95 TSi AWD Build (Shiva)

[WES_393]

WES_393's Early 95 TSi AWD Build (aka Shiva)

Sections (Click to jump)
•Intro (you are here)
•Engine Build
•First Mods (not super exciting)
•Transmission, Drivetrain, Punishment FMIC
•Wheels and Suspension (plus 2gb spoiler)
•Holset H1E Install
•Holset First Startup (Video)
•Water Cooled Wastegate
•Engine Bay Cleanup


Intro​

Hey Tuners! Here is the past and current progress on my Early 1995 TSi AWD. I purchased the car in junkyard condition during April of 2011. She came with a hatch full of parts and a Chilton repair manual. My original goal was to just get it running! But now I'm aiming for the 500whp mark. This is what the engine bay looked like:

Here she sits today.

Enjoy! ​

 

[WES_393]

Engine Build​

It turns out she spun a rod bearing and destroyed the head, crank, and rod.

Carnage on the crank.

Now I already rebuilt this engine once. I had a wrist pin walk out (due to my own ignorance) and scar the cylinders. So this is the second and hopefully final build for a while.

Here's the block after a trip to the machine shop. Bored to 86mm to remove the damage, honed, and cleaned.

The donor crank that has been all cleaned up. New slugs in the oil gallies as well.

Here is the rockstar of the show. Manley 86mm forged pistons and eagle H-beam rods.

Note the size difference between the stock combo and the manley/eagle combo. The stock combo was also about 2x as heavy in my hands.

Bottom end assembled

That's one fresh 7-bolt!

Random pics of assembling the engine.

That's a 16g BTW. I plan to push it to it's limits then go with an HX35.

Blocked EGR port. Not pretty, but seals tight.

 

[WES_393]

First Mods (snore)​

Getting the car all cleaned up for the new engine.

I eventually ditched the COP for stock coils and NGK wires.

I don't need to say anymore about this.

I wanted a 1g BOV but wanted to use a 2.5" pipe, so I cut a 1g flange and welded it to a peice of 2.5" steel pipe.

Here is my rather crazy intercooler setup.

Walbro 255

Aeromotive AFPR with SS DSM install kit.

Wideband O2 sensor welded into the exhaust.

Gauges in the pillar pod. Top to bottom: AEM Wideband, Glowshift Oil Pressure, and Glowshift Boost

Mitsubishi stub shaft

Fresh flywheel and Exedy stage 2 or 3 or whatever (I can't stand that term) clutch. Supposedly good for 350hp. We'll see about that...

The bumper was pretty tore up so I repainted it

The turbo drain I made for the 16g.

I blacked out the tail lights and painted the TALON with the factory color of the car.

Stock 2g Eclipse rims before

And after

 

[JusMX141]

Build threads go here:

DSM Build Journals - DSM Forums


The Hangout is not the place for this. You obviously didn't research the build thread concept much prior to starting this thread.

 

[WES_393]

Drivetrain and Punishment FMIC​

Well, I think it's time for an update. Let's start where we left off over a year ago...

Shortly after that last photo I ran into issues with the transmission. So I yanked it out and dropped it off at Jacks for a Stage 1.2 build with a welded center differential. I also picked up a South Bend Clutch from TMZ along with a Mitsu TOB and accumulator delete kit.

I also replaced the rotted rubber carrier bushings with some Torque Solutions solid bushings.

Dropped in. You might also notice the engine bay was painted with black semi-gloss.

Then came the Punishment FMIC and modified/repainted 2ga bumper.

At the track with all the new goodies. Ran a slow but proud 14.3! To be fair, the corrected DA was over 8,000ft and I was still on 91 pump gas...

That Fall I converted to E85 with FIC 1150's and the same old 255lph. The resulting power increase was absolutely incredible. I went from around 20psi and very low timing to nearly 30psi and 17-18* timing across the board. It was stupid fast between lights, which is probably why I didn't see that pot-hole...

 

[WES_393]

Wheels and Suspension​

Naturally, I knew that a single blown tire meant I should replace the wheels and tires along with the entire suspension setup. I tossed on a set of lightly used Enkei EKM3's (18x8) and Pirelli P-Zero Nero tires (235/40). Also installed Tokico Blue shocks and HP springs, new OEM lateral control arms, Precision wheel bearings (not pictured), new rotors and Ceramic pads, and Energy bushings all around.

Let me add that finding an affordable set of rear rotors and pads for my Early 95 was very difficult. I knew Oreilly carried them, but the wait time and price was crazy. I eventually found what I needed at NAPA and still payed dearly. I think it was around $200 for the rear pads/rotors alone. WTF It also turned out that I still had the original suspension with over 150k miles of hard use. The shocks could be easily compressed by hand.

Before and after.

While the car was down, I finally found one of these nifty pieces.

End result:

 

[WES_393]

Holset H1E Install​

With the car much more steady and safe, I decided to shoot for 500whp. I was still considering an HX35 and remembered a buddy of mine was selling a Holset a few months back. My timing was perfect since he was in a very tight spot financially and nobody wanted to buy the turbo. I'd never heard of a "Holset H1E" so I low-balled and he accepted. Turns out this H1E is basically a 60mm 8-blade HX40 and was recently rebuilt by Holset. So I didn't feel so bad for paying a whopping $50 for it!

(16g on the right)

Because I'll be running E85 still and the car is street-driven, I opted for the .55 BEP housing. Picked up an FP Race Manifold, Punishment MVS O2 housing, and pieced together the feed/drain setup (with the great help of Justin and a few others).

(stock housing vs BEP bolt-on)

(modified FP restrictor)

The water pipe had to be dented, the coolant banjo removed from the block, and some material removed form the bell housing flange area. Tight fit!

 

[WES_393]

Holset H1E Install (Cont.)​

My latest task has been beefing up the supporting mods and setting up the SD sensors. A 400lph fuel pump, STM filter-to-rail kit, Manley valve springs, BC 272 cams (I know, they'll be replaced with Kelfords soon), GM IAT sensor, and Omni-power 4 bar (Mitsu style).

(Notice the Fortune Cookie that STM sent with my package. )

(IAT bung)

So that's my current progress! I hope to have the car running this weekend and driving around next week. I'll update when she's whistling and purring this weekend.

(Please, if you have any quick questions or short comments feel free to send me a PM. Not to imply that reply's aren't welcome, just trying to make the moderation staff's job a tad easier!)

 

[Nicklepage1010]

This thing looks great Wes.
Im going the same route, but a lot slower.
Is there anything you would have done different so far?

 

[WES_393]

This thing looks great Wes.
Im going the same route, but a lot slower.
Is there anything you would have done different so far?

Thanks! There's not much I'd do differently, I spent a good amount of time planning the whole setup. Having the manifold/turbine flange machined to increase the mounting angle VERY slightly would have helped. The H1E has a fat compressor cover.

If anything, I'd really like to try water-cooling the Tial wastegate. I might still figure out a way to do so. But honestly, it would be a "just because" mod since it's not necessary.

 

[barebackerr]

Stunning build. I hope to one day have the time and money to do this to my 99 gs-t.

 

[MathixPerforman]

hopefully someday my 2g will end up this sexy. Very nice build

 

[WES_393]

Holset First Start (Video)​

Got her running today.

[ame=http://www.youtube.com/watch?v=d7ZL89TGgIs]DSM Holset H1E- First Start 2 - YouTube[/ame]

 

[WES_393]

Water Cooled Wastegate​

Thanks for the compliments. Unfortunately, I haven't gotten far lately due to bad weather. But I still made some progress today. I decided to run water lines to the wastegate. For now they are just rubber hose covered with DEI heat shielding. I plan on doing some testing to see just how effective they are. If the lines are worth keeping, I'll redo everything with braided lines and whatnot. If not, then I just have a few extra feet of hose and heat wrap.

The line that's tucked under the PS pump will be moved. I was unsure of the heat tolerances of the DEI heat wrap, but after some research it should be fine sitting next to the manifold rathe than crammed where it is.

 

[tay97gst]

When I saw that Holset compared to the 16g my jaw hit the floor haha. Can't wait until I finally find a gsx so I can run an hx35 on it. Really awesome build man.

 

[WES_393]

Engine Bay Cleanup​

Small update on some recent changes. The Holset has been going great, but I'd decided the engine bay needed a little attention. Here's basically all of what I did:

-Moved AFPR to right above the fuel filter
-Moved coil pack to the AC bracket
-Routed the CAS, CPS, and coil pack wires through the manifold
-Ran throttle cable under the manifold
-Switched to a Miata AGM battery
-Fabricated a cage/basket for it to sit in with tie down bar and mounted it near the subframe
-Moved coolant overflow to the SMIC hole
-Mounted fuse box below the intake pipe
-Blocked the FIAV (which was slowly leaking coolant into the manifold)
-Made an acrylic spark plug cover
-Ordered a Calan catch can with all the hose, end fittings, and bulkhead fittings needed to install it

Pics:

Before

After

(big thanks to tsmith for taking these next two pics)

And a few glamor shots for kicks.