4g63 Sand rail... the upgrades

[BoostforBreakfast]

Ok, now I have too many toys. I just traded a 95 zj jeep and another 4g63 stroker for this little rail. Already has a 6 bolt 4g63 swap, stage 2 kennedy clutch, 5-rib bus trans and a BSE kit. Not too sure if anything else in the engine has been upgraded.
I got it running like crap with no maf and a blown out clutch slave cylinder (which I just replaced). I have a 90 tsi parts car so I robbed the maf and made an intake for it. It runs VERY rich when cold and once warmed up, I have to turn it off and then back on to get it run normally. I replaced the CTS from the parts car with the same affect. I wired in a 5k potentiometer and I can KINDA get it to run correctly when cold. It has a 3" gm maf in the IC piping so I got a MAFT form my buddy and am snagging a SAFC from him as well for the time being. This upcoming weekend I may be ordering dsmlink/aem for it
It has a wastegate actuator off of something else that was cut and rewelded. on ran 4-5psi. I've since swapped in the stock actuator off the parts car. Also I temporarily put on a fart can to quiet it a bit while I get it sorted out until I can fab the exhaust




plans are: 16g, aem/link, wideband, arp's (already have), 650-850cc injectors, different intercooler (it has a rx7 tmic right now), long travel front suspension, and eventually stretch it and add back seats

 

[dsm_94_4ever]

Pretty sweat!But wheres the lower timing cover?

 

[BoostforBreakfast]

good question..... it didnt have any timing covers on it when I got it. the top one is off the parts cars. I'll eventually put the covers on once I get it running right

more pics: Engine


Turbo manifold/Maf set-up


intercooler


intake/GM maf piping


Ecu/fuses (behind seat in an ammo box)


steering, gauges (SRT boost, Autometer tach, autometer oil press, autometer temp)


tow hitch, fogs


the parts TSi

 

[dave99gst]

No updates ?????

 

[BoostforBreakfast]

Just ordered dsmlink v2.5, lc1 wideband, 750cc injectors, nxs(sp?) mbc, ebay 16g, new gauge box, new stub axle (passenger side had 2 snapped bolts), new oem front torsion bars, and some towing lights. Parts should start arriving on friday

 

[BoostforBreakfast]

DSMlink came today. I have to cut the data port out of my parts car and splice it into the harness the previous owner taped up in the rail so I can access the ecu. I'm rewiring and tuning my buddy's Hy35 Rb20 s14 at the same time so I'm bouncing from project to project.

Dave: I love your buggy. How's that coming along lately?

 

[90gsxdakilla]

Thats a cool project man. I'm building a rail too. Mine is using a ga16de out a of a nissan nx. Except I wont be using the vw trans I will be mounting it mid-engine in the back of the rail the way it would be in the car. Keep up the good work!

 

[BoostforBreakfast]

IIRC you can mid-mount vw trans and run them backwards with certain engines. I havent messed much with old skool veewee tech so I'm still researching stuff.

My wife's family has a reunion in a couple months up in the mountains and her uncles and brothers always bring their quads, so I'm wanting this fairly stable by then

 

[BoostforBreakfast]

ok, I got dsmlink in and the connector soldered. I zero'd out the previous tune and BAM! it runs perfect. Purrs like a kitten. I have the seats and a half shaft out so I couldnt run it around the block. I think the old ecu was bad (caps?).
After a couple idling and revving datalogs I noticed that with the throttle peddle, I am only seeing 60% throttle. Blipping the tb by hand yeilds 100% so I have some reengineering to do

 

[BoostforBreakfast]

Wideband, mbc, and injectors came today. Woot

 

[BoostforBreakfast]

more goodies: 16g, new front torsion leaves, new stub axle, and new cv boots showed up also

 

[javierabrahamgv]

Wow...I want to see this running!

 

[mitsubishikid]

Get that lower timing cover ordered dude!!!
you don't want a timing belt disaster in the form of a stray pebble or two, you can get it brand new for cheep here http://www.rockauto.com/catalog/moreinfo.php?pk=2922828&cc=1172359
otherwise I like what I see, great work man.

 

[BoostforBreakfast]

I'll have the 16g and injectors in this weekend with a decent tune on wastegate boost. I hope my new gauge box comes in soon so I can mount the wideband gauge. I might get enough time tonight to get the 16g and injectors in

 

[BoostforBreakfast]

Checklist for the "BoostBuggy":
Install 16g turbo
Install 750cc injectors
Install ARP headstuds
Install Wideband
Install Gauge box
Install MBC
Install new front torsion leave
Install new type 1 to type 2 stub axle
Install new front tires
Replace an alternator nut
Install timing cover <--- ordered. Thanks Mitsubishikid for that link
Mount fuel filter
Fix broken knock sensor wire
Install missing engine-to-adapter bolt
Check/change trans fluid
Make cover for ECU/electronics
Build PCV catchcan set-up
Change oil/filter
Install coolant overflow bottle
Do alignment
Redo the rear shock mounts
Fix annoying ass roof rattle
Build rear skidplate
Check for boost leaks

 

[BoostforBreakfast]

ok, so here is some pics:
dsmlink v2.5


Diagnostic port from the parts car


dsmlink installed and diag port soldered in


smartfire 750cc hires injectors


china e316g



nxs mbc


out with the old


in with the new


injectors installed


made a jumper to eliminate the resistor box as these are hi-res injectors

 

[BoostforBreakfast]

I was having issues with one of the lines for the turbo coolant so I just bypassed running coolant to the turbo. The o2 housing on the 14b was being a pain in the ass so I scrounged around in my garage until I found another o2 housing from one of the few dsm's I've had before. I got her all buttoned up and fired up on a base tune to check for leaks. found out my radiator is leaking a bit from a small crack. So I'll be yanking that out soon.
I'll install the LC-2 wideband tomorrow and will install the "exhaust" (or what u can call an exhaust). Anyways, enough for tonight...

 

[BoostforBreakfast]

Everything in. Tracking down a small boost leak - thinking its a cap-off on the intercooler. New timing cover on. Conservative timing tune on 10psi. Ill get a vid and pics soon

 

[BoostforBreakfast]

 

[BoostforBreakfast]

Video of a small rolling launch on 10psi

 

[cano86]

Is looking nice, am moving to Az this year and hope to be able to buy a rail sometime they seem lots of fun.

 

[awdmonster1904]

How did you adapt the engine to the trans ? Kit ?

 

[TheBrownMike]

Probably Kennedy Engineering adapter, they have adapters for almost any motor