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greengoblin's AWD Project

greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
INDEX

Post 1: Eagle captured
Post 2: Cage built
Post 3: Fuel cell
Post 5: Hording parts
Post 6: Hording parts
Post 7: Sound deadener removal
Post 8: Sun roof ( roof skin removal)
Post 10: Cleaning of the wells
Post 11 : Racked (a poor mans lift)
Post 12: Undercoating and seam sealer removal
Post 17: Rear knuckles cleaned and coated. 3G UCA beefed up and coated.
Post 18: Start of upper spring hats and reinforcing rear cross member.
Post 20: Rear cross member solid bushing built and installed. Dampener forks coated. Upper hats done.
Post 23: Bearings in SCP front UCA and front LCA
Post 29: K&W coil overs Dg and Robi Spec style
Post 32: Rear UCA and knuckles loaded with bearings
Post 33: Front Cross member bushings greengoblin and black_gst style.
Post 34 Comp Works Rear Trailing arm, lateral arm and toe arm.
Post 35 Front cross member reinforced and powder coated.
Post 36: Front knuckles shaved and coated. Power steering rack rebuild.
Post 37: Stitch welding
Post 38: Rear diff mount welded on to cross member and cross member powder coated.
Post 39: AMB Aero wide body kit arrives
Post 42: Quick look at kit
Post 44: Comp Works splinded rear sway bar
Post 45: Eagle has landed( for now)
Post 46: & 47: Body kit fitting.
Post 48: Body/fiberglass work
Post 64: fiberglass work



History

So after building my GST and making enough power to do burn outs on the highway at 80 I decided AWD was in order. So I sold my GST to my little brother and started this build. It's a 95 Eagle Talon AWD. These are the pics right after picking it up and the start of my journey. My plans have changed many times during the build already and I'm sure more will come. It still will be a mixed use car with a Very heavy road race? hill climb theme. I hope you enjoy reading about what I have done and I'll try to bring the build thread up to where I'm current as quick as I can. So here we go.

Date 11/29/07
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greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
First stop was to the cage builder. Dennis at Black Stone Racing here in Boise built the cage and seat brackets as well. I was in China while it was being built. So something where not done (well) right. So Those things will be fixed at a later date


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greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
While the car was Dennis's I figured I should go ahead and figure out the fuel cell setup. After talking to Dennis and drawing a few different plans this is what we came up with.


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Three Door Slosh box. The cell has foam too.

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Since I want to keep the factory gage cluster we came up with this to mount the fule level senders.
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I also want to be able to fill the tank up with out opening the hatch. So here is how we did it.
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Mount for fuel pump. Aeromotive eliminator
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Fire sheild for cell.

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Since I plan on running some for of alchole based fuel I had the cells anodized.
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Dyesuperman

Proven Member
523
19
Mar 10, 2009
Minot, North_Dakota
I love this build. I have looked at almost every page of it on mitsu-media I believe and it is phenomenal. Props on building one of the most amazing 2Gs ever! I can't wait to see this thing finished.
 

greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
I have been hording parts as I go along. When I find a good prices I pick things up here and there.
Here is what I have hidden away.

Since I do powder coating I shot a few parts for fun.

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I ported my oil filter housing. Hope it helps keep the pressure down.

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Picked up this head for a good price. I'm going to have it gone through and put pack togther.
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Did I mention it is CNC ported.
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Cams
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God's gift of valve springs for the 4G63.
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Cam gears.
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My favorite bolt. LOL

ARP crank bolt.
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Jay racing saturn alt relocation kit.

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Kiggly 6bolt girdle.
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Oil pan
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greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
More of the hording!


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Fuel stuff : Magnus -10 fuel rail, aeromotive AFP and Eliminator Fuel Pump
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JM fab intake
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AEM will be contolling everything this time.
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Need to stop. EVO calipers with JDM galant knuckles.
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CDI for COP
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Sparco harnness
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Soild rear diff bushings: Theo
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Scatter sheild
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seats
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FFtec throttle body.
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I pickde up a pretty rare Taboo Speed Billet clutch fork. This thing is beefy.

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greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
Some time in 2008

One of the goals is to take out wieght.
Removing sound deadener.

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Scrape, scrape, scape. It was not a very fun job. Just a little bit left up front under the dash area. I need to pull the steering column so I can remove the jute mat to get to it.
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greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
Some time in 2009

I'm taking the sunroof out of the car and putting a non sun roof skin on. After all we are trying to light this car up right?
I had not seen this documented in many places so I took a lot of pics.

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I used a Dremmel with a cut off wheel to cut the brazing out. That gave me more control than using my angle grinder. I don't want to cut any deeper or more than needed. Not the best pics. Sorry.

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I used a spot weld cutter to get the roof skin off.

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The roof skin is off! Woot. Now it will sit for a bit. I have to work on getting my powder oven up and running again.

In case you wanted to know what a spot weld cutter looks like.

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Roof skin

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No roof skin

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greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
01-18-2009

Since I sold Austin(northendtrooper) pretty much my complete OEM driver side suspension after his Ken Block drift episode. A little bit of cleaning on the shell was in order. I figured since the the suspension is out of the way why not. I have to say it was a mess. There is quite a bit of work left. My car is now 2lbs lighter. No really that is how much crude I pulled off just one wheel well.

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greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
Sometime in 2008

So I built a rack a little while ago and finally have the pig up in the air. This will make cleaning and working on the underside so much less of a pain.

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For those who want to know how the hell I got it up there.

I used four factory jacks, four jack stands, 24 cinder blocks, 2x6 pieces to spread the load on the bocks and a lot of time. I went up very slowly. I'm gong to build a retaining wall in my basment/very large crawl space so I had the cinder blocks on hand. Here is a pic that kinda shows how I did it. The block in this pics have been moved around already since the car was on the rack. Still you get the idea.
Yes, I'm a bit crazy.

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greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
01-20-2009 to 01-23-2009

I'm starting to remove the undercoating. It really wasn't that bad. Seam sealer on the other hand sucks to remove. I found it easiest to take my Halogen lights and place them on the back side of the sheet metal. This really softed up the under coating and it comes right off with a painters tool.

Here are a few pics.

Lights on the back side.
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You can see that the under coating softened up.
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Like buttter
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Not even one side and I still need to remove the seam sealer.
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Here is what 1hr, angle grinder and twisted wire cup brush can do for you. I have to say this is the only way I could see removing the seam sealer. It worked very well but makes a hell of a mess.


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I now have all the wheel wells pretty much clean and the entire under side. I'm going to have to take the rest of the paint off the seams before I start welding and burn out what is left of the seam sealer. That can wait until right before I start to weld though. I went through one twist wire wheel and one disk. There is almost nothing left of them. I still have to do the inside.:screwy

The pass side rear wheel well
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Pass side front well
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I now have all the wheel wells pretty much clean and the entire under side. I'm going to have to take the rest of the paint off the seams before I start welding and burn out what is left of the seam sealer. That can wait until right before I start to weld though. I went through one twist wire wheel and one disk. There is almost nothing left of them. I still have to do the inside.:screwy
 

GsXdSmKingGsX

Proven Member
4,582
31
Dec 13, 2008
Plainview, Minnesota
So what made you choose AEM for engine management?
 

NWHTanK

Proven Member
1,388
270
Apr 23, 2011
Odessa, Missouri
Do still have the engine out? I was wondering if u could post a pick of the front suspension crossmember? I can see it in one of your pics but its blocked buy other things. It would help me with my build and thanks. Great build buy the way...
 

greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
So what made you choose AEM for engine management?
At the time of that post I chose AEM because dsmlink was only on V2 and I was still learning about engine mangament. At this point I dont know if I'll use AEM. I have been looking at Motec al ot latley. So IDK what I will use in the end.

Subbed for awesomeness!! One day ill go crazy like you on the gsx.

Thanks!

If you don't mind me asking, how much did the galant knuckles cost?

Around 500 from mitu-missile(sp) here on tuners. That was several year back though.

Do still have the engine out? I was wondering if u could post a pick of the front suspension crossmember? I can see it in one of your pics but its blocked buy other things. It would help me with my build and thanks. Great build buy the way...

I have TONS of suspension pics that I'll be posting up as I bring this build up to speed on this site. If your in a big hurry you can go here: Goblins AWD project - Mitsu-Media

That is where my most uptodate build thread is.

I love this build. I have looked at almost every page of it on mitsu-media I believe and it is phenomenal. Props on building one of the most amazing 2Gs ever! I can't wait to see this thing finished.


Thanks you sir! Post like this keep me going!


Thanks again everyone,

KEvin
 

greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
04-18-2009 to 05-28-2009

I did a little bit of prep work on the other rear knuckle. Figured I show some before and after shots.

Here what mine looked like at the start.
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Here you can see where I removed the casting flash.
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Next will be media blasting and treating with iron phosphate before I powder coat them.:)

I just finshed up powder coating one of the rear suspension knuckles in black semi gloss to freshen it up. It looks much better I think. Not much of and update but at least I did something to the car. :)


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I picked up some 3g upper rear control arms today to see how well they will work. They look to be very stout. I'm going to still beef up the ends where the knuckle bolt on since I plan on running sphereical bearing there and that is going to make my peak loads go up.

You can find some of what I've have found out here:3g rear control arms in 2g - Mitsu-Media

Here are a few pic of the rear upper arms. I'm going to blast them and powder coat them. At the moment they are ditry. You can see more in the link above.

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Final had a chance to get the rear upper arms beefed up and coated. Yeah!

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greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
06-09-2009-07-19-2009

My neighbor and I (mostly Jake) started machining my upper shock mounts. These are based of the units that DG made public. It's really awsome that DG did that and a BIG BIG thanks to Jake for milling them for me. More to come soon.
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I removed the stock rear diff bushing out f the rear crossmember a few days ago. Now I hav to decided if i'm going to use the soild ones I have or pick up a set of poly. HHMMM I'll have to tin about it more. I can't wait to get the up graded diff cover that's being made. It's looks sweet. I'll post pics when I get it.

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Let it be known that these bushing are fluid filled with a nasty black goo. You have been warned!
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My father and I beefed up the rear crossmember. I'm really happy how it turned out. I should be getting my dampners and will beef up the front crossmember soon. More to come very soon!

Holes cut for the plug welds.

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My father welding the plugs.
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Plate fully plug weled in place.
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Added a gusset here for fun.
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We stitched up the sides.
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I need to do a bit of clean up then on to coating it.

Kevin
 

greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
07-28-2009 to 08-07-2009


These came in today. They are the spherical bearings for my upper shock mounts that I'm building off DG plans.

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I should have for more for my front lower control arms tomorrow. It's strange how some times the littlest parts make you the most excited. These bearing are just neat. IMO

Just finished making the soild crossmember bushings. I hope to install them and finish my upper shock plates tomorrow. I also managed to get my dampner forks blasted and coated today too. Slowly but surely as they say.....

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Here are the installed pics.

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We also finished up my upper shock mounting plates!!!!
Now the question is do I hard anodize them or shoot them in powder. If do powder them what color? Hmmm
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greengoblin

Supporting Vendor
1,573
391
Mar 10, 2006
McKinney, Texas
08-27-2009 to 09-17-2009


My brother just sent me a pic of my front lower lateral arm (lower control arm) with the new spherical bearings installed. You can also see the standoffs in the pic too. I decided to do this after reading DG's website info.

Far North Racing - The Car - Modified A-Arm and Other Stuff

I don't normally post crappy cell pics but this is one of those thing I'm excited about. Can't wait for them to get to me so I can really look them over.

If you really want to learn about our suspension then do yourself a favor and check it out.

Far North Racing - Home

Enjoy the crappy pic. I'll post good ones when I have the arms in my hands.
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Had some free time so I made marks on my upper control arms to make changing the camber a bit easier. I got this idea off dsmtuners. I just used a scribe, t-square and patient. I'm happy with how it turned out. The marks are in 8th inch increments. I will most likely put a line through the center plan of the hole on the upper washer too as an alignment mark.


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Here a up close look at my front lower lateral arms loaded up with the spherical bearings and standoffs. good stuff!

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Here you can see the groove I had cut for the retaining clips

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The SPC front upper control arms have crappy vulcanized rubber bushings in them that are not going to cut it. So I went ahead and load the inboard pickups with spherical bearings. To do this I had sleeves built for the bearings and cut grooves for the retaining ring. The circle clips had to have a bit of the edge ground down where the pliers engage them but the dremel made short work of that,

They turned out killer! Here is a peek.


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