2G Total Teardown and Rewire

[riopgtmn]

KL-Motorsports Image Gallery - 2G DSM

I posted up 30 pics from todays progress, have tons more. Stay tuned, will post the rest and more tomorrow.. Have 70 more on the cam waiting to go up.. . after all the pics are uploaded going to make a complete build log.

The ___ ENTIRE___ car is being gutted, completely . All the AC< heater core, interior, dash, door panels, everything is being gutted, re-wired with Tefzil wire/MilSpec/WeatherPack connections, all hidden away. Get rid of the clutter, the un-needed garbage, tons of weight reduction, We will be using all solid-state relays from Aircraft, full relocation of all the fuse panels and such to the trunk, going to fab up a plate for that, Then do alot of powdercoating in the engine bay... So far we've removed, including the AC< heater core, un-needed wire, ABS module and all that shit, Airbags, Aftermarket wheel + the passenger side is faulty anyway..Over 100 lbs and counting.. The pile of shit from this fat lady is getting big on the first day.. . After this is all done, Off to Shep the car goes.. When will it end? No one knows!

-- Austin

posted alot more.. still have tons more to upload.. but the entire car is now gutted.. everything. It's very exciting and a little scary..

 

[snowborder714]

FYI, this is the power transistor, not the ISC.

So you're going to mount the fusebox in the trunk along with the battery? What's the reason for moving it all the way back there vs. going under the dash where the HVAC stuff used to be?

Where are you getting your wiring supplies from?

 

[riopgtmn]

Wiremasters, Inc.. 1,897.20 in wire/connectors and counting

All aircraft supplies.. Why? Because im mentally ill I suppose.

I want everything in one area, and I think it would be cool to mount it all in the back

Cleaning the engine bay... oh my goodness... Lol. Crazy ammount of grime.

Oh, By the way.. Solid State Relays.. For the win.

Ultra-Badass.

Thats all

Ok, well removed alot more crap from the engine bay.. the amount of delete is unreal.. When the AEM is totally re-pinned, there will be something like 23 wires going into the engine bay.. We have a water proof barrel connector that will be mounted on a billet plate on the firewall.. Need to remove the engine? One barrel connector, unbolt, done.

Now we're going to remove the un-needed fuel lines from under the car, as it has 10 AN lines to and from the fuel cell. That should be another 3-4 pounds of crap. Simple simple simple is the goal. We will keep a few "create comforts" such as power door locks and windows. The power mirrors work so crappy anyway, We will remove them for manual parts, a little more weight savings.

We will have :

Power Windows
Power Locks
Wipers
Sunroof
Headlights - Lo/High beam
Turn Signal
Tail Lights
Brake Lights
F/M Radio + CD Player *Factory Unit*
Gauge Cluster *It's using all Auto-Meter anyway*
Cigarette Lighter ( Need to plug in my cell phone, )


As far as the speakers, We'll use two simple Pioneer 6x9 in the back, The tweeters and door speakers = deleted

On other notes :

This morning I will remove and prep the following for powdercoating

Intake Manifold
Throttle Body
Cam Angle Sensor
Thermostat Housing
Water Pipes
Power Steering Bracket

Maybe more if I can find some other small parts

I've also purchased new bolts, as the ones in the bay are dirty

Other then that, I'll keep uploading pics as progress continues, im way way behind on the pics.. I'll get caught up eventually

-- Austin

 

[Dsmj89]

Looks good bro. So what's the goals for this car ? Track-only ?

 

[riopgtmn]

Nah, I'll drive it around from time to time. I just like to do things correct.. Im pretty OCD..

Hell, I've spent over 3,000 on wiring equipment thus far, Its all from Wiremasters - Tefzel wire, Solid state Relays, ect.. It's Aircraft Supplies. It's an unreal amount of work.. At least things will work correctly and be clean. So tired of these modded cars that have trash wiring..

Oh, Also. I've found the reason as to what fails in the Cam Angle sensor. The wires going into it are mounted with circle ends that are screwed down inside the sensor, It's covered by plastic and what happens is, the bracket is pushing this wire at a hard angle, thus causing the ends to fail and grime to get inside of this connector, Since these are inside a plastic clip thats sealed from the top, the wire breaks from the O-Ring inside and tada, fails.

If anyone would like to have their sensor fixed, disassembled, cleaned, Powdercoated, and re-wired, with the Tefzel wire.. Shoot me a PM, We'd be glad to do it for you.. I have pics, just none that are uploaded yet

-- Austin

 

[snowborder714]

I want pictures of all your wiring stuff - I can't imagine $3k+ in wiring!! Although I went to that company's website and I'm guessing they don't have pictures of their connectors and such? I wanted to compare it to the stuff my brother is using to redo his harnesses.

I believe rewiring the engine bay and fuse box is beyond OCD...especially when it involves spending a ridiculous amount of money to do so

 

[riopgtmn]

I got pics of of it all, I'll keep uploading.. This will be the best wired DSM there is.. I HIGHLY doubt that anyone has gone to this extreme..The barrel connector was 101.50 as an example, the aircraft splices, for a bag was 154.50.. Some of the shielded wire is over 1.00/ foot ect.. We'll have a full build log.. just dumping pics as I have the time.

 

[snowborder714]

I don't consider expensive to be extreme. As long as it's clean and functional, then I'll like it. But if you and my brother did the same thing and you spent 5x what he did, I wouldn't say yours is any better than his.

Drew had his car rewired a bit, which you can see in this thread.
http://www.dsmtuners.com/forums/road-course-autocross/325313-time-attack-build-blog.html

 

[riopgtmn]

It has to do with the quality of connector, wire, relays . Did he use Tefzel Wire or PVC automotive wire? If he used PCV there is no comparison. Tefzel Wire is whats used in aircraft, Its has the highest shear resistance, heat / melting point is much much higher.

PVC Wire = Garbage
Tefzel Wire = The best, Every aircraft is wired this way..

We are literally going pin by pin from to back and re-pinning the OE connectors to go into the AEM. It takes quite a bit of time to re-pin those tiny connectors, So we re-pin them, XCrimp, then solder the join. We are also going up 1 gauge size for every wire.

Time Attack build looks nice, I like the idea of putting the fuse box where the airbag was. Nice idea.

We purchased factory new connectors from a rep overseas and then re-pinned every connector, we have re-pinned the CAS. The connectors inside the engine bay will be GM-Weatherpack

We're still working on ideas.. Getting better as we go along.

-- Austin

 

[snowborder714]

He is using the stock wiring, unless he needed to upgrade to combine powers/grounds. But if it's worked on our cars for this long, it's fine with me! Yes, there's always room to improve, but honestly, what would you get out of it?

But I agree that repinning would take A LOT of time!!

 

[riopgtmn]

These wires are silver coated copper (No. It's solder.), will last alot longer, way more heat resistant, way more chemical resistant, way more abrasion resistant, lower temp for same current... Many Many benefits..

Stock is meant to work, not perform.

High performance on everything else.. The most important part is the wiring.. The entire thing is dead without the wires.. People buy the best turbos, best manifolds, ect.. But old crap wires.. Makes no sense to me. Do you need to do what I did? Absolutely not.. Am I mentally ill? Yep

So, Would anyone like their Cam Angle Sensor fixed correctly? PM me for details..

 

[snowborder714]

What do you mean by "fixed correctly"?

I sent you a PM the other day, by the way.

 

[riopgtmn]

Im put in a call to see if its ok to give you that information.

What I mean by fixed correctly, is if you look at the wires going into the cas, they are bent and 90% of the time have cracked wires and thus making the sensor fail and or read innacurate.

What we will do is disassemble, clean, re-pin them inside the CAS and on the other side with Tefzel wire.

That's all

 

[snowborder714]

Got it.

I would really appreciate it if you could get me that information

 

[riopgtmn]

Couple of new pics :

KL-Motorsports Image Gallery - 2G DSM/Sneak Peak of Powdercoating - Silver Vein!

KL-Motorsports Image Gallery - 2G DSM/Thats all we need for the AEM.. Yep.

 

[riopgtmn]

Its down in Alabama at the moment.. where the shop is.

We have alot more work to do.. i bought it as a nice platform, and we are engineering some new performance solutions to see what we can max out the 3052 at on pump, I believe the record on pump is 468? Anyone know?

We are engineering some solutions for the condition under the hood, as far as temps go. gets HOT in there, We need to drop our ambient engine bay temp by about 40 Degrees F as well as work more on our fueling situion..

Aside from that, The ENTIRE suspension is dropped, we are stripping it down, putting all the Prothane bushings in it, and powdercoating it all.. Including the subframe

Everything under the car will be Powdercoated, Talk about some labor.., After we do that, Im going to put on some KW Varient 3 Coilovers

We will then send the car off to shep to get the full workout, Stage 4 trans, 300M Transfercase, DSS 1000HP Rear axle setup, DSS Front Axles, DSS 2 Piece Driveshaft.. I'll have him install it and shim the rear end, install the LSD.. Quartermaster Clutch, Scattershield.. ect.

It's our intent to get the record for the 3052 turbo..We'll see what happens

-- Austin

 

[riopgtmn]

Talked to magnus, They want 15,800 for a long block, ready to be dropped in.. With everything top to bottom.

Hmmmm...

 

[snowborder714]

Specs?

 

[t_jones8062]

Austin...your gonna kill yourself. .. and i hope im not in the car when you do. o. or some random big trucks gonna come (again) and rip the entire side off of your car

 

[riopgtmn]

.

I had a 2008 C6 Z06 that a garbage truck totaled.. Sucks.. Was a 5 MPH impact but garbage truck vs fiberglas = Loose

Ah well, Nice insurance payout

 

[riopgtmn]

New Pics..

MINT CAS

KL-Motorsports Image Gallery - 2G DSM/CAS Taken Apart.. MINT CAS

More Powdercoating

KL-Motorsports Image Gallery - 2G DSM/More powdercoating

COP Plate

KL-Motorsports Image Gallery - 2G DSM/New COP plate

 

[Gooberlog]

.

I had a 2008 C6 Z06 that a garbage truck totaled.. Sucks.. Was a 5 MPH impact but garbage truck vs fiberglas = Loose

Ah well, Nice insurance payout

Ouch! Is that where all of the funding for the 2g is coming from ha.

 

[riopgtmn]

Nah, Money is not a problem.. We do pretty well.. its more of the engineering/development aspect of it..

It'll be a hell of a machine when finished..

I don't spend much, About 1k a week on car stuff, so 52,000/year on car isnt too bad.

 

[riopgtmn]

Here is some more progress.

AEM to Firewall harness WITH male-side of 37 pin barrel connector.

KL-Motorsports Image Gallery - 2G DSM/Completed AEM to firewall harness.

Picture of the delete so far.. More delete to come!

KL-Motorsports Image Gallery - Last additions/Delete to date..'

 

[Gooberlog]

Nah, Money is not a problem.. We do pretty well.. its more of the engineering/development aspect of it..

It'll be a hell of a machine when finished..

I don't spend much, About 1k a week on car stuff, so 52,000/year on car isnt too bad.

I'm sorry did you type, $1,000.00 a week is spent on your talon? Good god. This thing truly is going to be the sickest dsm in this galaxy. If you had a dsm shop and this was your "shop car" could you write it off for tax purposes?
BTW: Is your company hiring? I'm am looking for a job and i'm in the area.