1G Engine build - 300+ AWHP

[Ish416]

I have a 93 Talon TSi I purchased about a year ago. While driving the car home, the engine ran lean and let go after about 80 miles of leaving the sellers house. The engine ran so lean that the manifold cracked, the turbo doesn't spin freely, the rods are bent, pistons melted .. it's basically a total loss on the engine. As to how this happend, don't let friends drive "fast" vehicles home. I was later told that the wideband was reading between 15.7 - 17 AFR for about 20 minutes prior to it letting go.

The block is not in good shape and I have been searching for an engine to drop in. I simply cannot find a 1g 6 or 7bolt locally that is in decent shape. After talking to several local shops that deal with DSM's none will build the engine I want. They all want to go overkill with builds that will support over 600Whp and they are backed up with much higher dollar builds than mine.

The previous build was: Evo 3 16G @ 17PSI, Evo 8 pistons/rods, Evo 8 injectors (560cc), 2G MAF, 255 fuel pump and 2 1/2" exhaust.

My goals: reliable 300 - 350awhp build capable of trapping 110+, good street manners, 18 - 22mpg on the highway and a final cost of around $3,000 - $3,500 and driving by November. My LS1 might have ruined me on the MPG part - 11.4 @ 128 and 26mpg so not sure if 22mpg is reasonable or not.

New build: 1G 7bolt, standard bore, 2g pistons/dsm graveyard frankenstein rods (would like something around 9:1), reconditioned crank, Evo 3 16G @ 20PSI, larger injectors (unsure of what size) and OEM cams.

Are the DSM Graveyard crate engines decent for the money or is there a better place to go for my needs? I would build it myself but just don't have the time to get much accomplished outside of work for the next few months other than swapping in the new engine.

I already have DSMLink and will likely be taking it to Fathouse Fabrication for tuning.

Also was going to replace the suspension with KYB AGX units assuming they are decent?

Any suggestions, comments or criticism related to this build are appreciated.

Thanks

 

[phillytalon]

go for meth kit, if used properly it can gain nice power and keep your iat down low. a lot easier then nos and e85 depending on where you live

 

[Ish416]

That should work nicely. I'm getting ready to start building a 6 bolt here soon. Not a DSM but it will be 4G63 powered and AWD so it will be a fun toy.

Nice, this a build for autocross?

 

[Kickerbeast]

Not "for" autocross but more for a general street build. But it will see the autocross courses just to go out and have fun. It is a car but not a mitsu. I want people to go "huh" when I open the hood. Hopefully it works out like I'm planning. I was thinking of starting a thread on here but I figured it might just get bashed and I'll just end up answering people's questions about why I'm not just building a DSM. The car weighs about the same as a DSM so I should be able to predict the performance fairly easily. It is just one that I have had a soft spot for since they came out. Kinda like the 1gb.

 

[Breezio69]

Not "for" autocross but more for a general street build. But it will see the autocross courses just to go out and have fun. It is a car but not a mitsu. I want people to go "huh" when I open the hood. Hopefully it works out like I'm planning. I was thinking of starting a thread on here but I figured it might just get bashed and I'll just end up answering people's questions about why I'm not just building a DSM. The car weighs about the same as a DSM so I should be able to predict the performance fairly easily. It is just one that I have had a soft spot for since they came out. Kinda like the 1gb.

Hahaha, so what is it? People cant really give you crap when your putting the heart and soul of a dsm into another chassis.

 

[Kickerbeast]

Focus ZX3 AKA FrankenFocus (yes it will be green when I'm done). Doing 6 bolt and possibly 2.3 build with a 2g head and electronics. AWD with an 8.8 rear end and likely grab and IRS out of a t-bird or something with a similar width. Still need to research that part. I'm going for torque over HP but still want to be around 350-400 at the wheels. If I get really crazy then I might even think about twincharging it, . Some of those are a long way off but I have the car and stripped the drivetrain. I have the block, trans, waiting on the head to be shipped, wiring, ecu (socketed and ready for link), and cluster. Just need to find some time to start wiring in the 2g harness and start on the mounts for the engine/trans. Sorry Ish. I'll keep anything more about this out of your thread. I don't want to get off topic. Although the engine part does work here, .

 

[turtleb00st]

This is the cheapest most reliable easiest thing to do.

Buy a jdm motor. Do a new hg (mitsu composite since it seals better on un perfect surfaces), arp head studs, water pump, front cover and timing belt.

This right here is good for 500awhp all day with a proper tune. I know 3 locals all who have out down 500+ with a totally stock bottom end.

All you need is a evo3 turbo e85 and 25psi you will be well over 300awhp, and should be over 350hp Your from the ls1 world who doesn't really use e85 but in the turbocharged world it's a god send. Spend money on some 950cc at least. That will be good for close to 48lb a min if flow.

 

[DRTredHEAD]

I have a 93 tsi I daily drove for 10 years 320 hp minimal upgrades no problems. All I had was 720cc injectors, 2g maf, stock 14b @ 24psi (before I get blasted 14b wont last at 24psi I replaced it about every 3 months from over boosting, at $50 a pop used i didnt care, but a 16g or big 16g will handle that and make a lot more power 350-425hp safely), ARP head studs (the cheap ones L19 not needed), godspeed front mount, crushed 1g bov, megan down pipe, 3" cat back, act 2600 w/ 6 puck unsprung, and dsmlink 2.5 (cause that was the latest version then) I put 120k on this set up and beat on the car daily. 200+ track passes and was out every weekend in Fort Worth picking fights in it. Your power and budget goals are right on. Back when I did my 6 bolt swap it was a direct drop no rewire picked it up 1650 shipped complete long block but that12yrs ago and it was a jdm.

Edit: forgot the whinebro 255

 

[faulkner]

i would consider the same build you had with maybe a little bigger injectors and turbo with a solid tune.

 

[Ish416]

I ended up building a fresh 6 bolt. It has Eagle rods and Mahle 9:1 pistons. The engine build is covered at this point. Is it overkill for what I am wanting to achieve, uh, yes. The option to make power is there if I choose at a later date.

I am not shooting for anything more than 300whp but would happily deal with 330whp.

As for E85, even though I literally live 2 miles from an ethanol plant, the nearest E85 station is over 40 miles away. E85 is not a possibility for me, 93 octane gas however, is and that is what the car will be running on. This will not be a race car. Just looking to have a fun DD that I can drive year round without any worries.

The final build at this point is going to be the fresh 6 bolt with Eagle rods and Mahle 9:1 pistons (I already have it so no need to suggest anything else), stock head and cams, larger injectors (likely 660 - 720), rebuild the evo3/16G, keep the 2G maf, keep the 255 fuel pump, keep the 2.5" exhaust, re-tune the car with dsmlink and that will be it. I think with that setup my goal will be easily achievable.

"Kickerbeast,

Focus ZX3 AKA FrankenFocus (yes it will be green when I'm done). Doing 6 bolt and possibly 2.3 build with a 2g head and electronics. AWD with an 8.8 rear end and likely grab and IRS out of a t-bird or something with a similar width. Still need to research that part. I'm going for torque over HP but still want to be around 350-400 at the wheels. If I get really crazy then I might even think about twincharging it, . Some of those are a long way off but I have the car and stripped the drivetrain. I have the block, trans, waiting on the head to be shipped, wiring, ecu (socketed and ready for link), and cluster. Just need to find some time to start wiring in the 2g harness and start on the mounts for the engine/trans. Sorry Ish. I'll keep anything more about this out of your thread. I don't want to get off topic. Although the engine part does work here, ."

The frankenfocus sounds awesome. Keep me updated on what you end up doing. I somehow keep picturing a green Toyota Celica GT-Four instead of your frankenfocus.