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95 TSI AWD Build Named Bloo

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bradselph

Supporting VIP
917
10
Jun 14, 2010
sebring, Florida
Well i figured i would start a build thread to just help keep track of things.

I purchased the car as a project in February of 2012.

I borrow my fathers truck rented a U haul trailer and made the 80 mile journey to pick it up and drove home.

This is a quick stop on the way home.
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At home finally!
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All the goodies that were a bonus to buying the shell. It came with a newer split thrust bearing block with evo 9 rods and pistons, a complete 1g head, and all the other parts necessary to put the car back together.
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The interior was very clean and missing very few parts. Sorry for the bad picture didn't realize the sun was so bad.
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Only 70K on the odometer. :D
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Got it tucked away ready to be worked on.
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The original plan for the car was to use it for a awd swap on my 1999 Spyder GS that i turboed back in 2010, well plans didn't work out that way as i wanted to build a Coupe after getting annoyed with the convertible.


I started tearing ento the car a few days later and found a nice amount of goodies.

Nasty and naked!
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EEPROM ecu
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AEM Big brakes
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Rear vented rotors :p
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Later on i got deeper in the tear down of the car and realized the fuel tank was FULL! OMG The car was sitting since 2005 with a full tank of gas, so i had to drop the tank and clean it. i also discovered the quickly you gotta remove the rear subframe to drop the tank. WTF

Nasty subframe.
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Clean subframe. :thumb:
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some time went by and i been neglecting the Spyder so i took it to a dyno day just to see what it had in it. Results were not the best but surprising! :cool:

Strapped down.
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Video of best pull.
https://www.youtube.com/watch?v=hGRgUZ7rAVs

Results.
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Back to Bloo, i drove to Orlando and picked up a better dash that didn't have peeling issues around the defrost vents. and while it was out since the car wasn't gonna have Heat or A/C i stripped the dash underneath.

Before.
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After.
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I also removed all HVAC components while the dash was out.
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I also stripped out some other things from the trunk, like the spare tire, jack/tools, and the windshield washer assembly.
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After all that i started on the interior by stripping the sound deadening on the floor and the firewall. i then reinstalled everything that i had on hand. i lost several of these pictures sadly.

I had plans to build a 2.4 Engine with a 2g DOHC head before getting Bloo, so i had a freshly machined 2g head with bronze guides sitting in a box waiting to be finished.

So in came the parts!

Manley springs and titanium retainers.
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Revised Lifters
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Installed springs and lifters.
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I also cleaned up the 7 bolt block and installed some ARP head studs.
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Finished the BSE with a true sprocket delete.
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Installed and torqued down the head.
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DKS 280 cams installed.
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FFWD FFOFH
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After all that was done i had to take a few weeks break but it wasn't long before i pull out the sand blaster and cleaned up the trans and Tcase. then i was ready to install the engine and trans in the car.

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While i was at this stage i installed a 2300 pound pressure plate that felt like a 2100 with a ACT sprung 6 puck disc and Fidanza light weight Flywheel.


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After installing i tapped up every possible hole to insure nothing bad got inside while i waited on other parts.
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I then started buying the other items need to get it going and look good.

Vent pod installed, the gauges were cheap ones that were laying around just to check fitment.
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Chrome Plug wire cover.
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Ebay stock fitment manifold, was free but i later found out why it was free as any turbo i put on it hit the block. :|
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Started plugging in everything and routing the wires.
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Just a cool picture :rocks:
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I got my walbro 255HP installed
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My first of many holsets, this is the 8 blade 58mm.
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Ebay SRS catback exhaust fit pretty good!
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BEP Bolt on housing!
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Checking water pipe clearance.
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Recieved my FP manifold
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Painted and temporarily installed.
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Got these from a friend just so the car would have a matching set of rims, there to big for my liking but they had some hoosiers on them and free. :p
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I received my battery and tray from extremepsi.
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So I then installed the gauges i had.
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I later on started up the car for the first time! i didnt have any exhaust or intercooler pipping so it was kinda loud but sounded nasty :hellyeah:

[ame=http://www.youtube.com/watch?v=WUa-i9cnUbw]Talon hx40 280 cams no exhaust 2nd startup - YouTube[/ame]


I then mounted my intercooler.
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I also received my o2 housing from punishment racing.
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Installed everything else including a fp 4 inch intake and k&n filter then started driving and having fun with the car.
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Car was fun for a few weeks then disaster!
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So i sent that pile of scrap to justin to see what could be done and it wasn't to be saved. only thing useable were the compressor cover and bep housing. so he built be a new 8 blade turbo and sent it out. while i waited for this to arrive i received my methanol/water injection system from Snow performance.

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Turbo received!
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Got everything installed!
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Started driving the car for a few more weeks, and realized the clutch was slipping. the 2300 pound pressure wasnt enough. i realized i had a ACT pressure plate already that is a 2600 pounder that i thought was a 2100 untill further inspection. so that was installed and fixed the slipping issue.

a few months went by and the huge 18 inch wheels got old so i picked up some rota knock offs and installed some 225 falkens on them.
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Installed some new headlights, made the entire car look a million times better OMG
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I then went junk yard hunting just to see what i could find. It turned out very well as i found a 95 GSX with a complete rear subframe. so i took that home and while i was there i grabbed the awd swap parts that were left to sell or use later. the best part about that subframe was it had a manual 3.545 rear LSD differential and axles. i quickly swapped these parts over to Bloo.
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I then installed a new aluminum radiator and prothane engine mounts all around.
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The car was then ready for some drag passes, i had a conservative tune on 32psi with 93 pump gas and 50/50 water/meth mix, ran a best time of 7.8 @ 93.4mph. Was spinning a bit out the hole but still managed some good 1.7 second 60 foots. the car was driven to the track and back from the track over 70 miles each way.

My uncle was very excited in the video ROFL
[ame=http://www.youtube.com/watch?v=emAWeTM8U4Y]Talon hx40 7.8 at 94mph - YouTube[/ame]

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A week later i drove the car another 65 miles each way to bradenton motorsports park and ran a good 11.9 @ 116mph with my little cousin in the car :p

[ame=http://www.youtube.com/watch?v=UUM6jqcrS10]11.9 116mph jan 20 2013 Bradenton IFO test and tune - YouTube[/ame]

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During the 11.9 run i noticed some bad missfires in 4th that were not apparent at the 1/8th mile so i upgraded to a MSD ignition with some 300m coils.
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Shortly after upgrading my ignition i noticed i seemed to be pushing some coolant. so a teardown was needed again. i replaced the headgasket and upgraded my BOV to a 50mm. I also sent my turbo off to justin again to be check out as it had some extreme thrust plate wear, and while it was in his hands i had it upgraded to a 60mm 6 blade! :hellyeah:

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During the wait time of over a month for all the new parts i sold my Spyder to my uncle and purchased a brand new 2012 f150 to haul this thing to the track and back without worry of breakage at the track.

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I then finished removing the HVAC control's by installing a carbon fiber piece in the dash. and switched over to all AEM gauges.
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Another week went by and i received my new turbo from justin and quickly installed everything! :hellyeah:

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Also with the addition of my new truck i was able to drive and pickup some E85 so i converted to e85 and got some FIC 1600cc injectors installed. i also contacted a local friend who retuned my car on e85. we only got up to 26-27psi of boost with e85 as i didn't have enough fuel pump to support more boost.

So i loaded it up on the trailor for the first time and drove out to lakeland motorsports park again to run the 1/8th mile.

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While i was there i ran a new best time of 7.5 @ 97mph I also used the wet box this time as i wasn't afraid of breaking the car. The clutch started slipping bad after that pass so i packed up and went home.

[ame=http://www.youtube.com/watch?v=pj1JjSS33tA]Talon hx40 7.5 at 97mph - YouTube[/ame]

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So when i got home i ordered a new clutch and a inline 255 fuel pump with a fuel lab AFPR.

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I then got it all back together and went out again to lakeland motorsports park to do a some new runs with the new fuel setup and new clutch, only to roll out the hole 2 times and trap nearly 97mph on low boost with afrs pig rich up top. :thumb:

on the 3rd pass i upped the boost and retuned the injectors only to be rained out. :cry:

I also received my custom tag
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Then out for a test drive i gave the car a good 3rd gear tuning pull out to 8500rpms only to shred a alternator belt LOL

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Later that week i drove the car to work just because streetcar. :hellyeah:.

and on the way home it started knocking pretty bad as i was pulling in it stalled.

So i pulled the engine out completely to inspect what went wrong.

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1 of the rods was also bent.
Shortly after pulling my own engine i found myself in the upullit yard in orlando scouting around for a 91 plymouth laser RS that they just received and my instincts told me it had to be a turbo model.

when i finally found it i was amazed to find a nice complete 4g63 6bolt! :rocks:

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a couple hours later it was out.

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Got home with the new engine and started the tear down, the odometer on the car said 112k miles and the engine looked almost new. the block is a standard bore block and crank in perfect and uncut. the head is a virgin head never been touched no cracked valve guides or anything the car was well cared for it seems like.

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So while the car is down i made a new plan that's being set in motion already.

The new plan included a 6 bolt block built with some wiesco/manley rods, arp mains and kiggley girdle. The head is not fully decided on yet but will get a good treatment to compliment the bottom end as well. while all this is getting worked on justin has received my turbo once again to be inspected and clean out all the metal shavings. I will also be moving away from the bolt on options and going with a T3 setup.

After i receive my main studs, girdle, pistons and rods i will be dropping the block off at the machine shop to get bored, deck, cleaned, and line hone the mains.
 
Well its been a few weeks, Figured it was time to update this.


I dropped off my block at the machine shop 2 weeks ago and went and picked it up yesterday.

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I then got everything out and ready to go in the block.

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Sadly i forgot to remove the oil squirters before i gave the block to the machine shop and now they are gone. :ohdamn:


So for now i packed everything back up and ordered everything i need to get the car going again besides exhaust parts. :hellyeah:

I will give another update when all those parts come in and i start installing them.
 
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Jeez! You make it look so easy LOL

Very cool build, despite the issues you've been hit with. GL with the coming work :thumb:

Haha thanks :thumb:
 
Nice work man. You're build has a "zero to hero" kind of feel. The car came out well!

Thanks, Hoping to hit a 10 in the 1/4 or a high 6 in the 1/8th very soon. :hellyeah:
 
Hey man great build, sorry to see the motor give up the ghost, but you look like your well on your way to a new beasty setup:cool:.

I believe I may have met you briefly a little over a year ago at a dyno day where there was another blue 95 AWD Talon there with a pretty wicked set up (parted out though now:cry:), but he had a fuse issue on his inline fuel pump and had to settle for 400hp that day. I was inspired by that car and found a blue 95 AWD Talon (auto tranny though) myself, so thanks for keeping me going and good luck with the new build:thumb:
 
Hey man great build, sorry to see the motor give up the ghost, but you look like your well on your way to a new beasty setup:cool:.

I believe I may have met you briefly a little over a year ago at a dyno day where there was another blue 95 AWD Talon there with a pretty wicked set up (parted out though now:cry:), but he had a fuse issue on his inline fuel pump and had to settle for 400hp that day. I was inspired by that car and found a blue 95 AWD Talon (auto tranny though) myself, so thanks for keeping me going and good luck with the new build:thumb:

Thanks, I may have met you that day but honestly can't place you to a face as I met a lot of nice people that day. I do remember the blue car your referring to as well, I also remember seeing an amazing amount of Evo 1-3.
 
I received a pretty large box of parts last week.

In that box was

4 oil squirters with check valves and crush washers
A set of ARP L19s
OEM head gasket
OEM front case
BSE delete
Gates Waterpump
New auto tensioner


I quickly got to assembling everything

I started by putting the waterpump and front case on to grind down the 2g engine mount to fit and then painted to avoid rust.

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I then moved to the bottom end by blocking of the rear balance shaft bearings then installing my ACL bearings, ARP Main studs and Kiggly Brace.

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Then weighed, Gapped the rings and assembled the pistons and rods, then installed them in the block.

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Installed the BSE delete and torqued everything down.

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Timing gears with the auto tensioner, i also painted it to prevent rust.

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Installed my AWESOME looking L19s

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Head installed and torqued down.

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Then i bleed and installed my 3g lifters with rockers.

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Last but not least i installed my cams, cam gears, timing belt, valve cover, and intake. the engine is basically ready to go in.

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For now im waiting on a 6 bolt AWD flywheel as all i have are 7 bolts. ROFL
Then i need a t3 manifold and BEP t3 housing for my hx40.
 
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cat VS downpipe? explain more?

I might have misread but didn't you put on a Catback? Sorry definitely a noob, but I seen many others put catback exhaust systems on their talon and I always thought having an open down pipe helps more with HP.
 
I might have misread but didn't you put on a Catback? Sorry definitely a noob, but I seen many others put catback exhaust systems on their talon and I always thought having an open down pipe helps more with HP.

It was a full 3" exhaust, the word catback just explains the exhaust from the catalytic converter back.
 
Update Time!

I ordered a new 6bolt AWD Fidanza Flywheel, found a good deal on a T3 DNP Manifold, and even ordered my BEP t3 housing for my hx40.

Everything came in a few weeks later even my Turbo came back in from justin!

I didnt get a picture of the Flywheel before install simply because who wants to see a flywheel LOL.

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I then began to install everything back into the car.

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Then about all that was left to do was fab up a downpipe/o2housing for the vband outlet and make a dump tube for the wastegate before i could do the engine breakin.

So i cutup my old FWD 3" Dowpipe and used the 3" flange with a Bullseye vband to make a bolt on housing.

For my first time welding and doing pie cuts i think i did pretty good, even with a stick welder. :hmm:

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Fully welded and added a o2 bung.

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I then cut and welded up a dumptube, simple but it works.

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All buttoned up and ready.

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I began to do the motoman breakin with wastegate pressure, everything went smoothly during the breakin, now im gonna check the torque on my headstuds and change the oil, While the oil is out im gonna port my filter housing because during the 3 full throttle breakin runs i noticed oil pressure peaking about 120PSI at only 6200rpm OMG.

So not much longer before i can go get some new track numbers with this setup. :thumb:
 
Its been a little while since i updated this.

I finished the motoman break in and drained the oil did a few mods to the oil filter housing and got oil pressure to a reasonable level of about 85psi at 7k rpm.

Everything was good so i loaded it up on the trailer and me and my uncle went to PBIR. Arrived a bit late at night, passed tech inspection with a warning that i can only make 1 SOLID run and then i couldn't go any faster than a 14 second E.T. since i didn't have a helmet or any safety equipment. :|

so i decided to target a bit higher boost number than i really wanted on a first pass, but sense i was racing against my uncles 383 truck i figured why not, so i set my boost controller to about 25psi and let it rip.

Did my little awd burnout staged and waited what seemed like forever for my uncle to find the line. :ohdamn:

Launched pretty hard, spun first and short shifted to second causing a long bog, caught 3 and 4 nice after that i turned a not too bad 12.2 @ 120mph run.

Video and time slip.

[ame=http://www.youtube.com/watch?v=M5sUChvBi_g]Me VS Uncle - YouTube[/ame]

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Sadly during decel of that run it felt like i slammed on the brakes and smelled rubber burn like a tire was rubbing on a fender the sound was horrible so i shifted to neutral and the engine stall instantly, popping the hood looking around i seen nothing wrong even underneath the car was fine. Attempted to start the car and it would only turn over not fire, looked under the hood while i attempted to start it and the cam gears were not turning with the crank! WTF

Later inspection after i loaded the car up and got it home i discovered about 120 or so teeth missing on the timing belt and a locked up oil pump.

so the partial rebuild began with pulling the engine out and inspecting and cleaning everything. The only damage found besides the oil pump were 2 slightly bent valves that got replaced and relapped. :thumb:

then ordered all new seals again for the things i need to separate, and new bearings because mine were fine but showed small spots on the surface suggestion contamination most likely from the oil pump.

Spent all day Friday cleaning and rebuilding the engine, then all day Saturday reinstalling the engine, at about 9 pm Saturday i fired it up and it idled perfect.


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[ame=http://www.youtube.com/watch?v=ddwy3Qq85Ak]First Start Up After Oil Pump Failure - YouTube[/ame]

So with all that, im still here and never gave up now to go get that first 10 second pass! :thumb:
 
I'm not sure what caused the lock up other than some side loading in the oil pump case, I had no signs of oil starvation on the bearings or anywhere else, and had good oil pressure the entire time. The pump did have helical gears, now I'm running straight cut gears.

The builds tab well... I stopped counting that a long time ago.
 
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