Street Build 1g build - The Real Life Trials and Tribulations of building a DSM

[Anfurnyy]

How did you shim it without a lower race?

Shim goes in side the bearing case, yeah? Or does it go in the big middle Case?

I put all the shims back where I got them from teardown.. perhaps that's not right

 

[Anfurnyy]

New hardline crossovers came in from JNZ i had to slightly bend them a little to get them to fit but they fit fine afterwards. All Brake pads came in. I did order all new hardware and seals and what not to completely rebuilt all calipers. That all should be here this week. Man the wheel wells are looking really good with all the new/refurbed stuff.


Yesterday i busted my butt and was able to get the transmission back together and back in the car. Right away when i got home I got the transmission lubed up, sealed, torqued all back together. Ill tell you what though. Those nuts, sucked trying to get them torqued. I ended up putting it on the floor on top of some 2x4s so that the output shaft didnt hit the ground and wrapped my legs around the transmission and held it with my right arm and pushed the torque wrench with my left. Seriously what a pain.



Anyways while the rtv was setting i went and messed with my rear brakes and at dinner and then came back out and was able to get it back into the car. I covered up the sub frame and sway bar so that i didnt ding the transmission off them. I still managed to though. Took me a little bit of time to get it back in there right but I managed. While i was under the car putting the rear trans bolt in I put on the clutch slave cylinder, and the oil drain for the turbo. I had to cut the drain so that it wasnt kinking, and then i also installed an additional hose clamp kind of in the middle where it seemed prone to kinking too for some support.



I threw on the shifter cables and hopped in the car and shifted through the gears and all of them seemed to go in. Of course this doesnt mean much until the car is actually rolling and goes through the gears while moving. 5th/reverse seems a tad hard get the shifter over to so i think i might have to do some adjusting of the cables after its all done.

I can feel that im getting close guys! Lots of little things left but we're getting there!

 

[Anfurnyy]

Was able to get the rear brakes installed and everything back together.

Tidied up some stuff under the car from installing the hydraulic brake. Had to drop the front carrier bearing and the head shield.
Tightened up all the turbo feed and drain lines for both coolant and oil. Installed a primed oil filter and got the starter bolted up onto the trans. My goal for yesterday was to get the car primed with oil.


Took off the valve cover and drizzled some oil on the cams and what not and then installed the valve cover. Got all the wiring for the starter connected not ideally though. I still need to clean this up a bit.


Anyways I filled it up with oil as well and verified everything should be good to go. I started turning it over.



I had issues where it wasnt pulling oil out of the pan but i pumped some oil into the oil filter housing hoping this would reach the pump and it must have because we have oil pressure! While turning over its got something like 20psi or so but almost immediately falls back down to 0 psi. I dont remember this happening on any other cars ive had before this quickly but maybe its just a 4g thing? I did verify that the Head is getting pressure as the oil feed port on the head had oil coming out of it steadily when i pulled the plug on it. Also, the oil drain from the turbo is leaking right at the flange so i know that has oil too.



Maybe this weekend ill throw on the t-case, and axles and put some oil in the trans as well. I probably should have done that before cranking the engine but hindsight is 20/20...

After those things its really just some vacuum hoses, cleaning up some wiring, VERIFYING some wiring, intercooler piping, exhaust and put some fuel in it and I think we're ready to start on the startup tune!

 

[Anfurnyy]

A little ahead of schedule but got Tcase filled and installed. And the axles in as well!

I learned the hard way that it's actually possible to install the sway bar upside down.. the hump in the middle came down instead of up so the Tcase wasn't fitting the first time I tried.

Surprisingly the sway bar mounts didn't put up much of a fight while re-installing them. Anyone that's done those on the 1g understands what an ungodly pain there can be. I lucked out.

 

[Anfurnyy]

Little bit done last night. All wiring.

Wired up the boost control solenoid and loomed it. Tucked it in front of the radiator and the front radiator support. There's a nice pocket there where it sits freely

Now you see it

Now you don't


Loomed up my fan wiring harness as well. Turned out pretty good. Used some of the wire harness mounts on the lower rad. Worked out perfect!

 

[1cleangsx]

Man I’m excited for that first idle video

 

[CrackedDSM]

I feel like a lot of us are going to get going right around the same time. Wish we were all closer together, I'd love to meet up with like 4-5 freshly running DSMs.

 

[Anfurnyy]

Man I’m excited for that first idle video

Me too! I'm nervous still though. Lots has been done and lots to go wrong. Only leak I have is the turbo oil drain. I'll count that as a W for now

 

[Anfurnyy]

I feel like a lot of us are going to get going right around the same time. Wish we were all closer together, I'd love to meet up with like 4-5 freshly running DSMs.

That would be really cool, have like a regional meet or something.

 

[Anfurnyy]

Cleaned up my garage this weekend. Really needed it after doing all these things at once.


I ordered up some new Center caps for the wheels. For some reason I havent been able to find some that fit but hopefully these ones do

Also ordered up my caliper paint. I decided to just go with Red.. just like everyone else. I really wanted gunmetal but couldnt find specific caliper paint rated for chemicals and heat. Along with that paint i ordered a bead roller and an air filter for the inlet. Im going to be cutting and bead rolling my own intercooler pipes. figured it would save the cost of fab and it should still work just fine. the Really the only parts that will need changed are the passenger side out of the intercooler into the throttle body due to the new TB location because of the manifold.

did quite a bit of wiring stuff. I actually ran my wires where they needed to go and got about 70% of the harness loomed. I actually ran out of loom and had to order some more so thats on hold currently. I was able to run my Throttle body harness and the Speed Density harness where they need to go and got them zip tied to the main harness. I think that is probably just how ill run them.



Got the manifold mocked up once again and started with making some vacuum lines for the FPR, MAP sensor and what not. The OEM Brake booster line fits but im going to double check and make sure its not kinked or cracked anywhere. It doesn't seem brittle but i can definitely feel its age.


I Needed a stress relief for the harness back behind the motor going to the coil igniter. I ended up finding a hole that was perfect in the subframe for an m6. I tapped the hole and it made a perfect mounting point for my harness.


Last thing I did was I wanted to test the throttle body to make sure its still working after all the wiring stuff that's been going on. I don't remember making any changes to the DBW harness's or the tune but when i went to test it the throttle body kept oscillating back and forth quickly when I closed the throttle shut fast. Its also reading ~60% open when there's no Accelerator pedal usage. I tried re-calibrating and everything but it doesn't seem to be doing anything. Ill probably have to post in the Link ECU forums to see if I can get an answer. I seems to be something with the PID values in the tune.

Video

 

[Anfurnyy]

Fixed the oscillation. Turned out to be my Derivative Gain wasn't set high enough. Also figured out why my throttle body was stuck at 60% open. Because the intake/coolant temp sensor weighting was effecting the "idle" portion of my idle control.

 

[Anfurnyy]

Was at home all day after an IT Certification test. I focused on getting most of the small things figured out. Got quite a few harness mounts figured out.A couple for the CAN lambda wires and oil pressure wires and another for the wiring harness that goes to the thermostat housing and Injectors.
Tied up a few spare connectors that I won't be using also


I was also able to cut a few intercooler pipes. My bead roller and intake filter should be here any minute so I can get the beads rolled for them. I gotta say, what a perfect fit. I used a couple peices from an old intercooler piping kit I bought. Used a 45° off the intercooler and a 90° off the throttle Body and another 45° in between just cut to about 5 inches. It's damn near perfect. Clears everything.



I did also throw my speed factory racing intercooler up for sale and picked up a BNIB 4" ETS Race intercooler. I just didn't want to hack up this good speed factory one just to make It fit around the condenser. I think I'll be happier overall with this ETS. That should be here Thursday.

 

[92AWDHX40]

Well its coming man get her ready.

 

[Anfurnyy]

Some good updates!
Air filter showed up, its way too big. it looks goofy in the bay. So im sending that back and i picked up an AEM one from their site. We'll see how that turns out.


My bead roller showed up and this thing is the coolest little gadget, i tell ya. While they arent OEM they are definitely pretty great for a diy type of tool. Takes a couple passes tightening down the roller a bit between each but they turned out great. Very happy with it.


Threw some MT90 in the trans last night with no immediate leaks, and checked it again this morning again with no leaks so thats a huge win so far. Obviously ill check back when i start driving and fluid is being flung everywhere.

Cleaned up my fuel map in the Tune a little bit while on a break at work. Hopefully i did that right. Still learning Link ECU. Theres just so much to it. Lots of little nooks and crannies that settings can hide in and what not.

Caliper paint showed up. Going with Red. Hopefully that looks okay.


Cleaned up the passenger side floorboard, and re-mounted the ecu back in its correct place since it was sprawled all over the floorboard.


Intercooler should be here today. I also ordered up some 4" hose clamps, 3"-2" reducer couplers for the inlet and outlet, a new IAT Sensor bung for the intercooler piping, a new BOV Flange for it as well, and ordered up some Nylon pushlock fittings and line for the Boost control stuff.

Almost 2 years since i pulled the engine out and its finally dwindling down to a close! I literally cannot wait!

 

[CrackedDSM]

Some good updates!
Air filter showed up, its way too big. it looks goofy in the bay. So im sending that back and i picked up an AEM one from their site. We'll see how that turns out.
View attachment 699672

My bead roller showed up and this thing is the coolest little gadget, i tell ya. While they arent OEM they are definitely pretty great for a diy type of tool. Takes a couple passes tightening down the roller a bit between each but they turned out great. Very happy with it.
View attachment 699673View attachment 699674View attachment 699675

Threw some MT90 in the trans last night with no immediate leaks, and checked it again this morning again with no leaks so thats a huge win so far. Obviously ill check back when i start driving and fluid is being flung everywhere.

Cleaned up my fuel map in the Tune a little bit while on a break at work. Hopefully i did that right. Still learning Link ECU. Theres just so much to it. Lots of little nooks and crannies that settings can hide in and what not.

Caliper paint showed up. Going with Red. Hopefully that looks okay.
View attachment 699671

Cleaned up the passenger side floorboard, and re-mounted the ecu back in its correct place since it was sprawled all over the floorboard.
View attachment 699670

Intercooler should be here today. I also ordered up some 4" hose clamps, 3"-2" reducer couplers for the inlet and outlet, a new IAT Sensor bung for the intercooler piping, a new BOV Flange for it as well, and ordered up some Nylon pushlock fittings and line for the Boost control stuff.

Almost 2 years since i pulled the engine out and its finally dwindling down to a close! I literally cannot wait!

Looks great, man.

Don't suppose I could convince you to let me send you my pipes so you can bead roll them for me, could I? I'll include candy in the box or something to entice you further.

 

[Anfurnyy]

Looks great, man.

Don't suppose I could convince you to let me send you my pipes so you can bead roll them for me, could I? I'll include candy in the box or something to entice you further.

If you're serious I'd definitely be willing to! Lol
No candy needed!

 

[DreamChaser7]

Got a link where to buy the bead roller?

 

[Anfurnyy]

Got a link where to buy the bead roller?

Hiwowsport Tube Pipe Tubing Beader Tool Bead Roller Intake and Intercooler Piping Fits 5/8" https://a.co/d/2whFmXR

 

[Anfurnyy]

New Tesa Tape showed up. I was able to get the rest of the harness finished being loomed. It turned. All in all it turned out pretty good, not as good as I had hoped but better than I was IMO.


Got my Brakes painted. The fronts turned out great I think. The rears though are just okay. They weren't media blasted and I know that's why but I did clean and scuff them up before painting them. Oh well. I still need to pull them apart and rebuild them. I'll probably re-paint them then. Started rebuilding the fronts with the new seals, dust seals and retaining springs for the boot.


This paint was good however if I painted them again I would go with the G2 Brush on Caliper paint. Overall more accurate, less of a mess, less masking, no overspray. I feel like it would be a better overall experience

Dropped off the new ETS intercooler at the fab shop to have them weld on some threaded mounts to mount it. I've already got some aluminum straps ready to go for mounting.


I removed the front latch support to make room for the intercooler but then the latch seemed s bit flimsy. I never wanted to remove it but I guess in the sake of progress..
Anyways I ended up making a makeshift support out of some spare aluminum flat stock, and painted it black.

 

[92Turbski]

Coming along real nice, man! Great job! It's going to be bad ass to get to drive it again. I'm sure you're getting excited.

 

[Anfurnyy]

Little more work with the brakes. I was able to get the fronts rebuilt, and all 4 installed.
The paint on the rears came out better than I expected honestly. Better than the last update I posted. They are acceptable. I do kind of with i took the time to rebuild them and have them blasted but oh well.

Was able to get the brake pads installed an all 4 corners. The fronts went stupid smooth. The rears sucked. I did install new hardware on all pads. APPARENTLY on the rears the hardware direction matters. One side of the hardware is taller than the front. Caused me a headache for like an hour trying to get the rear pads installed. I figured it out and got them flipped around and the pads still put up a fight but they gave.

I gotta say i was worried how the red would look but it turned out okay. Im not ecstatic about it but they definitely dont look bad, and i think they look better than the blue.


Couplers, tbolt clamps, my BOV Flange and my nylon tubing and fittings all show up today. Might work on getting those installed.

 

[CrackedDSM]

So glad it's not just me that hates the rear brakes. Honest to God if I knew of an easy way to switch to a different rear e-brake setup on God I would get rid of the 1g rear brakes yesterday. If 1G DSM rear brakes was a person I'd punch them in the face. Twice.

 

[Anfurnyy]

So glad it's not just me that hates the rear brakes. Honest to God if I knew of an easy way to switch to a different rear e-brake setup on God I would get rid of the 1g rear brakes yesterday. If 1G DSM rear brakes was a person I'd punch them in the face. Twice.

Ahmen brother! Absolutely the worst rear brakes I've ever worked on I WISH there was an easier way to swap to brembos. Even if they're negligible difference, maintenance would be much easier.

 

[CrackedDSM]

Ahmen brother! Absolutely the worst rear brakes I've ever worked on I WISH there was an easier way to swap to brembos. Even if they're negligible difference, maintenance would be much easier.

For real, man. I honestly don't even care about performance, I'd swap to something 3x as expensive with zero performance benefit if it was easier or more straightforward to replace.

I honestly wonder how hard it'd be to just put on a second, tiny, 1 piston caliper as the e-brake using the OEM handle. Like a "drift brake" setup, but not actually used for drifting.

 

[Anfurnyy]

So, I decided to switch to the Nylon push lock fittings for boost control but after talking with a couple people here in the forums said they wouldn't recommend due to melting issues. I decided to listen to the people that have ran them before. Ill get rid of the push locks for some regular line. Ill pick that up today after work.


The new ETS intercooler is finally done at the shop having the fittings welded on for mounts. Turned out good. I spent a couple hours yesterday making some new mounts which i think they turned out great. Absolutely solid mounts. I could stand on the intercooler if i wanted to.
The intercooler fits with the new brackets with the bumper and it doenst look like ill have to do ANY trimming of the bumper somehow. One thing that still bothers me is that the bumper still covers half of the intercooler. Id really like to figure out a way to not completely butcher the bumper but still get more cooling capability out of the intercooler.

Some couplers, hose clamps, Center caps, showed up that i ordered a few days ago. 3"-2.5" reducers, although the driver side is too short and doesnt fit. Ordered a 6" long reducer, should be here this weekend i think.

Passenger side does fit though.
The Center caps surprisingly fit over the axle stub in the wheel. Definitely didnt think they would but.. they do. I think they look pretty good!

Dropped off a part of the intercooler piping to have the BOV and IAT bungs welded on as well. Hopefully those are done today.

New air filter is on the way

Not much left honestly. (that i can remember currently)
- fix oil drain leak
- figure out why my can lambda is reading either 0 or 1.5 lambda (probably either CAN setup issue or the resistor)
- fill with fuel
- go over tune
- go over all nuts and bolt
- build exhaust
- Catch can setup
- Coolant overflow