassembled and prepped for paint. The wing/wiper holes on the hatch, antenna hole, and rear window washed sprayer will all be filled.
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The shell is completely rust free and has no damage anywhere. Post-paint pictures will be up soon.
 

llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
UPDATE #12 - 1/14/2015 - Paint/Body/Catchcan/Launch Control Test

The body work and paint has been progressing quickly.
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Also received the new JMF catch can.

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Last edited:

llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
UPDATE #14 - 12/8/2015 - Suspension and Finished Paint

Tubular Front Lower Control Arms and Rear Toe Arms. These will be bolted up this winter along with the front and rear brake conversions, new wheels, and tires.

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Also, the car's paint was finished last spring, a few shots of how it sits now. Factory color, shaved rear wing, shaved rear wiper arm, shaved rear washer nozzle, and shaved antennae.

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llxkevinxll

10+ Year Contributor
444
203
Jan 29, 2012
Cleveland, Ohio
UPDATE #15 - 5/25/2016 - Turbo/Manifold/Wheel Bearings

Car has seen more attention in the last month than it has in the last two years so I expect progress and updates to come much quicker than they have been.

The turbo and manifold have been prepped and bolted together ready to be installed. I am still wrestling with the factory water lines.

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No name 3" O2 housing is going back on with the internal gate for now.

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Also had a bad rear bearing and decided to do all four corners at once while the brakes and suspension are taken apart.

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Cleaning the rear hubs as well.

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The new FP manifold had to be drilled and tapped for the EGT probe.

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The front 3000GT calipers are ready for paint and assembly.

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Also picked up a fiberglass hood locally. Needs a bit of cleanup but should look pretty good when it is done. Thanks again Aaron!

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I took the Evo 8 Enkeis off the 1g and mounted them up with the new rotors to see how they looked.

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Stock front rotor next to the new DBA front rotor.

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