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Street Build My 96' TSi DD Build

Idle_Serge

Proven Member
109
19
Dec 1, 2014
Prosser, Washington
Always been a fan of the 2G Eagle Talon TSi AWD! I use to have a fun one back in highschool but since the trans gave out and a bunch of other issues occurred, I didn’t have the funds to keep it on the road. So the swap was taken out and the rolling shell went behind the shop out at my parents’ house.

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About 8 years later, I’m talking to my brothers (which both own Talons) and the question about when will I get it running again comes up…why not now? I don’t have a second car, if I bought another car it would be car payment money and we have the rolling shell plus a bunch of spare parts to help me start the rebuild.
Another sad view: 

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First, my brother’s donated spare block, Evo crank, pistons and rods. Take the crank in to get some machine work since PO failed to be fully accurate about it and as quickly as I started the build, it came to a halt. Come to find out that the crank has not only already been cut once but it was the wrong crank—it was a 4G64, not a 4G63.

Not knowing what we were going to do next, I decide to seek for a transmission which was a major task on its own. After about 6 weeks of emailing junk yards, calling OP’s and so on, I find one posted on CL! Not only does he have trans and T Case but a motor as well! And this is were I prob got in over my head :/

It was a 95’ 4G63T Stroker 2.3L, 10:1, 102mm Crower Crankshaft, Crower Rods, Crower Pistons, ACL Race Bearings, BSE Kit, New Water/Oil Pumps, timing accessories, ARP Head Studs, Cometic HG, GSC Power Division Single Bee-Hive Valve Springs, Titanium Retainers and GSC 1MM OS Valves with about 7k on internals. For the price, some will raise speculations of red flags right away…but after speaking and arriving at the home address of the OP, I felt confident this was a great deal!

PO build pics:

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I needed the trans and t case no matter what and I was in need of either doing a complete stock rebuild from scratch or picking up this beast. Sure, I would still need to source a complete intake manifold, turbo, intercooler, fuel/engine management/tune plus a few odd and ends. So I am in fact spending more on this build then a stock rebuild but I hope not by too much.

So we bought the complete swap home:

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and began to source parts, starting with the Black Friday Sales on Extreme Psi:

-Gates Racing Performance Timing & Balance Belts
-OEM Axle Seals
-Competition Clutch Lightweight Steel Flywheel
-Competition Clutch Stage 3 - Street/Strip Series 2600 Clutch Kit
-OEM Pressure Plate to Flywheel Bolt
-OEM Timing Belt Cover Bolts
-Oil Feedline Kit (Oil Filter Location)
-Oil Return Line Kit (Socketless Hose Fitting)
-OEM Oil Return Line Gasket
-OEM Turbo Oil Return Line Bolt for Oil Pan
-OEM Turbo Oil Return Line Washer for Oil Pan
-Walbro Intank Fuel Pump Filter
-OEM Thermostat Kit
-Extreme PSI DSM 4G63T Stainless Steel Valve Cover Bolt Set
-OEM Intake Manifold Bolt
-OEM Transfer Case Bolt Kit
-Transmission Mounting Bolt Kit
-OEM Mitsubishi Crankshaft Rear Oil Seal Case Bolts
-OEM Fuel Filter : Mitsubishi Eclipse
-Exhaust Manifold Gasket (4 Ply)
-Oil Dipstick Tube
-OEM Oil Dip Stick O-Ring
-FIC Fuel Injector O-Ring Seal Replacement Set
-Fuel Injector Seat Cushion (Fuel Injector Sheet) Replacement Set
-Competition Clutch Forged Steel Release Fork & Pivot Ball
-OEM Clutch Release Clip
-ARP Pro-Series Flywheel Bolt Kit (7-pieces)
-OEM Clutch Pivot Ball (this is an extra since I failed to realize the Comp Fork came with one as well :/ )
-OEM Clutch Release Bearing
-OEM Evo9 Fuel Pump

That wraps up the current order, should be here early next week—my brothers are donating some parts as well such and cams, 550cc injectors, a nice VC (pervious one was shaved) and some other odd and ends.

Plans—simple, I hope. HP goal is to get it tuned for 300whp using a 20g. Motor is capable of much more but I honestly just want a reliable daily. Hope to get it buttoned up come spring time but with this type of build, that might be wishful thinking especially since I’m a complete noob in to the DSM world…who am I kidding, I’m a noob in general.

-Suspension—up in the air. Koni/Ground Control setup, Yonaka Coilovers, Feal Coils or maybe even just some lowering springs if I end up running stock 17s from an evo or something. But If I get coils, I plan on running something along the size of 18X9 +30 with at least a 245/35—not quite there yet tho, I’ll do some test fitting with the Work XD9s from my GF's TSX.

Some other plans are the OEM 3kgt 1G VR4 front calipers, with 2G rotors and custom Brackets. I got the brackets and calipers but I am going to powder coat and rebuild them prior to throwing them on. Plus, I got a nice fluidyne radiator.

Calipers:

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Brackets:

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Rad:

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Some additional fun facts :p

Gonna run a 2gb front bumper and OEM blk housed headlights and hopefully gonna have a buddy wrk his retro magic :biggrin: utilizing sportsautotech's kit. In addition, I didn’t like the bare look of the front and not many options were available when it comes to front lips so I asked if I could test fit the STi lip off my GF's TSX and since it was a little beat up from daily duties, she plans on getting a new one anyhow. Going to take a little trim work but it should flow ok with the oem talon twisties:

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That pretty much wraps up the beginning of this build. Plan to continue lurking in the DSM forums and of course I need to source the rest of the parts which will take some time based upon the fact that I’m broke now. Got the last 3 weeks off of this month, so I hope to get a little wrk done on cleaning it up and installing the new parts coming in—I will update along the way and bore the crap put of everyone.

Thanks for tuning in!
 

Idle_Serge

Proven Member
109
19
Dec 1, 2014
Prosser, Washington
Not much to report--started putting it back together as soon as I got on my 3 week vacation but halted as soon as I started.

There's a bunch of small shyt missing:
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Missing Keeper:
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As I'm helping my brother re seat the springs--I ask if we can use the cam caps off his spare head and he about slaps me:
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Little did I know--the cam caps CANNOT be interchanged. So I contact PO and he explains everything; keeper should have been there (gotta take pan off now) plug he used for his other motor he is building, and cam caps he forgot to throw in when I picked up the swap.

Ok--so I pay for shipping (he is 3 hours away). 5 business days later, they are still a no show. 1st they were sent to wrong addy than not enough postage was paid for (on his end). After that he was out of town, yada yada and they finally show up...after my brother has left town so the shop is closed and now I can't do shyt till he gets back.
In the meantime I ordered some misc things I needed. and cleaned up the intake:

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New OEM thermostat:
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The Cam Caps:
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More gaskets and such:

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Also picked up a brand new VRSF Kit with 1g BOV and gasket:

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Idle_Serge

Proven Member
109
19
Dec 1, 2014
Prosser, Washington
Nice build/project. Is that block glyptal coated?

Thanks!

I believe it is but I would have to contact the PO to get a more accurate answer.
 

Idle_Serge

Proven Member
109
19
Dec 1, 2014
Prosser, Washington

Idle_Serge

Proven Member
109
19
Dec 1, 2014
Prosser, Washington
Been spending a couple of hours a day out at the shop working on the 4G63--collecting parts and wasting money :p

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Extra set of Work Lugnuts

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New O-rings , gaskets and such for the 550cc injectors:
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Slowly...extremely slowly but making progress:

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painted some dull looking things:

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cleaned this oem manifold up...not sure if I will just coat it myself with some hi temp stuff and have it powder coated...I plan on running a shield so I might just do it myself:

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Snail should be on it's way. Otherwise, I still need some a middle timing cover and some sort of ecu management...looking at trying to get at least an ECM/DSMLink V2 or V3. AEM units are available for like 400 bucks but the local tuners, including English racing are telling me to steer away from those and get the DSMlink. If all else fails, running a stock ecu will get me going but I don't want to risk running my motor to the ground with improper specs...I might be overthinking it.

That's all for now.
 

myfreaklife85

Probationary Member
32
0
Mar 15, 2015
Whitesboro, Texas
Had a question what year was your eclipse? And what motor a 3.0? Or what was it a direct fit or did you have to re weld the motor mounts?
 

Idle_Serge

Proven Member
109
19
Dec 1, 2014
Prosser, Washington
You may want to go back thru my thread--I don't think you meant to comment on mine :/ as I don't have a 3.0...
 

Idle_Serge

Proven Member
109
19
Dec 1, 2014
Prosser, Washington
Sorry I meant 2.0 or 420a....dohc

My shell is a 96' AWD Turbo model so utilizing the stock mounts for this 2.3L 4G63.

This is great, its nice to hear of family working together especially a DSM FAM.!

Thanks for the support brotha!

FP20G should be on it's way! All I need now is a DSMLink...for now :p
 

myfreaklife85

Probationary Member
32
0
Mar 15, 2015
Whitesboro, Texas
Ok thanks . that's the difference you had the extra room on the left . the difference between the gs and gsx or gst
 

Idle_Serge

Proven Member
109
19
Dec 1, 2014
Prosser, Washington

Idle_Serge

Proven Member
109
19
Dec 1, 2014
Prosser, Washington

Idle_Serge

Proven Member
109
19
Dec 1, 2014
Prosser, Washington
Got some spare top hats and forks from Glen so I decided to put together the koni/GCs after I sand blasted the tophats and forks then coated them.

New vs old:

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1 done:

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And before I knew it, they were all wrapped up and ready for install:

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When time permits, I'll throw on the fuel filter and install motor. After that I'll install coils and see how it sits on my XD9s.
 

Idle_Serge

Proven Member
109
19
Dec 1, 2014
Prosser, Washington
Still haven't installed the dust boots--I simply haven't had time :sad:

but what I did do was install the wheels so I can move it around and finally get some real work done:

And lets start with the Rears:

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Close enough right? Shouldn't be very hard to fit these at all:

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I know, staggered wheels is frowned upon but the diameter difference is .03% not including the stretch which I will assume decreases it a tad?? idk but it's all I have at the moment and until I find another staggered set that matches this set to make 2 squared setups, I'll be rocking these.

Fronts: 18X9 +30 on 235/40:

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18X10 +38 with a 245/40:

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Once I get motor and tranny in place, I'll install the coils and get the wheels fitted. That is all.
 

Idle_Serge

Proven Member
109
19
Dec 1, 2014
Prosser, Washington
Correction on wheel fitment--I went to go push it closer to the concrete but it failed to move; come to realize the rear wheels actually didn't clear afterall but a 3mm spacers took care of that:

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And my brother had this shift knob sitting around so I decide to utilize it since I didn't have one install:

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Aside from that, nothing has been done. I simply haven't had the time nor motivation to get anything done. :sad:
 

Idle_Serge

Proven Member
109
19
Dec 1, 2014
Prosser, Washington
Thanks for the luv, Gus! It's greatly appreciated!

AAAAAAAAAAAAAAAnnnnnnnnd...quickly escalated, it did:

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A lil closer:

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No photoshop skills here:

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:laugh: so my brother @talonesi95t shoots me a txt about 4:15pm and ask if I wanted to throw the motor in...so I was like shyt why not :p

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Installed driver side motor mount, flywheel and clutch, new fuel filter and some misc things--about 2 hours of wrk if that.

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Maybe throw on the new OEM tranny Seals then install trans but I need to source a shield that goes in between trans and motor 1st :/

That is all.
 
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