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My 1g DSM story: 1990 Tsi awd clean street machine

Smilinjay

Proven Member
290
92
Jul 9, 2013
Anchorage, Alaska
Man I was seriously thinking the other day about you. "I wonder if he's Made any updates"

And here I am surprised !! That intake manifold just looks awesome with that Polished rail!

Did you add gloss to the intake?
Thanks! I didn't add any clear to the intake manifold, just 3 coats of primer and 4 coats of VHT engine enamel.
 

Smilinjay

Proven Member
290
92
Jul 9, 2013
Anchorage, Alaska
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I decided to try some high temp paint on my exhaust manifold and turbine housing. I understand this stuff has a reputation for fading and peeling over time but the bare evo 3 manifold was becoming an eye sore. I would love to run an fp manifold but i decided it wasnt worth the money right now for virtually no performance gain. If this doesnt hold up ill sandblast the parts and try something else.
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RipperXX

Proven Member
5,793
162
Feb 23, 2003
Royston, Georgia
Haha thank you! I certainly considered giving up, but im really glad I saw it through.

Yep, that's the block out of my old car (the one that I was told was "built" LOL) and the stock head off of my current car. I may just have future plans for it...

I really liked the fd wheels, but I couldn't justify getting extended studs and spacers for a 16" wheel as I may be going with bigger brakes in the future. Also I really like the fitment of the evo8's with the slightly lower offset.


Extended wheel studs... I didn't need any extended wheel studs. Though best I recall I did use 5mm hub centric spacers all the way around. I hated the idea of the rear being wider than the front. There only required in the rear though.....along with some grinding. ;)
 
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Smilinjay

Proven Member
290
92
Jul 9, 2013
Anchorage, Alaska
Extended wheel studs... I didn't need any extended wheel studs. Though best I recall I did use 5mm hub centric spacers all the way around. I hated the idea of the rear being wider than the front. There only required in the rear though.....along with some grinding. ;)
Haha I guess I should have clarified, at the time I had the fd wheels I wasn't willing to do any grinding to make them fit so I would have run larger spacers. I liked those wheels but I think they are better suited on a track car with some slicks than on a car like mine. Especially with how light they are.


I pretty much finished up the motor this week, aside from a few minor things.(If anyone has a spare 90' water pipe lmk asap!) Everything went smooth but I had to get a little creative to do the timing with no special tools.
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And then I realized the inner timing covers needed to go on first... Oh well, only took about 30 minutes to redo everything. Its 100x easier doing this out of the car and with no balance shafts.
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That's it for now. I'm waiting on extreme psi's black Friday sales to buy a few last minute goodies before the motor goes back in. In the meantime i'm making some major improvements to the engine bay, but that can wait for another update :thumb:
 

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Smilinjay

Proven Member
290
92
Jul 9, 2013
Anchorage, Alaska
I decided to go ahead and dig into the wiring harness last weekend. It is in great condition and not hacked/spliced up but it was beginning to become a huge eyesore. Many of the connectors are unused with how much I have removed from my engine bay, and the tape and loom was dirty and peeling. So the plan is to strip it down, reroute the wires in a way that makes more sense, cover in new tape and loom, and tuck it all out of sight at the bottom of the firewall.
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The engine harness is finished up, also rerouted some of the fusebox wiring. I still need to wire in my oil pressure gauge and extend some wires for the alternator relocation but im getting there.

Speaking of alternator relocations, I got a jay racing kit for free from a buddy and its seems to be missing a few things.
Had to make a spacer for the tensioner to fit
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Also got my avid racing mounts. Im very impressed with the quality.
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Oh yeah, I also picked up some new wheels. Because that's the most important thing when your car has no engine in it...Right?
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89Patches

Proven Member
115
0
Dec 9, 2012
Trenton, ON_Canada
New wheels look great! What did you paint your timing cover with? Probably gonna do it to mine.
 

Smilinjay

Proven Member
290
92
Jul 9, 2013
Anchorage, Alaska
This alternator relocation is really starting to make me mad :banghead:
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Wiring extended
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I could never find the right length studs for my tb. Stock was way too long and the one that came with my vrsf kit was a little too short. So I just made 4 new ones out of allthread.
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Got the engine in late last night. It put up a good fight with the new mounts but everything seems to line up fine.
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Here's how I ran the wiring. Im super happy with how well hidden the injector wires are.
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Smilinjay

Proven Member
290
92
Jul 9, 2013
Anchorage, Alaska
I took apart my nasty faded afpr and polished the cover. Looks much better in the engine bay now.
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I found a crack In my 90' water pipe so I modified a later model one to work with my air cooled ofh. I had a buddy tig up the hole (I could never take credit for welds this pretty LOL)
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For my clutch setup I opted for a 6 puck unsprung act disc, xact streetlite flywheel, and the act 2100 pressure plate that I used previously. Hopefully it will perform similar to the infamous xtd stage 4, just using higher quality reliable components.
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I also picked up this low mileage 92' trans out of a bone stock galant vr4 for super cheap! Im hoping it will out perform my tired stock transmission. The taller 1st gear is a bonus too.
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GST with PSI

DSM Wiseman
2,696
1,433
Jul 27, 2005
San Diego, California
This is currently one of my favorite 1G builds on the site. Great work!

...But, for the love of god, hack off that horrendous fukin exhaust pipe. It makes your car go from looking super clean and nice, to rice.
 

Smilinjay

Proven Member
290
92
Jul 9, 2013
Anchorage, Alaska
This is currently one of my favorite 1G builds on the site. Great work!

...But, for the love of god, hack off that horrendous fukin exhaust pipe. It makes your car go from looking super clean and nice, to rice.
Thanks for the kind words..
As for the exhuast, i built it off the car so i made it longer than necessary with the intention of cutting it down once i got the fitment right. The car hasnt even left the garage yet due to the bearing failure.
 

GST with PSI

DSM Wiseman
2,696
1,433
Jul 27, 2005
San Diego, California
Ah, gotcha. I figured that was the case, but just wanted to make sure ;)

Be careful with that GVR4 first gear. It's taller, but is also weaker than the DSM first. You'll really have to be nice to it out of the hole with a solid hub clutch disc. There's not virtually nothing to absorb the shock load of a launch.
 

iugrad92turbo

Supporting Member
12,884
813
May 22, 2007
Kalamazoo, Michigan
I got a welder I'm going to do the rocker panels on my car this spring I already cut the cancer out after all that primer sealer and I gotta paint it should be done for summer and the shoot out.
 

Smilinjay

Proven Member
290
92
Jul 9, 2013
Anchorage, Alaska
Ah, gotcha. I figured that was the case, but just wanted to make sure ;)

Be careful with that GVR4 first gear. It's taller, but is also weaker than the DSM first. You'll really have to be nice to it out of the hole with a solid hub clutch disc. There's not virtually nothing to absorb the shock load of a launch.
Yea we'll see how it holds up. Any idea how much weaker it is? I figured it's pretty close to a wash but I guess we'll find out. My main reason for the transmission change is my stock trans had the typical worn 2nd gear syncro. It was fine under normal driving conditions, but granny shifting when trying to do pulls is a huge buzz kill.
I got a welder I'm going to do the rocker panels on my car this spring I already cut the cancer out after all that primer sealer and I gotta paint it should be done for summer and the shoot out.
Nice, its good to see more people saving these cars :hellyeah:
 

Smilinjay

Proven Member
290
92
Jul 9, 2013
Anchorage, Alaska
I've been too busy lately to make much progress but i did get the transmission in. Ran into a few snags but everything turned out fine in the end. It seems like the new trans should shift perfectly with minor adjustment of my stock shifter cables.
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KFive

Probationary Member
6
1
Nov 3, 2002
Highlands Ranch, Colorado
Very Nice Build.. The new wheels sit very nice. What are the specs on those? Thanks!
 

Smilinjay

Proven Member
290
92
Jul 9, 2013
Anchorage, Alaska
Its been a while! I got pretty busy through the holidays and have not gotten as much done as i would have hoped, but heres the progress none the less.

I ran the alternator and gauge wiring out of sight under the chassis leg
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Cas and tps wiring extended to reach with how i routed my wiring harness. I made them long enough to tuck away under the intake manifold.
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I tried to make my transmission shift properly using the 90' shifter, cables and brackets but no matter what i tried it would not go all the way into 1st 3rd and 5th. I ended up just buying a 91' shifter with all solid bushings. Goes into all gears perfectly now and needless to say its the most solid and direct feel of any dsm shifter ive ever used.
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New axles in and got her back on the ground!
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I also got a second pusher fan. One just wasn't enough to keep it cool in traffic.
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