Street Build ITFLYS - 1Gina2G

[Justin DuBois]

Throttle Body - Rebuilt

It is time to swap in a rebuilt 1G throttle body. I have had a long standing issue with the shaft seals, waiting to be addressed and today is finally the day

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Amazed the old gasket came off nearly intact.

Rich Howell gave my e-bay 1G TB find a complete overhaul and refinish. Here are the comparison photos:
New mil-spec shaft seals, half-shaft mod powder coated gloss black and a killer silver/sparkle/clear combo for accents. Polished brass, and a 2G mod to better work with the EGR vacuum lines, which leave an additional port to support the bottom nipple on my greddy BOV.

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Super Bad ass job - did me proud people!

New Gaskets, a slight tweak to the water lines, and it’s right were it goes, torqued on to spec.

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[Justin DuBois]

Phase 1 (Exterior)
Things to locate:
Washer nozzles (that don’t suck)
2” thick 2Ga Eclipse door caps - Looking!

Body Shop:
Paint 2Ga door caps
Protective film install

Phase 2 (Engine and Interior)
Things to locate:
Low profile adjustable CAM gear hardware
Grey plastic interior door switch trim
Exhaust manifold studs and nuts (located!)

In progress:
Hood Latch - re-spring and refinish
Crank Pulley - Clean and paint
Bunch-o-brackets - Clean and powder-coat
Water Pipe powder coat
Water Neck powder coat

Things to do:
Interior Mirror Trim - epoxy reinforcement
E3 Manifold heat shield bolt repair (repaired!)
Modify TB Covers - cut and install (modified!)
H2o overflow sensor harness plug - (installed!)
PS Pump install - (when brackets return)
WEB Cam install - maybe?
2Gb CAS install - (requires a threaded intake cam)

Phase 3 (Suspension and Sub-frame)
Things to locate:
Front fender liners
Suspension arms with new ball joints
Suspension arm pivot replace or service
State of the art coil over struts - (OHLIN)

Things to do:
Refinish 3" exhaust components
RM AWD rear sway bar install
Rebuild and re-finish brake calipers
Rebuild and refinish suspension and sub frame components as needed
ABS light investigation (after driving again)
Track day alignment

 

[Justin DuBois]

This is the improved cut to the good timing cover. This allows the top and bottom covers to have 5 bolts or more so hopefully they will hold shape, and still give access to the tensioner.

It is much easier to remove them as separate covers regardless.

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[Justin DuBois]

Bigger torque wrench arrived, so now the crank gear is back on for real.

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and… Rich has a whole box of freshly powder coated parts ready for me. I love rust free parts!

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[Justin DuBois]

Drown myself in as many clean rust free powder coated parts as I can.

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[Justin DuBois]

Time to hang the AC compressor back on the engine. I forgot how big of a PITA it is to get that sucker aligned to bolt back on, by touch.

After several frustrating minutes, I decided to use a rope trick to hold the weight, and get it closer to where it goes, and get the bottom timing belt side bolt started first.

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[Justin DuBois]

AC compressor back where it goes.

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Next done - bunch of random tasks, working towards bolting powder coated things back in the engine bay.

With solenoids back on the bracket, the updated hose configuration can go forward. Ports P and E now go to the same backside Throttle Plate source. I removed a T and cut a couple new hoses to go direct to the TB ports individually.

Now none of the ports will be capped. Looks less modified?

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With the AC compressor in place, the AC hose bracket can go on.

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Brake Fluid Reservoir bracket, and wire harness tie down back on

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Put the Alternator bracket back in place

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[Justin DuBois]

Minor hose routing and shortening, groups and hangs better.
Before:

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After

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One of the nuts in the back cover under the motor mount was binding up on the bolt, so I cleaned up the threads with tap and die.

Lower cover and hardware, Installed.

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[CrackedDSM]

Love seeing DSMs keep their A/C. Bring back fast with class!


Love the build and the rope trick. Gonna have to remember that in the future as I’m gonna keep the A/C as well(Florida without A/C sucks. I don’t care who disagrees. Lol)

 

[Justin DuBois]

Love seeing DSMs keep their A/C. Bring back fast with class!


Love the build and the rope trick. Gonna have to remember that in the future as I’m gonna keep the A/C as well(Florida without A/C sucks. I don’t care who disagrees. Lol)

Oh I got a story about A/C.

I was being Mr smart guy, and removed the A/C belt before an epic road trip called Open Track Challenge, where in the touring class, you are required to drive your street registered track day car from track to track, 7 days in a row, Track event each day.

As we are leaving from home in LA (at the time) on our way to Pahrump - Nevada, (middle of summer) I dropped the news to my GF, now Wife that we have no A/C. She just looked at me gob-smacked, and said, you do know where we are going right? We are going through the middle of the desert, and its 105 deg in the shade.

Needless to say, after a shirt soaked sweat fest on the road, I put the belt back on that evening. And it has stayed on ever since.

 

[Dericsh]

my GF, now Wife

At least it wasn’t a deal breaker

 

[CrackedDSM]

Oh I got a story about A/C.

I was being Mr smart guy, and removed the A/C belt before an epic road trip called Open Track Challenge, where in the touring class, you are required to drive your street registered track day car from track to track, 7 days in a row, Track event each day.

As we are leaving from home in LA (at the time) on our way to Pahrump - Nevada, (middle of summer) I dropped the news to my GF, now Wife that we have no A/C. She just looked at me gob-smacked, and said, you do know where we are going right? We are going through the middle of the desert, and its 105 deg in the shade.

Needless to say, after a shirt soaked sweat fest on the road, I put the belt back on that evening. And it has stayed on ever since.

Absolutely. In my younger days I'd pull the A/C out and pretend that it wasn't absolutely hellfire misery in the car for an extra 10 hp and maybe 10lbs of weight reduction, but as I get older..I like my creature comforts too much. I think my favorite car to date was my 2GB Eclipse. Had A/C, power steering, electric everything, leather power seats, etc. Tuned on a 14B/black box ECU, it wasn't a world beater but it pulled great, sounded great, and was just so generally enjoyable to drive. Gonna mimic that with the Talon as best as I can. Stock converter, 16G-ish turbo/power, and all the comforts I can have.

 

[Justin DuBois]

Can the plastic reservoirs for brake and clutch be purchased?

Forgot to post this bracket:

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[Mello]

Clutch is MB911648. STM has it listed https://stmtuned.com/products/mitsubishi-clutch-master-cylinder-fluid-reservoir-2g-dsm
Brake reservoir w/o ABS is MB534534 & comes up discontinued. With ABS is MB534535 discontinued too. Might check JNZ @DSSA.

 

[Justin DuBois]

Manifold maintenance:
I have new heat shields, and bolts. The threads in the cast iron hot parts needed some cleanup, to remove the built up high temp anti-seize.

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These bottoming taps are progressively flatter at the end, and after a couple rounds with each, the bolts thread in smoothly by hand.

One of the taps has a snapped off bolt. That’s going to take a little more effort to remove.

 

[Justin DuBois]

Clutch is MB911648. STM has it listed https://stmtuned.com/products/mitsubishi-clutch-master-cylinder-fluid-reservoir-2g-dsm
Brake reservoir w/o ABS is MB534534 & comes up discontinued. With ABS is MB534535 discontinued too. Might check JNZ @DSSA.

I got one of the clutch reservoir, but i don’t think the lid is included. the lid is the part worst off but still working

 

[CrackedDSM]

Manifold maintenance:
I have new heat shields, and bolts. The threads in the cast iron hot parts needed some cleanup, to remove the built up high temp anti-seize.

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These bottoming taps are progressively flatter at the end, and after a couple rounds with each, the bolts thread in smoothly by hand.

One of the taps has a snapped off bolt. That’s going to take a little more effort to remove.

Where’d you get the new heatshields from? Do you have the turbo heatshield too? Nice work, gotta do the same to mine for sure.

 

[Justin DuBois]

Where’d you get the new heatshields from? Do you have the turbo heatshield too? Nice work, gotta do the same to mine for sure.

EXTREME PSI : Your #1 Source for In Stock Performance Parts

www.extremepsi.com

 

[Mello]

Clutch Reservoir Cap is MB555135 and also shows discontinued. Google search comes up with lots of hits for it though. They were used on numerous platforms so you might be able to still find one. Are you wanting a new cap because of discoloration? I've Purple Power cleaned mine & it removed all the discoloration & restored them (brake & clutch) back to pearly white.

 

[Justin DuBois]

Clutch Reservoir Cap is MB555135 and also shows discontinued. Google search comes up with lots of hits for it though. They were used on numerous platforms so you might be able to still find one. Are you wanting a new cap because of discoloration? I've Purple Power cleaned mine & it removed all the discoloration & restored them (brake & clutch) back to pearly white.

The rubber on the caps is now very old, total deteriation is probably near. I was able to locate the reservoir caps at EXTREME Psi! I'm getting new now so the rubber will last many more years without deterioration.

 

[Justin DuBois]

I’m running out of parts back from Rich to install. The next batch is in progress.

With the o2 and turbo housing bolt holes cleaned out. I can put the o2 sensor back in and put the lower heat shield in place. 12-15nm is snug, not cranked on tight. I’d rather replace a bolt that falls out than have to drill and tap a stuck bolt.

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And I found a small bullet connector and some wire loom to fix the PS pump pressure switch wire.

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[CrackedDSM]

I’m running out of parts back from Rich to install. The next batch is in progress.

With the o2 and turbo housing bolt holes cleaned out. I can put the o2 sensor back in and put the lower heat shield in place. 12-15nm is snug, not cranked on tight. I’d rather replace a bolt that falls out than have to drill and tap a stuck bolt.

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And I found a small bullet connector and some wire loom to fix the PS pump pressure switch wire.

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That looks incredible.


So uh, if one wanted to buy your old rusty turbo heatshield, how much would you sell it for?

 

[Justin DuBois]

That looks incredible.


So uh, if one wanted to buy your old rusty turbo heatshield, how much would you sell it for?

I’m probably going to refinish the old one for the backup motor on the stand. You would be surprised by one of the heat shield I recovered. My original shield was looking rusty 15 years ago. I stripped it down with a SS wire wheel on a buffer, then hit it with some cold galvanizing primer. On top of that, I used a product that was hanging out in the RRE paint cabnet called “Steelit” - a stainless steel incorporated spray paint. It held up well for 10 years. It’s still pretty good. Id use it today, but It has an EGT probe hole cut that I don’t need or want anymore.

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[Justin DuBois]

Finished this repair of the harness plug for the H20 reservoir empty sensor.

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This plug is located in a high traffic area, where the hood prop snaps closed. This should last a while now.

 

[Justin DuBois]

Could not resist a little pre-look. I’m going to unbolt the manifold and do my best to drill out the stuck bolt, but before that, I can take a look at the new shield.

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