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Slow day at the shop so I pressure washed and am in the middle of hand compounding the 90 TSI roller for an easier sale. Probably hasn’t been washed in 15 years.

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I replaced the turbo oil feed line banjo bolt. I'll snug it up tomorrow to make sure the crush washers seal properly. The old banjo bolt was broken off by whoever owned the donor engine before me (see photo). She's almost road ready.

I still have to replace the alternator relay to see if that fixes the issue with the battery dying. New battery, new alternator, both tested, both passed.

Other than that, once I get new tires, finish replacing the headlight bulb socket pigtails, I'll be able to complete the new headlight installation and finish putting on the "97-'99 front bumper cover. Then bleed the clutch and top off all fluids.

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Lastly, have to double check to see if the 16G turbo is hooked up to the stock BCS correctly, I'm sure there's a post on here about that somewhere...after that she'll be running solidly.

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She is alive and all back together and idles great. Only leak I have found so far was the stupid pressure line on the power steering... Seals are in great shape I think I fixed it the banjo bolt was about a 16th of a turn loose.

Going to throw the wheel and heat shields back on and take her for a spin. My oil pressure at idle went up to 15-16 from 11-13 so a little confused on that front.

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Running into the same issue, oil supply line banjo bolt was defective, in other words the previous owner must've used a banjo bolt that was broken and they attempted to overtorque it so it didn't leak instead of just buying a new one. I'll snug it up tomorrow to make sure it doesn't leak but, it's installed with new crush washers so a 1/4 turn or less is all it needs.

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Found out what was making a knocking noise in my motor last week

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What kind of sound? Was it checked for clearance of both piston and crank lobe during install, and it shifted/bent in use?
I just ask because I dealt with these assholes and used over 24 crush washers to do so because they just didn't want to work for me. I'd adjust, dry install, check, like it, then on torque down they'd be too close to the piston even though I tried to take that into account. It was a nightmare that lasted over a two weeks.

So I'm hoping I have mine setup well now, I bought a borescope in the process to see from a better angle.
 
Deep cleaned my 1GB Talon! Alot of work but looks amazing for a 32 year old car! The last few pics are of the paint before the corrections were done

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What kind of sound? Was it checked for clearance of both piston and crank lobe during install, and it shifted/bent in use?
I just ask because I dealt with these assholes and used over 24 crush washers to do so because they just didn't want to work for me. I'd adjust, dry install, check, like it, then on torque down they'd be too close to the piston even though I tried to take that into account. It was a nightmare that lasted over a two weeks.

So I'm hoping I have mine setup well now, I bought a borescope in the process to see from a better angle.
Yes I checked for clearance on assembly, they were all close but a small margin of room. I think it might have shifted slightly, it only left a tiny mark on the piston.

Being this is a drag car, they're going to be deleted. However, further disassembly this morning, I found the main culprit. I didn't feel the debris in the oil matched what I saw from the squirter.

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Yes I checked for clearance on assembly, they were all close but a small margin of room. I think it might have shifted slightly, it only left a tiny mark on the piston.

Being this is a drag car, they're going to be deleted. However, further disassembly this morning, I found the main culprit. I didn't feel the debris in the oil matched what I saw from the squirter.

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OMG

Was the squirter under that particular piston? I see a scratch in about the right place, just wondering if the wrist pin going is what caused it to tap the squirter enough to break the brazed joint
Basically I want to quell my own concerns LOL
 
OMG

Was the squirter under that particular piston? I see a scratch in about the right place, just wondering if the wrist pin going is what caused it to tap the squirter enough to break the brazed joint
Basically I want to quell my own concerns LOL
Squirter was #3, broken pin was on #4
 
Yes I checked for clearance on assembly, they were all close but a small margin of room. I think it might have shifted slightly, it only left a tiny mark on the piston.

Being this is a drag car, they're going to be deleted. However, further disassembly this morning, I found the main culprit. I didn't feel the debris in the oil matched what I saw from the squirter.

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Holy shit, man! That is crazy it snapped in half!
 
Powder coated and mounted tires on the oem gsx wheels. Used prismatic sharcoal color that did not look anything like picture showed on the web. Welded two piece design also did not allowed for lip polishe like oe, we'll see how it will look on the car.

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Squirter was #3, broken pin was on #4
Was it still running with that broken pin Jason? I am running .250 wall pins and yours look very stout. If it was STILL running, I say count your blessings! Things could have gotten VERY EXPENSIVE.
Any idea how the right foot could have broke that pin? Fk the squirter, I've found 3 of em in my pan before. Motor didn't care.
 
SO, WHAT DID I DO TODAY....I modded an expensive WG to work with all of the TD05 turbos by making one gate out of two. One stocker was broken and the Kinugawa gate had too small of a hole for the WG flapper arm. I cut, rebent and threaded a portion of the Kinugawa gates arm to work perfectly by adding the end arm of the original gate and now i can change springs if i want to. I only have one stock frame turbo car, at the moment, but I will be using this on it when we stab a new motor into it. :thumb: IIRC, it has a 20lb spring in it now. I may need to buy the complete spring kit. We'll see.
Marty

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Was it still running with that broken pin Jason? I am running .250 wall pins and yours look very stout. If it was STILL running, I say count your blessings! Things could have gotten VERY EXPENSIVE.
Any idea how the right foot could have broke that pin? Fk the squirter, I've found 3 of em in my pan before. Motor didn't care.
Yes it was running fine, oil pressure was perfect. It sounded like a rod bearing but having perfect pressure, even checking my log, nothing was off. I even started it up in the pits again. Agreed, it could have gone very bad. Right now I'm out a piston and the rod needs to be repaired, I'll count my blessing.

I'll be getting some upgraded pins, these were standards.

You can here it right at the end of the video, after I put it in neutral.

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I installed Energy Suspension Front Sway Bar Bushings which are a pain on a 1g DSM. The slot in the front subframe allows it to slide just enough to make getting the super short bolt back in with the fatter, stiffer poly bushing very difficult. This was my solution to get them back in and not strip the threads out the subframe like some have.

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SO, WHAT DID I DO TODAY....I modded an expensive WG to work with all of the TD05 turbos by making one gate out of two. One stocker was broken and the Kinugawa gate had too small of a hole for the WG flapper arm. I cut, rebent and threaded a portion of the Kinugawa gates arm to work perfectly by adding the end arm of the original gate and now i can change springs if i want to. I only have one stock frame turbo car, at the moment, but I will be using this on it when we stab a new motor into it. :thumb: IIRC, it has a 20lb spring in it now. I may need to buy the complete spring kit. We'll see.
Marty

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that turbine housing is not oem thats why as the OEM 16g turbine housing used an R clip not an external C clip like the T25 does, so the kinugawa would of fitting to the OEM turbine housing, even the casting and actuator flapper arm is not OEM. so no idea what housing you got there
 
I installed Energy Suspension Front Sway Bar Bushings which are a pain on a 1g DSM. The slot in the front subframe allows it to slide just enough to make getting the super short bolt back in with the fatter, stiffer poly bushing very difficult. This was my solution to get them back in and not strip the threads out the subframe like some have.

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this is a problem and i dont know why after so many years they still get it wrong! you can use the fronts in the OEM rear bracket also which i found odd as their rear bracket sucks balls and is the worst design going! It is also why i hate energy suspension bushes full stop, their design and logic never tie up and it's a shame prothane stopped 1g bushes as that would have been the choice to go with
 
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that turbine housing is not oem thats why as the OEM 16g turbine housing used an R clip not an external C clip like the T25 does, so the kinugawa would of fitting to the OEM turbine housing, even the casting and actuator flapper arm is not OEM. so no idea what housing you got there
Well Bobby, I have 3 of them and no aftermarket hotsides. My 14b has the same one (or looking at it anyway). The aftermarket gate worked but I had to grind down the actuator pin on the turbo I took it from so the new gates arm hole would fit over it (4-5 years ago).
I didn't want to do that again so I simply threaded part of Kinugawa's gate rod to accept the stock arm end. If I find another stock unit out in the shop, I'll do some more comparing. :thumb:
Thanks for pointing out something I wasn't aware of. The good - it works. The bad - it may not work for all TDO5s (but fits the 3 I have). Seriously, I have not ran a stock frame turbo in years but my White 1990 GSX (like the restore one you did) needs a fresh motor that is ready, so the E16g that I bought with Justin's initials on it was the only upgrade I wanted to do (not a Chinabay unit).
After seeing your post, I'm glad I got Prothane bushings when I wanted them! I didn't know they quit making them.
 
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