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92 Talon TSI AWD ... Project Revival

yhype

Proven Member
332
11
Nov 3, 2002
Thurmont, Maryland
I have been a member of this forum for more then 10yrs and had fallen out of the DSM crowd after being a dumb teenager and and throwing a rod out the side of my block and failing to get the car back together before other things in life happened (wife, house, kid, etc)...So after 9 years of neglect and never giving up on the idea I would get around to get the talon back together and on the road, this weekend was first milestone of digging it out of the ground and removing everything i had stored inside and finally get it back in the shop and give it the much needed love. My plans for the car is basically a "Pro-touring" style rebuild of it, get rid of everything that is un-need and make everything as cleanly and neat as possible and have a car that can autoX, drag race, or cruise down the highway. Here are some Pics from how it looked as I was cleaning it out and getting ready to pull/push it on the lift.

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DsMWookie

Proven Member
360
0
May 3, 2004
Birmingham, Alabama
I love seeing these cars saved and fall into hands that can truly take care of them. In your case the hands just needed to grow up :)

Good luck with the build. I am excited to see how it develops and what details you pay attention to while restoring the car.
 

yhype

Proven Member
332
11
Nov 3, 2002
Thurmont, Maryland
Took pretty much absolutey everything out of the engine bay so I can fill in un-used holes and smooth things out some. Plus had to remove the cradle to put in the new prothane bushings in that I've had and refreshened the front cross-member. I also cleaner off all the rust out the metal wiper cowl and put a couple coats of primer. Hopefully next weekend I can get the interior apart enough to figure out where I want to run wiring harnesses.

Man it still looks like a mess with all that hanging off the firewall.
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Ah....thats looking better
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Heres the newly repainted front cross member and wiper cowl
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The engine's temporary home
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yhype

Proven Member
332
11
Nov 3, 2002
Thurmont, Maryland
Got some more work done over the holiday weekend. Removed the dash and HVAC box so I could finally remove the harnesses completely out of the engine bay so I can place everything inside the cabin and am thinking of not putting the HVAC box back in as this will just be my fun weekend car and would just be one less less thing to re-install or fix later. Also got the fenders off and did some general cleaning of eveything left in the front. My anal attention to detail kicked in and I decided i didn't like the way the seam sealer looked, slopped over top all the seams. So I scraped all of it I could from the front end to either totally seam weld everyting or just seam weld all the structural areas, not sure which I'll do yet. For some reason the that little drip rail on the top side of the fire wall has always been a sore spot on the eye and have not seen anyone else attempt removing it. So I started trim out the corners of it so I can weld it to look a little nicer. Hopefully I can get some some gas this week so i can get to welding up all the spare hole and the firewall drip edge. And time for some pics.

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yhype

Proven Member
332
11
Nov 3, 2002
Thurmont, Maryland
Been a while since I last updated my thread...I have been slowly working on the car as I get some time to do so. I finally been through every wiring harness in the car did my first prelimary removal of wires to things I will not be keeping in the car. I got my battery mounted in an inexpensive summite racing battery box in the back on the passenger side and routed the postive cable up the front of the cab where I will be mounting the main distribution center. Permanently welded the seat belts in place and removed all of the seat belt tracks and motor.
I have gotten all of the small holes in the engine bay deleted and have got a couple of the bigger ones done as well. I decided to go with the 3k vr4 brake upgrade with cobra rotors, and got the matching brake booster and master cylinder which only required some messaging of the LF strut tower to allow enough room for a brake line to fit. I have also decided to complete remove the stock cluster and replace them with some Autometer ES gauges, when I get to the correct place in the build and have the funds. I also thought of a cheap way to rewire the fuel pump by re-using the rear defroster circuit to power the fuel pump as it uses a 10 or 12ga wire. Anyways heres a pic of the engine as of today and a teaser quick mock up pic of the brake upgrade.

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yhype

Proven Member
332
11
Nov 3, 2002
Thurmont, Maryland
Been a while since I last updated my build thread. Been slow going as the finances allow. Been tinkering with it here and there as I get time/motivation over the winter and now spring. I took a week off during the winter and clean up my shop and moved the car to the other side so I could get back to doing some other work on the side. I also decided to try using POR15 on the engine bay which pretty while still wet, but wasn't glossy enough for me when it finally dried, so no when I get back to the engine bay I am going to use some body filler so really smooth out everything I want on the firewall and fill in the to be un-used holes on the upper rad core support. I have also decided to ditch the OEM style hood latch and use some Aerocatch pins. I have also cleaned and recoated the front steering knuckles, re-packed the front wheel bearings with new seals of course, and installed the Prothane bushings in the front control arms. Most of the time I've been working on the car has been spent removing un-necessary wiring out the harness, so now the harnesss that runs across the dash looks like a rats nest or something for now. I have always wanted to relocate my P/S instead of the alternator and had bought a slightly used Jays Racing relocation kit and decide to experiment what I could do with the P/S pump and bracket. Take a look at the pics and let me know what you think. OH, and I decided to smooth the original 1g fuel rail as well. Thanks for looking.
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yhype

Proven Member
332
11
Nov 3, 2002
Thurmont, Maryland
Over the last few months I got all I wanted smoothed out on the firewall and then sprayed primer in the engine bay. I decided I wanted to mockup everything before I did a finally assembly in case I get anymore hair ball ideas. I also decided that I liked the alt better on the backside of the engine as it would make the harness a lot easier and trying to mount the p/s pump down where the alt used to be, but looks to need customs p/s lines if I stay with this idea. Also got to finally mockup the 3k GT big brake upgrade on car which looked like sex...and then I got the bright idea to see if the G35 wheels I had laying around and now I think I need to find 2 more to use on the back. Here is some pics.

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Yes it does stick out about 1/2 an inch or so...not sure if I can roll or pull the fenders out enough but I think I'll worry about it when I get that far. Now its time to get some bills paid so I can get the rest of the parts I would like to get to finish the mockup. Thanks for looking.
 

xyexz

Proven Member
148
3
Sep 8, 2004
Columbus, Ohio
Nice going on this, giving me inspiration to work on my talon :D

Been dragging it around for years hoping to get the time/money/motivation to work on it since I've been married, kid and house LOL - basically same situation as you.

Keep up the good work!
 

talonsnwbrdr

10+ Year Contributor
71
0
Sep 26, 2010
New Britain, Connecticut
Awesome man, can't wait to see more progress! I am constantly looking for more ideas for my eventual 1gb tear-down/rebuild and I'm dyin to see see what you come up with. I really like pro-touring style, especially on classic mustangs and chargers, and that'd be great if i could incorporate some of that style into my own build. Keep on it! Don't stop! Do you have any unique plans for the interior/exterior?
 

yhype

Proven Member
332
11
Nov 3, 2002
Thurmont, Maryland
Thanks for the kind words guys

So far for the interior all I have done is weld the track seatbelt solid and got rid of the rest the system and trying to remove useless wiring, the HVAC system is completely removed already . Only thing planned for the interior is to replace the cluster with some gauges and put a few in place of the old hvac controls.

For the exterior I would like to find something to use for a front lip. The rear spoiler has already been removed, and will weld up all the holes but would like to find a nascar style spoiler for the rear.

Thanks for looking
 

DSM_Roller

Proven Member
101
2
Feb 5, 2005
San Diego, California
Great job so far. I'll be doing the same soon. Can't wait to see the finished product.
 

yhype

Proven Member
332
11
Nov 3, 2002
Thurmont, Maryland
The project is still alive and been slowly working on it as money and spare time provides. Most of my time has been spent trying to figure out how I am going to route my wiring so its almost not existent. But i have gotten my YoshiFab front camber plates all mocked up and installed, mocked up some intercooler pipes with some ETS couplers. My major accomplishment (at least to me) was getting the electric steering installed and mated up to half the factory dsm column. Still on the to do list is to get a set of SpeedHut gauges, Torque Solutions mounts, Fluidamper, Plumbing to plumb fuel lines, catch can lines, and the wire up everything. Here are some recent pics of the progress.
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yhype

Proven Member
332
11
Nov 3, 2002
Thurmont, Maryland
Been a little while since I updated my build thread, haven't had to much time to work on the car or to much funds for it after selling my old POS s10 and buying an 07 Silverado. But i did take advantage of a black friday sale on Speedhut gauges, and this past week they showed up at the dooor. So this past weekend I spent some time modifying the original gauge cluster to house the gauges. I bought their Legacy gauges 3 3/8" tach and gps speedo, 2 5/8" boost, egt, fuel pressure, 2 1/4" fuel level, water temp, oil temp, and oil pressure. Here's a couple pics, let me know what you think.
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yhype

Proven Member
332
11
Nov 3, 2002
Thurmont, Maryland
Was able to get in a decent days work in on the car today. Decided to tear apart the rear end of the end, so I dropped out the catback, driveshaft, and then the rear cradle assembly, and finally removed the gas tank. after I got everything out I took the wire brush to everything to knock off the loose rust and then gave everything a bath. Being a 1G AWD the gas tank has the hump on top the tank and I want to cut out the hump out of the hatch area so I took the BFH to massage the hump on the tank. Now I can cut out the hump in the hatch and lay some flat steel down and seal it off. While everything is out I am going to under coat the car and cover most of eveything I removed in some black rust encapsulator. Also going to install my Calan dual 255 fuel sender assembly. Hopefully my paint will show up so I can get painting on New years.
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yhype

Proven Member
332
11
Nov 3, 2002
Thurmont, Maryland
Over the last month or so I was able to get the rear end stuff all cleaned up and painted, got the rear hump cut out and new sheet of steel welded and sealed down in the hatch area. Also assembled my Calan double pump fuel sender unit all put together, used my Walbro 255hp and old original fuel pump, had to massage the sender hole in the tank just slightly to get them in. Got a bunch of misc sized electrical connectors so i can make everything modular for easy removal and assembly, and a bunch or shrink wrap. Still trying to locate a decently priced MIL-spec connector for the engine harness unfortunately. Bought and installed some non-powered side mirrors for the car so i'll only have a total of 4 wires in each door.
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